Stator assembly, electric machine, electric fan and vehicle

Abstract

The application discloses a kind of stator assembly, motor, electronic fan and vehicle, stator assembly includes: insulating frame, multiple fixing pieces are provided on the insulating frame, stator winding, the stator winding is wound on multiple fixing pieces described above. According to the stator assembly of the embodiment of the application, the fixation of stator winding is realized by setting fixing pieces on the insulating frame, which can ensure the stability of stator winding. By using the above arrangement, a motor without stator teeth and slots can be formed, which can reduce the vibration and noise of the motor during operation and improve the performance of the motor.

Description

Technical Field

[0001] This invention relates to the field of electric motor technology, specifically to a stator assembly, an electric motor, an electric fan, and a vehicle. Background Technology

[0002] In some related technologies, the stator windings are directly bonded to the inside of the casing, which poses a risk of shaking and falling off during use, and there is room for improvement. Summary of the Invention

[0003] The present invention aims to at least solve one of the technical problems existing in the prior art. Therefore, one object of the present invention is to provide a stator assembly that reduces vibration and noise during operation, thereby improving performance.

[0004] According to a first aspect of the present invention, a stator assembly includes: an insulating frame having a plurality of fixing members disposed thereon, and a stator winding wound on the plurality of fixing members.

[0005] According to the stator assembly of the present invention, the stator winding is fixed by setting a fastener on the insulating frame, which can ensure the stability of the stator winding. Moreover, by adopting the above arrangement, a motor without stator slots can be formed, which can reduce the vibration and noise of the motor during operation and improve the performance of the motor.

[0006] According to an embodiment of the present invention, a plurality of fixing members are disposed on the end face of the insulating frame, and the plurality of fixing members are spaced apart circumferentially along the insulating frame.

[0007] According to an embodiment of the present invention, a plurality of fixing members are disposed on the end face of the insulating frame. The plurality of fixing members include a plurality of first fixing members and a plurality of second fixing members. The plurality of first fixing members are disposed on the first end face of the insulating frame, and / or the plurality of second fixing members are disposed on the second end face of the insulating frame. The first end face and the second end face are disposed opposite to each other along the axial direction of the insulating frame.

[0008] According to an embodiment of the present invention, the stator assembly includes a plurality of second fasteners, which include a plurality of first sub-fasteners and a plurality of second sub-fasteners, wherein the second sub-fasteners are closer to the center of the insulating frame than the first sub-fasteners.

[0009] According to an embodiment of the present invention, the number of the plurality of first fixing members and the plurality of first sub-fixing members are the same, and the plurality of first fixing members and the plurality of first sub-fixing members are at the same distance from the central axis of the insulating frame.

[0010] According to an embodiment of the present invention, in the stator assembly, the outer peripheral wall of each of the fixing members extends obliquely toward the direction close to the central axis of the insulating frame in a direction away from the corresponding end face of the insulating frame.

[0011] According to an embodiment of the present invention, in the stator assembly, the cross-sectional dimension of each of the fixing members gradually decreases along the direction away from the corresponding end face of the insulating frame.

[0012] According to an embodiment of the present invention, the stator assembly has a plurality of winding auxiliary slots between at least two of the first fixing members for accommodating a portion of the conductors of the stator winding.

[0013] According to an embodiment of the present invention, the stator assembly further includes a plurality of winding guide grooves between at least two of the first fixing members, and the plurality of winding guide grooves are symmetrically arranged between the two first fixing members.

[0014] According to an embodiment of the present invention, the stator assembly includes a plurality of winding guide slots and a plurality of winding auxiliary slots that correspond one-to-one, and the winding guide slots and the winding auxiliary slots are connected by a guide surface.

[0015] According to an embodiment of the present invention, the stator assembly further includes a stator core, the insulating frame defining an installation space, and at least a portion of the stator core being disposed within the installation space.

[0016] According to an embodiment of the present invention, the stator assembly includes: a first insulating frame and a second insulating frame, the first insulating frame and the second insulating frame being disposed opposite to each other to form an installation space, the first fixing member being disposed on the first insulating frame, and the second fixing member being disposed on the second insulating frame.

[0017] According to an embodiment of the present invention, in a stator assembly, the first insulating frame is provided with a first limiting member extending toward the second insulating frame, the first limiting member engaging with the inner circumference of the stator core to restrict the radial movement of the stator core; and / or, the second insulating frame is provided with a second limiting member extending toward the first insulating frame, the second limiting member engaging with the inner circumference of the stator core to restrict the radial movement of the stator core.

[0018] According to an embodiment of the present invention, the first limiting member is provided with reinforcing ribs; and / or, the second limiting member is provided with reinforcing ribs.

[0019] According to an embodiment of the present invention, the first limiting member is provided with a snap-fit ​​portion, the snap-fit ​​portion is provided on the side of the first limiting member close to the stator core, and the snap-fit ​​portion is adapted to snap-fit ​​with the stator core.

[0020] In the stator assembly according to an embodiment of the present invention, the snap-fit ​​portion is configured as a protrusion and / or a groove.

[0021] According to an embodiment of the present invention, the stator assembly includes a plurality of first limiting members, which are spaced apart circumferentially along the first insulating frame; and / or, the second limiting members include a plurality of second limiting members, which are spaced apart circumferentially along the second insulating frame.

[0022] According to an embodiment of the present invention, the first insulating frame and the second insulating frame are plugged into each other in the stator assembly.

[0023] According to an embodiment of the present invention, in the stator assembly, the first insulating frame has a first mounting member, the second insulating frame has a second mounting member, the first mounting member and the second mounting member form a column, the first mounting member is sleeved on the second mounting member, and the first mounting member and the second mounting member are provided with mounting holes for mounting the stator assembly to a motor.

[0024] According to an embodiment of the present invention, the first insulating frame is provided with a terminal mounting groove, and the terminal mounting groove is provided with limiting slots on two opposite side walls of the first insulating frame in the circumferential direction. The conductor of the stator winding is adapted to extend into the terminal mounting groove through the limiting slot.

[0025] According to an embodiment of the present invention, the first insulating frame has a snap-fit ​​portion at its end near the second insulating frame, and / or the second insulating frame has a snap-fit ​​portion at its end facing the first insulating frame, the snap-fit ​​portion cooperating with the stator core to restrict the axial movement of the stator core.

[0026] According to an embodiment of the present invention, the stator assembly further includes: an insulating ring disposed on the outer periphery of the stator core, and the insulating ring being located between the stator core and the stator winding.

[0027] According to an embodiment of the present invention, the insulating ring is an elastic insulating member wrapped around the outer periphery of the stator core; or, the insulating ring is insulating paper or insulating tape wrapped around the outer periphery of the stator core.

[0028] According to an embodiment of the present invention, the stator assembly further includes: a three-phase connecting bridge, the three-phase connecting bridge including a connecting plate, the connecting plate being mounted on the insulating frame; one of the connecting plate and the insulating frame having a positioning hole, and the other of the connecting plate and the insulating frame having a positioning post, the positioning post being adapted to be inserted into the positioning hole.

