Stator assembly, electric machine and pump

Abstract

The application relates to a stator assembly, a motor and a pump. The stator assembly comprises a stator core and two motor insulation skeletons respectively mounted to opposite axial ends of the stator core; the stator core comprises a plurality of stator core units, and the motor insulation skeleton comprises a plurality of skeleton units one-to-one corresponding to the plurality of stator core units, wherein the first bending groove is located on the radially inner side of the second bending groove, the profile line of the first bending groove and the profile line of the second bending groove correspond to each other and the interval is at least 0.3 mm, in the straight chain state, the second bendable connecting part is a circular arc shape protruding towards the radially outer side and the thickness at the thinnest point in the radial direction is at least 0.8 mm, and in the circular state, the maximum radial dimension of the motor insulation skeleton does not exceed the maximum radial dimension of the stator core.

Description

Technical Field

[0001] This application relates to the field of motor technology, and more particularly to stator assemblies, motors, and pumps. Background Technology

[0002] An electric motor includes components such as a frame, stator, and rotor. The stator is fixed inside the frame and typically includes a stator core and stator windings (usually enameled wire) wound around the stator core. The stator core and stator windings are usually separated by an insulating frame to prevent short-circuit faults in the motor.

[0003] Existing technologies include single insert-type skeletons and integral skeletons. Single insert-type skeletons have a higher slot fill rate, but relatively low production efficiency, and are prone to issues such as missed insertion, incorrect insertion, or incomplete insertion. Integral skeletons have a relatively lower slot fill rate, but relatively higher production efficiency, and are easier to install and less prone to errors.

[0004] To combine the advantages of both, existing technologies have developed a chain-type insulating skeleton, which is installed on the chain-type stator core in a straight chain state and then wound to ensure a high slot fill factor. After the winding is completed, it changes from a straight chain state to a round state.

[0005] However, in the prior art, the connection structure between two adjacent skeleton units is prone to breakage after the chain-type insulating skeleton is formed into a circle, resulting in failure to form a circle. Summary of the Invention

[0006] The purpose of this application is to provide stator assemblies, motors, and pumps to solve the aforementioned technical problems.

[0007] To achieve the above objectives, in a first aspect, embodiments of this application provide a stator assembly, including: A stator core includes multiple stator core units, each stator core unit including a first yoke, a first bendable connecting portion being provided between the first yoke portions of two adjacent stator core units, and a first bending groove being formed between the first bendable connecting portion and the two adjacent first yoke portions; and Two motor insulation frames are respectively installed to two opposite axial ends of the stator core. The motor insulation frame includes multiple frame units that are correspondingly installed to multiple stator core units. Each frame unit includes a second yoke, which includes an axial abutment portion that abuts against the axial end face of a first yoke. A second bendable connecting portion is provided between the axial abutment portions of two adjacent frame units, and a second bending groove is formed between the second bendable connecting portion and the two adjacent axial abutment portions. The first bending groove is located radially inside the second bending groove, and the outlines of the first bending groove and the second bending groove correspond to each other with a distance of at least 0.3 mm. In the straight chain configuration, the second bendable connector is an arc shape protruding radially outward, and its thinnest point in the radial direction has a thickness of at least 0.8 mm. In the circular state, the maximum radial dimension of the motor insulation frame does not exceed the maximum radial dimension of the stator core.

[0008] Secondly, embodiments of this application provide an electric motor, including the stator assembly described above, wherein the stator assembly is in a circular state.

[0009] Thirdly, embodiments of this application provide a pump, including the aforementioned motor.

[0010] Compared with the prior art, the embodiments of this application have at least the following beneficial effects: By optimizing the dimensional parameters of the second bendable connection, a good buffering effect is provided, which allows the stress at the second bendable connection to be effectively dispersed when two adjacent skeleton units are bent, avoiding stress concentration that could cause the second bendable connection to break and generate debris, and ensuring that the chain insulation skeleton can be completely rounded. Attached Figure Description

[0011] Figure 1 A schematic diagram of a stator assembly in a straight-chain state according to an embodiment of this application is shown from one perspective.

