Production method of all-plastic-sealed motor stator and all-plastic-sealed motor stator

Abstract

The application discloses a production method of a full-plastic-sealed motor stator and the full-plastic-sealed motor stator, and the production method comprises the following steps: winding a stator winding in a stator slot of a stator core to obtain a stator piece a; then performing plastic sealing treatment on the stator piece a, so that the stator piece a is completely wrapped by injection plastic and a plastic sealing layer is formed, thereby obtaining a stator piece b; then mounting holes for connecting brake discs are formed on the surface of mounting pieces, and then the mounting pieces are fixedly connected to the stator piece b, and a circumferential limiting part is formed between the mounting pieces and the stator piece b, thereby obtaining a finished motor stator. The application can improve the processing stability and universality of the full-plastic-sealed motor stator.

Description

Technical Field

[0001] This invention relates to a fully encapsulated motor stator, and more particularly to a method for producing a fully encapsulated motor stator and the fully encapsulated motor stator itself. Background Technology

[0002] Fully encapsulated motor stators typically employ a structure where the stator core and stator windings are integrally encapsulated in plastic. The plastic layer covers the outer periphery of the stator core and the axially protruding portion of the stator windings, fixing the stator core, stator windings, and plastic layer together to form an integrated structure. This structure improves the protection of the stator core and stator windings, effectively preventing external moisture, dust, oil, and other impurities from corroding the stator windings or intruding into the gaps in the stator core, avoiding motor failures caused by deterioration of the stator winding insulation performance, and ensuring long-term stable operation of the motor. Furthermore, compared to semi-encapsulated motor stators or traditional motor stators, it eliminates the need for a metal housing required for motor installation, simplifying the motor structure and reducing costs.

[0003] Based on the fully encapsulated washing machine motor stator, current washing machine brake discs are typically mounted to the end of the motor stator using screws. Specifically, threaded holes are machined directly into the encapsulation layer at the stator end, and then the brake disc is fixed to the encapsulation layer with screws. However, this structure has a drawback: because the threaded holes are machined close to and directly facing the stator windings, they can easily penetrate the encapsulation layer and damage the stator windings during drilling. This increases the precision requirements for the motor stator's machining and poses a significant quality risk.

[0004] On the other hand, since the mounting holes for brake discs of washing machines from different brands are different, manufacturers need to customize the threaded holes of the motor stator for different brake disc mounting holes during processing, which is not conducive to the manufacturer's standardized production and unified inventory.

[0005] Furthermore, because the encapsulation layer of a fully encapsulated motor stator is thicker in the stator winding area than in the stator core—a measure designed to ensure complete coverage and insulation of the stator windings—the injection mold must inject the plastic directly from the radially outer side of the stator windings to achieve proper encapsulation and filling. However, this injection molding method has a drawback: due to the high viscosity of the BMC (Body Molding Molding) plastic and the need for high-temperature, high-pressure encapsulation of the motor stator, the injection pressure is directly transmitted to the stator windings via the plastic. This causes the flexible stator windings to radially shift under the injection pressure and contact the mold cavity wall, resulting in partial exposure of the stator windings after the encapsulation layer is formed. On the other hand, the high injection pressure of the BMC plastic can also easily cause frictional damage to the insulation layer on the stator winding surface, affecting the subsequent operational stability of the motor.

[0006] Therefore, the existing fully encapsulated motor stators used in washing machine motors suffer from poor processing stability and low versatility. Summary of the Invention

[0007] The purpose of this invention is to provide a method for manufacturing a fully encapsulated motor stator and a fully encapsulated motor stator itself. This method improves the processing stability and versatility of the fully encapsulated motor stator.

[0008] The technical solution of the present invention: a method for producing a fully encapsulated motor stator, comprising the following steps:

[0009] A. The stator winding is wound into the stator slots of the stator core to obtain stator component a;

[0010] B. Perform plastic encapsulation on stator component a, so that the injection plastic completely wraps the outside of stator component a and forms a plastic encapsulation layer, to obtain stator component b;

[0011] C. A mounting hole for connecting the brake disc is made on the surface of the mounting plate, and then the mounting plate is fixedly connected to the stator component b, so that a circumferential limit is formed between the mounting plate and the stator component b, thus obtaining the finished motor stator.

[0012] In the aforementioned method for producing a fully encapsulated motor stator, step B specifically includes the following steps:

[0013] B1. Place and fix stator component a in the injection mold, and form a first injection cavity on the outside of the stator core of stator component a, and form a second injection cavity on the outside of the stator winding of stator component a. The second injection cavity is located on both sides of the first injection cavity along the axial direction, and the first injection cavity and the second injection cavity are interconnected through a third injection cavity.

[0014] B2. The injection plastic is injected into the first injection cavity from the feed port on the radially outer side of the first injection cavity. After entering the first injection cavity, part of the injection plastic fills the first injection cavity circumferentially, and the other part enters the second injection cavity through the third injection cavity.

[0015] B3. After the injection molding material enters the second injection cavity, part of it fills the second injection cavity circumferentially, and the other part enters the first injection cavity, which is far away from the feed port area, through the third injection cavity.

[0016] B4. The injection plastics in the first, second, and third injection cavities are interconnected after curing to form a plastic seal layer, resulting in stator component b.

