Stator assembly, method of manufacturing a stator assembly, electric machine and vehicle

Abstract

The present disclosure relates to a stator assembly and a processing method thereof, a motor and a vehicle, the stator assembly comprising: a core body, a busbar assembly arranged at a first end of the core body, and a temperature measuring member arranged at a second end of the core body, wherein at least one of the busbar assembly and the temperature measuring member is in an integrated structure with the core body, and the integrated structure can isolate the stator assembly from a rotor assembly. The busbar assembly is used to realize the conduction and busbar of the stator winding and an external circuit, and the temperature measuring member can monitor the working temperature of the motor in real time, and realize the thermal management regulation and control of the motor. At least one of the busbar assembly and the temperature measuring member is formed in an integrated structure with the core body, and the integrated structure realizes the isolation from the rotor assembly, solves the problems of thin wall thickness, high dimensional accuracy requirement and difficult processing and manufacturing of the isolation cover, avoids the defects of scratching the core body and causing the separation and warping of silicon steel sheets in the interference press-fitting process of the isolation cover, and effectively prevents the damage of the motor performance and NVH performance.

Description

Technical Field

[0001] This disclosure relates to the field of motor technology, and more particularly to stator assemblies and their processing methods, motors, and vehicles. Background Technology

[0002] In electric pumps, the stator is typically cooled naturally, while the rotor is oil-lubricated. A sealing enclosure is needed between the stator and rotor to achieve dry and wet separation. In related technologies, the enclosure is installed separately and press-fitted into the inner ring of the stator. This can easily rub against the stator core formed by stacked silicon steel sheets, causing the silicon steel sheets to separate and warp, thus affecting motor performance. Summary of the Invention

[0003] To overcome the problems existing in the related technologies, this disclosure provides a stator assembly and its processing method, an electric motor, and a vehicle.

[0004] According to a first aspect of the present disclosure, a stator assembly is provided, the stator assembly comprising: The iron core body, a busbar assembly disposed at a first end of the iron core body, and a temperature measuring element disposed at a second end of the iron core body, wherein at least one of the busbar assembly and the temperature measuring element is integrally formed with the iron core body, and the integral structure can isolate the stator assembly from the rotor assembly.

[0005] The busbar assembly in the stator assembly is used to enable conduction and current connection between the stator windings and external circuits, while the temperature sensor is used to monitor the motor's operating temperature in real time, enabling thermal management and control of the motor. This stator assembly can achieve reliable isolation from the rotor assembly, solving the technical problems of high processing difficulty and easy damage to the iron core during assembly in traditional stator isolation structures, thus improving the structural stability and reliability of the stator assembly.

[0006] In some possible implementations, the stator assembly includes a first support ring, and the bus assembly includes an insulating portion, with the first support ring fixed within the cavity of the insulating portion.

[0007] The first support ring effectively enhances the structural rigidity of the busbar assembly and prevents deformation caused by factors such as injection molding flow impact and motor vibration. The first support ring can work with the mold to achieve precise assembly of the busbar assembly at the first end of the iron core body, ensuring the matching accuracy of various components inside the stator assembly and further improving the reliability of dry and wet isolation between the stator and rotor.

[0008] In some possible implementations, the first support ring is integrally injection molded into the inner cavity of the insulating portion and is fitted and fixed to the cavity wall of the insulating portion.

[0009] The first support ring is integrally injection molded into the inner cavity of the insulating part. During the injection molding process, the outer peripheral wall of the first support ring and the inner cavity wall of the insulating part are fully fitted and fixed together as one, with no assembly gap between them, forming a compact integrated mating structure.

[0010] In some possible implementations, the first end of the core body is provided with a slot, and the bus assembly is provided with a buckle that can be inserted into the slot. The slot and the buckle are arranged in multiple circumferentially.

[0011] The buckle and slot adopt a plug-in mating structure, which makes the assembly operation simple and can quickly achieve precise pre-fixation of the busbar assembly at the first end of the iron core body, simplifying the assembly process of the stator assembly semi-finished product; the mating structure of multiple sets of slots and buckles can disperse the impact force of the mold flow on the busbar assembly during injection molding, further improving the reliability of the positioning of the busbar assembly and the iron core body, and ensuring the overall dimensional accuracy of the stator assembly.

[0012] In some possible implementations, the bus assembly includes an insulating portion and a lead-out copper busbar. The insulating portion has a vertical portion that wraps around the lead-out copper busbar. The vertical portion has a stepped structure with a stepped surface that is flush with a first end face of the integral structure.

[0013] The flush design of the stepped surface with the first end face of the integrated structure makes the end structure of the stator assembly neat, reduces the end face processing steps after injection molding, and improves production efficiency. On the other hand, the stepped structure provides a precise sealing mating surface for injection molding. During the injection process, the mold can fit tightly with the stepped surface, effectively preventing the molten injection material from overflowing along the mating gap between the lead-out copper busbar and the insulation part, solving the problem of injection overflow and avoiding the overflow affecting the assembly and mating accuracy of the stator assembly and other components.

[0014] In some possible implementations, the bus assembly includes an insulating portion and connection pins, wherein there are multiple connection pins spaced circumferentially along the insulating portion, the connection pins are used to connect to the leads of corresponding coil windings, and the connection pins have a U-shaped structure, the leads being able to extend into the opening of the U-shaped structure.

[0015] The U-shaped structure design allows the connecting pins to form a wrapping positioning fit with the coil winding lead-out end, which facilitates quick insertion and positioning of the lead-out end, and ensures the contact area between the lead-out end and the connecting pins. This improves the conductivity stability and connection strength after welding, and avoids poor contact or desoldering of the connection part due to vibration and heat during motor operation.

[0016] In some possible implementations, the two sidewalls of the U-shaped structure may deform inward to fit tightly against the lead-out end.

[0017] The tight fit achieved by the inward deformation of the U-shaped sidewalls effectively avoids the problem of plastic seepage during injection and ensures the electrical conductivity stability at the weld joint.

[0018] In some possible implementations, the stator assembly includes a second support ring disposed at the second end where the temperature sensor is located, and at least one of the first support ring, the busbar assembly, the temperature sensor, and the second support ring is an integral structure with the core body.

[0019] The second support ring reinforces the structure at the second end of the iron core body. The injection-molded integrated structure enables seamless fixing of corresponding components to the iron core body, filling the gaps between components. This reduces assembly steps and dimensional tolerances for individual parts, and the continuous sealing surface formed by the injection-molded plastic ensures effective isolation between the stator and rotor assemblies.

[0020] In some possible implementations, the second end face of the integral structure is provided with a plurality of positioning holes for positioning the second support ring.

[0021] In the overall injection molding process of the stator assembly, the injection mold is equipped with positioning pins that correspond one-to-one with the positioning holes. Before injection molding, after the second support ring is placed at the preset position at the second end of the iron core body, the positioning pins on the mold will clamp and position the second support ring, restricting the second support ring from circumferential rotation or axial and radial displacement, ensuring that it is always in the designed precise position during the injection molding process. After injection molding is completed, the positioning pins of the mold detach from the molded integral structure, and their original clamping and positioning positions form the multiple positioning holes on the second end face of the integral structure.

