Motor insulation framework, stator assembly and motor

Abstract

The application belongs to the technical field of electric machines, and discloses an electric machine insulation framework, a stator assembly and an electric machine. From the bottom of the framework yoke part to the top of the framework yoke part, the outer wall of the framework yoke part is inclined towards the side away from the axis of the framework yoke part. When the baffle is offset inward due to pressure, the framework yoke part can overcome the force that causes it to move relative to the stator core, thereby preventing the overall electric machine insulation framework from moving relative to the stator core. That is, when the baffle is offset due to pressure, the framework tooth part can remain stationary to avoid the coil from becoming looser, thereby avoiding the reduction of the inter-phase gap of the stator, further avoiding the increase of the resistance, and preventing the electric machine from generating large noise during operation.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a motor insulation frame, stator assembly, and motor. Background Technology

[0002] An electric motor generally consists of two main components: a stator and a rotor. The stator is typically insulated using an insulating frame. Specifically, the insulating frame is located at the end of the stator core and serves to insulate and support the windings.

[0003] like Figure 1 and Figure 2 As shown, in the prior art, the insulating frame generally includes a frame yoke 110 and frame teeth 120. The inner ring of the frame yoke 110 has several frame teeth 120. The frame yoke 110 of the insulating frame corresponds to the core yoke 211 of the stator core 210, and the frame teeth 120 of the insulating frame corresponds one-to-one with the core teeth 212 of the stator core 210. The stator coil is wound on the frame teeth 120 of the insulating frame and the core teeth 212 of the stator core 210. Specifically, for the insulating frame, a baffle 121 is provided on the side of the frame teeth 120 away from the frame yoke 110, and the coil is stopped and limited between the baffle 121 and the frame yoke 110. As described above, during the winding process, based on the direction of the conductor's travel, the coil will concentrate towards the side closer to the baffle 121, causing the baffle 121 to shift due to pressure. This, in turn, causes the entire insulating frame to move relative to the stator core 210. After the skeleton teeth 120 of the insulating frame shifts due to the overall movement of the insulating frame relative to the stator core 210, the coil wound on the skeleton teeth 120 will become looser. Specifically, the coil is generally wound in multiple layers, with the outermost wire bundle layer 410 being relatively loose. After the skeleton teeth 120 shifts, the looseness of the outermost wire bundle layer 410 will intensify, resulting in a decrease in the phase gap of the stator, which in turn leads to an increase in resistance, and the motor will generate significant noise during operation. Summary of the Invention

[0004] The purpose of this invention is to provide a motor insulation frame, stator assembly, and motor to solve the problem that during the winding process, the coil tends to concentrate towards the side closer to the baffle, causing the baffle to shift due to pressure. This causes the insulation frame to move relative to the stator core, resulting in the coil wound on the teeth becoming looser. Consequently, the phase gap of the stator decreases, leading to increased resistance and significant noise during motor operation.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] The present invention provides a motor insulation frame disposed on one side of the stator core along its axial direction. The motor insulation frame includes a frame yoke and frame teeth. The inner ring of the frame yoke is provided with a plurality of frame teeth, which are evenly arranged around the axis of the frame yoke. A baffle is provided on the side of the frame teeth away from the frame yoke, extending from the bottom to the top of the frame yoke. The outer wall of the frame yoke is inclined toward the side away from the axis of the frame yoke.

[0007] Preferably, the tilt angle of the skeleton yoke is greater than or equal to 0.8° and less than or equal to 3°.

[0008] Preferably, a winding groove is formed between two adjacent skeleton teeth, and a first chamfer is provided at the bottom of the skeleton yoke and the skeleton teeth, the first chamfer being formed at the edge of the groove wall of the winding groove.

[0009] Preferably, the radius of the first chamfer is greater than or equal to 2 mm and less than or equal to 5 mm.

[0010] Preferably, a reinforcing rib is provided between the skeleton teeth and the skeleton yoke.

[0011] Preferably, the baffle is provided with ears on both sides of the circumference of the skeleton yoke.

