Method for processing stator teeth of a magnetic flux motor, stator disc assembly process and assembly tooling

Abstract

The application discloses a magnetic flux motor stator tooth processing method, a stator disc assembling process and an assembling tool; the application relates to the technical field of axial flux motors; the preset angle of the multi-station slotting jig is used for performing perpendicularity constraint on the processing plane of a workpiece and the main shaft of equipment. The No. 1 / No. 2 slotting jig 6 / 9 adopts a double-V-shaped guide rail design, three-point constraint is formed by using linear contact between the guide rail and the workpiece tooth shoe reference surface, and the translational degree of freedom t y / t z and the rotational degree of freedom r z are eliminated. When the workpiece is processed on one side tooth groove, the positioning groove of one jig in the multi-station slotting jig constrains the translational degree of freedom t y and the rotational degree of freedom r z of the workpiece. The multi-station modular design realizes automatic reference alignment through a geometric self-positioning structure, does not need external parameter calibration, avoids cumulative errors of segmented processing from the design source, and forms a natural unified electromagnetic working plane and angle reference in the processing stage through geometric self-positioning and pressure equalization design, thereby avoiding reference deviation in traditional segmented processing.

Description

Technical Field

[0001] This invention relates to the field of axial flux motor technology, specifically to the design of a permanent magnet yokeless segmented stator processing technology and its assembly tooling, particularly to a flux motor stator tooth processing method, stator disk assembly process and assembly tooling. Background Technology

[0002] The YASA (Yonchless Axial Stator) permanent magnet axial flux motor, with its compact design, excellent power density characteristics, and outstanding torque density, shows significant application prospects in fields such as electric vehicle hub drive systems and aerospace actuators. [1]-[5] These types of motors generally employ a combination of dual rotor disk layout, axial magnetic field path, and fractional slot concentrated winding technology. [3][6] The YASA motor's topology architecture, by abandoning the traditional stator yoke structure and introducing segmented stator modules, achieves an effective increase in torque density and a significant reduction in motor size. [6]-[7] .

[0003] However, the unique yokeless stator structure of the YASA motor is directly exposed to the main magnetic flux loop. [8] Therefore, the stator tooth tip geometry, tooth groove shape, axial positioning accuracy, and three-dimensional spatial positioning accuracy have a decisive influence on the effectiveness of each stator tooth in cutting magnetic flux. [9] Any geometric deviation or spatial position error can cause uneven distribution of stator tooth flux linkage, leading to problems such as increased interphase back EMF deviation and aggravated torque pulsation, ultimately affecting the smoothness of motor operation. [9]-

[12] Torque pulsation, as an undesirable fluctuation component in the motor torque output, arises from the coupled effects of multiple factors, including defects in the motor's geometric structure, non-ideal characteristics of power electronic devices, and imperfections in the digital control system. [2]-[3] .

[0004] In existing manufacturing processes, stator core teeth are mostly produced using a radially stacked, split-processing method, which involves stacking silicon steel laminations of different sizes to construct the stator tooth structure. [1] This method suffers from problems such as a wide variety of lamination specifications and high manufacturing complexity. Furthermore, in actual production, adjacent laminations are prone to confusion, making it difficult to guarantee the consistency of stator core tooth machining and dimensional accuracy. [3] Furthermore, after the stator core teeth have been wound, multiple independent stator core teeth need to be assembled circumferentially to form an integral, yoke-free stator structure. Current assembly processes largely rely on potting supports or manual adjustment for positioning, making it difficult to achieve high consistency in assembly across the radial, axial, and circumferential dimensions simultaneously. [1]-[3][6] .

[0005] Specifically, radial position deviation will lead to differences in the effective working radius of each stator core tooth, causing inconsistent electromagnetic torque output of each tooth, and ultimately exacerbating torque pulsation. [7]-

[10] Axial deviation will directly change the working air gap length. [9] Given that axial flux motors typically employ a very small air gap design, such deviations are extremely sensitive to changes in air gap length and cannot be corrected once assembled and solidified. This can easily induce uneven flux distribution and torque pulsation problems. [9] For example, in the air gap region, the edge flux phenomenon induced by the edge effect of the magnetic field will induce parasitic eddy currents and additional heat, affecting motor efficiency and loss characteristics. Meanwhile, circumferential positional deviations will cause a shift in the spatial phase relationship of the stator windings, thereby increasing cogging torque and torque ripple amplitude.

[11] Therefore, current research is focusing on effectively suppressing torque ripple through innovative methods such as rotor skew optimization and asymmetric stator / rotor structure design. [6] .

[0006] For example, Chinese patents

[12] One approach involves separately molding the stator teeth and fixing them with riveting, then inserting the wound stator teeth into a potting bracket to complete the assembly. In this method, the separate machining and riveting processes are prone to deformation and dimensional deviations, and the assembly stage relies heavily on bracket positioning, making it difficult to ensure the consistency of each stator tooth within the electromagnetic working plane. Another example is a Chinese patent...

[13] The integral disc stator core makes the surface to be processed naturally perpendicular to the equipment, allowing for direct wire cutting and avoiding axial geometric error problems. However, the technical route of segmented processing followed by splicing is characterized by avoiding direct processing difficulties by adding processing and assembly steps, but this introduces the problem of the accumulation of errors from multiple processing and assembly processes, and such errors are difficult to compensate for after assembly and solidification.

[0007] The inventors analyzed that the accumulation of manufacturing and assembly errors remains a key bottleneck restricting the performance improvement of YASA motors, which needs to be further addressed through process optimization and structural design innovation. Therefore, this invention proposes a method for machining stator teeth in a flux motor, a stator disk assembly process, and assembly tooling.

[0008] The cited references for this background technology are as follows:

[0009] [1]Wang X, Zhao X, Gao P, et al. Comparative Study of Yokeless andSegmented Armature Machines With Different Stator Cores for Electric VehicleIn-Wheel Applications [J]. IEEE Transactions on Applied Superconductivity,2024, 34(8): 1–5. [2]Wang G, Wang Y, Gao Y, et al. Thermal Model Approach to the YASAMachine for In-Wheel Traction Applications [J]. Energies, 2022, 15(15): 5431. [3]Kulan M C, Baker N J. Design and Construction of a Fault-TolerantYokeless and Segmented Armature Axial Flux Motor for Aerospace ActuatorApplications [C]. 2025 IEEE International Electric Machines& DrivesConference (IEMDC), 2025: 176–181. [4]Hao Z, Ma Y, Wang P, et al. A Review of Axial-Flux Permanent-Magnet Motors: Topological Structures, Design, Optimization and ControlTechniques [J]. Machines, 2022, 10(12): 1178. [5]Gerlando A D, Foglia G, Ricca C. Analytical Design of a HighTorque Density In-Wheel YASA AFPM Motor [C]. 2020 International Conference onElectrical Machines (ICEM), 2020: 402–408. [6]Weiwei G, Zhuoran Z, Qiang L. High Torque Density Fractional-SlotConcentrated-Winding Axial-Flux Permanent-Magnet Machine with Modular SMCStator [J]. IEEE Transactions on Industry Applications, 2020: 1–1. [7]Woolmer T J, McCulloch M D. Analysis of the Yokeless And SegmentedArmature Machine [C]. 2007 IEEE International Electric Machines& DrivesConference, 2007: 704–708. [8]Chen H, Geng W, Tang C, et al. A New Yokeless Stator StructureWith Low Loss and High Mechanical Strength for AFPM Motor: Design, Analysisand Experimental Verification [J]. IEEE Transactions on IndustrialElectronics, 2025, 72(12): 12208–12218. [9]Jia L, Lin M, Yang A, et al. Analytical Modeling of Stator ModuleMisalignment in YASA Machines [C]. 2023 IEEE International Conference onApplied Superconductivity and Electromagnetic Devices (ASEMD), 2023: 1–2.

[10] Cakal G, Sarlioglu B. Torque Ripple Reduction of Yokeless and Segmented Armature (YASA) Motors by Novel Asymmetric Armature [C]. 2023International Aegean Conference on Electrical Machines and Power Electronics(ACEMP)& 2023 International Conference on Optimization of Electrical andElectronic Equipment (OPTIM), 2023: 1–5.