[0012] Figure 2 This diagram shows another perspective view of a stator assembly in a straight-chain state according to an embodiment of this application.

[0013] Figure 3 An exploded view of a stator assembly in a straight-chain state according to an embodiment of this application is shown.

[0014] Figure 4 An exploded view of another perspective of a stator assembly in a straight-chain state according to an embodiment of this application is shown.

[0015] Figure 5 An exploded view of the stator core unit and frame unit according to an embodiment of this application is shown.

[0016] Figure 6 An assembly diagram of the stator core unit and frame unit according to an embodiment of this application is shown.

[0017] Figure 7 A top view of a stator assembly in a straight-chain state according to an embodiment of this application is shown.

[0018] Figure 8 A schematic diagram of a motor insulation frame in a straight-chain state according to an embodiment of this application is shown.

[0019] Figure label: 10. Stator core; 11. Stator core unit; 111. First yoke; 112. First tooth; 1121. First toothed shoe; 113. First bendable connection; 114. First bending groove; 1141. First sidewall; 1142. First bottom wall; 20. Motor insulation frame; 21. Frame unit; 211. Second yoke; 2111. Axial abutment part; 2112. Radial abutment part; 2113. Protrusion; 212. Second tooth; 2121. Second toothed shoe; 213. Second bendable connection part; 214. Second bending groove; 2141. Second side wall; 2142. Second bottom wall; 215. Back groove; 2151. Left arc segment; 2152. Central arc segment; 2153. Right arc segment; 201. Upper frame; 202. Lower frame; 31. First arc segment; 32. Second arc segment; 33. Third arc segment; 34. Fourth arc segment. Detailed Implementation

[0020] The technical solution of this application will be further described below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely for explaining this application and not for limiting it. Furthermore, it should be noted that, for ease of description, only the parts relevant to this application are shown in the accompanying drawings, not all of them.

[0021] This application defines certain directional terms. Unless otherwise stated, the directional terms used, such as "up," "down," "left," "right," "inner," and "outer," are used for ease of understanding and therefore do not constitute a limitation on the scope of protection of this application.

[0022] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0023] In the description of this application, unless otherwise expressly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0024] An electric motor consists of a stator assembly and a rotor assembly. The stator assembly drives the rotor assembly to rotate within it. In an electric motor, the stator assembly is typically annular (circular). However, during the manufacturing process of the stator assembly, for purposes such as increasing slot fill factor, the stator assembly may be straight (straight-chain state), and after being wound with enameled wire, it is bent from the straight-chain state to the circular state.

[0025] To ensure that the stator assembly can be smoothly bent from a straight state to a round state without breakage or damage, the embodiments of this application provide a stator assembly.

[0026] like Figure 1 and Figure 2 As shown, the stator assembly includes a stator core 10 and two motor insulation frames 20. In this embodiment, the motor insulation frame 20 located on the upper part of the stator core 10 is defined as the upper frame 201, and the motor insulation frame 20 located on the lower part of the stator core 10 is defined as the lower frame 202. Therefore, the upper frame 201 and the lower frame 202 are respectively mounted to two opposite axial ends of the stator core 10. The motor insulation frames 20 are typically made of plastic.

[0027] like Figure 3 and Figure 4 As shown, the stator core 10 includes a plurality of stator core units 11 connected to each other. Exemplarily, the number of stator core units 11 shown in the figure is six, but it is not limited thereto.

[0028] The multiple stator core units 11 shown in the figure are in a straight chain state. However, the head of the first stator core unit 11 can be connected to the tail of the last stator core unit 11 by bending, thereby bending the multiple stator core units 11 from a straight chain state to a round state.