[0017] In the aforementioned method for producing a fully encapsulated motor stator, during the encapsulation process of stator component a in step B, a wire clamp is placed on one side of stator component a, and the lead wires of the stator winding are extended to the outside through the wire clamp; the wire clamp protects and guides the lead wires during the encapsulation process, and the encapsulation layer wraps and fixes the wire clamp after the encapsulation is formed.

[0018] A fully encapsulated motor stator is also provided. This fully encapsulated motor stator is manufactured by the aforementioned method for producing a fully encapsulated motor stator. Specifically, it includes a stator core, on which stator windings are wound. The two ends of the stator windings extend to the axial outer side of the stator core and form protrusions. The stator core and stator windings are covered with a plastic encapsulation layer. Mounting plates are fixedly connected to the outside of the plastic encapsulation layer. Several mounting holes for connecting brake discs are distributed around the mounting plates. The mounting plates and the plastic encapsulation layer are connected to each other by limiting members.

[0019] In the aforementioned fully encapsulated motor stator, the limiting component includes a limiting block and a limiting groove that interlock with each other, and the limiting block and the limiting groove are respectively disposed on the encapsulation layer and the mounting plate.

[0020] In the aforementioned fully encapsulated motor stator, the outer side of the mounting plate is provided with an annular first bend, which engages with the outer circular surface of the encapsulation layer, and the limiting groove is located on one side of the first bend.

[0021] In the aforementioned fully encapsulated motor stator, the mounting plate has an inwardly recessed step in the middle, and one end of the encapsulation layer has a fixing groove that matches the step. The mounting plate is fastened to the fixing groove via the step and forms an interference fit with the encapsulation layer.

[0022] In the aforementioned fully encapsulated motor stator, the encapsulation layer includes a first encapsulation layer that is annularly wrapped around the stator core and a second encapsulation layer that is wrapped around the two protruding parts. The first encapsulation layer and the second encapsulation layer are connected to each other via a connecting part.

[0023] In the aforementioned fully encapsulated motor stator, a wire clamp is connected to one side of the second plastic coating layer. The lead wire of the stator winding passes through the wire clamp, passes through the second plastic coating layer, and extends to the outside. The second plastic coating layer is used to fix the wire clamp to the stator core and the stator winding after plastic coating.

[0024] In the aforementioned fully encapsulated motor stator, several grounding holes are distributed around the stator core. The encapsulation layer has a stepped groove that connects to the grounding holes. A grounding terminal is fastened and connected in the stepped groove. One end of the grounding terminal is fastened and connected in the grounding hole and forms an interference fit with the grounding hole. The grounding terminal is used to electrically connect the grounding wire to the stator core.

[0025] Compared with the prior art, the present invention has the following characteristics:

[0026] (1) The present invention first encapsulates the stator component to form an encapsulation layer, and then fixes the mounting plate with mounting holes on the stator component, so that the mounting hole for connecting the brake disc can be transferred from the encapsulation layer to the mounting plate. Thus, on the one hand, there is no need to drill holes in the encapsulation layer, which effectively avoids the damage to the stator winding caused by drilling. On the other hand, the manufacturer can also process mounting plates of different specifications according to the mounting hole position of the brake disc and fix the mounting plate to the outside of the motor stator of the same structure. Thus, the manufacturer does not need to customize the motor stator based on the brake disc, which facilitates the standardized production and unified inventory of the motor stator.

[0027] (2) By limiting the injection molding method of the encapsulation layer, the inlet can be set on the radial outside of the first injection cavity, so that the injection pressure of the plastic during feeding can be applied to the side wall of the stator core, which effectively reduces the impact on the stator winding and avoids the problem of exposure of the stator winding due to pressure displacement. On this basis, by setting and limiting the structure of the third injection cavity, the plastic can flow evenly into the second injection cavity and the first injection cavity far away from the inlet area through the third injection cavity, thereby improving the encapsulation effect of the encapsulation layer on the one hand and reducing the impact force of the plastic on the stator winding during the injection process on the other hand. With the above combination, the defect rate of the stator of the present invention can be reduced from 5-8% to less than 0.5% compared with the existing fully encapsulated motor stator.

[0028] (3) Based on the stator of the fully encapsulated motor, by limiting the structure of the wire clamp, the lead wire of the stator winding can pass through the wire clamp through the second plastic layer and extend to the outside. The wire clamp is used to position and protect the lead wire. On the one hand, it prevents the lead wire from being damaged by friction during the injection molding process. On the other hand, the wire clamp is used to guide the lead wire so that the lead wire extends out of the plastic layer from the specified position and the exit angle under the guidance.

[0029] (4) By limiting the connection structure between the mounting piece and the plastic encapsulation layer, on the one hand, the mounting piece can be firmly fixed on the plastic encapsulation layer of the fully encapsulated motor stator. On the other hand, by setting the limiting part, the circumferential position of the plastic encapsulation layer and the mounting piece can be limited, thereby ensuring the installation accuracy of the motor stator and the brake disc, and avoiding the misalignment problem of the mounting piece during installation. Through the cooperation of the stepped part and the fixing groove, the mounting piece can be axially and radially limited, thereby ensuring the installation stability and installation accuracy of the mounting piece on the plastic encapsulation layer, and ensuring that the mounting piece and the stator part are in the same concentricity after the mounting piece is fixed.