[11] Wang

[12] School of Mechanical and Electrical Engineering, Guangdong University of Petrochemical Technology. Stator gear machining technology for permanent magnet yokeless segmented stator axial flux motor: CN202510738907.6[P]. 2025-10-10.

[13] Wuxi Deco Optoelectronic Technology Co., Ltd. Combined Raman pump source and Raman amplifier: CN107171169A[P]. 2017-09-15. Summary of the Invention In view of this, the present invention aims to provide a method for machining stator teeth of a flux motor, a stator disk assembly process, and assembly tooling, in order to solve or alleviate the technical problem in the prior art of not being able to lock in the key geometric consistency of stator teeth at the source by forming an integral structure of stator core teeth with a unified datum and overall rigidity during the machining stage and completing the tooth groove machining in this integral state; the technical solution of the present invention is implemented as follows: Firstly, the method for machining stator teeth of a flux motor includes performing a cutting operation on the pre-treated iron core laminations and constraining the perpendicularity between the machining plane of the workpiece and the spindle of the equipment based on the preset angle of the multi-station grooving fixture.

[0010] In one embodiment, the No. 1 / No. 2 grooving fixture 6 / 9 adopts a double V-shaped guide rail design, utilizing the line contact between the guide rail and the workpiece toothed shoe reference surface to form a three-point constraint, eliminating the translational degree of freedom t. y / t z and rotational degrees of freedom r z When machining a toothed groove on one side of a workpiece, in a multi-station grooving fixture, the positioning groove of one fixture constrains the translational degree of freedom t of the workpiece. y and rotational degrees of freedom r z The positioning groove of the other fixture constrains the translational degree of freedom t of the workpiece. z and rotational degrees of freedom r y ; When the workpiece is being machined on the other side of the tooth groove, one fixture releases the translational degree of freedom t. y and t z and rotational degrees of freedom r z and t y After keeping the datum unchanged, the positioning groove of the other fixture re-constrains or maintains the translational degree of freedom t of the workpiece. z and rotational degrees of freedom r y This continues until the tooth grooves on the workpiece are machined. Through the coordinated action of the two fixtures, the rotational degree of freedom r can be further controlled. y The step-by-step constraint strategy uses a "fix first - release then fix again" logic to complete the workpiece flipping while keeping the reference plane position unchanged, thus avoiding repeated positioning errors.

[0011] In one embodiment, in a multi-station grooving fixture, the positioning groove of another fixture constrains the translational degree of freedom t through a positioning pin hole pair. x Furthermore, the "datum" mentioned above refers to the degree of freedom t retained through the locating pin hole pair. x The responsible part is to release the translational degree of freedom t y and t z and rotational degrees of freedom r z and r y The benchmark.

[0012] In one embodiment, the translational degree of freedom t y and rotational degrees of freedom r z The constraint method is formed by a fixture forming a clearance fit with the workpiece through the difference in width between the positioning groove and the workpiece tooth tip, and the inclined surface of the groove wall forming a line constraint with the edge line of the workpiece tooth tip; translational degree of freedom t z and rotational degrees of freedom r y The constraint method is formed by another fixture forming a clearance fit with the workpiece through the width difference of the positioning groove, and the arc surface of the groove wall forming a point constraint with the workpiece.

[0013] In one embodiment, the linear constraint is that the groove slope and the workpiece tooth tip edge are in the same translational degree of freedom t. y Nonlinear constraints on multi-line contact in different directions; point constraints are between the groove inclined surface and the workpiece tooth tip edge in rotational degree of freedom t. y Nonlinear constraints on the direction of the constraint moment gradient. Point constraints are three-point contact constraints where the positioning groove and the workpiece form a clearance fit with a width difference, and the groove wall and the workpiece also form a clearance fit with a width difference.

[0014] In one embodiment, a motion controller performs wire EDM tooth cutting on a workpiece; the motion controller includes a closed-loop control system and performs machining path compensation during the wire EDM operation.

[0015] Secondly, the stator disk assembly process for the stator teeth of the flux motor includes the following steps: S1. Fix the stator teeth to the contact surface of the bracket; S2. Align the workpiece tooth shoe datum surface with the stator tooth assembly positioning fixture datum surface; the alignment method lies in constraints, including: Axial constraint is used to hold the stator tooth clamping block in place until they form the same electromagnetic working plane. Radial constraint is used to control the clearance between the radial skeleton of the stator gear fixing bracket and the side of the workpiece. Circumferential constraint aims to arrange workpieces at a predetermined angle along the circumference.

[0016] S3. Perform potting molding and curing on the workpiece; S4. Demold and obtain the finished product.

[0017] In one embodiment, the electromagnetic working plane is formed by pressing the workpiece to the same axial reference plane using stator tooth pressure blocks; The gap between the radial frame of the fixed bracket and the side of the workpiece is constrained by the stator gear assembly positioning fixture, which controls the translational degree of freedom t. y And the radial support constrained rotational degree of freedom r formed by the adhesive after potting and curing. y The formed; The translational degree of freedom t is constrained by the circumferential positioning surface of the multi-station grooving fixture. x Furthermore, the bracket fixing block is secured to the bracket base by bolts, which tighten the stator teeth, thus constraining the rotational degree of freedom r. x This allows the workpieces to be arranged at a predetermined angle along the circumference.

[0018] Thirdly, the assembly tooling for the stator teeth of the flux motor includes, A multi-station grooving fixture for axial, radial, and circumferential positioning of workpieces; Support fixing blocks to prevent relative displacement during assembly and molding processes; Stator tooth pressure block for controlling the tooth tip height difference; Stator gear fixing bracket for mounting the above-mentioned device.

[0019] Compared with the prior art, the mechanism by which this invention overcomes the defects of traditional technical solutions lies in: 1. The multi-station fixture's line contact, multi-point contact, and tooth profile matching structure utilize the workpiece's own geometric features to achieve automatic positioning without external parameter calibration, locking the processing datum from the design source; the involute curved surface design of the stator tooth pressure block ensures that the clamping force is evenly transmitted to all stator teeth through the principle of pressure distribution self-balancing, avoiding geometric inconsistencies caused by local deformation; the U-shaped groove structure of the bracket radial skeleton and the adhesive layer form an elastic-rigid composite support, which not only ensures positioning accuracy but also suppresses running vibration through elastic buffering, improving overall rigidity; the sawtooth texture and trapezoidal locking structure of the bracket fixing block form an anti-loosening mechanism through mechanical interlocking, ensuring no relative displacement during assembly and forming, and maintaining the overall structural rigidity; II. In terms of details, axial constraint is achieved through the wedge-shaped clamping surface design of the stator tooth clamping block. The contact surface between the clamping block and the workpiece adopts an involute curved surface, and the pressure distribution is automatically homogenized during the clamping process, ensuring that all stator teeth synchronously form the same electromagnetic working plane during the clamping process, avoiding geometric deformation caused by local stress concentration. Radial constraint is achieved through the U-shaped groove structure of the radial skeleton of the bracket and the clearance fit with the side of the workpiece. The opening design of the U-shaped groove allows the adhesive to fill naturally, forming an elastic support layer after curing. This ensures radial positioning accuracy and suppresses running vibration through the elastic buffer of the adhesive layer. Circumferential constraint is achieved through the trapezoidal locking structure of the bracket fixing block. The locking surface adopts a sawtooth texture design, which increases the friction coefficient and forms a mechanical fit. Combined with the preload of the bolts, it forms an anti-loosening mechanism, ensuring no relative displacement during assembly and molding.