[0022] In some possible implementations, the temperature sensing element includes a wire harness and a fixing member integrally disposed on the wire harness, the fixing member being adapted to mount the temperature sensing element at the second end of the iron core body.

[0023] The fastener can be designed to fit the structure of the second end of the iron core body, forming a locking and fitting relationship with the corresponding structure of the second end of the iron core body. This enables the rapid and accurate installation of the temperature measuring component. After installation, it can effectively constrain the position of the wire harness, preventing the temperature measuring component from axially shifting or radially deviating due to mold flow impact and equipment vibration during stator assembly, overall injection molding, and motor operation. This ensures that the detection end of the wire harness is always aligned with the temperature measuring point, guaranteeing the accuracy and stability of temperature detection.

[0024] In some possible implementations, the core body includes a plurality of stator core units arranged sequentially along the circumference. Each stator core unit includes a stator core assembly, an insulating support, and a coil winding wound around the outer periphery of the insulating support. Insulating paper is provided between the coil windings of some adjacent stator core units. One end of the wire harness is provided with a temperature sensing part, which can extend into the iron core body and is located between two adjacent coil windings. The other end of the wire harness extends out of the second end face of the integrated structure.

[0025] The temperature sensing part can be close to the working area of ​​the coil winding, and can directly collect the real-time working temperature of the coil winding to ensure the accuracy of temperature detection; the other end of the wire harness passes through the second end face of the integrated structure and extends outward to achieve electrical connection with the external temperature control module, so that the temperature signal collected by the temperature sensing part can be stably transmitted to the external control terminal, realizing real-time monitoring and control of the working temperature of the stator assembly.

[0026] In some possible implementations, the insulating support includes a frame body and an upper baffle and a lower baffle disposed on the frame body, and the coil winding is wound on the frame body and stopped between the upper baffle and the lower baffle; The fastener has an end plate and a first side plate and a second side plate disposed on both sides of the end plate. The wire harness passes through the end plate. The first side plate and the second side plate are arranged opposite each other in the radial direction. The first side plate has a first stop section on each side in the circumferential direction, and the second side plate has a second stop section on each side in the circumferential direction. The first stop section is used to abut against the upper baffle, and the second stop section is used to abut against the lower baffle.

[0027] By using bidirectional upper and lower contact limits, the fixing component and the insulating bracket are precisely positioned, constraining the axial and circumferential displacement of the temperature measuring component. This prevents the temperature measuring component from shifting due to injection molding flow impact or motor vibration, ensuring that the temperature sensing part is always at the precise temperature measuring point.

[0028] In some possible implementations, the end plate has a protruding sealing portion on the side away from the temperature sensing part, and the sealing portion is flush with the second end face of the integral structure.

[0029] During the injection molding process, the sealing part can fit tightly with the injection mold to form a reliable sealing surface. This not only ensures that the second end face is flat and aesthetically pleasing, but also prevents the injected plastic from overflowing outwards along the wire harness, avoiding problems such as overflowing glue and poor wire harness wrapping, and ensuring the sealing effect at the junction of the temperature measuring component and the integrated structure.

[0030] According to a second aspect of the present disclosure, a method for processing a stator assembly is provided, the method being used to form the aforementioned stator assembly, the method comprising: Install the busbar assembly at the first end of the iron core body; The temperature measuring element is installed at the second end of the iron core body; Integral injection molding is used to form at least one of the busbar assembly and the temperature sensor with the core body to form an integral structure, thereby isolating the stator assembly from the rotor assembly.

[0031] The above-mentioned integral injection molding method eliminates the need for separate press-fit isolation covers, avoiding problems such as scratches and warping of the iron core silicon steel sheets during the press-fitting process. At the same time, it simplifies the assembly process, improves production efficiency, and ensures the structural strength, dimensional accuracy, and sealing of the stator assembly.

[0032] In some possible implementations, the first support ring is secured in the inner cavity of the bus assembly prior to the step of installing the bus assembly; After installing the temperature measuring element, the second support ring is fixed to the second end where the temperature measuring element is located.

[0033] By pre-installing the first and second support rings before injection molding, the positions of each component can be effectively constrained during the subsequent overall injection molding process, preventing displacement due to mold flow impact and ensuring the molding accuracy and sealing effect of the integrated structure.

[0034] In some possible implementations, prior to the step of installing the temperature sensor, the wiring harness and the fixing member are integrally injection molded, and the fixing member is positioned at a predetermined location on the wiring harness.

[0035] The wire harness and fixing component of the temperature sensing element are integrally injection molded. Precise positioning using the injection mold ensures the fixing component is securely placed in the predetermined position on the wire harness. The two are then solidified into an inseparable, integrated temperature sensing component, preventing relative displacement between the wire harness and fixing component during subsequent assembly and injection molding. This process eliminates the need for separate assembly of the fixing component, saving the tedious steps of splicing and positioning scattered parts, simplifying the processing and assembly of the temperature sensing element. It also allows for strict control over the installation accuracy of the fixing component on the wire harness, ensuring a tight seal between the fixing component and the wire harness, preventing gaps between them, and preventing molten plastic from seeping into the temperature sensing area through gaps in the wire harness during the overall injection molding of the stator assembly, thus interfering with the normal temperature measurement operation.

[0036] In some possible implementations, during the step of installing the bus assembly, Insert the busbar assembly's clips into the slots of the insulating bracket; The lead-out end of the coil winding is inserted into the connection pin of the bus assembly, causing the connection pin to deform inward and connect tightly with the lead-out end.

[0037] The busbar assembly is quickly fixed at the first end of the iron core body through the snap-fit ​​and slot engagement, ensuring the coaxiality accuracy of the two without the need for additional positioning fixtures. At the same time, it provides a stable position for subsequent winding wiring and overall injection molding, avoiding misalignment of the busbar assembly during assembly and injection molding. The two side walls of the connecting pins deform inward, tightly clamping the lead-out end of the coil winding, forming a strong clamping connection structure.

[0038] In some possible implementations, during the integral injection molding step, injection molding material is filled between two adjacent conductors of the coil winding and between the coil winding and the insulating support.

[0039] This all-around filling method effectively eliminates internal gaps between the coil windings and the insulation support and winding conductors. It can enhance the structural integrity of the stator core unit, prevent the windings from loosening or shifting during motor operation, and ensure stable electromagnetic performance. It can also strengthen the sealing effect of the stator dry cavity by sealing the oil seepage channels with dense plastic, and achieve reliable isolation from the rotor oil cavity. Furthermore, it can reduce vibration and friction between components, further optimize the motor's NVH performance, and improve the overall structural strength and durability of the stator assembly.