[0030] (5) By limiting the grounding wire connection structure, the operator can directly snap the grounding wire onto the plastic seal layer through the grounding terminal during installation, and use the compression of the grounding terminal to make the grounding wire and the stator core stick together to form an electrical connection, thereby effectively improving the installation convenience of the grounding wire;

[0031] Therefore, this invention can improve the processing stability and versatility of fully encapsulated motor stators. Attached Figure Description

[0032] Figure 1 This is an external view of Example 1 from one side;

[0033] Figure 2 This is a view of the other side of Example 1;

[0034] Figure 3 This is an outline drawing of the mounting plate in Example 1;

[0035] Figure 4 This is an external view of Example 1 after the mounting plate has been removed;

[0036] Figure 5 yes Figure 2 Enlarged view along line A after removing the grounding terminal;

[0037] Figure 6 This is an outline drawing of the grounding terminal in Example 1;

[0038] Figure 7 This is a schematic diagram of the injection mold structure in Example 2;

[0039] Figure 8 This is a schematic diagram showing the connection between the injection mold and the locating pin in Example 2;

[0040] Figure 9 This is an external view of Example 3;

[0041] Figure 10 This is an external view of Example 4;

[0042] Figure 11 This is an external view of Example 5.

[0043] The labels in the attached diagram are as follows: 1-Stator core, 2-Plastic coating layer, 3-Mounting piece, 4-Mounting hole, 5-Limiting block, 6-Limiting groove, 7-Wire clamp, 8-Grounding terminal, 9-Upper mold core, 10-Lower mold core, 11-First injection cavity, 12-Second injection cavity, 13-Third injection cavity, 14-Positioning pin, 15-Feed hole, 16-Mounting block, 101-Grounding hole, 201-First plastic coating layer, 202-Second plastic coating layer, 203-Connecting part, 204-Fixing groove, 205-Step groove, 301-First bending part, 302-Step part, 303-Second bending part. Detailed Implementation

[0044] The present invention will be further described below with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the present invention.

[0045] Example 1. A fully encapsulated motor stator, configured as follows: Figure 1-6 As shown, it includes a stator core 1, on which a stator winding is wound. The two ends of the stator winding extend to the axial outer side of the stator core 1 and form protrusions. The stator core 1 and the stator winding are covered with a plastic sealing layer 2. A mounting piece 3 is fixedly connected to the outside of the plastic sealing layer 2. Several mounting holes 4 for connecting brake discs are distributed around the mounting piece 3. The mounting piece 3 and the plastic sealing layer 2 are connected to each other by a limiting member.

[0046] The limiting component includes a limiting block 5 and a limiting groove 6 that interlock with each other. The limiting block 5 and the limiting groove 6 are respectively disposed on the plastic sealing layer 2 and the mounting piece 3. The limiting block 5 and the limiting groove 6 are used to circumferentially limit the mounting piece 3 after they interlock with each other.

[0047] The mounting piece 3 has an annular first bending portion 301 on its outer side. The first bending portion 301 is engaged with the outer circular surface of the plastic sealing layer 2. The limiting groove 6 is located on one side of the first bending portion 301.

[0048] The limiting block 5 is located on the outer circular surface of the sealing layer 2 and is integrally injection molded with the sealing layer 2.

[0049] The mounting piece 3 has an inwardly recessed step 302 in the middle, and one end of the plastic sealant 2 has a fixing groove 204 that matches the step 302. The mounting piece 3 is fastened and connected in the fixing groove 204 through the step 302 and forms an interference fit with the plastic sealant 2. The step 302 is used to axially limit the mounting piece 3 after fastening, so that the mounting piece 3 and the plastic sealant 2 are fixed to each other.

[0050] The middle part of the stepped portion 302 forms a bearing chamber for placing the ball bearing.

[0051] The mounting piece 3 on the outside of the mounting hole 4 is bent inward to form a second bent portion 303 in the shape of a round tube, and the inner hole of the second bent portion 303 constitutes the mounting hole 4.

[0052] The plastic coating layer 2 includes a first plastic coating layer 201 that is annularly wrapped around the stator core 1 and a second plastic coating layer 202 that is wrapped around the two protrusions. The first plastic coating layer 201 and the second plastic coating layer 202 are connected to each other via a connecting part 203.

[0053] The encapsulation layer 2 forms a mounting plate for mounting the fully encapsulated motor stator at the first encapsulation layer 201, and the mounting plate is located axially on the side of the first encapsulation layer 201 near the mounting piece 3.

[0054] A wire clamp 7 is connected to one side of the second plastic coating layer 202. The lead wire of the stator winding passes through the wire clamp 7 through the second plastic coating layer 202 and extends to the outside. The wire clamp 7 is used to protect the lead wire during injection molding and to guide the lead wire exit direction. The second plastic coating layer 202 is used to fix the wire clamp 7, the stator core 1 and the stator winding into one piece after plastic coating. One end of the wire clamp 7 extends to the outside of the second plastic coating layer 202 after plastic coating. After the lead wire extends out from the wire clamp 7, the outside is covered with a flexible wire sleeve to achieve wrapping protection.

[0055] The wire clamp 7 includes two separate clamping pieces, each with a wire routing opening. When the two clamping pieces are closed together, they form a wire routing hole for the lead wire to pass through. The two clamping pieces are attached and fixed together after the second plastic coating layer 202 is injection molded.