[0020] Compared with the prior art, the beneficial effects of the present invention are: the multi-station modular design achieves automatic reference alignment through a geometric self-positioning structure, eliminating the need for external parameter calibration and avoiding the cumulative error of segmented processing from the design source; through geometric self-positioning and pressure equalization design, a naturally unified electromagnetic working plane and angular reference are formed in the processing stage, avoiding the reference offset of traditional segmented processing. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the stator core tooth welding fixture structure of the present invention. The left half of the figure is shown as an exploded view. Figure 2 This is a schematic diagram of the pre-processed stator core lamination structure of the present invention; Figure 3 The present invention is illustrated in part (A) as a fixture structure and part (B) as a schematic diagram of another fixture structure. Figure 4 This is a schematic diagram of the stator core teeth side slotting process of the present invention; Figure 5 This is a schematic diagram of the machining process for opening a slot on the other side of the stator core teeth according to the present invention; Figure 6 This is a schematic diagram of the final structure of the stator core teeth of the present invention; Figure 7 This is an exploded view of the stator core gear assembly tooling structure of the present invention; Figure 8 This is a schematic diagram of the stator core gear assembly tooling structure of the present invention; Figure 9 A three-dimensional surface diagram illustrating the influence of axial dimensional deviation (±0.02mm) and radial position deviation (±0.01mm) on torque pulsation (%) in this invention. Figure 10 A schematic heatmap illustrating the combined effect of temperature (-40℃~180℃) and vibration frequency (0~200Hz) on torque density improvement rate (%) in this invention; Figure 11 This is a schematic diagram of the relationship between several nonlinear parameters in a preferred embodiment of the present invention; Figure 12 This is a schematic diagram of several nonlinear parameter relationships in another preferred embodiment of the present invention; Figure 13 This is a schematic diagram of the relationship between several nonlinear parameters in Embodiment 3 of the present invention; Figure 14 This is a schematic diagram of the parameters under a preferred embodiment of the present invention; Figure 15 This is a schematic diagram of the parameters under another preferred embodiment of the present invention; Figure 16 This is a schematic diagram of the relationship between several nonlinear parameters in Embodiment 4 of the present invention; Figure 17 This is a schematic diagram of the parameters under a preferred embodiment of the present invention (V). Figure 18 This is a schematic diagram of the parameters under another preferred embodiment of the present invention; Figure 19 This is a schematic diagram of the relationship between several nonlinear parameters in Embodiment Six of the present invention; Figure 20 This is a schematic diagram of the finite element simulation of stator gear assembly with multi-line contact constraints in an application example of the present invention; Figure 21 This is a schematic diagram of the stator gear assembly effect in a finite element simulation of an application example of the present invention; Figure 22 This is a finite element simulation diagram of the stator core gear assembly tooling in an application example of the present invention.

[0023] Figure reference numerals: 1. Stator core lamination welding groove; 2. Pressing block fastening bolt; 3. Fixing bolt; 4. Roughly machined stator core; 5. Pressing block; 6. No. 1 slotting jig; 7. Unslotted stator core tooth; 8. One-side slotted stator core tooth; 9. No. 2 slotting jig; 10. Slotted stator core tooth; 11. Glue-filling jig; 12. Support base; 13. Stator tooth fixing bracket; 14. Stator core tooth after winding; 15. Stator tooth pressing block; 16. Support fixing block. Detailed Implementation

[0024] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0025] Explanation of relevant terms: (1) Preset angle: The angle parameters are set in advance when designing the slotting fixture to ensure that the No. 1 / No. 2 fixture is perpendicular to the spindle movement direction of the wire EDM machine, so that the plane to be processed and the movement direction of the equipment are kept at 90° when the tooth grooves on both sides of the stator core are processed, thus eliminating axial geometric error.

[0026] (2) Perpendicularity constraint: The mechanical limiting structure of the slotted jig achieves the perpendicular relationship between the plane to be processed of the stator core teeth and the spindle of the processing equipment, avoiding uneven magnetic flux distribution caused by processing posture deviation.

[0027] (3) Motion controller: Closed-loop control of the wire cutting machine's motion trajectory, performing processing path compensation (such as 0.1mm precision control of tooth groove depth) to ensure consistent tooth groove processing.

[0028] (4) Benchmark: (4.1) Machining reference: Preset angle of the iron core lamination welding groove and the slotting jig; (4.2) Assembly reference: The reference surface of the stator tooth assembly positioning jig is used to uniformly position each stator core tooth.

[0029] (5) Positioning pin hole pair: The bracket and stator gear assembly positioning fixture achieves radial / circumferential precise positioning through pin hole cooperation, with assembly deviation ≤0.01mm.

[0030] (6) Point constraint & (7) Line constraint: The stator tooth pressure block presses the tooth shoe reference surface through point contact, constraining axial translation; the slotted jig ensures that the plane to be processed is perpendicular through line contact, forming multi-line contact to enhance stability.

[0031] (8) Translational degree of freedom t y t z &(9) Rotational degrees of freedom r z t y Degrees of freedom refer to the number of independent motion parameters required for a mechanism in a mechanical system to produce definite motion. Their specific definition and parametric design are equivalent to the concept of mechanical degrees of freedom and its specific definition and calculation formula in this field. In this scheme, the slotting fixture prevents displacement or rotational deviation of the stator core teeth during processing by constraining the translational and rotational degrees of freedom of the Y / Z axes. The X, Y, and Z axes are all determined based on the Cartesian coordinate system.

[0032] (10) Multiple line contact: Multiple line contact points are distributed between the jig and the stator core teeth, which improves the constraint stiffness and suppresses processing / assembly vibration.

[0033] (11) Constraint torque gradient: The torque gradient distribution of the fixture ensures constraint stability (such as control of the uniformity of the pressure of the pressing block).

[0034] (12) Workpiece tooth shoe reference surface: The stator tooth shoe end face serves as a machining / assembly reference surface to ensure consistency of tooth groove depth and axial position.

[0035] (13) Positioning fixture reference surface: The reference surface of the assembly fixture is used to align the workpiece tooth shoe reference surface to form a unified electromagnetic working plane.

[0036] (14) Electromagnetic working plane: By constraining the axial position of each tooth by the stator tooth pressure block, all stator core teeth are in the same plane, ensuring uniform magnetic flux distribution and reducing torque pulsation.

[0037] (15) Axial: Along the motor axis, the axial dimension deviation of the stator teeth (±0.02mm) and the uniformity of the air gap need to be controlled.

[0038] (16) Radial: Perpendicular to the axis direction, the radial position of the stator teeth needs to be constrained to ensure that it is consistent with the air gap of the rotor.

[0039] (17) Circumferential: Around the axis, the circumferential arrangement angle of the stator teeth needs to be controlled to avoid increasing the tooth cogging torque.

[0040] (18) Constraints: By restricting the degree of freedom of related workpieces through mechanical structures (such as jigs and pressure blocks), the machining / assembly accuracy is ensured, and a stable electromagnetic working plane is ultimately formed to improve the smoothness of motor operation.

[0041] Example 1. In traditional processes, stator teeth require pre-machining of the tooth grooves before assembly, which can easily lead to accumulated errors. Please refer to... Figures 1-8 This embodiment discloses a method for machining stator teeth of a flux motor.

[0042] In this embodiment, the core laminations need to undergo pre-processing, including: P1. A five-axis linkage CNC wire cutting machine is used to perform precision machining on the silicon steel laminations. A U-shaped welding groove structure with a width of 0.5mm and a depth of 1.2mm is reserved in the stator core lamination welding groove 1 area. P2. Transfer the processed stacked wafers to an ultrasonic cleaner for 30 minutes of degreasing, and weigh them in groups using an electronic scale with an accuracy of 0.001g to ensure that the total weight deviation of each group of stacked wafers is ≤0.05g. P3. After grouping, use a welding jig with V-shaped positioning grooves to perform three-dimensional positioning of the stacked pieces, and achieve precise radial / circumferential alignment through the positioning pin holes embedded in the jig. P4. A fiber laser welding machine with a power of 1200W and a speed of 0.2m / min is used to complete the lamination laser welding to form a pretreated iron core lamination structure.

[0043] Specifically, after the pre-processed core laminations are welded and formed, the rough-machined stator core 4 is placed into the first slotting fixture 6. The perpendicularity of the machining plane to the wire EDM spindle is calibrated using the built-in laser alignment system of the fixture, ensuring a deviation of ≤0.01mm. The first tooth groove machining is then performed, forming the slotted stator core tooth 8. After completing the first side machining, the workpiece is transferred to the second slotting fixture 9. The machining plane is flipped using the fixture's preset 180° complementary angle, and the perpendicularity is calibrated again to complete the second side tooth groove machining, ultimately forming the slotted stator core tooth 10. Throughout the cutting process, a motion controller monitors the spindle vibration in real time and dynamically adjusts the cutting parameters to maintain perpendicularity constraints.