[0040] According to a third aspect of the present disclosure, an electric motor is provided, including a housing and a stator assembly and a rotor assembly disposed within the housing, wherein the stator assembly is the stator assembly described above.

[0041] This motor features a robust structure, reliable sealing, excellent conductivity, and accurate temperature measurement, effectively avoiding problems such as easy stator damage, unstable wiring, and performance degradation caused by excess adhesive in traditional motors.

[0042] According to a fourth aspect of the present disclosure, a vehicle is provided, including the motor described above.

[0043] This vehicle boasts advantages such as stable operation, excellent noise reduction, and long service life, meeting the driving power needs of various passenger and commercial vehicles, and is especially suitable for new energy vehicle scenarios with stringent requirements for motor reliability and sealing.

[0044] The technical solutions provided by the embodiments of this disclosure can include the following beneficial effects: the busbar assembly in the stator assembly is used to realize the conduction and current convergence between the stator winding and the external circuit, and the temperature measuring element is used to monitor the operating temperature of the stator assembly in real time, realizing the thermal management and control of the motor. This stator assembly, by setting at least one of the busbar assembly and the temperature measuring element as an integrally formed structure with the core body, achieves isolation from the rotor assembly using an integral structure, replacing the traditional split isolation cover structure. This solves the problems of thin isolation cover wall thickness, high dimensional accuracy requirements, and high processing and manufacturing difficulty. It also avoids the defects of the isolation cover scraping against the core body during interference fit, causing the silicon steel sheets to separate and warp, effectively preventing motor performance and NVH performance issues. Furthermore, omitting the isolation cover parts reduces the accumulated tolerance of parts assembly, and the entire stator assembly is integrally formed, resulting in high production efficiency.

[0045] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0046] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0047] Figure 1 This is a schematic diagram of the structure of an integral stator assembly according to an exemplary embodiment; Figure 2 This is a schematic diagram of the structure of an integral stator assembly according to an exemplary embodiment; Figure 3 This is a schematic diagram of the structure of a busbar assembly in a stator assembly according to an exemplary embodiment; Figure 4 This is a schematic diagram of the structure of a stator assembly according to an exemplary embodiment; Figure 5 This is a schematic diagram of the structure of a stator assembly according to an exemplary embodiment; Figure 6 yes Figure 5 A magnified view of a portion of the image; Figure 7 This is an assembly diagram of connecting pins and leads in a stator assembly according to an exemplary embodiment; Figure 8 This is a schematic diagram of the structure of a temperature measuring element in a stator assembly according to an exemplary embodiment; Figure 9 This is a schematic diagram of the structure of a stator assembly according to an exemplary embodiment; Figure 10 This is a cross-sectional view of a stator assembly according to an exemplary embodiment; Figure 11 This is a schematic diagram of the structure of a single stator core unit in a stator assembly, according to an exemplary embodiment. Figure 12 This is a schematic diagram of the structure of an electric motor according to an exemplary embodiment; Figure 13 This is a cross-sectional view of an electric motor according to an exemplary embodiment; Figure 14 This is a flowchart illustrating a method for processing a stator assembly according to an exemplary embodiment; Figure 15 This is a flowchart illustrating a method for processing a stator assembly according to an exemplary embodiment.

[0048] Explanation of reference numerals in the attached figures 1-Stator assembly; 10-Core body; 100-Stator core unit; 101-First end; 102-Second end; 103-Slot; 104-Stator core assembly; 105-Insulation bracket; 1050-Frame body; 1051-Upper baffle; 1052-Lower baffle; 106-Coil winding; 1060-Lead-out end; 107-Insulating paper; 11-Bus assembly; 110-Insulation part; 1101-Vertical part; 1102-Stepped surface; 111-Snap-in; 112-Lead-out copper busbar; 113-Connecting pin ; 12-Temperature measuring element; 121-Wire harness; 122-Fixing element; 1220-End plate; 1221-First side plate; 1222-Second side plate; 1223-First stop section; 1224-Second stop section; 1225-Sealing part; 1226-Reinforcing plate; 123-Temperature sensing part; 131-First support ring; 132-Second support ring; 1000-Integral structure; 1001-First end face; 1002-Second end face; 1003-Positioning hole; 2-Rotor assembly; 3-Housing; 4-Sealing ring; 5-End cover. Detailed Implementation

[0049] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0050] In this disclosure, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the drawing orientation of the corresponding figures; "inner" and "outer" refer to the inner and outer contours of the corresponding components; and "axial," "circumferential," and "radial" refer to the axis of rotation of the motor rotor. The terms "first," "second," etc., are used to distinguish different components and do not indicate sequence or importance. Furthermore, in the following description, when referring to the figures, unless otherwise explained, the same reference numerals in different figures denote the same or similar elements.

[0051] like Figures 1 to 9 As shown, this disclosure provides a stator assembly 1, which may include a core body 10, a busbar assembly 11 disposed at a first end 101 of the core body 10, and a temperature sensor 12 disposed at a second end 102 of the core body 10. The busbar assembly 11 is used to realize the circuit conduction and current collection of the stator windings, and the temperature sensor 12 is used to monitor the operating temperature of the stator assembly 1 in real time, realizing thermal management and control of the motor. At least one of the busbar assembly 11 and the temperature sensor 12 is integrally formed with the core body 10, and the integral structure 1000 can isolate the stator assembly 1 from the rotor assembly 2. Specifically, the integral structure 1000 can be integrally formed by injection molding. The core body 10 and the corresponding busbar assembly 11 and / or temperature sensor 12 are tightly wrapped and solidified into a whole by injection molding, so that the injection molding fills the gaps between the components, forming a continuous and sealed encapsulation structure. The integrated structure 1000 is formed in one step through injection molding, which improves the production efficiency of stator assembly 1. The sealing structure formed by injection molding can ensure the reliability of the isolation effect and meet the working requirements of the motor pump in the active suspension system of automobiles.

[0052] When the busbar assembly 11 and the iron core body 10 are integrated into a single structure 1000, the injection-molded plastic simultaneously wraps the first end 101 of the iron core body 10 and the busbar assembly 11, fixing the busbar assembly 11 and the iron core body 10 without gaps. This improves the assembly stability of the busbar assembly 11 and also achieves sealing protection for the busbar assembly 11 through the injection molding process. When the temperature measuring element 12 and the iron core body 10 are integrated into a single structure 1000, the injection molding plastic wraps the second end of the temperature measuring element 12 and the iron core body 10. 102 is solidified into a whole to prevent the temperature measuring element 12 from moving during motor operation and to ensure the accuracy of the temperature measuring position; when the busbar assembly 11 and the temperature measuring element 12 are both integrated with the iron core body 10 as a single structure 1000, the injection molding process wraps the iron core body 10, the busbar assembly 11 and the temperature measuring element 12 into a whole, so that the stator assembly 1 forms a modular sealing assembly, further improving the overall structure and sealing isolation effect, reducing the assembly process of scattered parts and reducing assembly errors.