[0056] The stator core 1 has several grounding holes 101 distributed around its perimeter. Each grounding hole 101 penetrates the stator core 1. The plastic sealing layer 2 has a stepped groove 205 that connects to the grounding holes 101. A grounding terminal 8 is fastened into the stepped groove 205. One end of the grounding terminal 8 is fastened into the grounding hole 101 and forms an interference fit with the grounding hole 101. The grounding terminal 8 is used to electrically connect the grounding wire to the stator core. During installation, one end of the grounding wire is sleeved on the outside of the grounding terminal 8 and, under the squeezing action of the grounding terminal 8, it is in contact with the stator core 1 at the inner end of the stepped groove 205. The other end of the grounding wire extends through the stepped groove 205 to the outside of the stepped groove 205, thus realizing the grounding function.

[0057] In this embodiment, during installation, the operator first fastens the mounting piece 3 through the stepped portion 302 into the fixing groove 204 of the plastic sealant layer 2, and then engages the limiting groove 6 with the limiting block 5 on the plastic sealant layer 2 after the mounting piece 3 is installed. Then, the washing machine brake disc is fixed to the mounting piece 3 with screws through the mounting hole 4, thus using the mounting piece 3 instead of the plastic sealant layer 2 to fix the washing machine brake disc with screws.

[0058] On the other hand, the structural cooperation between the grounding terminal 8 and the plastic encapsulation layer 2 allows the grounding wire to be snapped into the stepped groove 205 and closely fitted to the stator core 1 during installation via the grounding terminal 8, thereby improving the ease of installation of the grounding wire. By structurally defining the wire clamp 7, it can replace the plastic encapsulation layer 2 in wrapping and leading out the stator winding leads, thereby improving the positioning accuracy and protection effect of the leads, and preventing damage to the leads caused by the plastic encapsulation layer 2 during injection molding.

[0059] Example 2. A method for producing a fully encapsulated motor stator, wherein the fully encapsulated motor stator in Example 1 is processed and formed by this method, specifically including the following steps:

[0060] A. The stator winding is wound into the stator slots of the stator core to obtain stator component a;

[0061] B. Perform plastic encapsulation on stator component a, so that the injection plastic completely wraps the outside of stator component a and forms a plastic encapsulation layer, to obtain stator component b;

[0062] C. A mounting hole for connecting the brake disc is made on the surface of the mounting plate, and then the mounting plate is fixedly connected to the stator component b, so that a circumferential limit is formed between the mounting plate and the stator component b, thus obtaining the finished motor stator.

[0063] Step B specifically includes the following steps:

[0064] B1. Place and fix stator component a in the injection mold, and form a first injection cavity on the outside of the stator core of stator component a, and form a second injection cavity on the outside of the stator winding of stator component a. The second injection cavity is located on both sides of the first injection cavity along the axial direction, and the first injection cavity and the second injection cavity are interconnected through a third injection cavity.

[0065] B2. The injection plastic is injected into the first injection cavity from the feed port on the radial side of the first injection cavity, so that the impact force of the injection plastic when entering the first injection cavity is directly applied to the stator core; after entering the first injection cavity, part of the injection plastic fills the first injection cavity circumferentially, and the other part enters the second injection cavity through the third injection cavity.

[0066] B3. After the injection molding material enters the second injection cavity, part of it fills the second injection cavity circumferentially, and the other part enters the first injection cavity, which is far away from the feed port area, through the third injection cavity.

[0067] B4. The injection plastics in the first, second, and third injection cavities are interconnected after curing to form a plastic seal layer, resulting in stator component b.

[0068] In step B, during the plastic encapsulation process of stator component a, a wire clamp is placed on one side of stator component a, and the lead wire of the stator winding is extended to the outside through the wire clamp; the wire clamp protects and guides the lead wire during the plastic encapsulation process, and the plastic encapsulation layer wraps and fixes the wire clamp after the plastic encapsulation is formed.

[0069] The injection mold is composed of the following: Figure 7-8 As shown, it includes an upper mold core 9 and a lower mold core 10. The cavities of the upper mold core 9 and the lower mold core 10 form an injection cavity after being enclosed. The shape of the injection cavity matches the shape of the molding layer. The injection cavity includes a first injection cavity 11, a second injection cavity 12 and a third injection cavity 13 that are interconnected. The first injection cavity 11 is provided with a plurality of positioning pins 14. The two ends of the positioning pins 14 are respectively fastened to the upper mold core 9 and the lower mold core 10. The radial outer side of the first injection cavity 11 is provided with a feed hole 15. There are two second injection cavities 12 and they are distributed on both sides of the axial direction of the first injection cavity 11.

[0070] The feed hole 15 is used to inject the injection plastic into the first injection cavity 11;

[0071] The first injection cavity 11 is used to injection mold the first plastic coating layer 201;

[0072] The positioning pin 14 is used to position the stator core 1, the upper mold core 9, and the lower mold core 10 relative to each other after passing through the grounding hole 101 of the stator core 1.

[0073] The second injection cavity 12 is used to allow the second plastic coating layer 202 to completely wrap the protrusion and injection mold it;

[0074] The third injection cavity 13 is used to allow the injection plastic in the first injection cavity 11 to flow into the second injection cavity 12, and to injection mold the connecting part 203.