[0029] Similarly, such as Figure 3 and Figure 4As shown, the motor insulation frame 20 includes a plurality of frame units 21 connected to each other. Exemplarily, six frame units 21 are shown in the figure, but the number is not limited to this. The number of frame units 21 corresponds to the number of stator core units 11, and during installation, the plurality of frame units 21 are installed one-to-one with the plurality of stator core units 11. For example, the first frame unit 21 is installed to the first stator core unit 11, the second frame unit 21 is installed to the second stator core unit 11, and so on.

[0030] The multiple skeleton units 21 shown in the figure are in a straight chain state. However, by bending them, the head of the first skeleton unit 21 can be connected to the tail of the last skeleton unit 21, thereby bending the multiple skeleton units 21 from a straight chain state into a circular state.

[0031] like Figure 5 As shown, the stator core unit 11 includes a first yoke 111 and a first tooth 112. The first yoke 111 is arc-shaped and has a radially inner surface and a radially outer surface. The first tooth 112 extends from the radially inner surface of the first yoke 111 toward the radially inner side, making the stator core unit 11 generally "T" shaped.

[0032] like Figure 5 As shown, a first bendable connecting portion 113 is provided between the first yoke portions 111 of two adjacent stator core units 11, and a first bending groove 114 is formed between the first bendable connecting portion 113 and the two adjacent first yoke portions 111. The stator core unit 11 and the first bendable connecting portion 113 are usually integrally formed.

[0033] When two adjacent stator core units 11 are bent, the first bendable connecting part 113 deforms, causing the opening of the first bending groove 114 to gradually shrink, thereby causing the first yokes 111 of the two adjacent stator core units 11 to gradually approach each other, and finally causing the centers of the two first yokes 111 to be at the same point.

[0034] like Figure 5 and Figure 6 As shown, the skeleton unit 21 includes a second yoke 211 and a second tooth 212. The second yoke 211 is arc-shaped and has a radially inner surface and a radially outer surface. The second tooth 212 extends from the radially inner surface of the second yoke 211 toward the radially inner side, making the skeleton unit 21 approximately "T"-shaped. Furthermore, a mounting groove is provided on the side of the skeleton unit 21 facing the stator core unit 11 to facilitate mounting the skeleton unit 21 to one axial end of the stator core unit 11.

[0035] like Figure 5As shown, the second yoke 211 includes an axial abutment portion 2111 and a radial abutment portion 2112 connected to each other. The axial abutment portion 2111 abuts against the axial end face of the first yoke 111. The radial abutment portion 2112 abuts against the radial inner surface of the first yoke 111.

[0036] like Figure 5 As shown, a second bendable connecting portion 213 is provided between the axial abutment portions 2111 of two adjacent skeleton units 21, and a second bending groove 214 is formed between the second bendable connecting portion 213 and the two adjacent axial abutment portions 2111. The axial abutment portions 2111 and the second bendable connecting portion 213 are usually integrally formed.

[0037] When two adjacent skeleton units 21 are bent, the second bendable connecting part 213 deforms, causing the opening of the second bending groove 214 to gradually shrink, so that the axial abutment parts 2111 of the two adjacent skeleton units 21 gradually approach each other, and finally the centers of the two axial abutment parts 2111 are at the same point.

[0038] Since the second bendable connector 213 is typically made of plastic, it is prone to breakage or damage during bending. To address this issue, the dimensional parameters of the second bendable connector 213 have been optimized in this embodiment.

[0039] Specifically, the embodiments of this application optimize the spacing between the first bending groove 114 and the second bending groove 214 on the one hand, and optimize the thickness of the second bendable connecting portion 213 on the other hand.

