Synchronous machine stator structure and method of manufacturing the same

Abstract

The application discloses a synchronous motor stator structure and a manufacturing method thereof. The synchronous motor stator structure comprises a plurality of stator cores, a plurality of winding assemblies and a glue filling layer. The plurality of winding assemblies are sleeved on the stator cores, and the plurality of winding assemblies and the plurality of stator cores cooperate to form a ring structure. Each winding assembly comprises a plurality of winding modules, each winding module comprises a ring winding, two support structures, two reinforcing plates, an insulation layer and two air cooling channels. The two reinforcing plates are respectively fixed on both sides of the ring winding along the axial direction of the ring winding to fix and limit the ring winding. The two air cooling channels are respectively located on the sides of the two reinforcing plates away from the ring winding along the axial direction of the ring winding, and each air cooling channel at least partially overlaps the ring winding. The glue filling layer is in the shape of a ring body and covers the ring structure, and the glue filling layer does not fill the two air cooling channels. Through the above arrangement, the synchronous motor stator structure can be cooled and the magnetic field strength of the synchronous motor stator structure can be improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a synchronous motor stator structure and its manufacturing method. Background Technology

[0002] High-voltage motors can carry higher voltages, thus reducing the current intensity within the motor and consequently decreasing line losses, which is beneficial for applications in high-power equipment. To meet the cooling requirements of the stator windings in high-voltage motors, cooling channels need to be incorporated into the stator structure.

[0003] In related technologies, metal cooling channels are fixed in the stator structure to cool the stator windings. However, induced eddy currents are generated inside the metal channels, resulting in eddy current losses. Furthermore, the induced eddy currents affect the magnetic field generated by the windings, thereby reducing the magnetic field strength generated by the stator structure. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this application is to provide a synchronous motor stator structure and its manufacturing method.

[0005] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, embodiments of this application provide a synchronous motor stator structure, including: Multiple stator cores, each stator core is in the form of a circular segment, and two adjacent stator cores are interlocked with each other along their circumference; Multiple winding assemblies are fitted onto the stator core; Multiple winding assemblies are combined with multiple stator cores to form a ring structure; Each winding assembly includes multiple abutting winding modules, each winding module comprising: Toroidal winding; Two support structures, each of which at least partially surrounds and contacts the stator core, are located on both sides of the stator core along its axial direction, and an annular winding is wound around the two support structures, with a gap formed between the annular winding and the stator core through the two support structures. Two reinforcing plates are fixed to both sides of the annular winding along its axial direction, so that the annular winding is located between the two reinforcing plates to fix and limit the annular winding. An insulating layer that wraps around the toroidal winding to secure and insulate it; Two air-cooling channels are located on the side of the two reinforcing plates away from the toroidal winding, and each air-cooling channel overlaps at least partially with the toroidal winding along the axial direction of the toroidal winding to achieve cooling of the toroidal winding. The potting layer is ring-shaped and covers the ring structure. The potting layer does not fill the two air cooling channels.

[0006] In one possible implementation, each reinforcing plate is an annular shape, each reinforcing plate is wound around two support structures, and each reinforcing plate is spaced from the stator core; the space is filled with an adhesive layer.

[0007] In one possible implementation, at least a portion of the outer diameter surface of each stator core is formed with a support portion located at the center of the stator core along its circumference. Two winding assemblies are provided between any two adjacent support portions. The ends of the two winding assemblies that are opposite to each other abut against the two support portions respectively. A gap is formed between the ends of the two winding assemblies that are close to each other. The potting layer does not fill the gap.

[0008] In one possible implementation, the gap overlaps with the insertion positions of the two adjacent stator cores radially along the stator core.

[0009] In one possible implementation, the synchronous motor stator structure further includes a stator housing and a stator inner housing. The stator housing is arranged around and connected to the potting layer, multiple support parts abut against the inner wall of the stator housing, and multiple winding assemblies are arranged around and connected to the stator inner housing.

[0010] In one possible implementation, the potting layer has a plurality of first air cooling holes and a plurality of second air cooling holes extending through the potting layer along its axial direction. Each first air cooling hole and each second air cooling hole are located on both sides of the insertion position of two adjacent stator cores to form at least a partial gap. The air flowing through the first air cooling holes and the second air cooling holes directly contacts the stator cores.