[0075] The second injection cavity 12 has a groove on one side for forming the limiting block 5.

[0076] The center of the positioning pin 14 passes through the grounding hole 101 and positions the stator core 1.

[0077] The upper mold core 9 and the lower mold core 10 are provided with support blocks on the axial outer side of the positioning hole. After the upper mold core 9 and the lower mold core 10 are fixed, they are attached to each other and formed by the support blocks to form axial limiting. After the plastic sealing layer 2 is injection molded, a stepped groove 205 is formed in the support block area.

[0078] The injection cavity is provided with a mold ring in the middle. There are two mold rings, which are integrally formed with the upper mold core 9 and the lower mold core 10 respectively. The outer radial side of the mold ring forms a second injection cavity 12. The mold ring is used to extend into the central hole of the stator core 1 during injection molding and serve as the forming surface of the second plastic coating layer 202.

[0079] A mounting block 16 is provided on one side of the injection cavity. The mounting block 16 and the feed hole 15 are staggered in the circumferential direction. The two ends of the mounting block 16 are fastened to the upper mold core 9 and the lower mold core 10. The middle part of the mounting block 16 forms a wire clamp groove for placing the wire clamp 7. The end of the wire clamp 7 placed in the wire clamp groove extends into the second injection cavity 12. After the upper mold core 9 and the lower mold core 10 are fitted together, they cooperate with the mounting block 16 to seal the injection cavity at the position of the wire clamp 7, so that the injection plastic cannot overflow from the connection of the three.

[0080] The upper mold core 9 and the lower mold core 10 are provided with mounting grooves for fastening and connecting the mounting block 16. The mounting groove of the upper mold core 9 is located on one side of the second injection cavity 12 and is interconnected with the second injection cavity 12.

[0081] The wire clamp groove includes a slot for fastening the connecting wire clamp 7. After fastening, one end of the wire clamp 7 extends to the outside of the mounting block 16 and is located in the second injection cavity 12. The radially outer side of the slot is provided with a wire outlet groove for the stator winding lead wire to pass through.

[0082] Based on Example 1, this example defines the structure of the upper mold core 9 and the lower mold core 10. On the one hand, it can cooperate with the support block and the positioning pin 14 to limit the stator core 1 and form an injection cavity for generating the plastic seal layer. On the other hand, it can also install the wire clamp 7 through the mounting block 16, so that the wire clamp 7 is in the plastic seal position during the injection molding process and is fixed as one piece with the second plastic seal layer 202.

[0083] During injection molding, the injection plastic first enters one side of the first injection cavity 11 through the feed port 15. Then, a portion of the injection plastic flows horizontally along the first injection cavity 11 and fills it, while the other portion flows into the two second injection cavities 12 along the third injection cavities 13 on both sides. After entering the second injection cavities 12, the injection plastic can completely fill the second injection cavity 12 to form the second coating layer 202, and it can also flow into the first injection cavity 11, which is away from the area of ​​the feed port 15, through the third injection cavities 13, thereby ensuring the filling effect of the injection plastic on the injection cavity.

[0084] Example 3. A fully encapsulated motor stator, configured as follows: Figure 9 As shown, it includes a stator core 1, on which a stator winding is wound. The two ends of the stator winding extend to the axial outer side of the stator core 1 and form protrusions. The stator core 1 and the stator winding are covered with a plastic sealing layer 2. A mounting piece 3 is fixedly connected to the outside of the plastic sealing layer 2. Several mounting holes 4 for connecting brake discs are distributed around the mounting piece 3. The mounting piece 3 and the plastic sealing layer 2 are connected to each other by a limiting member.

[0085] The limiting component includes a limiting block 5 and a limiting groove 6 that interlock with each other. The limiting block 5 and the limiting groove 6 are respectively disposed on the plastic sealing layer 2 and the mounting piece 3. The limiting block 5 and the limiting groove 6 are used to circumferentially limit the mounting piece 3 after they interlock with each other.

[0086] The mounting piece 3 has an annular first bending portion 301 on its outer side. The first bending portion 301 is engaged with the outer circular surface of the plastic sealing layer 2. The limiting groove 6 is located on one side of the first bending portion 301.

[0087] The limiting block 5 is located on the outer circular surface of the sealing layer 2 and is integrally injection molded with the sealing layer 2.

[0088] The mounting piece 3 has an inwardly recessed step 302 in the middle, and one end of the plastic sealant 2 has a fixing groove 204 that matches the step 302. The mounting piece 3 is fastened and connected in the fixing groove 204 through the step 302 and forms an interference fit with the plastic sealant 2. The step 302 is used to axially limit the mounting piece 3 after fastening, so that the mounting piece 3 and the plastic sealant 2 are fixed to each other.

[0089] The middle part of the stepped portion 302 forms a bearing chamber for placing the ball bearing.

[0090] The mounting piece 3 on the outside of the mounting hole 4 is bent inward to form a second bent portion 303 in the shape of a round tube, and the inner hole of the second bent portion 303 constitutes the mounting hole 4.

[0091] The plastic coating layer 2 includes a first plastic coating layer 201 that is annularly wrapped around the stator core 1 and a second plastic coating layer 202 that is wrapped around the two protrusions. The first plastic coating layer 201 and the second plastic coating layer 202 are connected to each other via a connecting part 203.