[0040] like Figure 7 As shown, the first bending groove 114 is located radially inside the second bending groove 214, meaning the outline of the first bending groove 114 surrounds the outer periphery of the outline of the second bending groove 214. Furthermore, the outlines of the first bending groove 114 and the second bending groove 214 correspond to each other, making the first bending groove 114 and the second bending groove 214 have substantially the same shape. The distance between the corresponding outlines in the first bending groove 114 and the second bending groove 214 is at least 0.3 mm. This dimension prevents breakage and debris generation when the second bendable connecting part 213 is bent into a circle, thus avoiding failure to form a circle, and also prevents welding failure of the first and last stator core units. Specifically, the inventors conducted experiments on embodiments with different spacings and found that when the spacing is 0.1 mm, breakage and welding failure are highly probable; when the spacing is 0.2 mm, breakage and welding failure occur occasionally; and when the spacing is 0.3 mm, breakage and welding failure no longer occur. Therefore, a spacing of at least 0.3 mm is required to ensure that the plastic particles do not fail to form a complete circle even when they deform during the process of forming the circle.

[0041] Furthermore, to avoid the enameled wire contacting the stator core, the spacing should not exceed 0.5 mm.

[0042] like Figure 7 As shown, in the straight-chain state, the second bendable connection 213 is an arc shape protruding radially outward, and its thinnest point in the radial direction has a thickness of at least 0.8 mm. This helps ensure that the second bendable connection 213 has sufficient thickness, preventing breakage or damage during bending and ensuring smooth demolding during manufacturing, thus avoiding breakage or damage during demolding or handling. Furthermore, in the rounded state, the maximum radial dimension of the motor insulation frame 20 does not exceed the maximum radial dimension of the stator core 10. This helps ensure that the rounded stator assembly can be properly installed into the motor housing and limits the maximum thickness of the second bendable connection 213.

[0043] For example, the thickness of the second bendable connector 213 at its thinnest point in the radial direction can be 0.8 mm to 1 mm.

[0044] like Figure 7 and Figure 8 As shown in the embodiment of this application, the first bending groove 114 includes a first sidewall 1141 and a first bottom wall 1142. The first sidewall 1141 is a straight line, and the first bottom wall 1142 is an arc. The second bending groove 214 includes a second sidewall 2141 and a second bottom wall 2142. The second sidewall 2141 is a straight line, and the second bottom wall 2142 is an arc. The first sidewall 1141 and the second sidewall 2141 are parallel to each other, and the first bottom wall 1142 and the second bottom wall 2142 are concentric. Thus, the first bending groove 114 and the second bending groove 214 have similar shapes, and when the first bending groove 114 bends, the second bending groove 214 bends substantially simultaneously and correspondingly.

[0045] like Figure 7 and Figure 8 As shown, in this embodiment of the application, the first sidewall 1141 is defined by the circumferential side surface of the first yoke 111, and the first bottom wall 1142 is defined by the radially inner side surface of the first bendable connecting portion 113. The second sidewall 2141 is defined by the circumferential side surface of the axial abutment portion 2111, and the second bottom wall 2142 is defined by the radially inner side surface of the second bendable connecting portion 213.

[0046] like Figure 7 and Figure 8 As shown, a back groove 215, opposite to the second bending groove 214, is also formed between the second bendable connecting portion 213 and the two adjacent axial abutment portions 2111. By providing the back groove 215, stress concentration in the second bendable connecting portion 213 during bending can be alleviated.

[0047] For example, the back groove 215 includes a left arc segment 2151, a central arc segment 2152, and a right arc segment 2153 connected in sequence. The central arc segment 2152 protrudes radially outward, and the left arc segment 2151 and the right arc segment 2153 are symmetrical. The left arc segment 2151 and the right arc segment 2153 each include at least two arc sub-segments connected to each other.

[0048] By setting at least two arc sub-segments on both sides of the central arc segment 2152, the stress on both sides of the central arc segment 2152 can be effectively dispersed, so that the stress on both sides of the central arc segment 2152 is transmitted to both sides during bending, thereby avoiding the central arc segment 2152 from breaking or being damaged.