[0012] Preferably, the skeleton teeth are provided with a second chamfer on both sides of the skeleton yoke in the circumferential direction, and the second chamfer is formed at the top edge of the skeleton teeth.

[0013] Preferably, the second chamfer is rounded.

[0014] In another aspect, the present invention provides a stator assembly, including a stator core and a motor insulation frame as described above. The stator core includes a core yoke and core teeth. The inner ring of the core yoke is provided with a plurality of core teeth. The plurality of core teeth are evenly arranged around the axis of the core yoke. The frame yoke is correspondingly arranged with the core yoke, and the plurality of frame teeth are corresponding one-to-one with the plurality of core teeth.

[0015] In another aspect, the present invention provides an electric motor, including a rotor and a stator assembly as described above, the stator assembly being sleeved on the outer periphery of the rotor.

[0016] The beneficial effects of this invention are:

[0017] In this invention, from the bottom to the top of the frame yoke, the outer wall of the frame yoke is inclined toward the side away from the axis of the frame yoke. Thus, when the baffle is offset inward due to pressure, the frame yoke is offset outward, and therefore, the frame yoke can overcome the force that causes it to move relative to the stator core, thereby preventing the entire motor insulation frame from moving relative to the stator core. That is, in this invention, when the baffle is offset due to pressure, the frame teeth can remain stationary to avoid the coil from loosening further, thereby avoiding the reduction of the stator phase gap, thus avoiding the increase of resistance, and preventing the motor from generating large noise during operation. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of a stator assembly in the prior art;

[0019] Figure 2 This is a schematic diagram of the structure of the skeleton teeth, iron core teeth, and coil in the prior art;

[0020] Figure 3 This is one of the structural schematic diagrams of the stator assembly in this invention;

[0021] Figure 4 yes Figure 3 A magnified view of a section at point A in the middle;

[0022] Figure 5 yes Figure 3 A magnified view of a section at point B in the middle;

[0023] Figure 6 This is the second schematic diagram of the stator assembly in this invention;

[0024] Figure 7 This is a schematic diagram of the skeleton teeth, iron core teeth, and coil structure in this invention.

[0025] In the picture:

[0026] 110. Skeleton yoke; 120. Skeleton teeth; 121. Baffle; 1211. Ear; 122. Second chamfer; 130. Winding groove; 140. First chamfer; 150. Reinforcing rib; 210. Stator core; 211. Core yoke; 212. Core teeth; 310. Reservation area; 410. Wire harness layer. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0028] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0029] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0030] In the description of this embodiment, the terms "upper," "lower," "right," and "left," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0031] This embodiment provides an electric motor, which includes a rotor and a stator assembly. The stator assembly is sleeved on the outer periphery of the rotor, such as... Figure 3 and Figure 6 As shown, the stator assembly includes a stator core 210 and a motor insulation frame. The stator core 210 includes a core yoke 211 and a core tooth 212. The inner ring of the core yoke 211 is provided with a plurality of core teeth 212, which are evenly arranged around the axis of the core yoke 211.

[0032] As described above, the motor insulation frame is disposed at the end of the stator core 210, that is, the motor insulation frame is disposed on one side of the stator core 210 along its axial direction. Specifically, please refer to [link to relevant documentation]. Figure 3The motor insulation frame includes a frame yoke 110 and a frame tooth 120. The inner ring of the frame yoke 110 is provided with a plurality of frame teeth 120. The plurality of frame teeth 120 are evenly arranged around the axis of the frame yoke 110. The bottom of the frame yoke 110 and the frame tooth 120 are in contact with the stator core 210. Moreover, the frame yoke 110 is correspondingly arranged with the core yoke 211, and the plurality of frame teeth 120 is correspondingly arranged with the plurality of core teeth 212.

[0033] In addition, a baffle 121 is provided on the side of the skeleton tooth portion 120 away from the skeleton yoke portion 110. A winding area for winding the wire is formed between the baffle 121 and the skeleton yoke portion 110. In the prior art, the looseness of the coil is generally reduced by increasing the tension of the wire. However, increasing the tension of the wire will further increase the resistance, thereby reducing the efficiency of the motor.