[0044] Furthermore, the No. 1 / No. 2 grooving fixture 6 / 9 adopts a double V-shaped guide rail design, utilizing the line contact between the guide rail and the workpiece toothed shoe datum surface to form a three-point constraint, eliminating the translational degree of freedom t. y / t z and rotational degrees of freedom r z The preset angle is precisely set via an angle dial on the fixture body, forming a closed-loop control system combined with optical feedback from the laser alignment system.

[0045] Example 2. Based on the previous examples, this example further provides a specific implementation scheme for constraining the degrees of freedom of the workpiece toothed shoes using the No. 1 / No. 2 grooving fixture 6 / 9.

[0046] During stator gear machining, both slotting fixture 6 (No. 1) and slotting fixture 9 (No. 2) employ a double V-shaped guide rail structure, forming a three-point constraint system through the line contact between the guide rails and the workpiece gear shoe datum surface 13. Specifically, when machining one side of the gear groove, the positioning groove of fixture 6 constrains the translational degree of freedom t through the V-shaped guide rails. y and rotational degrees of freedom r z Meanwhile, the positioning groove of the second fixture 9 constrains the translational degree of freedom t. z and rotational degrees of freedom r y This enables three-dimensional spatial positioning. After processing on one side is completed, the system automatically releases the t. y t z r z and t y Degrees of freedom, keeping the position of datum plane 13 unchanged, and re-constraining t of jig 9 in position 2. z and r y The workpiece is rotated 180° by a motion controller to complete the machining of the other side of the tooth groove in the second fixture 9, ultimately forming the slotted stator core tooth 10. The entire process uses a laser alignment system to monitor the perpendicularity in real time and dynamically adjust the cutting parameters to maintain a perpendicularity deviation of ±0.01mm.

[0047] Specifically, the double V-shaped guide rail, through a 60° included angle design, forms three line contact zones at the workpiece toothed shoe datum plane 13. According to the spatial geometric constraint theory, the three-point constraint can eliminate three degrees of freedom (t). y t z r z Furthermore, through the synergistic effect of the two fixtures, the rotational degree of freedom r can be further controlled. y The step-by-step constraint strategy, through a "fix first - release then fix again" logic, completes the workpiece flipping while keeping the position of datum plane 13 unchanged, avoiding repeated positioning errors. Perpendicularity control directly affects the machining accuracy of the tooth grooves—when the perpendicularity deviation exceeds 0.02mm, the difference in the distribution of magnetic flux at the tooth tip will increase by 30%, leading to a 15% increase in torque pulsation. Therefore, this design uses closed-loop control to strictly control the perpendicularity deviation within 0.01mm.

[0048] Understandably, from an application perspective, the three-point constraint and step-by-step control strategy of the double V-shaped guide rails controls the axial dimension deviation of the stator core tooth 10's tooth groove machining to within ±0.01mm and the radial position deviation to ≤0.005mm, providing a nanometer-level precision foundation for the uniformity of the electromagnetic working plane. Precise degree-of-freedom control and perpendicularity assurance reduce motor torque ripple to below 1.5%, improving operational stability by 40% compared to traditional processes. Simultaneously, by maintaining the position of the reference plane 13 unchanged, cumulative errors caused by repeated positioning are avoided, ultimately achieving the core goal of increasing YASA motor torque density by 20%. Just as... Figures 9-10 As shown, the curved surface exhibits nonlinear decay characteristics, forming a minimum pulsation region (<1.5%) near zero deviation, with the pulsation increasing exponentially as the deviation increases. The torque density in the high-temperature region first increases and then decreases, reaching a peak increase of 22% at a vibration frequency of 200Hz.

[0049] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: a double V-shaped guide rail system is adopted using a first slotting jig 6 and a second slotting jig 9. The first jig constrains the translational degree of freedom t through a 90° included angle guide rail. y and rotational degrees of freedom r z The workpiece is initially positioned by applying 50N axial pressure with the pressure block 5; the second fixture constrains the translational degree of freedom t through the vertical guide rail. z and rotational degrees of freedom r y The stator tooth clamping block 15 applies 60N of pressure to complete secondary positioning. When machining one side of the tooth groove, the wire EDM machine feeds along the guide rail at a speed of 100mm / min; after machining is completed, the pressure is released. y / t z / r z / r yThe workpiece tooth shoe reference surface 13 is kept unchanged by using a laser centering system, and then transferred to the second fixture to reconstrain the tz / ry degree of freedom for processing on the other side, ultimately forming the slotted stator core tooth 10.

[0050] Understandably, the three-point contact mechanism of the double V-shaped guide rail in this scheme is based on the theory of spatial geometric constraints—the 90° included angle guide rail forms three constraint points through line contact, corresponding to t respectively. y t z r z Degrees of freedom. The locating pin hole pair serves as an auxiliary locating element, achieving t through a hole-pin clearance fit (clearance ≤ 0.01mm). x Secondary constraints on degrees of freedom. When releasing degrees of freedom, a hydraulic buffer device ensures a smooth transition, preventing displacement of the datum plane 13. This design controls the axial deviation of the tooth groove machining to ±0.01mm, improving accuracy by 3 times compared to traditional processes. The dual-station fixture's collaborative constraint achieves 98% consistency in tooth groove depth and ≤2% difference in magnetic flux distribution, directly reducing torque pulsation by 15%. As... Figure 11 As shown, the nonlinear mapping between the upper left hole-pin clearance (0.005-0.015mm) and axial deviation forms a minimum deviation inflection point (0.005mm) at a clearance of 0.01mm. The upper right shows a nonlinear relationship between hydraulic buffer pressure (0.1-0.5MPa) and torque pulsation. The broken line exhibits exponential decay superimposed sinusoidal fluctuation characteristics. The lower left shows a nonlinear relationship between temperature (-20℃~120℃) and magnetic flux distribution differences. The scatter plot shows a U-shaped distribution, with the smallest magnetic flux difference (≤2%) at the center temperature of 50℃. The lower right shows a nonlinear relationship between vibration frequency (0-300Hz) and tooth groove depth consistency. The broken line exhibits quadratic function superimposed sinusoidal fluctuation characteristics, with 98% consistency at a frequency of 150Hz.

[0051] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: a positioning pin hole system is integrated into the No. 1 / No. 2 slotting fixture 6 / 9. The No. 1 fixture is constrained by double V-shaped guide rails. y / r z At the same time, the locating pin hole pair is used to constrain t. x Degrees of freedom (pin hole clearance 0.008mm); Fixture No. 2 is constrained by the vertical guide rail. z / r y The positioning is reinforced by locating pin holes. When machining one side, pressure block 5 applies 55N of pressure, and the wire cutting speed is 120mm / min; after machining is completed, the pressure block is released. x / t y / r z Degrees of freedom, maintaining the position of the toothed shoe reference plane 13, transfer to the second fixture and re-constrain t z / r yWith the degree of freedom, the stator tooth pressure block 15 applies 65N pressure to complete the machining on the other side.

[0052] Understandably, the positioning pin-hole pair in this scheme achieves secondary constraint through a "hole-pin" interference fit. Its design follows the principle of "over-positioning compensation"—when the primary positioning (V-shaped guide rail) undergoes slight deformation, the pin-hole pair absorbs the error through elastic deformation, maintaining the stability of the datum plane 13. When releasing the degree of freedom, a pneumatic ejection device is used to achieve rapid separation of the pin and hole, avoiding mechanical damage. This scheme controls the tooth tip height deviation to ±0.008mm, improving accuracy by 20% compared to the basic scheme. As... Figure 12 As shown, the nonlinear mapping between the upper left interference (0.002-0.015mm) and the tooth tip height deviation forms the minimum deviation inflection point (0.003mm) at an interference of 0.008mm. The nonlinear relationship between the upper right temperature (-20℃~120℃) and the stability of the reference surface exhibits a quadratic function superimposed with sinusoidal fluctuations, with stability reaching its peak (100%) at the center temperature of 50℃. The nonlinear relationship between the lower left vibration frequency (0-300Hz) and accuracy improvement exhibits an exponential decay superimposed with sinusoidal fluctuations, with accuracy improvement reaching 20% ​​at 150Hz. The nonlinear relationship between the lower right humidity (30%~90%) and pneumatic ejection efficiency exhibits a quadratic function superimposed with cosine fluctuations, with the highest efficiency (95%) at 60% humidity.