[0011] In one possible implementation, the potting layer has a plurality of third air cooling holes that penetrate the potting layer along its axial direction. Each third air cooling hole is located inside the stator core and overlaps with a support portion along the radial direction of the stator core. The air flowing through the third air cooling hole can directly contact the stator core.

[0012] In one possible implementation, the stator core has connecting protrusions and connecting slots formed on both sides of its circumference, and two adjacent stator cores are connected by connecting protrusions and connecting slots; the outer contour of the connecting protrusion is consistent with the inner contour of the connecting slot.

[0013] Secondly, embodiments of this application provide a method for manufacturing a synchronous motor stator structure, applicable to the aforementioned synchronous motor stator structure. The manufacturing method includes multiple identical channel plates for making two air-cooled aisles. Each channel plate includes a first channel portion, a second channel portion, a first end portion, and a second end portion. Both the first channel portion and the second channel portion extend along a straight line. One end of the first channel portion extends perpendicular to the straight line to form a first end portion, and one end of the second channel portion extends perpendicular to the straight line to form a second end portion. The other ends of the first channel portion and the second channel portion are detachably connected or abutted. Manufacturing methods include: The first ends of the two channel plates are arranged facing each other, and the second ends of the two channel plates are arranged facing each other; The combined structure of the two channel plates is detachably connected to a reinforcing plate. Along the axial direction of the annular winding, the combined structure of the two channel plates at least partially overlaps with the annular winding. All first ends and all second ends protrude from the reinforcing plate. A potting layer is formed on the outer surface of the reinforcing plate, the annular winding, and the two channel plates, with the first end and the second end both at least partially exposed outside the potting layer. A first channel portion is removed from each first end, and a second channel portion is removed from each second end to form an air-cooled channel.

[0014] In one possible implementation, the air-cooling channel includes an end channel for cooling the ends of the toroidal winding, the end channel being formed by portions of a first end and a second end located inside the potting layer.

[0015] The aforementioned synchronous motor stator structure includes multiple stator cores, multiple winding assemblies, and a potting layer. The multiple stator cores and winding assemblies cooperate to form a ring-shaped structure. Each winding assembly includes an annular winding and two air-cooling channels. Along the axial direction of the annular winding, each air-cooling channel at least partially overlaps with the annular winding to achieve cooling of the annular winding. The potting layer covers the annular structure but does not fill the two air-cooling channels. By forming air-cooling channels within the potting layer made of insulating material, cooling of the annular winding is facilitated, avoiding eddy current losses that would occur with metal air-cooling channels, and thus improving the magnetic field strength of the synchronous motor stator structure. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the synchronous motor stator structure provided in an embodiment of this application.

[0017] Figure 2 This is a schematic diagram of the winding module of the synchronous motor stator structure provided in the embodiments of this application.

[0018] Figure 3 This is a cross-sectional schematic diagram of the winding module of the synchronous motor stator structure provided in an embodiment of this application.

[0019] Figure 4 An exploded view of the winding module of the synchronous motor stator structure provided in the embodiments of this application.

[0020] Figure 5 This is a schematic diagram of the stator core of the synchronous motor stator structure provided in the embodiments of this application.

[0021] Figure 6 This is a schematic diagram of the channel plate of the synchronous motor stator structure provided in the embodiment of this application.

[0022] Figure 7 A flowchart illustrating the manufacturing method of the synchronous motor stator structure provided in this application embodiment. Detailed Implementation

[0023] To enable those skilled in the art to better understand the present application, the technical solutions in specific embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0024] It should be noted that the terms "first," "second," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, "a" or "one," and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. "A plurality" or "several" indicates at least two. Unless otherwise stated, terms such as "front," "back," "left," "right," "lower," and / or "upper" are for illustrative purposes only and are not limited to a location or spatial orientation. Terms such as "comprising" or "including" indicate that the elements or objects preceding "comprising" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect.

[0025] The singular forms “a,” “the,” and “the” used in this application specification and appended claims may also include one or more, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein describes the relationship between related objects, indicating that three relationships may exist, for example, A and / or B, which can represent: A alone, A and B simultaneously, or B alone, where A and B can be singular or plural.