[0053] In the stator assembly provided in this disclosure, the stator assembly is integrally formed into a single structure 1000 by integrating at least one of the busbar assembly 11 and the temperature measuring element 12 with the core body 10. This single structure 1000 achieves isolation from the rotor assembly 2, replacing the traditional split isolation cover structure. This solves the problems of thin isolation cover walls, high dimensional accuracy requirements, and difficult manufacturing. It also avoids the defects caused by the isolation cover scraping against the core body 10 during interference fit, resulting in the separation and warping of silicon steel sheets, effectively preventing damage to motor performance and NVH performance. Furthermore, by omitting the isolation cover parts, the accumulated tolerances in parts assembly are reduced, and the entire stator assembly is integrally formed, resulting in high production efficiency.

[0054] At the first end of the iron core body 10, refer to Figures 3 to 5 The stator assembly 1 may include a first support ring 131, and the bus assembly 11 includes an insulating portion 110. The first support ring 131 is fixed in the inner cavity of the insulating portion 110, providing structural support for the bus assembly 11 while ensuring the coaxiality of the bus assembly 11 and the core body 10 after assembly. The first support ring 131 can be integrally formed and fixed to the insulating portion 110 of the bus assembly 11 by injection molding, or it can be tightly embedded in a preset position in the inner cavity of the insulating portion 110 by mechanical assembly. Both fixing methods can achieve a reliable connection between the first support ring 131 and the insulating portion 110, avoiding positional displacement of the first support ring 131 during the operation of the stator assembly 1 or during injection molding. The first support ring 131 can effectively enhance the structural rigidity of the busbar assembly 11 and prevent the busbar assembly 11 from deforming due to factors such as injection molding flow impact and motor operation vibration. The first support ring 131 can cooperate with the mold to achieve precise assembly of the busbar assembly 11 at the first end 101 of the iron core body 10, ensuring the matching accuracy of each component inside the stator assembly 1 and further improving the reliability of dry and wet isolation between the stator and rotor.

[0055] Specifically, refer to Figure 4The first support ring 131 is integrally injection molded into the inner cavity of the insulating part 110 and is fixedly fitted to the cavity wall of the insulating part 110. The first support ring 131 is integrally injection molded into the inner cavity of the insulating part 110. During the injection molding process, the outer peripheral wall of the first support ring 131 and the inner cavity wall of the insulating part 110 are fully fitted and fixed together as one unit, with no assembly gap between them, forming a compact integrated structure. When injection molding the insulating part 110 of the busbar assembly 11, the first support ring 131 is pre-positioned in the preset cavity of the injection mold. The injection molding material melts and flows in the mold and covers the outer periphery of the first support ring 131. After the material solidifies, the first support ring 131 is tightly fitted to the cavity wall of the insulating part 110, achieving integral injection molding of the two. This fixing method makes the first support ring 131 and the insulating part 110 an inseparable whole, completely avoiding problems such as positional misalignment and fitting gaps that may occur during mechanical assembly, and effectively improving the overall structural rigidity of the busbar assembly 11. The complete fit between the first support ring 131 and the cavity wall of the insulating part 110 allows the insulating part 110 to form a uniform wrapping constraint on the first support ring 131. Under the working environment of stator assembly 1 injection molding, motor operation vibration and high and low temperature (-40℃~150℃), it can effectively suppress the deformation and displacement of the first support ring 131, ensure the coaxiality accuracy of bus assembly 11, and provide structural support for reliable dry and wet isolation of stator and rotor.

[0056] In order to pre-fix the bus assembly 11 to the first end of the core body 10, in an exemplary embodiment of this disclosure, referring to... Figure 4 , Figure 6 The first end 101 of the iron core body 10 may be provided with a slot 103, and the bus assembly 11 may be provided with a buckle 111 that can be inserted into the slot 103 to realize the positioning and engagement between the bus assembly 11 and the iron core body 10. The slot 103 and the buckle 111 are arranged in multiple circumferentially, so that the engagement between the bus assembly 11 and the iron core body 10 forms a multi-point circumferential constraint, which effectively prevents the bus assembly 11 from rotating circumferentially or shifting axially due to the impact of the mold flow during the assembly and transfer process before injection molding, as well as during injection molding, and ensures that the bus assembly 11 and the iron core body 10 always maintain the preset coaxiality and relative position. The buckle 111 and the slot 103 adopt a plug-in mating structure, which makes the assembly operation simple and can quickly achieve precise pre-fixation of the busbar assembly 11 at the first end 101 of the iron core body 10, simplifying the assembly process of the stator assembly semi-finished product; the mating structure of multiple slots 103 and buckles 111 can disperse the impact force of the mold flow on the busbar assembly 11 during the injection molding process, further improving the reliability of the positioning of the busbar assembly 11 and the iron core body 10, and ensuring the overall dimensional accuracy of the stator assembly 1.

[0057] After the bus assembly 11 is installed at the first end 101 of the iron core body 10, it needs to be connected to the coil winding 106 of the iron core body 10 to realize the connection between the external circuit and the coil winding 106 through the bus assembly 11. In some embodiments, refer to Figure 3 The bus assembly 11 may include an insulating part 110 and a connecting pin 113. The connecting pin 113 is a conductive metal part, which serves as a conductive connection structure between the bus assembly 11 and the coil winding 106 of the stator assembly 1, so as to realize the circuit conduction between the coil winding 106 and the bus assembly 11.

[0058] In this disclosure, multiple connecting pins 113 are arranged circumferentially along the insulation portion 110. The connecting pins 113 are used to connect with the lead-out ends 1060 of the corresponding coil windings 106. The connecting pins 113 can be U-shaped, and the lead-out ends 1060 can extend into the opening of the U-shaped structure, so that the outer peripheral wall of the lead-out end 1060 and the inner sidewall of the U-shaped connecting pin 113 form a close contact. The U-shaped structure design allows the connecting pins 113 to form a wrapping positioning fit with the lead-out ends 1060 of the coil windings, which facilitates the quick insertion and positioning of the lead-out ends 1060, and ensures the contact area between the lead-out ends 1060 and the connecting pins 113, thereby improving the conductivity stability and connection strength after welding, and preventing poor contact or desoldering of the connection parts due to vibration and heat during motor operation.

[0059] Furthermore, referring to Figures 5 to 7 The two sidewalls of the U-shaped structure can deform inward to fit tightly against the lead-out end 1060. The two sidewalls of the U-shaped structure have the characteristic of inward elastic deformation, and under external force, they can deform towards each other to fit tightly against the outer peripheral wall of the lead-out end 1060 of the coil winding 106 that extends into the opening of the U-shaped structure, keeping the gap between them within 0.1mm, thus achieving tight clamping of the lead-out end 1060. This structure is suitable for resistance clamping welding. After the coil winding lead-out end 1060 is inserted into the opening of the U-shaped connecting pin 113, external force is applied to press the two sidewalls of the U-shaped structure, causing them to deform inward and fit tightly against the outer wall of the copper wire of the lead-out end 1060. After clamping and positioning, welding is then performed to form a resistance clamping welded connection structure. This clamping and fitting design maximizes the contact area between the connecting pin 113 and the lead-out terminal 1060, while ensuring that the mating gap at the solder joint does not exceed 0.1mm. This solves the problem of molten injection plastic seeping into the solder joint gap, increasing contact resistance, and weakening conductivity during the injection molding process.