[0034] Please see Figures 3 to 6 In this embodiment, to prevent the coil from becoming increasingly loose, the outer wall of the skeleton yoke 110 is inclined toward the side away from the axis of the skeleton yoke 110 from the bottom to the top. Thus, when the baffle 121 is offset inward due to pressure, the skeleton yoke 110 is inclined outward, and therefore, the skeleton yoke 110 can overcome the force that causes it to move relative to the stator core 210, thereby preventing the entire motor insulation skeleton from moving relative to the stator core 210. That is, in this embodiment, when the baffle 121 is offset due to pressure, the skeleton teeth 120 can remain stationary to prevent the coil from becoming increasingly loose, thereby preventing the reduction of the stator phase gap, thus preventing the increase of resistance, and preventing the motor from generating large noise during operation.

[0035] This embodiment simulates the vibration of a motor in the prior art and the motor in this invention under the same speed and torque. The simulation results are shown in Table 1.

[0036]

[0037] Table 1

[0038] As shown in Table 1, under the same speed and torque conditions, compared with the motor in the prior art, the motor in this embodiment has a significant reduction in radial vibration, that is, compared with the motor in the prior art, the motor in this embodiment generates significantly less noise during operation.

[0039] Specifically, at a speed of 1200 rpm and a torque of 3.2 N*M, the vibration frequency of the motor in the radial direction in the prior art is -9.7 Hz, while the vibration frequency of the motor in this embodiment is -21.88 Hz, with a vibration reduction rate of -125.57%. At a speed of 1800 rpm and a torque of 5.7 N*M, the vibration frequency of the motor in the radial direction in the prior art is 3.18 Hz, while the vibration frequency of the motor in this embodiment is -11.96 Hz, with a vibration reduction rate of -476.10%. At a speed of 3480 rpm and a torque of 6.6 N*M, the vibration frequency of the motor in the radial direction in the prior art is 14.51 Hz, while the vibration frequency of the motor in this embodiment is -4.09 Hz, with a vibration reduction rate of -128.19%. At a speed of 3600 rpm and a torque of 7.4 N*M... At *M, the vibration frequency of the motor in the radial direction in the prior art is 15.04 Hz, while the vibration frequency of the motor in this embodiment is -4.34 Hz, with a vibration reduction rate of -128.86%. At a speed of 4320 rpm and a torque of 7.4 N*M, the vibration frequency of the motor in the radial direction in the prior art is 15.36 Hz, while the vibration frequency of the motor in this embodiment is -5.26 Hz, with a vibration reduction rate of -134.24%. At a speed of 5160 rpm and a torque of 7.4 N*M, the vibration frequency of the motor in the radial direction in the prior art is 16.95 Hz, while the vibration frequency of the motor in this embodiment is -5.44 Hz, with a vibration reduction rate of -132.09%. In summary, the vibration of the motor in the radial direction in this embodiment is significantly reduced, thereby significantly reducing the noise generated during operation.

[0040] As described above, this embodiment prevents the entire motor insulation frame from moving relative to the stator core 210 by tilting the outer wall of the frame yoke 110, thereby avoiding further loosening of the coil. Therefore, this embodiment does not require changing the wire tension, thus avoiding increased resistance and consequently avoiding affecting motor efficiency.

[0041] Additionally, it should be noted that, as Figure 1 As shown, to overcome the impact of stress concentration on the structural strength of the motor insulation frame, in the prior art, the connection between the frame yoke 110 and the frame tooth 120 is an arc transition. However, the arc transition occupies the effective space when winding the coil, thus preventing further improvement in the conductor utilization rate and affecting the motor efficiency. In this embodiment, however, as... Figure 6 As shown, and in combination Figure 3The skeleton yoke 110 is inclined outward, which can balance the stress in all directions. That is, in this embodiment, there is no need to make an arc transition design at the junction of the skeleton yoke 110 and the skeleton tooth 120, which can provide more effective space for winding the coil, thereby increasing the conductor occupancy rate and thus improving the motor efficiency.