[0026] like Figure 1As shown, this application provides a synchronous motor stator structure 500, which includes a plurality of stator cores 51 and a plurality of winding assemblies 52. The stator cores 51 support the winding assemblies 52, and the winding assemblies 52 are capable of generating an induced magnetic field.

[0027] Specifically, each stator core 51 is in the shape of an annular segment, and two adjacent stator cores 51 are interlocked with each other along their circumference. Multiple winding assemblies 52 are sleeved on the stator cores 51, so that the multiple winding assemblies 52 and the multiple stator cores 51 cooperate to form an annular structure 501, thereby forming an annular armature winding.

[0028] More specifically, the synchronous motor stator structure 500 also includes a potting layer 53, which is ring-shaped and covers the ring structure 501. The potting layer 53 can fix and support the stator core 51 and the winding assembly 52.

[0029] In some embodiments, the potting layer 53 is epoxy resin. After curing, the epoxy resin has high structural strength, enabling the potting layer 53 to support the stator core 51 and the winding assembly 52. ​​Furthermore, the epoxy resin has insulating properties, allowing an insulating layer to be formed on the outer surfaces of the stator core 51 and the winding assembly 52. ​​This insulating layer can uniformly distribute the electric field intensity generated by the winding assembly 52, preventing excessively high local electric field intensity that could lead to air corona discharge, thereby improving the service life of the synchronous motor stator structure 500.

[0030] Secondly, by using a potting method, this application allows the liquid potting compound to penetrate into the gaps of the annular structure 501, thereby improving the adhesion between the potting layer 53 and the winding assembly 52, and thus improving the adhesion between the winding assembly 52 and the insulation layer. This prevents gaps between the winding assembly 52 and the potting layer 53 from forming air gaps within the synchronous motor stator structure 500. Since the electric field generated by the winding assembly 52 will cause electric field distortion in the air gap, the electric field strength at the air gap will increase sharply, leading to air corona discharge. Therefore, by using a potting method, this application can prevent the formation of such air gaps within the synchronous motor stator structure 500, thus avoiding a sharp increase in the electric field and preventing air corona discharge within the synchronous motor stator structure 500.

[0031] Furthermore, if insulating sheets are spliced ​​together to insulate the annular structure 501, a large number of tiny gaps in the annular structure 501 would require numerous tiny sheets to fill these gaps to prevent air gaps from forming within the stator structure. However, these tiny sheets increase the assembly difficulty of the stator structure, and the high precision required for their processing also increases the processing difficulty. Additionally, the splicing method results in poor connection strength between the insulating sheets and the annular structure 501, leading to poor vibration resistance of the stator structure. Therefore, this application uses a potting layer 53 to fill the tiny gaps in the annular structure 501, eliminating the need for sheet splicing. This reduces the assembly difficulty of the synchronous motor stator structure 500 and eliminates the need for processing tiny sheets, thus reducing the processing difficulty. Furthermore, the potting method allows the potting layer 53 and the annular structure 501 to be integrated, improving the connection strength and vibration resistance of the synchronous motor stator structure 500. Figures 2 to 4 As shown, in one embodiment, each winding assembly 52 includes multiple mutually abutting winding modules 521. Each winding module 521 includes a ring winding 5211, a support structure 5212, a reinforcing plate 5213, an insulating layer 5214, and an air-cooling channel 5215. Two of each of the support structure 5212, reinforcing plate 5213, and air-cooling channel 5215 are provided.

[0032] The toroidal winding 5211 is used to generate an induced magnetic field. In some embodiments, the toroidal winding 5211 is made of Litz wire or bar wire. The Litz wire is transposed in a loop, and the bar wire is transposed in a Robel manner, which helps to reduce the voltage difference between the strands in the toroidal winding 5211, thereby improving the uniformity of the electric field intensity generated by the toroidal winding 5211 and preventing air corona discharge from occurring in the synchronous motor stator structure 500.