[0053] Example 3. Based on the previous examples, this example further provides a specific constraint scheme for the positioning groove of another fixture in a multi-station grooving fixture system. In the multi-station grooving fixture system, the second grooving fixture 9 achieves precise constraint of the translational degree of freedom tx through a locating pin hole pair.

[0054] In practice, a 0.8mm diameter positioning hole is pre-set on the stator core gear workpiece to form an interference fit (fit clearance ≤ 0.005mm) with a φ0.8mm positioning pin on the fixture. When machining one side of the tooth groove, fixture 6 is constrained by double V-shaped guide rails. y / r z The system has multiple degrees of freedom, including the tx degree of freedom constrained by the positioning pin hole pair; after machining, the t is released by a mechanical jacking device (e.g., a hydraulic jack). y / t z / r z / t y Degrees of freedom, but the locating pin hole pair retains t x Degrees of freedom constraints ensure that the positional deviation of the workpiece toothed shoe datum surface 13 is ≤0.003mm. After transferring to jig number 2 9, the locating pin hole pair continues to be constrained. x Degrees of freedom, combined with stator tooth clamping block 15 applying 65N pressure constraint t z / r y With a degree of freedom, complete the machining of the tooth groove on the other side.

[0055] Understandably, this design is based on the collaborative positioning principle of "primary constraint + secondary constraint". The positioning pin-hole pair achieves t through hole-pin geometric constraints. x The precise control of the degrees of freedom is achieved through a "over-positioning compensation" mechanism. When the main positioning (double V-shaped guide rail) undergoes slight deformation, the pin hole pair absorbs the error through elastic deformation, maintaining the stability of the reference surface 13. During the release of the degrees of freedom, a closed-loop control system monitors the displacement of the reference surface 13 and dynamically adjusts the hydraulic jacking force to ensure that the positional deviation during release is ≤0.002mm. This mechanism controls the tooth tip height deviation to ±0.006mm, improving accuracy by 30% compared to traditional processes. As... Figure 13 As shown, the nonlinear mapping between the upper left interference (0.003-0.012mm) and the tooth tip height deviation forms the minimum deviation inflection point (0.002mm) at the 0.007mm interference. The nonlinear relationship between the upper right temperature (-40℃~150℃) and the stability of the reference surface exhibits a quadratic function superimposed with a sinusoidal fluctuation characteristic, with the stability reaching its peak (100%) at the 50℃ center temperature. The nonlinear relationship between the lower left vibration frequency (0-300Hz) and the accuracy improvement exhibits an exponential decay superimposed with a sinusoidal fluctuation characteristic, with the accuracy improvement reaching 30% at the 150Hz frequency. The nonlinear relationship between the lower right humidity (30%~90%) and the hydraulic ejection efficiency exhibits a quadratic function superimposed with a cosine fluctuation characteristic, with the highest efficiency (98%) at 60% humidity.

[0056] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: a cooperative constraint mechanism of locating pin hole pair and double V-shaped guide rails is adopted. The locating pin hole pair constrains t through the interference fit (fit clearance ≤ 0.003mm) between the φ0.8mm tapered pin and the stator core tooth hole. x Degrees of freedom, combined with double V-shaped guide rail constraints t y / r z Degrees of freedom. When machining one side of the tooth groove, the pressure block 5 applies a pressure of 50N to ensure the stability of the iron core laminations; after machining is completed, the hydraulic ejection device releases the pressure. y / t z / r z / r y Degrees of freedom, but t is maintained by the locating pin hole pair. x With freedom constraints, the positional deviation of datum plane 13 is ≤0.002mm. After transfer to slotting jig 9, stator tooth clamping block 15 applies a 100N pressure constraint. z / r y The other side is processed with a degree of freedom. Epoxy resin is used for potting, with a pressure of 0.2 MPa and a curing time of 24 hours.

[0057] In this scheme, the tapered pin enhances t through its self-locking effect. xDirectional constraint stability, double V-shaped guide rails through line contact constraint t y / r z The degree of freedom, with its 90° V-shaped included angle design, ensures a three-point constraint mechanism. The hydraulic ejection device dynamically adjusts the ejection force when releasing the degree of freedom, ensuring a positional deviation ≤0.002mm. This design controls the axial deviation of the gear groove machining to ±0.006mm, and the magnetic flux distribution difference to ≤1.2%. As... Figure 14 As shown, under the combined influence of the upper left taper angle (1°~5°) and hydraulic jacking force (0.002~0.01N) on the axial deviation (±0.006mm), the curved surface exhibits a nonlinear decay characteristic, forming a minimum deviation zone at a 3° taper angle and a 0.006N jacking force; the upper right V-shaped angle (85°~95°) and the nonlinear relationship between the magnetic flux distribution difference (≤1.2%) show a minimum difference inflection point at a 90° angle; the lower left hydraulic jacking force (50~200N) and the position deviation (≤0.002mm) control effect show an exponential decay characteristic, with the deviation stabilizing below 0.002mm after the jacking force exceeds 100N; the lower right temperature (-20℃~120℃) and vibration frequency (0~300Hz) combined influence on the accuracy improvement (%) shows an accuracy improvement of up to 30% in the low temperature and low frequency range, and a decay to 15% in the high temperature and high frequency range.

[0058] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: the locating pin hole pair is constrained by a φ0.75mm cylindrical pin mating with the hole (clearance 0.004mm). x Degrees of freedom, double V-shaped guide rails coated with wear-resistant coating, constraint t y / r z Degrees of freedom. During processing on one side, pressure block 5 applies 80N; after processing is complete, the pneumatic ejector releases pressure. y / t z / r z / r y Degrees of freedom, but maintained by magnetic attraction. x The degree of freedom is constrained, and the position deviation of the datum plane 13 is ≤0.0015mm. After being transferred to the second fixture, the stator tooth clamping block 15 is subjected to a pressure constraint of 150N. z / r y It offers a degree of freedom, uses polyurethane for potting, has an adjustable pressure of 0.15-0.25MPa, and a curing time of 30 minutes.

[0059] In this design, the magnetic adsorption plate generates a 0.3T magnetic field in region 13 of the reference plane, enhancing positioning stability. The wear-resistant coating of the double V-shaped guide rails reduces wear over long-term use, and the elastic support elements compensate for machining errors. This design improves positioning accuracy to ±0.002mm, and the axial deviation of the tooth groove machining is ≤0.005mm. As... Figure 15As shown, the combined effect of the magnetic field strength (0.1-0.5T) and tooth groove axial deviation (0.001-0.005mm) on the positioning accuracy (±0.002mm) of the upper left three-dimensional curved surface forms the minimum accuracy zone at the 0.3T magnetic field and 0.002mm tooth groove deviation. The nonlinear relationship between the wear-resistant coating thickness (0.05-0.3mm) and wear amount (mm) in the upper right shows an exponential decay characteristic, and the wear amount stabilizes below 0.1mm after the coating thickness exceeds 0.2mm. The relationship between the elastic support stiffness (100-500N / mm) and machining error compensation (mm) in the lower left shows a nonlinear growth characteristic, and the compensation ability approaches 0.005mm after the stiffness exceeds 300N / mm. The combined effect of temperature (-20℃~120℃) and vibration frequency (0-300Hz) on the positioning accuracy in the lower right shows that the positioning accuracy reaches 0.002mm in the low temperature and low frequency zone, and decays to 0.005mm in the high temperature and high frequency zone.

[0060] Example 4. This example, based on the previous examples, further provides a translational degree of freedom t. y and rotational degrees of freedom r z The constraint method is as follows: The No. 1 grooving fixture 6 forms a clearance fit with the workpiece tooth tip width difference (groove width is 0.2mm wider than tooth tip width) through the positioning groove. The inclined surface of the groove wall forms a multi-line contact constraint with the tooth tip edge at a 15° angle, realizing the translational degree of freedom t. y and rotational degrees of freedom r z The constraints are as follows: In specific implementation, the wire EDM machine feeds along the guide rail at a speed of 15mm / min, and the pressure block 5 applies a pressure of 60N to ensure the stability of the stacked iron core sheets. The No. 2 grooving fixture 9 forms a clearance fit through the difference in the width of the positioning groove (groove width is 0.3mm wider than tooth tip width), and the arc surface of the groove wall forms a three-point contact constraint with the workpiece with a curvature of R5mm, realizing the translational degree of freedom t. z and rotational degrees of freedom r y Constraints. Stator tooth clamping block 15 applies 120N pressure to ensure assembly stability. Epoxy resin is used for potting at a pressure of 0.18MPa and a curing time of 24 hours.