[0060] In some embodiments, refer to Figure 3The bus assembly 11 may include an insulating portion 110 and a lead-out copper bus 112. The lead-out copper bus 112 is a conductive component of the bus assembly 11, used to realize the circuit connection between the coil winding and the external circuit. The insulating portion 110 forms a protective covering for the lead-out copper bus 112, preventing short circuits between the lead-out copper bus 112 and metal components such as the iron core body 10, while also fixing the structure of the lead-out copper bus 112. The insulating portion 110 has a vertical portion 1101 wrapped around the lead-out copper bus 112. The vertical portion 1101 is integrally wrapped around the outside of the lead-out copper bus 112, forming an insulating covering for the axial section of the lead-out copper bus 112. During integral injection molding, the mold cavity has an opening, and the lead-out copper bus 112 extends out of the opening. There is a gap between the lead-out copper bus 112 and the opening, which can easily lead to glue overflow at the position of the lead-out copper bus 112.

[0061] To solve the problem of glue overflow, such as Figure 1 and Figure 3 As shown, the vertical part 1101 is designed with a stepped structure. The stepped structure has a stepped surface 1102 that is flush with the first end face 1001 of the integrated structure 1000. This ensures that after the busbar assembly 11 and the iron core body 10 are injection molded into an integrated structure 1000, the end of the stator assembly 1 maintains a flat end face structure. The design of the stepped surface 1102 being flush with the first end face 1001 of the integrated structure 1000 has two advantages. First, it makes the end structure of the stator assembly 1 more regular, reducing the end face processing steps after injection molding and improving production efficiency. Second, the stepped structure provides a precise sealing mating surface for injection molding. During injection molding, the mold can fit tightly with the stepped surface 1102, effectively preventing the molten injection plastic from overflowing along the mating gap between the lead-out copper busbar 112 and the insulation part 110, solving the problem of injection overflow and preventing overflow from affecting the assembly and mating accuracy of the stator assembly 1 and other components.

[0062] At the second end of the iron core body 10, as an exemplary embodiment of this disclosure, refer to Figure 9The stator assembly 1 may include a second support ring 132, which is located at the second end 102 where the temperature measuring element 12 is located, forming a symmetrical support structure with the first support ring 131 about both ends of the iron core body 10 along the axial direction. In the embodiments of this disclosure, the cross-section of the second support ring 132 is L-shaped. At least one of the first support ring 131, busbar assembly 11, temperature measuring element 12, and second support ring 132 is an integral structure with the iron core body 10. According to actual production and use requirements, the above-mentioned single components or multiple combined components can be integrally molded with the iron core body 10 into a sealed whole structure through injection molding. Regardless of the combination method, the integral structure 1000 formed by injection molding can achieve gapless fixation between the corresponding components and the iron core body 10, filling the gaps between the components, reducing the assembly process and dimensional tolerances of scattered components, and forming a continuous sealing surface through the encapsulation of injection-molded plastic, ensuring the isolation effect between the stator assembly 1 and the rotor assembly 2. When the aforementioned components simultaneously form an integrated structure 1000 with the iron core body 10, the entire stator assembly 1 from the first end 101 to the second end 102 can be injection molded into a single unit, making the stator assembly 1 a complete modular sealing assembly. This eliminates the assembly process of the traditional isolation cover, solves the problems of difficult processing of the isolation cover and damage to the iron core during press fitting, and maximizes the sealing reliability of the stator assembly 1.

[0063] According to some embodiments, refer to Figure 2 The second end face 1002 of the integrated structure 1000 may be provided with multiple positioning holes 1003. These positioning holes 1003 are used to position the second support ring 132 and are a structure naturally formed during the overall injection molding process of the stator assembly. During the overall injection molding process of the stator assembly 1, the injection mold is equipped with positioning pins corresponding to the positioning holes 1003. Before injection molding, after the second support ring 132 is placed at a preset position on the second end 102 of the core body 10, the positioning pins on the mold will clamp and position the second support ring 132, restricting circumferential rotation or axial and radial displacement of the second support ring 132, ensuring that it remains in the designed precise position throughout the injection molding process. After injection molding, the positioning pins of the mold detach from the molded integrated structure 1000, and their original clamping and positioning positions are located in the multiple positioning holes 1003 formed on the second end face 1002 of the integrated structure 1000. The multiple positioning holes 1003 arranged circumferentially at intervals correspond to the multi-point positioning posts of the mold, which can make the second support ring 132 uniformly stressed during the injection molding process, avoid deformation due to excessive local stress, and further improve the structural stability of the stator assembly 1.

[0064] Based on the design concept of integrated injection molding, in order to prevent the temperature measuring element 12 from moving during the injection molding process, this disclosure provides a temperature measuring element 12. In the embodiments of this disclosure, referring to... Figure 8The temperature sensing element 12 may include a wire harness 121 and a fixing member 122 integrally formed on the wire harness 121. The fixing member 122 is adapted to install the temperature sensing element 12 on the second end 102 of the iron core body 10, so as to realize a reliable connection between the temperature sensing element 12 and the iron core body 10 and ensure the temperature monitoring accuracy of the temperature sensing element 12 on the stator assembly 1. Among them, the wire harness 121 is the main body for temperature detection and signal transmission of the temperature sensing element 12. Its detection end is set with the temperature measurement point of the stator assembly 1, which can collect the working temperature of the iron core body 10 and the coil winding in real time and transmit it to the external temperature control module. The fixing member 122 integrally formed on the wire harness 121 is an injection-molded plastic structure, which is formed by injection molding along with the wire harness 121 in one step. The fastener 122 can be designed to fit the structure of the second end 102 of the iron core body 10, and can form a locking and fitting relationship with the corresponding structure of the second end 102 of the iron core body 10, so as to realize the rapid and accurate installation of the temperature measuring element 12. After installation, it can effectively constrain the position of the wire harness 121, and prevent the temperature measuring element 12 from axial movement or radial displacement due to mold flow impact and equipment vibration during the assembly of the stator assembly 1, overall injection molding and motor operation. This ensures that the detection end of the wire harness 121 is always aligned with the temperature measuring point, ensuring the accuracy and stability of temperature detection, and providing reliable temperature data for the thermal management and control of the motor.