[0092] The encapsulation layer 2 forms a mounting plate for mounting the fully encapsulated motor stator at the first encapsulation layer 201, and the mounting plate is located axially on the side of the first encapsulation layer 201 away from the mounting piece 3.

[0093] A wire clamp 7 is connected to one side of the second plastic coating layer 202. The lead wire of the stator winding passes through the wire clamp 7 through the second plastic coating layer 202 and extends to the outside. The wire clamp 7 is used to protect the lead wire during injection molding and to guide the lead wire exit direction. The second plastic coating layer 202 is used to fix the wire clamp 7, the stator core 1 and the stator winding into one piece after plastic coating. One end of the wire clamp 7 extends to the outside of the second plastic coating layer 202 after plastic coating. After the lead wire extends out from the wire clamp 7, the outside is covered with a flexible wire sleeve to achieve wrapping protection.

[0094] The wire clamp 7 includes two separate clamping pieces, each with a wire routing opening. When the two clamping pieces are closed together, they form a wire routing hole for the lead wire to pass through. The two clamping pieces are attached and fixed together after the second plastic coating layer 202 is injection molded.

[0095] The stator core 1 has several grounding holes 101 distributed around its perimeter. Each grounding hole 101 penetrates the stator core 1. The plastic sealing layer 2 has a stepped groove 205 that connects to the grounding holes 101. A grounding terminal 8 is fastened into the stepped groove 205. One end of the grounding terminal 8 is fastened into the grounding hole 101 and forms an interference fit with the grounding hole 101. The grounding terminal 8 is used to electrically connect the grounding wire to the stator core. During installation, one end of the grounding wire is sleeved on the outside of the grounding terminal 8 and, under the squeezing action of the grounding terminal 8, it is in contact with the stator core 1 at the inner end of the stepped groove 205. The other end of the grounding wire extends through the stepped groove 205 to the outside of the stepped groove 205, thus realizing the grounding function.

[0096] Compared with Example 1, this example adjusts the position of the mounting plate on the first plastic coating layer 201 to make it suitable for different motor installation environments.

[0097] Example 4. A fully encapsulated motor stator, configured as follows: Figure 10 As shown, it includes a stator core 1, on which a stator winding is wound. The two ends of the stator winding extend to the axial outer side of the stator core 1 and form protrusions. The stator core 1 and the stator winding are covered with a plastic sealing layer 2. A mounting piece 3 is fixedly connected to the outside of the plastic sealing layer 2. Several mounting holes 4 for connecting brake discs are distributed around the mounting piece 3. The mounting piece 3 and the plastic sealing layer 2 are connected to each other by a limiting member.

[0098] The limiting component includes a limiting block 5 and a limiting groove 6 that interlock with each other. The limiting block 5 and the limiting groove 6 are respectively disposed on the plastic sealing layer 2 and the mounting piece 3. The limiting block 5 and the limiting groove 6 are used to circumferentially limit the mounting piece 3 after they interlock with each other.

[0099] The mounting piece 3 has an annular first bending portion 301 on its outer side. The first bending portion 301 is engaged with the outer circular surface of the plastic sealing layer 2. The limiting groove 6 is located on one side of the first bending portion 301.

[0100] The limiting block 5 is located on the outer circular surface of the sealing layer 2 and is integrally injection molded with the sealing layer 2.

[0101] The mounting piece 3 has an inwardly recessed step 302 in the middle, and one end of the plastic sealant 2 has a fixing groove 204 that matches the step 302. The mounting piece 3 is fastened and connected in the fixing groove 204 through the step 302 and forms an interference fit with the plastic sealant 2. The step 302 is used to axially limit the mounting piece 3 after fastening, so that the mounting piece 3 and the plastic sealant 2 are fixed to each other.

[0102] The middle part of the stepped portion 302 forms a bearing chamber for placing an oil-impregnated bearing.

[0103] The mounting piece 3 on the outside of the mounting hole 4 is bent inward to form a second bent portion 303 in the shape of a round tube, and the inner hole of the second bent portion 303 constitutes the mounting hole 4.

[0104] The plastic coating layer 2 includes a first plastic coating layer 201 that is annularly wrapped around the stator core 1 and a second plastic coating layer 202 that is wrapped around the two protrusions. The first plastic coating layer 201 and the second plastic coating layer 202 are connected to each other via a connecting part 203.

[0105] A wire clamp 7 is connected to one side of the second plastic coating layer 202. The lead wire of the stator winding passes through the wire clamp 7 through the second plastic coating layer 202 and extends to the outside. The wire clamp 7 is used to protect the lead wire during injection molding and to guide the lead wire exit direction. The second plastic coating layer 202 is used to fix the wire clamp 7, the stator core 1 and the stator winding into one piece after plastic coating. One end of the wire clamp 7 extends to the outside of the second plastic coating layer 202 after plastic coating. After the lead wire extends out from the wire clamp 7, the outside is covered with a flexible wire sleeve to achieve wrapping protection.

[0106] The wire clamp 7 includes two separate clamping pieces, each with a wire routing opening. When the two clamping pieces are closed together, they form a wire routing hole for the lead wire to pass through. The two clamping pieces are attached and fixed together after the second plastic coating layer 202 is injection molded.