[0049] At least two arc segments can be two, three, four, or more arc segments. For example, such as... Figure 8 As shown in this embodiment, at least two arc segments include a first arc segment 31, a second arc segment 32, a third arc segment 33, and a fourth arc segment 34 connected sequentially. The first arc segment 31 is connected to the central arc segment 2152 at one end, and the first arc segment 31 protrudes radially inward. The concave and convex directions of adjacent arc segments are opposite.

[0050] For example, in this embodiment, the radius of the central arc segment 2152 is 1.4 mm to 2 mm. The radius of the first arc segment 31 is equal to the radius of the central arc segment 2152. The radius of the second arc segment 32 is 1 mm to 2.5 mm. The radius of the third arc segment 33 is 0.3 mm to 1 mm. The radius of the fourth arc segment 34 is 1 mm to 2.5 mm. This dimension is problematic because during the bending of the motor insulation frame and stator core into a circle, the motor insulation frame deforms along with the stator core, causing the surface of the motor insulation frame to extend beyond the surface of the stator core, thus affecting the subsequent installation of the stator assembly to the motor housing via heat fitting.

[0051] like Figure 6 As shown, the radially inner surface of the radially abutting portion 2112 has protrusions 2113 at both ends in the circumferential direction, protruding radially inward and extending axially. These protrusions 2113 and the second tooth portion 212 together define the winding slot. The presence of the protrusions 2113 ensures that the enameled wire does not exceed the protrusions 2113, thus keeping the enameled wire inside the winding slot. This increases the creepage distance and prevents the enameled wire from failing to withstand voltage due to being too close to the iron core. The protrusions 2113 also prevent excessively high slot fill factor in the winding slot. When the slot fill factor is too high, the densely packed enameled wires are easily pressed against each other and touch the stator iron core. Therefore, the protrusions 2113 enhance the electrical clearance and creepage distance of the motor.

[0052] For example, in the axial direction, the protrusion 2113 and the stator core unit 11 can be flush with each other (i.e., of equal height), thereby ensuring that the enameled wire in the winding slot does not come into contact with the stator core unit 11. In addition, for example, the length and width of the protrusion 2113 can be 1 mm and 0.8 mm, respectively.

[0053] like Figure 6 As shown, the first tooth portion 112 includes a first toothed shoe 1121, and the second tooth portion 212 includes a second toothed shoe 2121. The second toothed shoe 2121 abuts against the radially outer side of the first toothed shoe 1121, and the circumferential end profile of the second toothed shoe 2121 extends beyond the circumferential end profile of the first toothed shoe 1121 by at least 1 mm. This design effectively avoids excessively high slot fill factor in the winding slots, thereby preventing direct contact between the enameled wire and the stator core 10, and further enhancing the electrical clearance and creepage distance of the motor.

[0054] This application also provides an electric motor. The motor includes the stator assembly described above, and the stator assembly is in a circular state in the motor.

[0055] This application also provides a pump. The pump includes the motor described above.

[0056] Although this application has been described in detail above with general descriptions, specific embodiments, and experiments, some modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of this application fall within the scope of protection claimed in this application.

Claims

1. A stator assembly, characterized in that, include: A stator core (10) includes multiple stator core units (11), each stator core unit (11) including a first yoke (111), a first bendable connecting portion (113) being provided between the first yokes (111) of two adjacent stator core units (11), and a first bending groove (114) being formed between the first bendable connecting portion (113) and the two adjacent first yokes (111); and Two motor insulation frames (20) are respectively installed to the two opposite axial ends of the stator core (10). The motor insulation frame (20) includes a plurality of frame units (21) that are installed one-to-one with a plurality of stator core units (11). The frame unit (21) includes a second yoke (211). The second yoke (211) includes an axial abutment part (2111). The axial abutment part (2111) abuts against the axial end face of the first yoke part (111). A second bendable connecting part (213) is provided between the axial abutment parts (2111) of two adjacent frame units (21). A second bending groove (214) is formed between the second bendable connecting part (213) and the two adjacent axial abutment parts (2111). The first bending groove (114) is located radially inside the second bending groove (214), and the outlines of the first bending groove (114) and the second bending groove (214) correspond to each other with a spacing of at least 0.3 mm. In the straight chain configuration, the second bendable connector (213) is an arc shape protruding radially outward, and its thinnest point in the radial direction has a thickness of at least 0.8 mm. In the circular state, the maximum radial dimension of the motor insulation frame (20) does not exceed the maximum radial dimension of the stator core (10).