[0029] According to an embodiment of the present invention, in the stator assembly, the connecting plate is perpendicular to the axial direction of the stator core.

[0030] An electric motor according to a second aspect of the present invention includes: a support assembly, a rotor assembly, and a stator assembly according to a first aspect of the present invention, the stator assembly and the rotor assembly being disposed on the support assembly.

[0031] According to the present invention, by employing the above-described stator assembly, a stator-less motor can be formed, which can reduce vibration and noise during motor operation and improve motor performance.

[0032] The motor according to an embodiment of the present invention further includes: a conductive element disposed on the insulating frame and cooperating with the stator core and the support assembly respectively, for enabling the stator core and the support assembly to conduct electricity.

[0033] According to an embodiment of the present invention, the insulating frame has a mounting hole, one end of the conductive member extends into the mounting hole, and the insulating frame is fixedly connected to the bracket assembly by a fastener passing through the mounting hole, wherein the fastener contacts and engages with the conductive member.

[0034] According to an embodiment of the present invention, the conductive member includes a first conductive segment, a second conductive segment, and a third conductive segment. The first conductive segment is mounted on the insulating frame. The second conductive segment and the third conductive segment are respectively disposed at both ends of the first conductive segment. The second conductive segment extends toward the stator core to clamp between the insulating frame and the stator core. The third conductive segment defines a slot adapted to engage with the insertion.

[0035] According to an embodiment of the present invention, the included angle between the second conducting segment and the first conducting segment is α, where 150°≤α≤175°.

[0036] According to an embodiment of the present invention, the third conductive section includes a first folded edge, a second folded edge, and a third folded edge connected in sequence. The first folded edge is connected to the first conductive section, the second folded edge overlaps the edge of the mounting hole, and the third folded edge extends into the mounting hole of the insulating frame. The included angle between the third folded edge and the second folded edge is β, where 95°≤β≤120°.

[0037] According to an embodiment of the present invention, the insulating frame is provided with a limiting groove for mounting the conductive element; and / or, the insulating frame and the first conductive segment are connected by a limiting post and a limiting hole.

[0038] According to an embodiment of the present invention, the motor bracket assembly includes a bracket body and a central shaft. The stator assembly is mounted on one side of the bracket body, the central shaft is disposed on the same side of the bracket body and located in the middle of the stator assembly, and the other side of the bracket body is used to mount an electronic control board.

[0039] According to an embodiment of the present invention, the rotor assembly of the motor includes a rotor housing and a permanent magnet. The rotor housing includes an outer shell and an inner shell. The outer shell is located on the outer periphery of the stator assembly. The permanent magnet is disposed on the outer shell. The inner shell is adapted to be inserted into the inner hole of the stator assembly, and the inner shell is engaged with the central shaft through a bearing.

[0040] An electronic fan according to a third aspect of the present invention includes a motor according to a second aspect of the present invention. By employing the motor described above, vibration and noise during operation can be reduced, and the performance of the electronic fan can be improved.

[0041] A vehicle according to a fourth aspect of the present invention, including a motor according to a second aspect of the present invention, or an electronic fan according to a third aspect of the present invention, can reduce vibration and noise in the vehicle, improve vehicle performance, and enhance the user experience.

[0042] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0043] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0044] Figure 1 This is a schematic diagram of the stator assembly according to some embodiments of the present invention;

[0045] Figure 2 This is an exploded view of a stator assembly according to some embodiments of the present invention;

[0046] Figure 3 This is a schematic diagram of a stator assembly according to other embodiments of the present invention;

[0047] Figure 4 This is an exploded view of a stator assembly according to other embodiments of the present invention;

[0048] Figure 5 This is a schematic diagram of the fit between the insulating frame and the stator core according to some embodiments of the present invention;

[0049] Figure 6 This is a schematic diagram of the structure of a first insulating frame according to some embodiments of the present invention;

[0050] Figure 7 This is a schematic diagram of a first insulating frame from one viewpoint according to some embodiments of the present invention;

[0051] Figure 8 This is a schematic diagram of the first insulating frame according to some embodiments of the present invention from another perspective;

[0052] Figure 9 This is a schematic diagram of the first insulating frame according to some embodiments of the present invention from another perspective;

[0053] Figure 10 This is a cross-sectional view of a first insulating frame according to some embodiments of the present invention;

[0054] Figure 11 This is a schematic diagram of the structure of the first insulating frame according to other embodiments of the present invention;

[0055] Figure 12 yes Figure 11 The center circle shows a magnified view of point A;

[0056] Figure 13 This is a schematic diagram of the first insulating frame according to other embodiments of the present invention from one viewpoint;

[0057] Figure 14 This is a schematic diagram of the structure of the second insulating frame according to some embodiments of the present invention;

[0058] Figure 15 This is a schematic diagram of a second insulating frame from one perspective according to some embodiments of the present invention;

[0059] Figure 16 This is a schematic diagram of a second insulating frame according to some embodiments of the present invention from another perspective;

[0060] Figure 17 This is a cross-sectional view of a second insulating frame according to some embodiments of the present invention;

[0061] Figure 18 This is a schematic diagram of a second insulating frame according to other embodiments of the present invention;

[0062] Figure 19 yes Figure 18 The center circle shows a magnified view of point B.

[0063] Figure 20 This is a schematic diagram of the structure of a three-phase bridge according to some embodiments of the present invention;

[0064] Figure 21 This is a schematic diagram of a three-phase bridge according to some embodiments of the present invention from one perspective;

[0065] Figure 22This is a schematic diagram of the structure of a connection terminal according to some embodiments of the present invention;

[0066] Figure 23 This is a schematic diagram of the structure of a piercing terminal according to some embodiments of the present invention;

[0067] Figure 24 This is a schematic diagram of a piercing terminal from one perspective according to some embodiments of the present invention;

[0068] Figure 25 This is a schematic diagram of the structure of a stator winding according to some embodiments of the present invention;

[0069] Figure 26 This is a schematic diagram of the installation of stator windings according to some embodiments of the present invention;

[0070] Figure 27 This is a schematic diagram of the structure of a stator core according to some embodiments of the present invention;

[0071] Figure 28 This is a partial structural schematic diagram of the stator core strip according to some embodiments of the present invention;

[0072] Figure 29 This is a partial structural cross-sectional view of the stator core strip according to some embodiments of the present invention;

[0073] Figure 30 yes Figure 29 The center circle shows a magnified view of point C;

[0074] Figure 31 This is a schematic diagram of the winding of a stator core strip according to some embodiments of the present invention;

[0075] Figure 32 This is a schematic diagram of the first layer of the stator core strip according to some embodiments of the present invention;

[0076] Figure 33 This is a schematic diagram of the second layer of the stator core strip according to some embodiments of the present invention from one perspective;

[0077] Figure 34 This is a schematic diagram of the second layer of the stator core strip according to some embodiments of the present invention from another perspective;

[0078] Figure 35 This is a schematic diagram of the cooperation between the conductive element and the insulating frame according to some embodiments of the present invention;