[0061] In this embodiment, the solution is based on the geometric constraint theory of "multi-line contact + three-point constraint". The 15° angle design of the No. 1 fixture's inclined surface forms a nonlinear constraint through multi-line contact, enhancing the t y / r z Stability of degrees of freedom: The R5mm curvature of the No. 2 jig's arc surface is constrained by three-point contact to achieve local high-pressure constraint, ensuring precise control of the tz / ry degrees of freedom. The clearance fit tolerance range (0.2-0.3mm) was determined through experimental optimization, ensuring both assembly flexibility and avoiding excessive looseness. Line constraint suppresses vibration through multi-line contact between the inclined surface and the edge, while point constraint achieves precise positioning through three-point contact on the arc surface, together controlling the axial deviation of the tooth groove machining within ±0.007mm.

[0062] Understandably, in this solution, the synergistic effect of multi-line contact and three-point constraint ensures a tooth tip height deviation of ≤0.008mm and a magnetic flux distribution difference of ≤1.3%, improving accuracy by 20% compared to traditional processes. Furthermore, optimized clearance tolerances reduce assembly stress, line constraints suppress machining vibration, and point constraints ensure positioning accuracy, collectively reducing torque pulsation by 18%. The adjustable pressure parameters of the pressure block (60-120N) adapt to different thicknesses of iron core laminations, combined with a wire cutting speed of 15mm / min, achieving a balance between processing efficiency and accuracy, meeting the stringent requirements of YASA motors for high torque density and low torque pulsation. As... Figure 16 As shown, the combined effect of wire cutting speed (5-25 mm / min) and tooth tip deviation (0.006-0.01 mm) on machining efficiency (%) on the upper left three-dimensional curved surface forms the efficiency peak area at a speed of 15 mm / min and a deviation of 0.008 mm; the effect of pressure block pressure (60-120 N) on tooth tip deviation (blue) and magnetic flux difference (red) on the upper right shows that the tooth tip deviation reaches 0.008 mm and the magnetic flux difference reaches 1.3% at a pressure of 90 N; the effect of clearance fit tolerance (0.005-0.02 mm) on assembly stress (green) and torque pulsation (purple) on the lower left shows a non-linear inverse trend, with stress surging and pulsation dropping sharply after the tolerance exceeds 0.01 mm; the combined effect of temperature (-20℃~120℃) and vibration frequency (0-300 Hz) on torque pulsation (%) on the lower right shows that the pulsation is lowest in the low temperature and low frequency region (18%), and rises to 20% in the high temperature and high frequency region.

[0063] Example 5. Based on the previous examples, this example further provides specific preferred solutions for line constraints and point constraints. During stator gear machining, the groove slope of the first grooving fixture 6 forms a multi-line contact constraint with the workpiece tooth tip edge at an angle of α=15°, achieving translational degree of freedom t. y Nonlinear linear constraint in direction. In specific implementation, the wire cutting speed is adjusted to 12mm / min by the motion controller, and 55N pressure is applied by the pressure block 5 to ensure the stability of the iron core laminations. The groove wall arc surface of the second grooving fixture 9 forms a three-point contact constraint with the workpiece with a curvature of R3mm, realizing the rotational degree of freedom t. y The constraint torque gradient is nonlinear, constrained at points. The positioning groove and the workpiece tooth tip form a clearance fit with a width difference of 0.25mm. The groove wall surface and the workpiece form three-point contact. The stator tooth pressure block 15 applies 110N pressure to ensure assembly stability. High-performance polyurethane is used for potting at a pressure of 0.22MPa and a curing time of 28 hours.

[0064] It is understandable that the 15° inclined surface of the No. 1 tire forms a t through multi-line contact. y The directional nonlinear constraint, whose contact stiffness changes nonlinearly with displacement, effectively suppresses translational vibration; the R3mm arc surface of the No. 2 jig forms a t through three-point contact.y The directional constraint torque gradient is nonlinearly constrained, with the torque gradient increasing nonlinearly with the rotation angle, enhancing rotational stability. The clearance fit tolerance of 0.25mm was determined through experimental optimization, balancing assembly flexibility and positioning accuracy. Multi-line contact suppression... y Directional translation error, three-point contact control t y The rotational error, together with the axial deviation of the tooth groove machining, controls the deviation within ±0.006mm.

[0065] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: adopting a 15° groove inclined plane angle design, and forming translational degree of freedom t through multi-line contact. y Nonlinear line constraint in direction. In specific implementation, the wire EDM machine feeds at a speed of 10mm / min, and pressure block 5 applies 50N of pressure to ensure the stability of the stacked iron cores. The positioning groove and the workpiece tooth tip form a clearance fit with a width difference of 0.2mm. The inclined surface of the groove wall and the tooth tip edge form three contact lines, achieving t y Translational constraint. Epoxy resin is used for potting, with a pressure of 0.18 MPa and a curing time of 24 hours. The 15° groove slope forms a non-linear constraint through multi-line contact; the contact stiffness increases non-linearly with displacement, effectively suppressing translational vibration. The clearance fit tolerance of 0.2 mm was determined through experimental optimization, balancing assembly flexibility and positioning accuracy. Multi-line contact will... y The directional translation deviation is controlled within ±0.005mm, improving accuracy by 30% compared to traditional processes. Just as... Figure 17 As shown, the combined effect of the angle (10°~20°) and displacement (0.01~0.1mm) of the upper left groove slope on the contact stiffness (N / mm) forms a peak stiffness region at a 15° angle and a 0.05mm displacement, with the contact stiffness exhibiting a nonlinear growth characteristic with displacement. The nonlinear relationship between the upper right displacement (0.01~0.1mm) and contact stiffness shows an exponential growth trend, with stiffness increasing sharply after the displacement exceeds 0.05mm. The effect of the clearance fit tolerance (0.1~0.3mm) on the assembly flexibility (green) and positioning accuracy (purple) of the lower left shows that the flexibility reaches 80% and the positioning accuracy reaches 0.005mm at a tolerance of 0.2mm. The combined effect of the temperature (-20℃~120℃) and vibration frequency (0~300Hz) on the translation deviation (mm) of the lower right shows that the deviation is smallest in the low temperature and low frequency region (0.005mm), while the deviation increases in the high temperature and high frequency region.

[0066] Furthermore, based on the implementation scheme of this embodiment, the following operation can be further preferred: adopting an R3mm groove wall curvature design, and forming rotational degree of freedom t through three-point contact. yThe constraint torque gradient is nonlinear at the point of constraint in the direction. In practice, the wire EDM machine feeds at 15 mm / min, and the stator tooth pressure block 15 applies 120 N of pressure to ensure assembly stability. The positioning groove and the workpiece tooth tip form a clearance fit with a width difference of 0.3 mm, and the groove wall arc surface forms three-point contact with the workpiece, achieving t y Rotational constraint. Polyurethane is used for potting, with a pressure of 0.22 MPa and a curing time of 28 hours. The R3mm groove wall forms a non-linear constraint through three-point contact; the constraint torque gradient increases non-linearly with the rotation angle, enhancing rotational stability. The clearance fit tolerance of 0.3mm was determined through experimental optimization, balancing assembly flexibility and positioning accuracy. The three-point contact will... y The directional rotation deviation is controlled within ±0.003°, improving accuracy by 25% compared to traditional processes. Just as... Figure 18 As shown, the combined effect of rotation angle (0°~15°) and displacement (0.1~0.5mm) on the constraint torque gradient (N·m / °) in the upper left corner shows that the constraint torque gradient increases non-linearly with increasing rotation angle, forming a peak torque gradient region at 5° angle and 0.3mm displacement. The effect of clearance fit tolerance (0.2~0.4mm) on assembly flexibility (green) and positioning accuracy (purple) in the upper right corner shows that flexibility reaches 80% and positioning accuracy reaches 0.003° at a tolerance of 0.3mm. The combined effect of temperature (-20℃~120℃) and vibration frequency (0~300Hz) on rotation deviation (°) in the lower left corner shows that the deviation is smallest in the low temperature and low frequency region (0.003°), and the deviation increases in the high temperature and high frequency region. The non-linear relationship between rotation angle (0°~15°) and rotation deviation (°) in the lower right corner shows an exponential decay trend, and the deviation decreases significantly after the rotation angle exceeds 5°.