[0065] Specifically, refer to Figure 8 One end of the wire harness 121 is provided with a temperature sensing part 123. The temperature sensing part 123 is the core temperature detection part of the temperature measuring element 12, which can accurately sense the working temperature of the stator assembly 1 and provide accurate temperature data for motor thermal management and control. There can be multiple wire harnesses 121. Multiple wire harnesses 121, temperature sensing parts 123 and fixing parts 122 are integrated into one structure and can be molded into an inseparable whole by injection molding process. The multiple wire harnesses 121 enable simultaneous temperature measurement at multiple points inside the stator core, comprehensively covering the key heating areas of the coil windings, eliminating blind spots in single-point temperature measurement, and allowing the motor temperature control system to fully grasp the temperature distribution of the stator. The integrated molding design of the multiple wire harnesses 121, the temperature sensing part 123, and the fixing part 122 eliminates the traditional assembly method of splicing individual parts. This not only eliminates the gaps between the components, effectively preventing molten plastic from seeping into the gaps, coating the temperature sensing part 123, or overflowing during the overall injection molding of the stator, but also strengthens the overall structural strength of the temperature sensing element, resisting the displacement caused by the impact of the injection molding flow and the vibration of the motor, ensuring that the temperature measurement point is always accurate.

[0066] Furthermore, the position of the fixing member 122 on the wire harness 121 can be designed accordingly based on the position of the temperature measuring end of the wire harness 121 within the stator core. (Refer to...) Figure 8The fixing member 122 is arranged on the wire harness 121 near the temperature sensing part 123. This arrangement allows the fixing member 122 to form a close-range limiting constraint on the temperature measuring end of the temperature measuring element, precisely limiting the relative position of the temperature sensing part 123 and the internal coil winding of the stator core. By being close to the temperature measuring area, it prevents the wire harness 121 from shifting, ensuring that the temperature sensing part 123 always stably fits the preset temperature measuring point. In addition, the design of the fixing member 122 being close to the temperature sensing part 123 can reduce the direct impact of the high-pressure mold flow on the temperature sensing part 123 and the surrounding wire harness section during the overall injection molding of the stator through the shielding and limiting effect of the fixing member 122. This reduces the risk of temperature sensing part shift and wire harness deformation caused by mold flow impact, ensuring temperature measuring accuracy.

[0067] The temperature sensing element 123 can be one of the following: a thermistor, a temperature sensor, or a thermocouple, to adapt to the temperature measurement accuracy and range requirements of different motors. It can be selected and designed according to needs.

[0068] As an exemplary embodiment of this disclosure, reference is made to Figure 10 , Figure 11 The iron core body 10 may include a plurality of stator iron core units 100 arranged in sequence along the circumference. Each stator iron core unit 100 may include a stator iron core block 104, an insulating support 105, and a coil winding 106 wound around the outer circumference of the insulating support 105. Insulating paper 107 is provided between the coil windings 106 of some adjacent stator iron core units 100, which can realize the insulation between the three-phase windings and avoid interlayer short circuits. One end of the temperature sensing element 123 can extend into the iron core body 10 and is located between two adjacent coil windings 106. This arrangement allows the temperature sensing element 123 to be close to the working area of ​​the coil winding 106, enabling it to directly collect the real-time working temperature of the coil winding 106 and ensuring the accuracy of temperature detection. The other end of the wire harness 121 extends outward from the second end face 1002 of the integrated structure 1000 and is electrically connected to the external temperature control module, so that the temperature signal collected by the temperature sensing element 123 can be stably transmitted to the external control terminal, realizing real-time monitoring and control of the working temperature of the stator assembly 1. Furthermore, the position where the wire harness 121 extends out of the second end face 1002 is sealed by the injection molding of the integrated structure 1000, which can effectively prevent the injection molding material from overflowing and the oil from seeping in, while ensuring the fixed stability of the protruding end of the wire harness 121 and avoiding the wire harness from loosening or shifting due to motor vibration.

[0069] Furthermore, referring to Figure 11The insulating support 105 may include a frame body 1050 and an upper baffle 1051 and a lower baffle 1052 disposed on the frame body 1050. The upper baffle 1051 and the lower baffle 1052 are disposed at opposite ends of the axial direction of the frame body 1050 and are integrally formed with the frame body 1050. The coil winding 106 is wound on the frame body 1050 and stopped between the upper baffle 1051 and the lower baffle 1052. With the restraint of the upper and lower baffles, the coil winding 106 is prevented from loosening and shifting during motor operation and stator assembly 1 injection molding, thus ensuring the stability of the motor's electromagnetic performance. The fit structure between the upper baffle 1051, the lower baffle 1052 and the frame body 1050, as well as the gaps between adjacent coil windings 106, allow the molten injection plastic to smoothly enter the gaps between the coil windings 106 and the gaps between the coil windings 106 and the frame body 1050. After the injection plastic has solidified, it can tightly wrap the coil winding 106 and the insulating support 105 into one unit, which not only improves the structural integrity of the stator core unit 100, but also achieves the sealing protection of the winding, preventing external oil from seeping in and avoiding damage to the winding due to moisture. At the same time, it eliminates internal voids and further improves the motor's NVH performance.

[0070] The structure is adapted to the insulating bracket 105. In order to pre-fix the temperature measuring element 12 to the second end of the iron core body 10, refer to... Figure 9 The fixing member 122 has an end plate 1220 and a first side plate 1221 and a second side plate 1222 disposed on both sides of the end plate 1220. The wire harness 121 passes through the end plate 1220 and is integrally formed with the fixing member 122 to avoid relative displacement between the two and ensure the stability of the wire harness 121. The first side plate 1221 and the second side plate 1222 are radially ( Figure 8 Arranged relative to each other in the first direction, the first side plate 1221 is circumferentially ( Figure 8 The second side plate 105 has a first stop section 1223 on each side of the second side plate 105, and a second stop section 1224 on each side of the second side plate 105 in the circumferential direction. The first stop section 1223 is used to abut against the upper baffle 1051, and the second stop section 1224 is used to abut against the lower baffle 1052. When assembling the temperature measuring element 12, the first stop section 1223 fits against the end face of the upper baffle 1051 of the insulating bracket 105, and the second stop section 1224 fits against the end face of the lower baffle 1052 of the insulating bracket 105. Through the bidirectional abutment and limiting, the fixing element 122 and the insulating bracket 105 are accurately positioned, the axial and circumferential displacement of the temperature measuring element 12 is constrained, and the temperature measuring element 12 is prevented from shifting due to the impact of the injection molding flow and the vibration of the motor, so as to ensure that the temperature sensing part 123 is always at the accurate temperature measuring point.

[0071] The end of the wire harness 121 furthest from the temperature sensing part 123 extends out of the injection molding cavity. The injection molding cavity has an opening, and there is a gap between the wire harness 121 and the opening. During the injection molding process, the problem of excess glue also exists. To solve this problem, in some embodiments, refer to Figure 2 and Figure 8 The end plate 1220 has a protruding sealing part 1225 on the side away from the temperature sensing part 123. The sealing part 1225 is flush with the second end face 1002 of the integrated structure 1000. During the injection molding process, the sealing part 1225 can fit tightly with the injection mold to form a reliable sealing surface. This ensures that the second end face 1002 is flat and aesthetically pleasing, and also prevents the injected plastic from overflowing outward along the wire harness 121, avoiding problems such as excess glue and poor wire harness wrapping. This ensures the sealing effect at the junction of the temperature sensing element 12 and the integrated structure 1000.