[0079] Figure 36 This is a schematic diagram of the structure of a conductive element according to some embodiments of the present invention;

[0080] Figure 37 This is a schematic diagram of a conductive element according to some embodiments of the present invention from one viewpoint;

[0081] Figure 38 This is a schematic diagram of the structure of the first insulating frame according to some embodiments of the present invention;

[0082] Figure 39 This is an exploded view of an electric motor according to some embodiments of the present invention;

[0083] Figure 40 This is a cross-sectional view of an electric motor according to some embodiments of the present invention;

[0084] Figure 41 yes Figure 40 The center circle shows a magnified view of point D;

[0085] Figure 42 yes Figure 40 The enlarged view at point E is shown in the center circle;

[0086] Figure 43 This is a partial structural cross-sectional view of an electric motor according to some embodiments of the present invention;

[0087] Figure 44 This is an exploded view of a rotor assembly according to some embodiments of the present invention;

[0088] Figure 45 This is a schematic diagram of the structure of a support assembly according to some embodiments of the present invention;

[0089] Figure 46 This is a schematic diagram of an electronic fan according to some embodiments of the present invention;

[0090] Figure 47 This is a schematic diagram of a vehicle according to some embodiments of the present invention.

[0091] Figure label:

[0092] Motor 1000, electric fan 2000, vehicle 3000

[0093] Stator assembly 100, bracket assembly 200, bracket body 201, central shaft 202, mounting boss 203, rotor assembly 300, rotor housing 301, outer housing 3011, inner housing 3012, permanent magnet 302, bearing 303, electronic control board 400, insulating frame 10, third limiting member 101, snap-fit ​​part 103, mounting hole 104, first insulating frame 11, first frame plate 111, first limiting member 112, first fixing member 113, first mounting member 114, second insulating frame 12, second frame plate 121, second limiting member 122, second fixing member 123, first sub-fixing member 1231, second sub-fixing member 1232, second mounting member 124, winding auxiliary groove 13, winding guide groove 14, guide surface 15, terminal mounting groove 16, limiting slot 161, limiting 171, 172, 173, 18, 181, 19, 20, 21, 22, 23, 24, 25, 26, 27, 30, 31, 40, 50, 50, 51, 52, 53, 54, 55, 60, 61, 62, 63, 64, 70, 71, 72, 80, 80, 82, 83, 84, 70, 81, 82, 83, 83, 84, 83, 84, 80, 83, 84, 85, 80, 83, 83, 83, 84, 83, 84, 90, 83, 84, 85, 90. Detailed Implementation

[0094] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0095] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0096] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0097] The following is for reference. Figures 1-47 The stator assembly 100, motor 1000, electric fan 2000, and vehicle 3000 of the present invention are described in embodiments thereof.

[0098] like Figures 1-38 As shown, a stator assembly 100 according to an embodiment of the present invention includes an insulating frame 10 and a stator winding 30.

[0099] The insulating frame 10 is provided with multiple fixing members, and the stator winding 30 is wound on the multiple fixing members. Thus, the stator winding 30 is directly mounted on the insulating frame 10, and the stator winding 30 does not need to be wound on the stator core 20. The stator core 20 can be designed as a slotless structure. By eliminating the slots, the cogging torque is eliminated, thereby reducing the vibration and noise of the motor 1000 during operation. The torque output of the motor 1000 is more stable, the dynamic response is faster, and the efficiency of the motor 1000 is improved. It can also simplify the assembly process of the stator assembly 100, reduce production complexity, and reduce manufacturing costs. In addition, the slotless stator core 20 can also reduce the volume of the stator assembly 100, which is conducive to reducing the size of the motor 1000 and meeting the installation requirements of small spaces.

[0100] According to the stator assembly 100 of the present invention, the stator winding 30 is fixed by setting a fixing member on the insulating frame 10, which can not only ensure the stability of the stator winding 30, but also form a motor 1000 without stator slots by adopting the above arrangement, which can reduce the vibration and noise of the motor 1000 during operation and improve the performance of the motor 1000.

[0101] In some embodiments, the stator assembly 100 further includes a stator core 20, and the insulating frame 10 defines an installation space. The stator core 20 is installed in the installation space, thereby achieving the positioning and installation of the stator core 20. Under the action of the insulating frame 10, the outside of the stator core 20 can be insulated to a certain extent, and the stator core 20 can be limited, thereby improving stability.

[0102] The stator winding 30 is wound on the fixing member of the insulating frame 10, and the stator winding 30 is located outside the stator core 20.

[0103] The stator winding 30 is directly arranged on the outside of the stator core 20, and thus the permanent magnet 302 of the rotor assembly 300 can be arranged on the outside of the stator winding 30. This allows for an appropriate increase in the air gap between the stator core 20 and the permanent magnet 302. A larger air gap can reduce the non-uniformity of the air gap magnetic flux density, reduce the harmonic components of the radial electromagnetic force, thereby reducing vibration and noise, reducing torque fluctuations caused by non-uniform magnetic circuits, and making the motor 1000 run more smoothly.

[0104] According to the embodiment of the present invention, the stator assembly 100 fixes the stator core 20 by cooperating with the insulating frame 10 and the stator core 20, thereby improving the stability of the stator core 20. By adopting the above arrangement, a motor 1000 without stator slots can be formed, which can reduce the vibration and noise of the motor 1000 during operation and improve the performance of the motor 1000.

[0105] In some embodiments, a plurality of fasteners are disposed on the end face of the insulating frame 10, and the plurality of fasteners are spaced apart along the circumference of the insulating frame 10. The fasteners can be boss structures protruding from the end face of the insulating frame 10, thereby facilitating the winding of the stator winding 30.

[0106] In some embodiments, the plurality of fasteners include a plurality of first fasteners 113 and a plurality of second fasteners 123. The plurality of first fasteners 113 are disposed on the first end face of the insulating frame 10, and the plurality of second fasteners 123 are disposed on the second end face of the insulating frame 10. The first end face and the second end face are disposed opposite to each other along the axial direction of the insulating frame 10. The first fasteners 113 and the second fasteners 123 protrude in opposite directions, thereby facilitating the winding of the stator winding 30.

[0107] like Figure 18As shown, the multiple second fixing members 123 include multiple first sub-fixing members 1231 and multiple second sub-fixing members 1232. The second sub-fixing members 1232 are closer to the center of the insulating frame 10 than the first sub-fixing members 1231. This allows the conductor 31 to be transferred to the first sub-fixing member 1231 for winding after completing the winding of the current coil on the first fixing member 113 and the first sub-fixing member 1231. By setting multiple sets of sub-fixing members, multi-layer multi-phase windings can be facilitated.

[0108] like Figure 26 As shown, in some examples, 123a, 123b, 123c, and 123d are the first sub-fixed members 1231, and 123e and 123f are the second sub-fixed members 1232. The direction of the stator winding 30 is ((113b)-(123b)-(123a)-(113a)-(113b)-(123b) after the specified number of turns of the winding)-(123e)-(123f)-((123c)-(113c)-(113d)-(123d) after the specified number of turns of the winding). This makes the enameled wire in this group of coils run in one direction, and also makes the coils 1 and 2 formed arranged in one direction.