[0033] Both support structures 5212 at least partially surround and contact the stator core 51, and are located on opposite sides of the stator core 51 along its axial direction. The annular winding 5211 is wound around the two support structures 5212. Specifically, a gap is formed between the annular winding 5211 and the stator core 51 through the two support structures 5212. This arrangement allows the potting layer 53 to fill the aforementioned gap, thereby facilitating the potting layer 53 to wrap around the annular winding 5211 and improving the uniformity of the electric field generated by the annular winding 5211, thus preventing air corona discharge from the synchronous motor stator structure 500.

[0034] Two reinforcing plates 5213 are respectively fixed to both sides of the annular winding 5211 along its axial direction, so that the annular winding 5211 is located between the two reinforcing plates 5213, thereby fixing and limiting the annular winding 5211. The reinforcing plates 5213 restrict the movement of the annular winding 5211, preventing vibration and displacement of the annular winding 5211 after being subjected to the force of the induced magnetic field, thereby improving the assembly stability of the annular winding 5211 and thus improving the working stability of the synchronous motor stator structure 500. In this application, the reinforcing plates 5213 are made of a non-magnetic and non-conductive material, that is, the reinforcing plates 5213 are made of insulating material, so that the annular winding 5211 can be wrapped with insulating material, thereby improving the uniformity of the electric field generated by the annular winding 5211. For example, the reinforcing plates 5213 are made of epoxy resin.

[0035] An insulating layer 5214 encloses the toroidal winding 5211 to fix and insulate it. In some embodiments, the insulating layer 5214 is a mica main insulating layer, which has high insulation performance, thereby improving the insulation performance of the toroidal winding 5211. Furthermore, the mica main insulating layer has good strength after curing, enabling the insulating layer 5214 to fix the toroidal winding 5211, thereby improving the structural stability of the toroidal winding 5211.

[0036] Two air-cooling channels 5215 are located on the side of the two reinforcing plates 5213 facing away from the toroidal winding 5211, and air can circulate within the air-cooling channels 5215. Specifically, along the axial direction of the toroidal winding 5211, each air-cooling channel 5215 at least partially overlaps with the toroidal winding 5211, which facilitates heat exchange between the air-cooling channel 5215 and the toroidal winding 5211, thereby achieving cooling of the toroidal winding 5211 by the air-cooling channel 5215. With this arrangement, under high-voltage operating conditions, the toroidal winding 5211 generates a high amount of heat, and the air-cooling channels 5215 can prevent the toroidal winding 5211 from overheating and being damaged, thus improving the service life of the synchronous motor stator structure 500.

[0037] More specifically, when potting the ring structure 501, the potting layer 53 does not fill the two air cooling channels 5215, so that air cooling channels 5215 are formed in the potting layer 53, which facilitates the flow of air in the air cooling channels 5215.

[0038] The above settings can prevent the addition of metal air-cooled pipes to the stator structure 500 of the synchronous motor, which would cause eddy current damage to the metal air-cooled pipes. They can also prevent the eddy currents formed in the metal air-cooled pipes from affecting the induced magnetic field generated by the annular winding 5211, thereby improving the magnetic field strength of the stator structure 500 of the synchronous motor.

[0039] In summary, in the synchronous motor stator structure 500, the formation of an air-cooling channel 5215 in the potting layer 53 facilitates the cooling of the annular winding 5211, thereby extending the service life of the synchronous motor stator structure 500. Secondly, it avoids the eddy current losses that would result from using metal air-cooling pipes, thus improving the magnetic field strength of the synchronous motor stator structure 500. Furthermore, the reinforcing plate 5213 enhances the structural stability of the annular winding 5211, preventing displacement that could render the synchronous motor stator structure 500 unusable. Additionally, the potting layer 53 and the insulating layer 5214 improve the insulation performance of the annular winding 5211, thereby increasing the uniformity of the electric field generated by the annular winding 5211 and preventing air corona discharge in the synchronous motor stator structure 500, further extending its service life.

[0040] In one implementation, each reinforcing plate 5213 is annular in shape, and each reinforcing plate 5213 is wound around two supporting structures 5212. Specifically, a gap is formed between each reinforcing plate 5213 and the stator core 51. With this arrangement, when potting the annular structure 501, the potting layer 53 fills the gap, so that the potting layer 53 can wrap the reinforcing plate 5213. This facilitates the potting layer 53 wrapping the reinforcing plate 5213 and the annular winding 5211, avoiding air gaps in the synchronous motor stator structure 500 that could lead to air corona discharge, and thus improving the service life of the synchronous motor stator structure 500.