[0067] Example 6. This example, based on the previous examples, will further provide a stator disk assembly process.

[0068] S1 Tooth fixing: Stator tooth clamping block 15 is used to fasten the stator tooth to the bracket contact surface with M6 screws at a torque of 20 N·m, ensuring that the parallelism between the tooth tip and the bottom surface of the bracket is ≤0.01 mm; S2 Three-dimensional constraint: Axial constraint applies 100N pressure through stator tooth pressure block 15 to align the tooth shoe reference surface with the fixture reference surface 13, forming the same electromagnetic working plane; Radial constraint controls the gap between the stator tooth fixing bracket and the workpiece side to 0.15mm, and forms radial support through potting and curing; Circumferential constraint utilizes the circumferential positioning surface of the multi-station fixture, and locks it with bolts in conjunction with the bracket fixing block 16, so that the workpiece is arranged along the circumference at 15° equal angles; S3 potting molding: Epoxy resin is used, the potting pressure is 0.2MPa, and the curing temperature is 80℃ for 2 hours to ensure that the resin fully fills the gap between the teeth; S4 Demolding Inspection: After curing, the pressure block and jig are automatically removed by a robotic arm. The tooth tip height deviation is ≤0.02mm and the air gap uniformity is ≤0.05mm by laser scanning.

[0069] Specifically, regarding constraints: (1) Axial constraint: Based on the technical solution of the above embodiment, the stator tooth pressure block 15 can be used to apply 100N axial pressure and tighten it to 20N·m torque by screwing, so as to ensure that the tooth shoe reference surface 13 is aligned with the reference surface of the stator tooth assembly positioning jig, forming the same electromagnetic working plane with a flatness deviation of ±0.01mm. (2) Radial constraint: Based on the technical solution of the above embodiment, the gap between the radial skeleton of the stator tooth fixing bracket and the side of the workpiece can be controlled to 0.15±0.02mm. After the epoxy resin is cured, it forms an elastic support, constrains the rotational degree of freedom ry, and suppresses the radial vibration displacement during operation. (3) Circumferential constraint: Based on the technical solution of the above embodiment, the circumferential positioning surface of the multi-station slotting fixture can be used in conjunction with the bracket fixing block 16 and locked with M8 bolts to make the workpieces arranged in equal angles of 15°±0.1° along the circumference, ensuring that the angle deviation is ≤0.1°.

[0070] Understandably, the axial 100N pressure achieves precise alignment of the stator tooth pressure block 15 with the tooth shoe reference surface 13, ensuring the consistency of the electromagnetic working plane; the radial 0.15mm gap is formed by potting and curing to create elastic support, balancing mechanical strength and air gap uniformity; the circumferential 15° equidistant arrangement achieves precise angle control through the fixture positioning surface, reducing magnetic flux asymmetry. After epoxy resin curing, an insulating layer is formed, increasing the electrical insulation strength to 50kV / mm, while the coefficient of thermal expansion matches the stator core, reducing temperature rise stress deformation.

[0071] Furthermore, regarding the control of the electromagnetic working plane, a stator tooth clamping block 15 can be used to apply 120N of axial pressure, which is then tightened with M6 screws at a torque of 25N·m to press the workpiece tooth shoe reference surface 13 onto the same axial reference plane. The flatness deviation is controlled within ±0.008mm, forming a high-precision electromagnetic working plane. The stator tooth assembly positioning fixture constrains the translational freedom t through double V-shaped guide rails. y After the epoxy resin is cured, it forms radial supports, constraining the rotational degree of freedom r. y The radial clearance is controlled at 0.18±0.03mm to ensure air gap uniformity ≤0.04mm; the circumferential positioning surface of the multi-station grooving fixture constrains the translational degree of freedom t. x The bracket fixing block 16 is locked to the stator gear fixing bracket and the bracket base by M8 bolts with a torque of 30 N·m, thus constraining the rotational degree of freedom r. x This ensures that the workpieces are arranged along the circumference at 12° equal angles, with an angle deviation of ≤0.08°.

[0072] Furthermore, the axial 120N pressure achieves precise alignment of the gear shoe reference surface 13 through the stator gear pressure block 15, ensuring the consistency of the electromagnetic working plane; the stator gear assembly positioning fixture is constrained by double V-shaped guide rails. y Degrees of freedom, combined with the curing of the adhesive to form radial support, suppress r y Vibration of degrees of freedom; circumferential positioning surface constraint of multi-station fixture t x Degrees of freedom, 16 locking constraints on the bracket fixing block r x The system achieves precise 12° equidistant alignment with a degree of freedom. After curing, the epoxy resin forms an insulating layer, increasing insulation strength to 60kV / mm. Its coefficient of thermal expansion matches the stator core to reduce temperature rise stress deformation. As... Figure 19 As shown, the combined effect of axial pressure (100-140N) and toothed shoe deviation (0.005-0.015mm) on electromagnetic plane consistency (mm) in the upper left corner forms the minimum plane deviation zone at 120N pressure and 0.01mm toothed shoe deviation. The nonlinear relationship between curing time (2-8h) and insulation strength (kV / mm) in the upper right corner shows that the insulation strength approaches 60kV / mm after curing time exceeds 6 hours. The relationship between epoxy resin thickness (0.5-2.0mm) and coefficient of thermal expansion (ppm / ℃) in the lower left corner exhibits an exponential decay characteristic, with the coefficient of thermal expansion approaching 15ppm / ℃ after thickness exceeds 1.5mm. The effect of temperature (-20℃~120℃) and vibration frequency (0-300Hz) on temperature rise stress deformation in the lower right corner shows that deformation is minimal in the low-temperature, low-frequency region (0.0001mm), while deformation increases in the high-temperature, high-frequency region.

[0073] It is understood that the process in this embodiment is based on the closed-loop control principle of "positioning-constraint-curing". The stator tooth pressure block 15 ensures the alignment of the tooth shoe reference surface 13 through axial pressure, forming a unified electromagnetic working plane; the radial clearance of 0.15mm forms an elastic support through potting and curing, suppressing vibration displacement during operation; the circumferential 15° equally divided angle arrangement achieves precise angle control through the fixture positioning surface, which can reduce magnetic flux asymmetry.

[0074] Example 7. (As shown) Figures 1-8 As shown, this embodiment, based on the foregoing embodiments, further provides an assembly fixture for implementing the above-described process, including: (1) Multi-station grooving fixture: It adopts a three-station design. The axial station controls the translational freedom t through a 0.2mm clearance fit and a 15° groove inclined plane line constraint. z The radial station constrains the ty degree of freedom through double V-shaped guide rails, while the circumferential station constrains the t degree of freedom through 12° equally divided positioning surfaces. x Degrees of freedom, positioning accuracy up to ±0.005mm; the multi-station fixture ensures axial / radial / circumferential degree of freedom constraint through precise positioning in three stations, and the positioning accuracy directly affects the uniformity of magnetic flux distribution; (2) Bracket fixing block: 304 stainless steel material is selected. The stator teeth are fixed to the bracket and the bracket base by M8 bolts with a torque of 35 N·m. Anti-loosening shims are used to achieve the anti-loosening function. After locking, the vibration displacement is ≤0.01 mm. The bracket fixing block achieves the anti-displacement function by high torque locking and anti-loosening shims, suppressing molding vibration. (3) Stator tooth pressure block: Apply 110N pressure to control the tooth tip height difference ≤0.01mm, and the flatness standard reaches ±0.003mm, to ensure that all stator teeth form the same electromagnetic working plane; the stator tooth pressure block controls the tooth tip height difference through 110N pressure to form a high-precision electromagnetic working plane; (4) Stator tooth fixing bracket: Made of 7075 aluminum alloy, with a radial skeleton design and honeycomb structure for weight reduction, reducing weight by 20% while maintaining tensile strength ≥450MPa. The bracket base is designed for easy disassembly after assembly to reduce redundant weight. The stator tooth fixing bracket achieves a balance between lightweight and high strength through aluminum alloy material and honeycomb structure, thereby improving power density.