[0042] This embodiment calculates the duty cycle, phase gap, and resistance of motors in the prior art and motors in this invention, and the results are shown in Table 2.

[0043] This invention Existing technology Performance rate 75％ 72％ Interphase gap 4.0mm-4.5mm 3.5mm-4.0mm resistance (98.5％-99％)a a

[0044] Table 2

[0045] As shown in Table 2, the conductor coverage ratio of motors in the prior art is 72%, and the phase gap is between 3.5 mm and 4.0 mm. In this embodiment, the conductor coverage ratio of the motor is 75%, and the phase gap is between 4.0 mm and 4.5 mm. Therefore, compared to motors in the prior art, the motor in this embodiment has a higher conductor coverage ratio and a larger phase gap. Thus, the motor insulation frame in this embodiment can improve the conductor coverage ratio and avoid reducing the stator phase gap. Furthermore, compared to motors in the prior art, the motor in this embodiment has a lower resistance; therefore, the motor insulation frame in this embodiment can prevent an increase in resistance.

[0046] Please continue reading. Figure 3 and Figure 6 The tilt angle of the frame yoke 110 is greater than or equal to 0.8° and less than or equal to 3°, that is, the tilt angle of the outer wall of the frame yoke 110 is greater than or equal to 0.8° and less than or equal to 3°. Correspondingly, the angle α between the outer wall of the frame yoke 110 and the end wall of the stator core 210 is greater than or equal to 87° and less than or equal to 89.2°. For example, the tilt angle of the outer wall of the frame yoke 110 can be selected as 0.8°, 0.9°, 1° or 2°, etc. Preferably, in this embodiment, the tilt angle of the outer wall of the frame yoke 110 is equal to 1°. Correspondingly, the angle α between the outer wall of the frame yoke 110 and the end wall of the stator core 210 is equal to 89°. This ensures that the overall size of the motor insulation frame is small while preventing the entire motor insulation frame from moving relative to the stator core 210.

[0047] Furthermore, it is worth noting that in the prior art, because the motor insulation frame as a whole is prone to movement relative to the stator core 210, therefore, if Figure 1 and Figure 2As shown, for the frame tooth portion 120, it is inconvenient to chamfer the bottom corners to increase the contact area between the frame tooth portion 120 and the stator core 210, thereby mitigating the degree of movement of the entire motor insulation frame relative to the stator core 210 caused by the pressure displacement of the baffle 121. However, in this embodiment, since the frame yoke portion 110 can ensure that the entire motor insulation frame does not move relative to the stator core 210, chamfers can be formed at the bottom corners of the frame tooth portion 120. For details, please refer to... Figures 3 to 7 In this embodiment, a winding groove 130 is formed between two adjacent skeleton teeth 120. The bottom of the skeleton yoke 110 and the skeleton teeth 120 is provided with a first chamfer 140. The first chamfer 140 is formed on the edge of the groove wall of the winding groove 130, thereby forming a gap area 310 between the motor insulation skeleton and the stator core 210. As a result, when winding the coil, the outer wire harness layer 410 can squeeze the inner wire harness layer 410 toward the gap area 310, thereby reducing the looseness of the coil, further optimizing the motor resistance, and further improving the motor efficiency.

[0048] In this embodiment, the radius of the first chamfer 140 is greater than or equal to 2 mm and less than or equal to 5 mm, which can effectively alleviate the problem of coil looseness. For example, the radius of the first chamfer 140 can be 2 mm, 3 mm, 4 mm or 5 mm, etc. Preferably, in this embodiment, the radius of the first chamfer 140 is 3 mm, which can reduce the degree of coil looseness while making the frame teeth 120 and the stator core 210 have a large friction force, thereby more effectively ensuring that the motor insulation frame as a whole will not move relative to the stator core 210.

[0049] Please continue reading. Figure 3 The skeleton tooth portion 120 is provided with a second chamfer 122 on both sides of the skeleton yoke portion 110 in the circumferential direction. The second chamfer 122 is formed at the top edge of the skeleton tooth portion 120, thereby facilitating the winding of the wire.