[0109] In addition, after the first layer of winding is completed, there is an empty area on the fixing part of the insulating frame, which can also accommodate 1 to 2 layers of winding with the same structure. In some examples, the winding has a total of 3 layers, and the angle between each layer of winding and the adjacent winding is 60 degrees.

[0110] like Figure 7 , Figure 16 and Figure 26 As shown, the number of multiple first fixing members 113 and multiple first sub-fixing members 1231 is the same, and the distance of multiple first fixing members 113 and multiple first sub-fixing members 1231 from the central axis of the insulating frame 10 is the same. This facilitates the winding of the stator winding 30. After winding, the part of the conductor 31 located outside the insulating frame 10 can remain vertical, and the formed coil is also arranged in a specified direction to generate a more uniform and stable magnetic field, thereby improving the operating efficiency of the motor.

[0111] like Figure 10 and Figure 17 As shown, in some embodiments, each fastener extends its outer peripheral wall at an angle toward the central axis of the insulating frame 10 along the direction away from the corresponding end face of the insulating frame 10, and the corresponding end face is the end face where the fastener is located, such as... Figure 10 As shown, the outer peripheral wall of the first fastener 113 extends inward and upward from bottom to top, as... Figure 17As shown, the outer peripheral wall of the second fastener 123 extends inward from top to bottom. This design helps to reduce the size of the fastener, reduce the weight and manufacturing cost of the insulation frame 10, and facilitates the fixed installation of the stator assembly 100 in the motor 1000, thus reducing the impact of the fastener installation on other components.

[0112] In some embodiments, the cross-sectional dimension of each fastener gradually decreases along the direction away from the corresponding end face of the insulating frame 10, and the corresponding end face is the end face where the fastener is located, such as... Figure 10 As shown, the cross-section of the first fastener 113 gradually decreases from bottom to top, as... Figure 17 As shown, the cross-section of the second fastener 123 gradually decreases from top to bottom. Through the above design, on the one hand, it is beneficial to reduce the size of the fastener, reduce the weight and manufacturing cost of the insulating frame 10, and on the other hand, reducing the size of the fastener can increase the space between two adjacent fasteners, so as to facilitate the winding of more wires.

[0113] like Figures 6-8 As shown, in some embodiments, at least two first fixing members 113 have a plurality of winding auxiliary slots 13 for accommodating a portion of the conductor 31 of the stator winding 30. That is, the winding auxiliary slots 13 are used to assist in wiring. The outer edge of the insulating frame 10 protrudes from the outer circle of the stator core 20. The conductor 31 of the stator winding 30 is wound on the fixing members of the insulating frame. A portion of the conductor 31 can be located in the winding auxiliary slots 13, so that the stator winding 30 is insulated from the stator core 20, while restricting the conductor 31 from moving in the circumferential direction. Here, the conductor 31 is a wire wrapped with an insulating layer, such as enameled wire. The winding auxiliary groove 13 here can be a concave arc structure. When each wire 31 is placed in the designated winding auxiliary groove 13, it can effectively prevent multiple wires 31 from squeezing each other on the circumference, thereby excessively squeezing the insulation frame and causing it to deform. In some examples, the wire diameter of the wire 31 is φd4, and the groove depth of the winding auxiliary groove is h, which is approximately d4 / 2. This can achieve a better wiring effect.

[0114] like Figures 11-13 As shown, in some embodiments, at least two first fixing members 113 are further provided with a plurality of winding guide grooves 14. The plurality of winding guide grooves 14 are symmetrically arranged between the two first fixing members 113. The setting of the winding guide grooves 14 will further improve the wiring and make it easier for the wire 31 to be guided into the winding auxiliary groove 13.

[0115] By setting the winding auxiliary groove 13 and the winding guide groove 14 on the first frame plate 111, the stator winding 30 can be tightly attached to the circumferential side of the insulating frame 10 and arranged neatly on the left and right sides in sequence, effectively avoiding the wires 31 from being squeezed and piled up on the circumference.

[0116] like Figure 12 As shown, in some embodiments, a plurality of winding guide grooves 14 are symmetrically arranged between two first fixing members 113, that is, the plurality of winding guide grooves 14 are symmetrically arranged with respect to the center line of the two first fixing members 113. There is a center line between the two first fixing members 113. Along the direction away from the center line, the angle between each winding guide groove 14 and the center line gradually decreases, thereby facilitating the winding of the wire 31 onto the corresponding fixing member and reducing the compression between adjacent wires 31.

[0117] like Figure 12 As shown, in some embodiments, multiple winding guide grooves 14 and multiple winding auxiliary grooves 13 correspond one-to-one. The winding guide grooves 14 and winding auxiliary grooves 13 are connected by a guide surface 15. The guide surface 15 forms an inclined surface and is used for angled transition. When the wire 31 is placed in front of the designated winding auxiliary groove 13 or winding guide groove 14, it can effectively avoid the wire 31 from having an excessively large bend angle, causing a local bulge at the bend. That is, the setting of the guide surface 15 makes the bending of the wire 31 more natural and reduces the risk of friction and noise.

[0118] like Figure 1 and Figure 2 As shown, in some embodiments, the insulating frame 10 includes a first insulating frame 11 and a second insulating frame 12, with an installation space defined between the first insulating frame 11 and the second insulating frame 12.

[0119] The first insulating frame 11 is provided with a plurality of first fixing members 113 for winding the stator winding 30. The second insulating frame 12 is provided with a plurality of second fixing members 123 for winding the stator winding 30. This facilitates the winding of the stator winding 30 on the two insulating frames 10, realizes the installation and fixation of the stator winding 30, and makes it easy for the stator winding 30 to be installed on the outside of the stator core 20.

[0120] The number of the first fixing member 113 and the second fixing member 123 is related to the number of slot poles, winding layers, parallel branches, and winding pitch of the motor, such as... Figure 7 As shown, in some examples, there are 24 first fasteners 113.

[0121] The first fixing member 113 and the second fixing member 123 are both distributed along the circumferential side of the two insulating frames. The second fixing member 123 can correspond to the position of the first fixing member 113, which facilitates the winding of the conductor 31 of the stator winding 30. The conductor 31 of the stator winding 30 can run in one direction, and the coil formed is also arranged in a specified direction.

[0122] In some embodiments, the first insulating frame 11 and the second insulating frame 12 are arranged opposite each other along the axial direction of the stator core 20. The side of the first insulating frame 11 facing the second insulating frame 12 is provided with a third limiting member 101, and the side of the second insulating frame 12 facing the first insulating frame 11 is also provided with a third limiting member 101. The third limiting member 101 cooperates with both ends of the stator core 20 along the axial direction to restrict the axial movement of the stator core 20.

[0123] like Figure 1 and Figure 2 As shown, in some embodiments, at least one of the first insulating frame 11 and the second insulating frame 12 is provided with a limiting member extending toward one side of the stator core 20. The limiting member extends into the stator core 20 and engages with the inner circumference of the stator core 20 to restrict the radial movement of the stator core 20.