[0107] The stator core 1 has several grounding holes 101 distributed around its perimeter. Each grounding hole 101 penetrates the stator core 1. The plastic sealing layer 2 has a stepped groove 205 that connects to the grounding holes 101. A grounding terminal 8 is fastened into the stepped groove 205. One end of the grounding terminal 8 is fastened into the grounding hole 101 and forms an interference fit with the grounding hole 101. The grounding terminal 8 is used to electrically connect the grounding wire to the stator core. During installation, one end of the grounding wire is sleeved on the outside of the grounding terminal 8 and, under the squeezing action of the grounding terminal 8, it is in contact with the stator core 1 at the inner end of the stepped groove 205. The other end of the grounding wire extends through the stepped groove 205 to the outside of the stepped groove 205, thus realizing the grounding function.

[0108] The plastic encapsulation layer 2 forms a mounting plate for mounting the fully encapsulated motor stator at the first plastic coating layer 201. The mounting plate is located axially on the side of the first plastic coating layer 201 near the mounting piece 3. The wire clamp 7 and the grounding terminal 8 are both disposed on the mounting plate.

[0109] Compared with Embodiment 1, this embodiment adjusts the structure of the step portion 302 so that it can connect the motor shaft through the cooperation of the bearing housing and the oil-impregnated bearing, thus making it suitable for motor structures based on oil-impregnated bearings.

[0110] Example 5. Fully encapsulated motor stator, configured as follows: Figure 11As shown, it includes a stator core 1, on which a stator winding is wound. The two ends of the stator winding extend to the axial outer side of the stator core 1 and form protrusions. The stator core 1 and the stator winding are covered with a plastic sealing layer 2. A mounting piece 3 is fixedly connected to the outside of the plastic sealing layer 2. Several mounting holes 4 for connecting brake discs are distributed around the mounting piece 3. The mounting piece 3 and the plastic sealing layer 2 are connected to each other by a limiting member.

[0111] The limiting component includes a limiting block 5 and a limiting groove 6 that interlock with each other. The limiting block 5 and the limiting groove 6 are respectively disposed on the plastic sealing layer 2 and the mounting piece 3. The limiting block 5 and the limiting groove 6 are used to circumferentially limit the mounting piece 3 after they interlock with each other.

[0112] The mounting piece 3 has an annular first bending portion 301 on its outer side. The first bending portion 301 is engaged with the outer circular surface of the plastic sealing layer 2. The limiting groove 6 is located on one side of the first bending portion 301.

[0113] The limiting block 5 is located on the outer circular surface of the sealing layer 2 and is integrally injection molded with the sealing layer 2.

[0114] The mounting piece 3 has an inwardly recessed step 302 in the middle, and one end of the plastic sealant 2 has a fixing groove 204 that matches the step 302. The mounting piece 3 is fastened and connected in the fixing groove 204 through the step 302 and forms an interference fit with the plastic sealant 2. The step 302 is used to axially limit the mounting piece 3 after fastening, so that the mounting piece 3 and the plastic sealant 2 are fixed to each other.

[0115] The middle part of the stepped portion 302 forms a bearing chamber for placing an oil-impregnated bearing.

[0116] The mounting piece 3 on the outside of the mounting hole 4 is bent inward to form a second bent portion 303 in the shape of a round tube, and the inner hole of the second bent portion 303 constitutes the mounting hole 4.

[0117] The plastic coating layer 2 includes a first plastic coating layer 201 that is annularly wrapped around the stator core 1 and a second plastic coating layer 202 that is wrapped around the two protrusions. The first plastic coating layer 201 and the second plastic coating layer 202 are connected to each other via a connecting part 203.

[0118] A wire clamp 7 is connected to one side of the second plastic coating layer 202. The lead wire of the stator winding passes through the wire clamp 7 through the second plastic coating layer 202 and extends to the outside. The wire clamp 7 is used to protect the lead wire during injection molding and to guide the lead wire exit direction. The second plastic coating layer 202 is used to fix the wire clamp 7, the stator core 1 and the stator winding into one piece after plastic coating. One end of the wire clamp 7 extends to the outside of the second plastic coating layer 202 after plastic coating. After the lead wire extends out from the wire clamp 7, the outside is covered with a flexible wire sleeve to achieve wrapping protection.

[0119] The wire clamp 7 includes two separate clamping pieces, each with a wire routing opening. When the two clamping pieces are closed together, they form a wire routing hole for the lead wire to pass through. The two clamping pieces are attached and fixed together after the second plastic coating layer 202 is injection molded.

[0120] The stator core 1 has several grounding holes 101 distributed around its perimeter. Each grounding hole 101 penetrates the stator core 1. The plastic sealing layer 2 has a stepped groove 205 that connects to the grounding holes 101. A grounding terminal 8 is fastened into the stepped groove 205. One end of the grounding terminal 8 is fastened into the grounding hole 101 and forms an interference fit with the grounding hole 101. The grounding terminal 8 is used to electrically connect the grounding wire to the stator core. During installation, one end of the grounding wire is sleeved on the outside of the grounding terminal 8 and, under the squeezing action of the grounding terminal 8, it is in contact with the stator core 1 at the inner end of the stepped groove 205. The other end of the grounding wire extends through the stepped groove 205 to the outside of the stepped groove 205, thus realizing the grounding function.