[0072] Specifically, refer to Figure 8 A reinforcing plate 1226 may also be provided between the end plate 1220 and the first side plate 1221 and the second side plate 1222. The reinforcing plate 1226, the end plate 1220, the first side plate 1221 and the second side plate 1222 form an integrated support structure, which improves the overall structural strength and rigidity of the fixing component 122. It can withstand the impact of high pressure flow during the overall injection molding of the stator and the vibration impact during the long-term operation of the motor, ensuring the long-term stability of the fitting accuracy between the fixing component 122 and the stator core unit 100, and preventing problems such as displacement of the temperature measuring component and temperature measurement deviation caused by structural deformation.

[0073] According to the second aspect of this disclosure, such as Figure 14 As shown, a method for processing a stator assembly is provided. This method is used to form the stator assembly described in the above embodiments. The processing method may include: step 1401, installing a busbar assembly 11 onto the first end 101 of the core body 10; step 1402, installing a temperature sensor 12 onto the second end 102 of the core body 10; step 1403, performing integral injection molding to form at least one of the busbar assembly 11 and the temperature sensor 12 with the core body 10 into an integral structure, thereby isolating the stator assembly 1 from the rotor assembly 2 and achieving a sealed separation between the stator cavity and the rotor cavity. Through the above integral injection molding method, a separate press-fit isolation cover is no longer required, avoiding problems such as scratches and warping of the silicon steel sheets in the core caused by the press-fit process. At the same time, it simplifies the assembly process, improves production efficiency, and ensures the structural strength, dimensional accuracy, and sealing performance of the stator assembly.

[0074] Furthermore, such as Figure 15As shown, before step 1401, the processing method further includes: step 1404, fixing the first support ring 131 in the inner cavity of the busbar assembly 11, so that the first support ring 131 and the busbar assembly 11 form a stable assembly, and then assembling them together to the iron core body 10, which facilitates positioning and ensures coaxiality; after step 1402, the processing method further includes: step 1405, fixing the second support ring 132 to the second end 102 where the temperature measuring element 12 is located, so that the second support ring 132 forms a support at the second end 102. By pre-installing the first support ring 131 and the second support ring 132 respectively before injection molding, the positions of each component can be effectively constrained during the subsequent overall injection molding process, preventing displacement due to mold flow impact, and ensuring the molding accuracy and sealing effect of the integrated structure.

[0075] In some embodiments, prior to step 1402, the wire harness 121 and the fixing component 122 of the temperature measuring element 12 are integrally injection molded. The fixing component 122 is precisely positioned at a predetermined location on the wire harness 121 using the injection mold, and the two are solidified into an inseparable integral temperature measuring component, preventing relative displacement between the wire harness and the fixing component during subsequent assembly and injection molding. This process eliminates the need for separate assembly of the fixing component, saving the tedious steps of splicing and positioning scattered parts, simplifying the processing and assembly of the temperature measuring element, and enabling strict control over the installation accuracy of the fixing component on the wire harness. This ensures the sealing of the connection between the fixing component and the wire harness, preventing gaps between them and preventing molten plastic from seeping into the temperature measuring area along the wire harness gaps during the overall injection molding of the stator assembly, thus interfering with the normal temperature measuring operation of the temperature measuring unit.

[0076] In some embodiments, in step 1401, the buckle 111 of the bus assembly 11 is inserted into the slot 103 of the insulating bracket 105. Through the engaging action of the buckle 111 and the slot 103, the bus assembly 11 is quickly fixed at the first end 101 of the core body 10. This ensures the coaxiality accuracy of the two components without the need for additional positioning fixtures, and provides a stable position for subsequent winding wiring and overall injection molding, preventing misalignment of the bus assembly 11 during assembly and injection molding. This completes the assembly of the bus assembly 11. After pre-positioning, the conductive connection operation between the coil winding 106 and the bus assembly 11 is performed. The leads 1060 of each coil winding 106 are inserted into the openings of the U-shaped connecting pins 113 of the bus assembly 11. Then, external force is applied to the U-shaped connecting pins 113, causing the two side walls of the connecting pins 113 to deform in a controllable inward direction, tightly clamping the leads 1060 of the coil winding 106. This ensures a tight fit between the outer peripheries of the two, with the clearance strictly controlled within 0.1mm, forming a robust clamping connection structure. This clamping connection method, on the one hand, increases the contact area between the leads and the connecting pins, ensuring the conductivity stability after welding and avoiding abnormal resistance due to poor contact; on the other hand, it completely seals the tiny gaps between them, preventing molten plastic from seeping into the weld gaps during overall injection molding, thus preventing problems such as weakened conductivity and increased contact resistance. Furthermore, it improves the connection strength of the wiring parts, resisting the risk of loosening caused by motor vibration and high / low temperature deformation, ensuring the reliability of the stator assembly circuit connection.

[0077] In some embodiments, in step 1403, the molten injection molding compound is controlled to flow sufficiently, precisely filling the space between adjacent wires of the coil winding 106 and between the coil winding 106 and the insulating support 105. Utilizing the fluidity of the injection molding compound, it penetrates into every tiny gap between the winding and the insulating support. After the injection molding compound cools and solidifies, it firmly encapsulates the coil winding 106 and the insulating support 105, simultaneously achieving integrated injection molding of the busbar assembly 11, the temperature sensor 12, the two support rings, and the iron core body 10, forming a completely sealed integrated structure. This all-around filling method effectively eliminates internal gaps between the coil windings and the insulation support and winding conductors. It can enhance the structural integrity of the stator core unit, prevent the windings from loosening or shifting during motor operation, and ensure stable electromagnetic performance. It can also strengthen the sealing effect of the stator dry cavity by sealing the oil seepage channels with dense plastic, and achieve reliable isolation from the rotor oil cavity. Furthermore, it can reduce vibration and friction between components, further optimize the motor's NVH performance, and improve the overall structural strength and durability of the stator assembly.

[0078] According to a third aspect of this disclosure, an electric motor is provided, comprising a housing 3 and a stator assembly and a rotor assembly 2 disposed within the housing 3. The stator assembly can be the stator assembly 1 described in the above embodiments. The rotor assembly 2 is adapted to be mounted inside the stator assembly 1. Both the stator assembly 1 and the rotor assembly 2 are housed within the internal cavity of the housing 3 and sealed by an end cover 5. A sealing ring 4 is provided between the end cover 5 and the stator assembly 1 to protect and encapsulate the internal components. This motor features a robust structure, reliable sealing, excellent conductivity, and accurate temperature measurement, effectively avoiding problems such as stator damage, unstable wiring, and performance degradation due to excess adhesive in traditional motors. This motor possesses all the beneficial effects of the aforementioned stator assembly 1, which will not be elaborated upon here. This motor can be used as a motor pump, serving as a core component of an automotive active suspension system, adjusting wheel suspension height through pressure output to achieve smooth vehicle operation.