[0124] In some embodiments, at least one of the first insulating frame 11 and the second insulating frame 12 is provided with a locking portion 103, which cooperates with the positioning portion 23 of the stator core 20 to restrict the circumferential movement of the stator core 20 and prevent the stator core 20 from rotating circumferentially. The locking portion 103 can be a protrusion or a groove, that is, it protrudes or is recessed toward the stator core 20.

[0125] In other words, the insulating frame 10 can be limited and insulated at the axial end of the stator core 20 by the third limiting member 101, and the insulating frame 10 can be limited and insulated on the inner circumference of the stator core 20 by the first limiting member 112 and the second limiting member 122; the insulating frame 10 can be limited in the circumferential direction of the stator core 20 by the snap-fit ​​part 103.

[0126] like Figure 8 As shown, a third limiting member 101 is formed on the edge of the first insulating frame 11 facing the stator core 20. The third limiting member 101 has an annular limiting surface, and one end face of the stator core 20 in the axial direction abuts against the third limiting member 101. Figure 15 As shown, the edge of the second insulating frame 12 facing the stator core 20 forms a third limiting member 101. The third limiting member 101 has an annular limiting surface. The other end face of the stator core 20 in the axial direction abuts against the third limiting member 101, thereby achieving axial limiting and insulation of the stator core 20.

[0127] like Figure 6 As shown, the first insulating frame 11 is provided with a first limiting member 112, which extends toward the second insulating frame 12. The first limiting member 112 extends into the inside of the stator core 20 and cooperates with the stator core 20. Thus, the first insulating frame 11 can radially limit the stator core 20. Figure 14As shown, the second insulating frame 12 is provided with a second limiting member 122. The second limiting member 122 extends toward the first insulating frame 11 and extends into the inside of the stator core 20 to cooperate with the stator core 20. Thus, both the second and second insulating frames 12 can radially limit the stator core 20. Of course, the limiting member used for radial limiting can be provided on only one insulating frame or on both insulating frames at the same time.

[0128] like Figure 6 and Figure 27 As shown, the first insulating frame 11 is provided with a snap-fit ​​part 103, and the stator core 20 is provided with a positioning part 23. The snap-fit ​​part 103 cooperates with the positioning part 23, thereby limiting the circumferential movement of the stator core 20 and preventing the stator core 20 from rotating circumferentially. Of course, the snap-fit ​​part 103 can also be provided on the second insulating frame 12, or the snap-fit ​​part 103 can be provided on the first insulating frame 11 and the second insulating frame 12 respectively.

[0129] The first insulating frame 11 and the second insulating frame 12 are arranged opposite each other along the axial direction of the stator core 20, which facilitates the assembly of the first insulating frame 11 and the second insulating frame 12, as well as the assembly of the stator core 20 with the first insulating frame 11 and the second insulating frame 12, thereby improving assembly efficiency.

[0130] In some embodiments, the first limiting member 112 and the second limiting member 122 for radial limiting may include multiple members, which are respectively arranged at intervals on the inner circumference of the stator core 20. The multiple limiting members improve the radial limiting effect on the stator core 20. At least a portion of the limiting members have a snap-fit ​​portion 103 on the side near the stator core 20. Figure 6 As shown, the first insulating frame 11 includes a plurality of first limiting members 112. At least some of the first limiting members 112 have a snap-fit ​​portion 103 on their outer side. The snap-fit ​​portion 103 can be a protrusion protruding from the first limiting member 112 or a groove recessed on the surface of the first limiting member 112. By directly forming the snap-fit ​​portion 103 on the limiting member, the limiting structure is fully utilized, the structure of the insulating frame 10 is simplified, and the manufacturing and molding of the insulating frame 10 is facilitated.

[0131] In some embodiments, a first limiting member 112 is disposed on a first insulating frame 11, and a second limiting member 122 is disposed on a second insulating frame 12. The first limiting member 112 and the second limiting member 122 are arranged alternately along the circumference of the stator core 20, that is, the second limiting member 122 is located between two adjacent first limiting members 112, and the first limiting member 112 is located between two adjacent second limiting members 122. This allows multiple limiting members to be provided on the inner circumference of the stator core 20, improving the limiting effect on the stator core 20. At the same time, it can simplify the structure of each insulating frame 10, facilitate the manufacturing of the insulating frame 10, and reduce manufacturing costs.

[0132] The second limiting member 122 and the first limiting member 112 are both evenly distributed along the center of the stator core 20. Their outer surfaces are all arc surfaces and are all on the same distribution circle for mounting the stator core 20. The second limiting member 122 and the first limiting member 121 are fitted with the inner surface of the stator core 20 with a small gap. A rib is provided on a part of the first limiting member 121 to form a snap-fit ​​part 103 to restrict the circumferential movement of the stator core 20.

[0133] like Figure 8 As shown, in some embodiments, the first limiting member 112 is provided with a reinforcing rib 19, which extends toward the axis of the first insulating frame 11, thereby improving the structural strength of the first limiting member 112 and improving the stability of the overall structural assembly.

[0134] like Figure 15 As shown, in some embodiments, the second limiting member 122 is provided with a reinforcing rib 19, which extends toward the axis of the second insulating frame 12, thereby improving the structural strength of the second limiting member 122 and improving the stability of the overall structural assembly.

[0135] like Figures 6-13 As shown, in some embodiments, the first insulating frame 11 includes a first frame plate 111, a first limiting member 112 is provided on one side of the first frame plate 111, and a plurality of first fixing members 113 are provided on the other side of the first frame body. The plurality of first fixing members 113 are used for winding the stator winding 30. The first fixing members 113 are close to the edge of the first frame plate 111 relative to the first limiting member 112, thereby facilitating the winding of the stator winding 30. At the same time, it is convenient for the stator winding 30 installed on the insulating frame to be located outside the stator core 20, reducing the interference between the stator winding 30 and the stator core 20.

[0136] like Figures 6-8As shown, in some embodiments, there are multiple winding auxiliary slots 13 between any two adjacent first fixing members 113. The winding auxiliary slots 13 are located on the outer periphery of the first frame plate 111 and are used to accommodate a portion of the conductor 31 of the stator winding 30. That is, the winding auxiliary slots 13 are used to assist in wiring. The outer edge of the insulating frame 10 protrudes from the outer circle of the stator core 20. The conductor 31 of the stator winding 30 is wound on the fixing member of the insulating frame. A portion of the conductor 31 can be located in the winding auxiliary slot 13, so that the stator winding 30 is insulated from the stator core 20, while restricting the conductor 31 from moving in the circumferential direction. Here, the conductor 31 is a wire wrapped with an insulating layer, such as enameled wire.

[0137] In some examples, the outer surface of the first limiting member 112 is an arc surface, which facilitates the engagement between the stator core 20 and the first limiting member 112.