[0121] The plastic encapsulation layer 2 forms a mounting plate for mounting the fully encapsulated motor stator at the first plastic coating layer 201. The mounting plate is located axially on the side of the first plastic coating layer 201 away from the mounting piece 3. The wire clamp 7 is disposed on the mounting plate, and the grounding terminal 8 and the mounting plate are staggered vertically along the axial direction of the motor stator.

[0122] Compared with Example 4, this example adjusts the position of the mounting plate on the first plastic coating layer 201 to make it suitable for different motor installation environments.

Claims

1. A method for producing a fully encapsulated motor stator, characterized in that, Includes the following steps: A. The stator winding is wound into the stator slots of the stator core to obtain stator component a; B. Perform plastic encapsulation on stator component a, so that the injection plastic completely wraps the outside of stator component a and forms a plastic encapsulation layer, to obtain stator component b; C. A mounting hole for connecting the brake disc is made on the surface of the mounting plate, and then the mounting plate is fixedly connected to the stator component b, so that a circumferential limit is formed between the mounting plate and the stator component b, thus obtaining the finished motor stator.

2. The method for producing a fully encapsulated motor stator according to claim 1, characterized in that, Step B specifically includes the following steps: B1. Place and fix stator component a in the injection mold, and form a first injection cavity on the outside of the stator core of stator component a, and form a second injection cavity on the outside of the stator winding of stator component a. The second injection cavity is located on both sides of the first injection cavity along the axial direction, and the first injection cavity and the second injection cavity are interconnected through a third injection cavity. B2. The injection plastic is injected into the first injection cavity from the feed port on the radially outer side of the first injection cavity. After entering the first injection cavity, part of the injection plastic fills the first injection cavity circumferentially, and the other part enters the second injection cavity through the third injection cavity. B3. After the injection molding material enters the second injection cavity, part of it fills the second injection cavity circumferentially, and the other part enters the first injection cavity, which is far away from the feed port area, through the third injection cavity. B4. The injection plastics in the first, second, and third injection cavities are interconnected after curing to form a plastic seal layer, resulting in stator component b.

3. The method for producing a fully encapsulated motor stator according to claim 1, characterized in that: In step B, during the plastic encapsulation process of stator component a, a wire clamp is placed on one side of stator component a, and the lead wire of the stator winding is extended to the outside through the wire clamp; the wire clamp protects and guides the lead wire during the plastic encapsulation process, and the plastic encapsulation layer wraps and fixes the wire clamp after the plastic encapsulation is formed.

4. A fully encapsulated motor stator, characterized in that: The fully encapsulated motor stator is manufactured by the production method of a fully encapsulated motor stator as described in any one of claims 1-3. Specifically, it includes a stator core (1), on which a stator winding is wound. The two ends of the stator winding extend to the axial outer side of the stator core (1) and form protrusions. The stator core (1) and the stator winding are covered with a plastic encapsulation layer (2). A mounting plate (3) is fixedly connected to the outside of the plastic encapsulation layer (2). Several mounting holes (4) for connecting brake discs are distributed around the mounting plate (3). The mounting plate (3) and the plastic encapsulation layer (2) are connected to each other by a limiting member.

5. The fully encapsulated motor stator according to claim 4, characterized in that: The limiting component includes a limiting block (5) and a limiting groove (6) that interlock with each other. The limiting block (5) and the limiting groove (6) are respectively disposed on the plastic sealing layer (2) and the mounting piece (3).

6. The fully encapsulated motor stator according to claim 5, characterized in that: The mounting piece (3) has an annular first bend (301) on its outer side. The first bend (301) is engaged with the outer circular surface of the plastic sealant (2). The limiting groove (6) is located on one side of the first bend (301).

7. The fully encapsulated motor stator according to claim 4, characterized in that: The mounting piece (3) has an inwardly recessed step (302) in the middle, and one end of the plastic sealant (2) has a fixing groove (204) that matches the step (302). The mounting piece (3) is fastened to the fixing groove (204) via the step (302) and forms an interference fit with the plastic sealant (2).

8. The fully encapsulated motor stator according to claim 4, characterized in that: The plastic seal (2) includes a first plastic seal (201) that is annularly wrapped around the stator core (1) and a second plastic seal (202) that is wrapped around the two protrusions. The first plastic seal (201) and the second plastic seal (202) are connected to each other via a connecting part (203).

9. The fully encapsulated motor stator according to claim 8, characterized in that: A wire clamp (7) is connected to one side of the second plastic coating layer (202). The lead wire of the stator winding passes through the wire clamp (7) through the second plastic coating layer (202) and extends to the outside. The second plastic coating layer (202) is used to fix the wire clamp (7) to the stator core (1) and the stator winding after plastic coating.

10. The fully encapsulated motor stator according to claim 4, characterized in that: The stator core (1) has several grounding holes (101) distributed around its perimeter. The plastic sealing layer (2) has a stepped groove (205) that connects to the grounding holes (101). A grounding terminal (8) is fastened and connected in the stepped groove (205). One end of the grounding terminal (8) is fastened and connected in the grounding hole (101) and forms an interference fit with the grounding hole (101). The grounding terminal (8) is used to electrically connect the grounding wire to the stator core.

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