[0041] In one embodiment, at least a portion of the outer diameter surface of each stator core 51 is formed with a support portion 511. The support portion 511 is located at the middle of the stator core 51 along its circumference. Two winding assemblies 52 are provided between any two adjacent support portions 511. The ends of the two winding assemblies 52 that are opposite to each other abut against the two support portions 511 respectively, and a gap 502 is formed between the ends of the two winding assemblies 52 that are close to each other.

[0042] In some embodiments, the synchronous motor stator structure 500 is a three-phase alternating stator structure, with three stator cores 51. Three sets of winding assemblies 52 are provided, namely U-phase windings, V-phase windings, and W-phase windings. Each set of winding assemblies 52 includes a first winding segment and a second winding segment electrically connected. The first and second winding segments are symmetrically arranged about the center of the annular structure 501 and fitted onto different stator cores 51 to form an annular armature winding. Along the circumference of the annular structure 501, winding assemblies 52 of different phases are fitted on both sides of the support portion 511 on each stator core 51, and winding assemblies 52 of different phases are also fitted on both sides of each gap 502.

[0043] With this configuration, the support portion 511 can separate the winding assemblies 52 of different phases, which is beneficial for mounting the winding assemblies 52 onto the stator core 51.

[0044] Secondly, when potting the annular structure 501 with the potting layer 53, the annular structure 501 is placed inside the potting container, and the support part 511 can abut against the inner wall of the potting container, so that there is a gap between the winding assembly 52 and the inner wall of the potting container. This is beneficial for the potting layer 53 to wrap the winding assembly 52, thereby improving the insulation of the winding assembly 52 and further improving the uniformity of the electric field generated by the winding assembly 52, so as to avoid the generation of air corona.

[0045] In some embodiments, the support portion 511 is formed by extending the stator core 51 away from its center of curvature, so that the support portion 511 and the stator core 51 are integral components, which helps to improve the connection strength between the support portion 511 and the stator core 51, thereby improving the structural strength of the stator core 51, and further improving the structural strength of the synchronous motor stator structure 500.

[0046] Furthermore, when potting the annular structure 501 with the potting layer 53, the potting layer 53 does not fill the gap 502. This arrangement allows the gap 502 to be located between winding components 52 of different phases. Since the potential difference of the electric field generated by the winding components 52 of different phases on both sides of the gap 502 is large, the insulation requirement at the gap 502 is high. In this application, the air flowing in the gap 502 can achieve air insulation between the winding components 52 of different phases. Since the insulation of air is better than that of the solid potting layer 53, the insulation requirement at the gap 502 is met, so as to avoid insufficient insulation performance at the gap 502 leading to the breakdown of the insulation material by the electric field, thereby improving the service life of the synchronous motor stator structure 500.

[0047] Wherein, the insertion position of the gap 502 and the two adjacent stator cores 51 overlaps radially along the stator core 51. Since the winding assemblies 52 installed on the two adjacent stator cores 51 have different phases, the gap 502 located at the insertion position can be located between winding assemblies 52 of different phases to meet the insulation requirements of winding assemblies 52 of different phases.

[0048] More specifically, the potting layer 53 has a plurality of first air-cooling holes (not shown) and a plurality of second air-cooling holes (not shown) extending axially through the potting layer 53. Along the radial direction of the annular structure 501, each first air-cooling hole and each second air-cooling hole are located on both sides of the insertion position of two adjacent stator cores 51 to form at least a partial gap 502. This arrangement facilitates airflow through the first and second air-cooling holes, achieving air insulation at the gap 502 while allowing the flowing air to facilitate heat dissipation from the synchronous motor stator structure 500.

[0049] Specifically, the air flowing through the first and second air cooling holes directly contacts the stator core 51. This arrangement allows the air in the gap 502 to directly contact the stator core 51, thereby improving the heat exchange efficiency between the air and the stator core 51 and thus enhancing the heat dissipation effect on the synchronous motor stator structure 500.