[0138] In some examples, the concave arc of the winding auxiliary groove 13 is on the same distribution circle, and the circle formed by it and the multiple first limiting members 112 is a concentric circle. The diameter of the distribution circle of the concave arc of the winding auxiliary groove 13 is φd2, and the outer diameter of the stator core is φd1. The stator core is made of metal sheet, which is prone to burrs on its edge. In order to avoid the burrs protruding from the stator core 20 scratching the paint film of the stator winding 30 and to avoid the stator winding 30 having poor withstand voltage after being energized, d1-d2 can be limited to between 0.4mm and 1mm. That is, d1-d2 can be any value of 0.4mm, 0.75mm, 1mm or any value between two of them. This can effectively avoid the stator winding 30 from contacting the upper and lower edges of the outer surface of the stator core 20, and at the same time, it will not occupy too much radial space.

[0139] like Figures 11-13 As shown, in some embodiments, there are also multiple winding guide grooves 14 between any two adjacent first fixing members 113. The winding guide grooves 14 are provided on the side of the first frame plate 111 where the first fixing members 113 are provided, and the multiple winding guide grooves 14 and multiple winding auxiliary grooves 13 correspond one-to-one. The setting of the winding guide grooves 14 will further improve the wiring and make it easier for the wires 31 to be guided into the winding auxiliary grooves 13.

[0140] like Figure 14-19As shown, in some embodiments, the second insulating frame 12 includes a second frame plate 121. The structure of the second frame plate 121 is the same as that of the first frame plate 111 and they are arranged opposite each other. On the side of the second frame plate away from the first frame plate 111, there are a plurality of second fixing members 123 for winding the stator winding 30, which facilitates the winding of the stator winding 30. The second fixing members 123 are located on the outer periphery of the second limiting member 122, and at the same time, it is convenient for the stator winding 30 installed on the insulating frame to be located outside the stator core 20, thereby reducing the interference between the stator winding 30 and the stator core 20.

[0141] In some embodiments, the first fixing member 113 and the second fixing member 123 are both distributed along the circumferential side of the two insulating frames. The second fixing member 123 can correspond to the position of the first fixing member 113, thereby facilitating the winding of the conductor 31 of the stator winding 30. The conductor 31 of the stator winding 30 can run in one direction, and the formed coil is also arranged in a specified direction. The outer periphery of the second frame plate 121 is also provided with a winding guide groove 13. The winding conductor grooves 13 on the two insulating frames are also corresponding in position. Thus, the conductor 31 can run vertically between the two second frame plates 121 and the first frame plate 111. After the conductor 31 runs vertically along the axial direction of the stator core, it can run across the groove above the frame and further enable it to continue running vertically along the axial direction.

[0142] like Figure 12 and Figure 19 As shown, in some examples, the winding guide groove 14 and the winding auxiliary groove 13 are connected by a guide surface 15. The guide surface 15 extends obliquely from the outside to the inside in a direction away from the second insulating frame 12, that is, the guide surface 15 forms an oblique surface. The guide surface 15 is used for oblique transition. When the wire 31 is placed in front of the designated winding auxiliary groove 13 or winding guide groove 14, it can effectively avoid the wire 31 from having too large an angle, causing a local bulge at the bend. That is, the setting of the guide surface 15 makes the bending of the wire 31 more natural and reduces the risk of friction and noise.

[0143] In some examples, the number of turns in each winding is n, the number of winding auxiliary slots 13 between two adjacent fixing members is 2n, the winding auxiliary slots 13 are all distributed along the outer circumference of the insulating frame 10, and the number of winding guide slots 14 is the same as the number of winding auxiliary slots 13, both being 2n. Figure 19 As shown, for example, if the number of turns is set to 3, the number of winding auxiliary grooves 13 between the two fixing parts is 6, and the guide grooves between adjacent fixing parts are 14a, 14b, 14c, 14d, 14e, and 14f respectively, then 14a, 14b, 14c, 14d, 14e, and 14f are symmetrically arranged along the center line between the two fixing parts, and the angles between the different winding guide grooves 14 and the center line are not equal, α > β > γ, and the closer to the center line, the larger the angle.

[0144] In some embodiments, the first insulating frame 11 and the second insulating frame 12 are interlocked, thereby facilitating the assembly of the two insulating frames. For example... Figure 8 and Figure 14 As shown, in some examples, the first insulating frame 11 has a first mounting member 114 extending toward the second insulating frame, and the second insulating frame 12 has a second mounting member 124 extending toward the first insulating member. The first mounting member 114 and the second mounting member 124 are interlocked. For example, after the first mounting member 114 is inserted into the second mounting member 124 in a specified direction, a cavity region can be formed between the first insulating frame 11 and the second insulating frame 12. The cavity region can be used to accommodate the stator core. The first mounting member 114 and the second mounting member 124 can be clearance-fitted for easy assembly.

[0145] like Figure 8 and Figure 14 As shown, in some examples, the first mounting member 114 and the second mounting member 124 are columnar, and each of the two mounting members has a mounting hole 104 defined in the middle. The mounting hole 104 is used for mounting the stator assembly 100 in the motor 1000. For example, by fastening the two mounting members, the first insulating frame 11 and the second insulating frame 12 are fixedly connected, and the insulating frame 10 is fixedly connected to the bracket assembly 200, thereby improving the stability of the entire stator assembly 100 structure.

[0146] like Figure 6 As shown, in some embodiments, the first insulating frame 11 is provided with terminal mounting slots 16 for mounting piercing terminals 60, facilitating wiring. Multiple terminal mounting slots 16 can be placed on the same distribution circle, distributed left and right close to the wire ends, fixing the wire ends of the conductor 31 and facilitating electrical interconnection between the conductor 31 and the outside world. The number of terminal mounting slots 16 is usually determined by the number of wire ends of the conductor 31. In some examples, there are 3 sets of windings, 3 wire ends, and 3 wire ends, that is, a total of 6 terminal mounting slots 16.

[0147] The terminal mounting slot 16 has two opposing limiting slots 161 on its two circumferentially opposite side walls along the first insulating frame 11. The conductors 31 of the stator winding 30 can extend into the terminal mounting slot 16 through the limiting slots 161. Figure 6As shown, a limiting slot 161 is provided on the side of the terminal mounting slot 16. The limiting slot 161 is connected to the terminal mounting slot 16. The wire 31 of the stator winding 30 can be inserted into the limiting slot 161 to prevent the wire ends from coming loose. The wire 31 extends into the terminal mounting slot 16. The limiting slot 161 is used to hold the wire 31. That is, the first insulating frame 11 can fix the wire 31 and prevent the stator winding 30 from coming loose. At the opening of the limiting slot 161, an angled structure is provided to guide the wire into the limiting slot 161.

[0148] In some examples, the width of the limiting slot 161 can be smaller than the outer diameter of the wire 31, for example, 0.05 to 0.2 mm smaller. When the wire head and tail of the wire 31 are oriented to the limiting slot 161, the wire head and tail can be roughly fixed by a small interference fit, which makes it easier for the piercing terminal 60 to be inserted into the terminal mounting slot 16 and pierce the wire 31.