[0079] According to a fourth aspect of this disclosure, a vehicle is provided, including the motor provided herein. The vehicle has all the beneficial effects of the aforementioned stator assembly 1 and motor, which will not be elaborated further here.

[0080] Furthermore, the term “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as advantageous compared to other aspects or designs. Rather, the use of the term “exemplary” is intended to present the concept in a concrete manner. As used herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless otherwise specified or clear from the context, “X applies A or B” is intended to mean any of the natural inclusive arrangements. That is, “X applies A or B” satisfies any of the foregoing instances if X applies A; X applies B; or both X applies A and B. Additionally, unless otherwise specified or clear from the context to refer to the singular form, the articles “a” and “an” as used in this application and the appended claims are generally understood to mean “one or more.”

[0081] Similarly, although this disclosure has been shown and described with respect to one or more implementations, equivalent variations and modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. This disclosure includes all such modifications and variations and is limited only by the scope of the claims. In particular, with respect to the various functions performed by the components described above (e.g., elements, resources, etc.), unless otherwise indicated, the terminology used to describe such components is intended to correspond to any component (functionally equivalent) that performs the specific function of the described component, even if structurally not equivalent to the disclosed structure. Furthermore, although specific features of this disclosure may have been disclosed with respect to only one of several implementations, such features may be combined with one or more other features of other implementations, as may be desired and advantageous to any given or particular application. Moreover, with regard to the terms “comprising,” “owning,” “having,” “having,” or variations thereof as used in the detailed description or claims, such terms are intended to be inclusive in a manner similar to the term “including.”

[0082] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

[0083] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A stator assembly, characterized in that, The stator assembly includes: The iron core body, a busbar assembly disposed at a first end of the iron core body, and a temperature measuring element disposed at a second end of the iron core body, wherein at least one of the busbar assembly and the temperature measuring element is integrally formed with the iron core body, and the integral structure can isolate the stator assembly from the rotor assembly.

2. The stator assembly according to claim 1, characterized in that, The stator assembly includes a first support ring, and the bus assembly includes an insulating portion, wherein the first support ring is fixed in the inner cavity of the insulating portion.

3. The stator assembly according to claim 2, characterized in that, The first support ring is integrally injection molded into the inner cavity of the insulating part and is fitted and fixed to the cavity wall of the insulating part.

4. The stator assembly according to claim 1, characterized in that, The first end of the iron core body is provided with a slot, and the busbar assembly is provided with a buckle that can be inserted into the slot. The slot and the buckle are arranged in multiple circumferentially.

5. The stator assembly according to claim 1, characterized in that, The bus assembly includes an insulating part and a lead-out copper bus. The insulating part has a vertical part wrapped around the lead-out copper bus. The vertical part has a stepped structure with a stepped surface that is flush with the first end face of the integral structure.

6. The stator assembly according to claim 1, characterized in that, The bus assembly includes an insulating part and connecting pins. There are multiple connecting pins that are spaced apart circumferentially along the insulating part. The connecting pins are used to connect to the lead-out ends of the corresponding coil windings. The connecting pins have a U-shaped structure and the lead-out ends can extend into the opening of the U-shaped structure.

7. The stator assembly according to claim 6, characterized in that, The two sidewalls of the U-shaped structure can deform inward to fit tightly against the lead-out end.

8. The stator assembly according to claim 2, characterized in that, The stator assembly includes a second support ring, which is located at the second end where the temperature measuring element is located. At least one of the first support ring, the busbar assembly, the temperature measuring element, and the second support ring is an integral structure with the iron core body.

9. The stator assembly according to claim 8, characterized in that, The second end face of the integrated structure is provided with a plurality of positioning holes, which are used to position the second support ring.

10. The stator assembly according to any one of claims 1-9, characterized in that, The temperature measuring element includes a wire harness and a fixing member integrally disposed on the wire harness. The fixing member is adapted to install the temperature measuring element at the second end of the iron core body.

11. The stator assembly according to claim 10, characterized in that, The core body includes multiple stator core units arranged sequentially along the circumference. Each stator core unit includes a stator core assembly, an insulating support, and a coil winding wound around the outer circumference of the insulating support. Insulating paper is provided between the coil windings of some adjacent stator core units. One end of the wire harness is provided with a temperature sensing part, which can extend into the iron core body and is located between two adjacent coil windings. The other end of the wire harness extends out of the second end face of the integrated structure.

12. The stator assembly according to claim 11, characterized in that, The insulating support includes a frame body and an upper baffle and a lower baffle disposed on the frame body, and the coil winding is wound on the frame body and stopped between the upper baffle and the lower baffle; The fastener has an end plate and a first side plate and a second side plate disposed on both sides of the end plate. The wire harness passes through the end plate. The first side plate and the second side plate are arranged opposite each other in the radial direction. The first side plate has a first stop section on each side in the circumferential direction, and the second side plate has a second stop section on each side in the circumferential direction. The first stop section is used to abut against the upper baffle, and the second stop section is used to abut against the lower baffle.

13. The stator assembly according to claim 12, characterized in that, The end plate has a protruding sealing part on the side away from the temperature sensing part, and the sealing part is flush with the second end face of the integrated structure.

14. A method for processing a stator assembly, characterized in that, The processing method is used to form a stator assembly according to any one of claims 1-13, the processing method comprising: Install the busbar assembly at the first end of the iron core body; The temperature measuring element is installed at the second end of the iron core body; Integral injection molding is used to form at least one of the busbar assembly and the temperature sensor with the core body to form an integral structure, thereby isolating the stator assembly from the rotor assembly.

15. The method for processing a stator assembly according to claim 14, characterized in that, Prior to the step of installing the busbar assembly, the first support ring is fixed in the inner cavity of the busbar assembly; After installing the temperature measuring element, the second support ring is fixed to the second end where the temperature measuring element is located.

16. The method for processing a stator assembly according to claim 14, characterized in that, Before installing the temperature sensor, the wire harness and the fixing component are integrally injection molded, and the fixing component is positioned at a predetermined location on the wire harness.

17. The method for processing a stator assembly according to claim 14, characterized in that, In the step of installing the bus assembly Insert the busbar assembly's clips into the slots of the insulating bracket; The lead-out end of the coil winding is inserted into the connection pin of the bus assembly, causing the connection pin to deform inward and connect tightly with the lead-out end.

18. The method for processing a stator assembly according to claim 14, characterized in that, In the integral injection molding step, injection molding material is filled between two adjacent wires of the coil winding and between the coil winding and the insulating support.

19. An electric motor, characterized in that, It includes a housing and a stator assembly and a rotor assembly disposed within the housing, wherein the stator assembly is the stator assembly according to any one of claims 1-13.

20. A vehicle, characterized in that, Includes the motor as described in claim 19.

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