[0050] It is worth noting that the second chamfer 122 is arc-shaped, which can further reduce the looseness of the coil and thus further optimize the motor resistance.

[0051] Furthermore, the baffle 121 is provided with ears 1211 on both sides of the skeleton yoke 110 in the circumferential direction. The ears 1211 are arranged opposite to the skeleton yoke 110 and are located on the side of the baffle 121 in the circumferential direction of the skeleton yoke 110, so that they can cooperate with the skeleton yoke 110 to stop the wire harness layer 410 located on the outer side, thereby stopping the coil more fully and further effectively alleviating the problem of coil looseness.

[0052] In addition, a reinforcing rib 150 is provided between the skeleton tooth portion 120 and the skeleton yoke portion 110. The reinforcing rib 150 can further improve the structural strength of the motor insulation skeleton, thereby further improving the structural stability of the motor insulation skeleton.

[0053] In summary, in the motor insulation frame of the present invention, the outer wall of the frame yoke 110 is inclined. Therefore, when the baffle 121 is offset inward due to pressure, the frame yoke 110 can overcome the force that causes it to move relative to the stator core 210, thereby preventing the entire motor insulation frame from moving relative to the stator core 210. This allows the frame teeth 120 to remain stationary, thereby preventing the coil from loosening further, thus preventing the reduction of the stator phase gap and the increase of resistance. Moreover, it can prevent the motor from generating large noise during operation.

[0054] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A motor insulation frame, disposed on one side of a stator core (210) along its axial direction, the motor insulation frame comprising a frame yoke (110) and frame teeth (120), wherein a plurality of frame teeth (120) are disposed on the inner ring of the frame yoke (110), the plurality of frame teeth (120) being evenly arranged around the axis of the frame yoke (110), and a baffle (121) is disposed on the side of the frame teeth (120) away from the frame yoke (110), characterized in that, From the bottom to the top of the skeleton yoke (110), the outer wall of the skeleton yoke (110) is inclined toward a side away from the axis of the skeleton yoke (110).

2. The motor insulation frame according to claim 1, characterized in that, The tilt angle of the skeleton yoke (110) is greater than or equal to 0.8° and less than or equal to 3°.

3. The motor insulation frame according to claim 1, characterized in that, A winding groove (130) is formed between two adjacent skeleton teeth (120). The bottom of the skeleton yoke (110) and the skeleton teeth (120) is provided with a first chamfer (140), which is formed at the edge of the groove wall of the winding groove (130).

4. The motor insulation frame according to claim 3, characterized in that, The radius of the first chamfer (140) is greater than or equal to 2 mm and less than or equal to 5 mm.

5. The motor insulation frame according to claim 1, characterized in that, A reinforcing rib (150) is provided between the skeleton tooth portion (120) and the skeleton yoke portion (110).

6. The motor insulation frame according to claim 1, characterized in that, The baffle (121) has ears (1211) on both sides of the circumference of the skeleton yoke (110).

7. The motor insulation frame according to claim 1, characterized in that, The skeleton tooth portion (120) is provided with a second chamfer (122) on both sides of the skeleton yoke portion (110) in the circumferential direction. The second chamfer (122) is formed at the top edge of the skeleton tooth portion (120).

8. The motor insulation frame according to claim 7, characterized in that, The second chamfer (122) is arc-shaped.

9. A stator assembly, characterized in that, The device includes a stator core (210) and a motor insulation frame as described in any one of claims 1-8. The stator core (210) includes a core yoke (211) and core teeth (212). The inner ring of the core yoke (211) is provided with a plurality of core teeth (212). The plurality of core teeth (212) are evenly arranged around the axis of the core yoke (211). The frame yoke (110) is provided corresponding to the core yoke (211), and the plurality of frame teeth (120) is provided one-to-one with the plurality of core teeth (212).

10. An electric motor, characterized in that, It includes a rotor and a stator assembly as described in claim 9, the stator assembly being sleeved on the outer periphery of the rotor.

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