[0149] In some embodiments, the stator assembly 100 further includes an insulating ring 40, which is disposed on the outer periphery of the stator core 20 and located between the stator core 20 and the stator winding 30. By providing the insulating ring 40 on the outer periphery of the stator core 20, insulation is achieved between the stator winding 30 and the stator core 20, effectively isolating the electrical connection between the stator core 20 and the stator winding 30, preventing current leakage or short circuit between the stator core 20 and the stator winding 30, increasing the electrical insulation performance between the stator winding 30 and the stator core 20, thereby ensuring the safe operation of the motor 1000.

[0150] When the conductor 31 of the stator winding 30 is wound between the first fixing member 113 and the second fixing member 114, the conductor 31 is usually straight. However, due to turnover and handling, the conductor 31 is easily bent and deformed towards the stator core 20, causing the stator winding 30 to be close to the stator core 20. As a result, the insulation distance is insufficient, which may easily lead to the risk of poor withstand voltage. Therefore, by setting an insulating ring 40 on the outer periphery of the stator core 20, the insulating ring is set to be at the same height as the stator core 20, and the inner surface of the insulating ring is in contact with the outer surface of the stator core, thereby forming an insulating layer between the stator core 20 and the stator winding 30, which can prevent the stator core 20 and the stator winding 30 from being in direct contact.

[0151] In some embodiments, the insulating ring 40 is an elastic insulating element wrapped around the outer periphery of the stator core 20. The insulating ring 40 is directly sleeved on the outer periphery of the stator core 20 to achieve insulation of the outer periphery of the stator core 20. The elastic insulating element is directly sleeved on the outside of the stator core 20, which is convenient for installation.

[0152] In other embodiments, the insulating ring 40 is insulating paper or insulating tape wrapped around the outer periphery of the stator core 20. By wrapping the stator core 20 with insulating paper or insulating tape, insulation of the outer periphery of the stator core 20 is achieved. Insulating paper or insulating tape is low in cost, easy to wrap, and easy to control.

[0153] The thickness of the insulating ring 40 is t, the outer diameter of the stator core is φd1, and the diameter of the distribution circle of the concave arc of the winding auxiliary groove 13 is φd2. φd1+2t≤φd2, so the insulating ring 40 can produce sufficient insulation effect while avoiding occupying radial space, thus ensuring the performance of the motor 1000.

[0154] like Figure 27 As shown, in some embodiments, an inner cylindrical surface 21 is formed on the inner surface of the stator core 20, and an outer cylindrical surface 22 is formed on the outer surface of the stator core 20. The centers of the inner cylindrical surface 21 and the outer cylindrical surface 22 coincide, thereby forming a roughly annular stator core 20. The stator core 20 has a simple structure. The slotless stator core 20 can reduce production complexity and manufacturing costs, and can also reduce the volume of the stator assembly 100, which in turn helps to reduce the size of the motor 1000 and meet the installation requirements of small spaces. The slotless stator core 20 can also reduce the vibration and noise of the motor 1000 during operation, making the torque output of the motor 1000 more stable, the dynamic response faster, and improving the efficiency of the motor 1000.

[0155] like Figure 27 As shown, in some embodiments, a portion of the inner surface of the stator core 20 is recessed outward to form a positioning part 23, that is, the positioning part 23 is a groove. The positioning groove 23 can be directly stamped during the manufacturing of the strip 24 of the stator core 20, which is convenient to manufacture.

[0156] like Figure 2 , Figure 3 , Figure 20 and Figure 21 As shown, in some embodiments, the stator assembly 100 further includes a three-phase connecting bridge 50, which includes a connecting plate 51 and three connecting bodies 52. The connecting plate 51 is mounted on the insulating frame 10, and the three connecting bodies 52 are located on the side of the connecting plate 51 near the stator core 20. The three connecting bodies 51 can be connected to the U-phase, V-phase, and W-phase wound on the stator winding 30 respectively, thereby realizing the electrical connection between the three connecting bodies 52 and the stator winding 30. This can realize a star connection structure and improve the convenience and reliability of the electrical connection.

[0157] In this case, the connecting plate 51 can be punched and bent in the same direction to form the connecting body 52. ​​The three connecting bodies 52 are distributed on the same arc. The connecting bodies can be connected to the piercing terminal 60, thereby achieving electrical connection with the U phase, V phase and W phase wound on the stator winding 30.

[0158] like Figure 6 and Figure 20 As shown, one of the connecting plate 51 and the insulating frame 10 has a positioning hole 53, and the other of the connecting plate 51 and the insulating frame 10 has a positioning post 18. The positioning post 18 can be inserted into the positioning hole 53, thereby realizing the positioning and installation of the connecting plate 51 on the insulating frame 10. This facilitates installation, improves the connection reliability of the three-phase connecting bridge 50, and prevents it from becoming loose.

[0159] like Figure 9 As shown, in some embodiments, the positioning post 18 is disposed on the insulating frame 10. The positioning post 18 includes two oppositely arranged limiting hooks 181. The two limiting hooks 181 are spaced apart to define an elastic gap. The connecting plate 51 is engaged with the limiting hooks 181.

[0160] The positioning post formed by the two limiting hooks 181 has a structure with a boss at the top, the outer diameter of which is p1. The lower part of the boss is a columnar segment with an outer diameter of p2. The inner diameter of the positioning hole 53 is P. The three conditions must satisfy p1>P≥p2, and p1 / P≈1.05~1.3. Since the two limiting hooks 181 are arranged at intervals to limit the elastic gap, the limiting hooks 181 can undergo slight deformation, allowing the two limiting hooks 181 to fit into the positioning hole 53 of the three-phase connecting bridge 50, where p1>P. After the limiting hooks 181 are fully fitted into the positioning hole 53, they are not easily dislodged, thus achieving a good anti-loosening effect.

[0161] In some examples, the connecting plate 51 is perpendicular to the axial direction of the stator core 20, that is, the three-phase connecting bridge 50 is flat and laid flat, so that it is placed on the insulating frame 10 and can fit into the terminal mounting slot. The three-phase connecting bridge 50 will not occupy too much axial space of the stator core 20, thereby reducing the axial length of the stator assembly 100 and the motor 1000.

[0162] like Figure 2 , Figure 3 , Figure 23 and Figure 24As shown, in some embodiments, the stator assembly 100 further includes a plurality of piercing terminals 60, each piercing terminal 60 being adapted to be installed in a corresponding terminal mounting slot 16 on the insulating frame 10 and snapped into the insulating frame 10. The piercing terminal 60 has a piercing portion 61, which is used to pierce the insulating wrapping layer of the wire 31 so that the piercing terminal 60 and the wire 31 are electrically connected. That is, after the piercing terminal 60 is inserted into the terminal mounting slot 16, the piercing portion 61 cuts the varnish film of the wire 31 and pierces into the conductor of the wire 31, so that the piercing terminal 60 and the wire 31 (wire head and wire tail) are electrically connected.