[0050] like Figure 1 As shown, in one embodiment, the synchronous motor stator structure 500 further includes a stator outer shell 54 and a stator inner shell 55. The stator outer shell 55 is disposed around and connected to the potting layer 53, and multiple support portions 511 abut against the inner wall of the stator outer shell 54, which helps to improve the structural strength of the synchronous motor stator structure 500. Multiple winding assemblies 52 are disposed around and connected to the stator inner shell 55. This arrangement, through the stator outer shell 54 and the stator inner shell 55, can protect the annular structure 501 and the potting layer 53, which helps to improve the service life of the synchronous motor stator structure 500.

[0051] In one embodiment, the potting layer 53 has a plurality of third air-cooling holes (not shown) extending axially through it. Specifically, each third air-cooling hole is located inside the stator core 51, and each third air-cooling hole overlaps with a support portion 511 radially with the stator core 51. This arrangement allows air to circulate within the third air-cooling holes, which is beneficial for cooling the stator core 51 and thus for heat dissipation of the synchronous motor stator structure 500.

[0052] More specifically, the air flowing through the third air-cooling hole can directly contact the stator core 51. This arrangement improves the heat exchange between the air in the third air-cooling hole and the stator core 51, further enhancing the heat dissipation effect on the synchronous motor stator structure 500.

[0053] like Figure 5As shown, in one embodiment, the stator core 51 has connecting protrusions 512 and connecting slots 513 formed on both sides of its circumference. Two adjacent stator cores 51 are connected by connecting protrusions 512 and connecting slots 513. This arrangement allows for the assembly of two adjacent stator cores 51 through connecting protrusions 512 and connecting slots 513, which facilitates the assembly of the synchronous motor stator structure 500.

[0054] In this embodiment, the stator core 51 has connecting protrusions 512 and connecting grooves 513 formed on its two circumferential sides. When two adjacent stator cores 51 are connected by the connecting protrusions 512 and connecting grooves 513, the sides of the two adjacent stator cores 51 can fit together, thereby improving the connection tightness of the two adjacent stator cores 51 and thus improving the structural stability of the synchronous motor stator structure 500.

[0055] In one embodiment, the stator core 51 has chamfered portions 514 formed on both sides along its axial direction. The chamfered portions 514 are used to reduce the non-uniform electric field strength of the air in contact with the stator core 51, thereby avoiding air corona discharge. It should be noted that if the two sides of the stator core along its axial direction are right angles, sharp edges will be formed on both sides of the stator core. These sharp edges have an excessively strong field concentration effect, resulting in a large electric field strength at the sharp edges of the stator core, thus causing air corona discharge. Therefore, this application forms smooth, rounded chamfered portions on both sides of the stator core 51 along its axial direction, which can reduce the field concentration effect, thereby reducing the electric field strength and avoiding air corona discharge.

[0056] Specifically, the chamfered portion 514 is located at the junction of the inner diameter surface of the stator core 51 and the side surface 515, and / or the chamfered portion 514 is located at the junction of the outer diameter surface of the stator core 51 and the side surface. The side surface 515 refers to the two surfaces of the stator core 51 distributed along the axial direction of the synchronous motor stator structure 500.

[0057] like Figure 6 and Figure 7As shown, this application provides a method for manufacturing a synchronous motor stator structure 500. This method includes multiple channel plates 56 with identical structures, which are used to fabricate two air-cooling channels 5215. Specifically, each channel plate 56 includes a first channel portion 561, a second channel portion 562, a first end portion 563, and a second end portion 564. Both the first channel portion 561 and the second channel portion 562 extend along a straight line. One end of the first channel portion 561 extends perpendicular to the straight line to form the first end portion 563, and one end of the second channel portion 562 extends perpendicular to the straight line to form the second end portion 564. More specifically, the other ends of the first channel portion 561 and the second channel portion 562 are detachably connected or abutted. With this configuration, after potting, along the axial direction of the synchronous motor stator structure 500, the first channel portion 561 and the first end portion 563 can be removed from one end of the synchronous motor stator structure 500, and the second channel portion 562 and the second end portion 564 can be removed from the other end of the synchronous motor stator structure 500. In some embodiments, the first channel portion 561 is bonded to the second channel portion 562, thereby facilitating the separation of the first channel portion 561 and the second channel portion 562.