[0075] Application Example. This application example is based on the YASA motor stator assembly process, and the simulation background is set as a new energy vehicle drive motor production workshop. Environmental parameters include a temperature range of -20℃ to 120℃, a vibration frequency of 0 to 300Hz, and a relative humidity of 40% to 60%. Specific working conditions are set as three typical assembly states: initial assembly state, optimized assembly state, and perfect assembly state, corresponding to the technical characteristics of three finite element simulation diagrams.

[0076] (I) Implementation process of technical parameters Axial pressure control: A 120N stator tooth pressure block is used to achieve precise alignment of the tooth shoe reference surface 13. The ty degree of freedom is constrained by the double V-shaped guide rail, and the tx degree of freedom is constrained by the circumferential positioning surface of the multi-station fixture. The rx degree of freedom is locked by the bracket fixing block 16, so as to achieve precise arrangement of 12° equally divided angles.

[0077] Material property matching: After the epoxy resin is cured, it forms an insulating layer, which increases the insulation strength to 60kV / mm. The coefficient of thermal expansion is 15ppm / ℃, which matches the stator core and reduces temperature rise stress deformation.

[0078] Degrees of freedom constraint system: Nonlinear constraints are formed through three-point contact, and the constraint torque gradient increases nonlinearly with the rotation angle, thereby enhancing rotational stability.

[0079] (II) Working Condition Simulation and Result Demonstration like Figure 20As shown: under the simulated working condition of axial error >0.1mm and alignment angle 88.5°, the stress distribution shows stress concentration at the tip of the groove (red area accounts for 15%), with a maximum stress value of 80MPa and a magnetic gap deviation of ±0.005mm, verifying the stress concentration risk in the initial assembly state.

[0080] like Figure 21 As shown: the stress distribution of the simulated three-dimensional structure in the optimized assembly state is marked with stress peaks of 125MPa and 145MPa. The stress concentration areas are located at the corners and connections of the structure. The stress peaks are reduced by 20% through structural optimization, which verifies the effectiveness of the degree-of-freedom constraint system.

[0081] Simulating a working condition with an axial error of <0.01mm and an alignment angle of 90.0°, the stress distribution is uniform (blue area accounts for 85%), the maximum stress value is <30MPa, and the magnetic gap consistency reaches ±0.001mm. The small graph in the upper right corner shows that the magnetic gap tends to stabilize as the assembly steps change, verifying the performance advantages under perfect assembly conditions. Simultaneously simulating a combined working condition of -20℃ to 120℃ temperature change cycling and 0~300Hz vibration, the thermal image shows that the temperature rise stress deformation of the insulation layer is <0.0001mm, verifying the effect of temperature rise stress control through material property matching.

[0082] (III) Demonstration of Technical Effects: like Figure 22 As shown, through axial pressure control and degree-of-freedom constraint systems, the stress concentration area is reduced by 30%, and the maximum stress value is reduced by 40%, meeting the consistency requirements of the electromagnetic working plane. Under perfect assembly conditions, the magnetic gap deviation is controlled within ±0.001mm, improving accuracy by 25% compared to traditional processes, ensuring electromagnetic working plane consistency reaches ±0.002mm. The epoxy resin insulation layer's thermal expansion coefficient matches the stator core, with temperature rise stress deformation <0.0001mm, meeting the requirements of high torque density and low torque pulsation.

[0083] All the above embodiments merely illustrate implementation methods for relevant practical applications of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for machining stator teeth of a flux motor, comprising performing a cutting operation on a pre-treated stack of iron core laminations, characterized in that, The workpiece's machining plane is perpendicular to the equipment spindle based on the preset angle of the multi-station grooving fixture; during machining, within the multi-station grooving fixture, When machining a workpiece with a toothed groove on one side, the positioning groove of a fixture constrains the workpiece's translational degree of freedom t. y and rotational degrees of freedom r z The positioning groove of the other fixture constrains the translational degree of freedom t of the workpiece. z and rotational degrees of freedom r y ; When the workpiece is being machined on the other side of the tooth groove, one fixture releases the translational degree of freedom t. y and t z and rotational degrees of freedom r z and t y After keeping the datum unchanged, the positioning groove of the other fixture re-constrains or maintains the translational degree of freedom t of the workpiece. z and rotational degrees of freedom r y This continues until the tooth grooves of the workpiece are machined.

2. The processing method according to claim 1, characterized in that: The workpiece is subjected to wire EDM for tooth cutting using a motion controller; the motion controller includes a closed-loop control system and performs machining path compensation during the wire EDM operation.

3. The processing method according to claim 1, characterized in that: The positioning groove of the other fixture constrains the translational degree of freedom t through the positioning pin hole pair. x ; The reference is the degree of freedom t retained by the locating pin hole pair. x The responsible part is to release the translational degree of freedom t y and t z and rotational degrees of freedom r z and r y The benchmark.

4. The processing method according to claim 1, characterized in that: Translational degree of freedom t y and rotational degrees of freedom r z The constraint method is formed by a fixture forming a clearance fit with the workpiece through the difference in width between the positioning groove and the workpiece tooth tip, and the inclined surface of the groove wall forming a line constraint with the edge line of the workpiece tooth tip; Translational degree of freedom t z and rotational degrees of freedom r y The constraint method is formed by another fixture forming a clearance fit with the workpiece through the width difference of the positioning groove, and the arc surface of the groove wall forming a point constraint with the workpiece.

5. The processing method according to claim 4, characterized in that: Line constraint is the constraint between the groove slope and the workpiece tooth tip edge in the translational degree of freedom t. y Nonlinear constraints on multi-line contact in different directions; Point constraint is the constraint between the groove slope and the workpiece tooth tip edge in rotational degree of freedom t. y Nonlinear constraints on the direction of the constraint moment gradient.

6. The processing method according to claim 4, characterized in that: Point constraint is a three-point contact constraint in which the positioning groove and the workpiece form a clearance fit with a width difference, and the groove wall surface and the workpiece form a clearance fit with a width difference.

7. A stator disk assembly process for implementing the processing method as described in any one of claims 1 to 6, characterized in that, include: S1. Fix the stator teeth to the contact surface of the bracket; S2. Align the workpiece tooth shoe reference surface with the stator tooth assembly positioning fixture reference surface; S3. Perform potting molding and curing on the workpiece; S4. Demold and obtain the finished product.

8. The assembly process according to claim 7, characterized in that: In S2, alignment is achieved through constraints, including: Axial constraint is used to hold the stator tooth clamping block in place until they form the same electromagnetic working plane. Radial constraint is used to control the clearance between the radial skeleton of the stator gear fixing bracket and the side of the workpiece. Circumferential constraint aims to arrange workpieces at a predetermined angle along the circumference.

9. The assembly process according to claim 8, characterized in that: The electromagnetic working plane is formed by pressing the workpiece to the same axial reference plane using stator tooth pressure blocks; The gap between the radial frame of the fixed bracket and the side of the workpiece is constrained by the stator gear assembly positioning fixture, which controls the translational degree of freedom t. y And the radial support constrained rotational degree of freedom r formed by the adhesive after potting and curing. y The formed; The translational degree of freedom t is constrained by the circumferential positioning surface of the multi-station grooving fixture. x Furthermore, the bracket fixing block is secured to the bracket base by bolts, which tighten the stator teeth, thus constraining the rotational degree of freedom r. x This allows the workpieces to be arranged at a predetermined angle along the circumference.

10. An assembly fixture for implementing the assembly process as described in claims 7-9, characterized in that, include, A multi-station grooving fixture for axial, radial, and circumferential positioning of workpieces; Support fixing blocks to prevent relative displacement during assembly and molding processes; Stator tooth pressure block for controlling the tooth tip height difference; Stator gear fixing bracket for mounting the above-mentioned device.

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