2. The stator assembly according to claim 1, characterized in that, The first bending groove (114) includes a first sidewall (1141) and a first bottom wall (1142), wherein the first sidewall (1141) is a straight line and the first bottom wall (1142) is an arc. The second bending groove (214) includes a second sidewall (2141) and a second bottom wall (2142), wherein the second sidewall (2141) is a straight line and the second bottom wall (2142) is an arc. The first sidewall (1141) and the second sidewall (2141) are parallel to each other, and the first bottom wall (1142) and the second bottom wall (2142) are concentric.

3. The stator assembly according to claim 2, characterized in that, The first sidewall (1141) is defined by the circumferential side of the first yoke (111), and the first bottom wall (1142) is defined by the radial inner side of the first bendable connecting portion (113); The second sidewall (2141) is defined by the circumferential side of the axial abutment portion (2111), and the second bottom wall (2142) is defined by the radial inner side of the second bendable connection portion (213).

4. The stator assembly according to claim 1, characterized in that, A back groove (215) opposite to the second bending groove (214) is also formed between the second bendable connecting part (213) and the two adjacent axial abutting parts (2111). The back groove (215) includes a left arc segment (2151), a central arc segment (2152) and a right arc segment (2153) connected in sequence. The central arc segment (2152) protrudes radially outward. The left arc segment (2151) and the right arc segment (2153) are symmetrical. The left arc segment (2151) and the right arc segment (2153) each include at least two arc sub-segments connected to each other.

5. The stator assembly according to claim 4, characterized in that, The at least two arc segments include a first arc segment (31), a second arc segment (32), a third arc segment (33), and a fourth arc segment (34) connected in sequence. The first arc segment (31) is connected to the central arc segment (2152) at one end near the central arc segment (2152), and the first arc segment (31) protrudes radially inward.

6. The stator assembly according to claim 5, characterized in that, The radius of the central arc segment (2152) is 1.4 mm to 2 mm; The radius of the first arc sub-segment (31) is equal to the radius of the central arc segment (2152); The radius of the second arc segment (32) is 1 mm to 2.5 mm; The radius of the third circular arc segment (33) is 0.3 mm to 1 mm; The radius of the fourth circular arc segment (34) is 1 mm to 2.5 mm.

7. The stator assembly according to claim 1, characterized in that, The second yoke (211) also includes a radial abutment (2112) connected to the axial abutment (2111), the radial abutment (2112) abutting against the radial inner side of the corresponding first yoke (111), and the radial inner side of the radial abutment (2112) is provided with protrusions (2113) at both ends in the circumferential direction that protrude toward the radial inner side and extend along the axial direction.

8. The stator assembly according to claim 1, characterized in that, The stator core unit (11) further includes a first tooth (112), which includes a first tooth shoe (1121). The skeleton unit (21) further includes a second tooth (212) corresponding to the first tooth (112), and the second tooth (212) includes a second toothed shoe (2121). The second toothed shoe (2121) abuts against the radial outer side of the first toothed shoe (1121), and the circumferential end profile of the second toothed shoe (2121) extends beyond the circumferential end profile of the first toothed shoe (1121) by at least 1 mm.

9. An electric motor, characterized in that, The stator assembly includes the stator assembly according to any one of claims 1 to 8, wherein the stator assembly is in a circular state.

10. A pump, characterized in that, Includes the motor as described in claim 9.

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