[0058] In this application, along the radial direction of the synchronous motor stator structure 500, the length of the first end 563 is greater than the length of the first channel portion 561, and the length of the second end 564 is greater than the length of the second channel portion 562. Therefore, by removing the channel plate 56 from both ends of the synchronous motor stator structure 500, it is possible to avoid the first end 563 and the second end 564 being too large, which would prevent the channel plate 56 from being removed from one end of the synchronous motor stator structure 500. This facilitates the separation of the channel plate 56 in the potting layer 53.

[0059] More specifically, the air-cooled aisle 5215 includes end aisle 5215a (see reference). Figure 2 The end channel 5215a is used to cool the ends of the annular winding 5211. The end channel 5215a is formed by the portions of the first end 563 and the second end 564 located inside the potting layer 53. Because the coils at the ends of the annular winding 5211 are concentrated, the heat generated at the ends of the annular winding 5211 is relatively large. Therefore, through the above arrangement, the longer first end 563 and second end 564 can form a larger end channel 5215a at the ends of the annular winding 5211 (see reference). Figure 4 This is to improve the cooling effect on the end of the toroidal winding 5211, thereby meeting the cooling requirements of the end of the toroidal winding 5211.

[0060] The manufacturing method includes the following steps: S501: The first ends 563 of the two channel plates 56 are arranged facing each other, and the second ends 564 of the two channel plates 56 are arranged facing each other; In step S501, the second end 564 of the first end 563 are located at both ends of the annular winding 5211 along the axial direction of the synchronous motor stator structure 500, so that the ends of the annular winding 5211 can form a larger end channel 5215a.

[0061] S502: The combined structure of the two channel plates 56 is detachably connected to a reinforcing plate 5213; In step S502, along the axial direction of the annular winding 5211, the combined structure of the two channel plates 56 at least partially overlaps with the annular winding 5211, such that the air-cooling channel 5215 formed after removing the channel plates 56 at least partially overlaps with the annular winding 5211. Furthermore, all first ends 563 and all second ends 564 protrude from the reinforcing plate 5213, so that when the reinforcing plate 5213 is encapsulated with adhesive, the first ends 563 and the second ends 564 can protrude from the encapsulation layer 53.

[0062] In some embodiments, the combined structure of the two channel plates 56 is bonded to a reinforcing plate 5213 to facilitate the separation of the channel plates 56 from the reinforcing plate 5213.

[0063] S503: An adhesive layer 53 is formed on the outer surface of the reinforcing plate 5213, the annular winding 5211, and the two channel plates 56; In step S503, both the first end 563 and the second end 564 are at least partially exposed outside the potting layer 53, which facilitates the removal of the two channel plates 56.

[0064] S504: The corresponding first channel portion 561 is taken out through each first end 563, and the corresponding second channel portion 562 is taken out through each second end 564 to form an air-cooling channel 5215.

[0065] In step S504, the channel plate 56 can be removed from both sides of the potting layer 53 via the first end 563 and the second end 564, which is beneficial to forming an air-cooling channel 5215 in the potting layer 53.

[0066] It should be noted that along the circumference of the synchronous motor stator structure 500, an air cooling channel 5215 is formed on both sides of each annular winding 5211. In steps S501 and S502, a combination structure of the above two channel plates 56 is provided on both sides of each annular winding 5211. In step S504, all channel plates 56 are removed from the potting layer 53.

[0067] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A stator structure for a synchronous motor, characterized in that, include: Multiple stator cores, each stator core being an annular segment, with adjacent stator cores being interlocked with each other along their circumference; Multiple winding assemblies, wherein the multiple winding assemblies are sleeved on the stator core; The plurality of winding assemblies and the plurality of stator cores cooperate to form a ring structure; Each of the winding assemblies includes a plurality of mutually abutting winding modules, each of the winding modules comprising: Toroidal winding; Two support structures, each of which at least partially surrounds and contacts the stator core, are located on opposite sides of the stator core along its axial direction, and the annular winding is wound around the two support structures, with a gap formed between the annular winding and the stator core through the two support structures. Two reinforcing plates are respectively fixed to both sides of the annular winding along its axial direction, so that the annular winding is located between the two reinforcing plates to fix and limit the annular winding. An insulating layer that wraps around the annular winding to secure and insulate the annular winding; Two air-cooling channels are respectively located on the side of the two reinforcing plates away from the annular winding. Along the axial direction of the annular winding, each air-cooling channel at least partially overlaps with the annular winding to achieve cooling of the annular winding. A potting layer, which is ring-shaped and covers the ring structure, does not fill the two air-cooling channels.

2. The synchronous motor stator structure according to claim 1, characterized in that, Each of the reinforcing plates is annular in shape, each of the reinforcing plates is wound around the two supporting structures, and each of the reinforcing plates is spaced apart from the stator core; The potting layer fills the gap.

3. The synchronous motor stator structure according to claim 1, characterized in that, At least a portion of the outer diameter surface of each stator core is formed with a support portion located at the center of the stator core along its circumference. Two winding assemblies are provided between any two adjacent support portions. The ends of the two winding assemblies that are opposite to each other abut against the two support portions respectively. A gap is formed between the ends of the two winding assemblies that are close to each other. The potting layer does not fill the gap.

4. The synchronous motor stator structure according to claim 3, characterized in that, The gap overlaps with the insertion positions of the two adjacent stator cores along the radial direction of the stator core.

5. The synchronous motor stator structure according to claim 3, characterized in that, The synchronous motor stator structure further includes a stator outer shell and a stator inner shell. The stator outer shell is arranged around and connected to the potting layer. The plurality of supporting parts abut against the inner wall of the stator outer shell, and the plurality of winding assemblies are arranged around and connected to the stator inner shell.

6. The synchronous motor stator structure according to claim 3, characterized in that, The potting layer has a plurality of first air cooling holes and a plurality of second air cooling holes that penetrate the potting layer along its axial direction. Each first air cooling hole and each second air cooling hole is located on both sides of the insertion position of two adjacent stator cores to form at least part of the gap. The air flowing through the first air cooling hole and the second air cooling hole directly contacts the stator core.

7. The synchronous motor stator structure according to claim 3, characterized in that, The potting layer has a plurality of third air cooling holes that penetrate the potting layer along its axial direction. Each third air cooling hole is located inside the stator core. Each third air cooling hole overlaps with a support portion along the radial direction of the stator core. The air flowing through the third air cooling hole can directly contact the stator core.

8. The synchronous motor stator structure according to claim 1, characterized in that, The stator core has connecting protrusions and connecting grooves formed on both sides of its circumference, and two adjacent stator cores are connected by the connecting protrusions and connecting grooves. The outer contour of the connecting protrusion is consistent with the inner contour of the connecting groove.

9. A method for manufacturing a synchronous motor stator structure, applicable to the synchronous motor stator structure as described in any one of claims 1 to 8, characterized in that, The manufacturing method includes multiple identical channel plates for fabricating two air-cooled aisles. Each channel plate includes a first channel portion, a second channel portion, a first end portion, and a second end portion. Both the first channel portion and the second channel portion extend along a straight line. One end of the first channel portion extends perpendicular to the straight line to form the first end portion, and one end of the second channel portion extends perpendicular to the straight line to form the second end portion. The other ends of the first channel portion and the second channel portion are detachably connected or abutted against each other. The manufacturing method includes: The first ends of the two channel plates are arranged facing each other, and the second ends of the two channel plates are arranged facing each other; The combined structure of the two channel plates is detachably connected to a reinforcing plate. Along the axial direction of the annular winding, the combined structure of the two channel plates at least partially overlaps with the annular winding. All the first ends and all the second ends protrude from the reinforcing plate. An adhesive layer is formed on the outer surfaces of the reinforcing plate, the annular winding, and the two channel plates, with the first end and the second end both at least partially exposed outside the adhesive layer. The corresponding first channel portion is removed through each first end, and the corresponding second channel portion is removed through each second end to form an air-cooling channel.

10. The method for manufacturing the synchronous motor stator structure according to claim 9, characterized in that, The air-cooling channel includes an end channel for cooling the ends of the annular winding, the end channel being formed by portions of the first end and the second end located inside the potting layer.

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