[0163] The piercing terminal 60 is used as an intermediate transfer point. One end of the piercing terminal 60 is pierced and connected to the conductor 31, and the other end of the piercing terminal 60 can be connected to the three-phase connecting bridge 50 or other external structures (such as connecting terminal 70). This makes the overall installation more convenient. Both the piercing terminal 60 and the three-phase connecting bridge 50 are arranged on the first insulating frame 11. The structure is reasonably set and can be easily assembled using automated equipment, thereby improving the production efficiency of the stator assembly 100.

[0164] The outer side of the piercing terminal 60 is provided with a locking protrusion 64, which can be locked into both sides of the terminal mounting groove 16, making it difficult for the piercing terminal 60 to fall out of the terminal mounting groove 16.

[0165] like Figure 23 and Figure 24 As shown, in some embodiments, the piercing terminal 60 defines a piercing groove 62 open on one side, and a spring piece 63 is provided in the piercing groove 62, such as... Figure 20 As shown, each connector 52 can be inserted into the piercing groove 62, and the connector 52 is engaged with the spring piece 63.

[0166] like Figure 20 As shown, the connector 52 has a first locking position 55, and the end of the spring piece 63 can be locked into the first locking position 55. This can prevent the connector 52 from disengaging from the piercing terminal 60, thereby improving the reliability of the engagement. At the same time, it can realize the electrical connection between the connector 52 and the piercing terminal 60, and thus realize the electrical connection between the three-phase bridge 50 and the conductor 31.

[0167] like Figure 20 As shown, in some examples, the connector 52 has a first clearance groove 54 with one end open, and the connector 52 can be inserted into the piercing groove 62. The first clearance groove 54 is used to avoid the wire 31 and prevent the enameled wire in the piercing groove 62 from being cut off.

[0168] like Figure 3 and Figure 4As shown, in some embodiments, the stator assembly 100 further includes a connecting terminal 70, one end of which extends into the piercing groove 62 and engages with the spring piece 63, and the other end of which can be electrically connected to the electronic control board 400, thereby realizing the electrical connection between the stator winding 30 and the outside world.

[0169] like Figure 22 As shown, in some examples, one end of the connecting terminal 70 has a second clearance groove 71, one end of which is open to allow the wire 31 to be inserted into the piercing groove 62, so as to avoid cutting the enameled wire in the piercing groove 62.

[0170] like Figure 22 As shown, one end of the connecting terminal 70 has two reinforcing structures, with a second clearance groove 71 defined between the two reinforcing structures. The outer sides of the two reinforcing structures protrude outwards relative to each other, which increases the mechanical strength of the end of the connecting terminal 70, making it less likely to bend when inserted into the piercing groove 62, and also increases its conductivity.

[0171] like Figure 22 As shown, the terminal 70 also has a second locking position 72. The end of the spring piece 63 of the piercing terminal 60 can be locked into the second locking position 72. This can prevent the terminal 70 and the piercing terminal 60 from disengaging, improve the reliability of the engagement, and at the same time realize the electrical connection between the terminal 70 and the piercing terminal 60, thereby realizing the electrical connection between the terminal 70 and the wire 31.

[0172] In some examples, after the conductor 31 is wound, there will be multiple phases and multiple wire ends. In this example, there are three phases, three wire ends, and three wire ends.

[0173] Specifically, after the insulating frame 10 and the stator core 20 are initially assembled into a whole, windings are then performed between the first fixing member 113 and the second fixing member 123 of the insulating frame 10 to form a winding structure. For example, in some examples, three windings are formed, namely U phase, V phase, and W phase, where U phase is the first winding, V phase is the second winding, and W phase is the third winding. Each phase has two taps, for a total of six taps, namely U1, U2, V1, V2, W1, and W2. U1, V1, and W1 are designated as wire ends, and U2, V2, and W2 are designated as wire ends. In other examples, two windings, four windings, etc., can be formed.

[0174] like Figures 20-25 As shown, in some examples, the stator assembly 100 is provided with six piercing terminals 60, which are respectively connected to U1, V1, U2, W1, V2, and W2.

[0175] The connecting terminal 70 is connected to the piercing terminal 60 at the designated position, so that the stator winding 30 can be connected to the outside (electrical control board). Here, it can be the piercing terminal 60 at the three wire ends (U2, V2, W2). The piercing terminal 60 connected to the wire ends U1, V1, and W1 is connected by a three-phase connecting bridge 50, so that the three wire ends (U1, V1, W1) are interconnected.

[0176] This enables the integration of the output section of motor 1000, facilitating assembly, effectively improving the production efficiency of stator assembly 100, and reducing production costs.

[0177] like Figures 27-34 As shown, in some embodiments, the stator core 20 is formed by spirally winding strip 24 along an axial direction to form a multi-layer structure. The width direction of the strip 24 is perpendicular to the axial direction, which is the axial direction of the stator assembly 100. The strip 24 is a narrow sheet, that is, the stator core 20 is formed by stamping and then rotating and winding a narrow sheet.

[0178] This reduces the processing difficulty of stator core 20 production, improves product qualification rate, reduces waste and improves material utilization, reduces production costs, and also reduces assembly steps and improves production efficiency.

[0179] like Figures 28-34 As shown, in some embodiments, the strip 24 is stamped with perforations 25 and multiple local bosses 26. Local grooves 27 are formed on the strip 24 at the local bosses 26. The local bosses 26 are suitable for insertion into the perforations 25 or local grooves 27 of the adjacent layers, thereby tightly connecting each layer of strip 24 with its adjacent strip 24, so that the stator core 20 becomes a whole with a fixed height. That is, the stator core 20 can be formed by stacking and riveting the strips 24, and the stator core 20 is not easy to fall apart.

[0180] like Figure 28 and Figure 29 As shown, the strip 24 is made of thin and narrow strip material. When the strip material is fed forward, the rivet points and positioning parts 23 are punched out, thereby forming positioning grooves and fixing structures with fixed spacing on the strip material 24.

[0181] The positioning part 23 can be directly punched through the strip 24 to form a semi-circular arc structure.

[0182] The strip 24 also features two types of fixing structures stamped on it. Specifically, each layer has six stamping positions, such as... Figure 32As shown, the first layer is punched to form a perforation 25. On the subsequent strip 24, a partial boss 26 is punched, that is, without punching, a partial groove 27 and a partial boss 26 are formed on the strip 24. Both the perforation 25 and the partial groove 27 are circular structures and have basically the same diameter. That is, the hole diameter of the perforation 25 and the inner diameter of the partial groove 27 are basically the same. The outer diameter of the partial boss 26 will be slightly larger than the inner diameter of the partial groove 27.

[0183] The strip 24 is wound in a ring to form a circular structure, and then stacked in the thickness direction to form a stator core of a certain height. The height of the stator core is H, and the thickness of the strip is t. The number of layers required is H / t. During the stacking process, the positioning part 23 of the upper strip 24 overlaps with the positioning part 23 of the lower strip 24. The local boss 26 of the second layer overlaps with the through hole 25 of the first layer, forming an interference fit. The local boss 26 of the third layer overlaps with the local groove 27 of the second layer, forming an interference fit. This connects the upper and lower strips into a whole. This process is repeated until several layers are stacked to form a complete stator core 20 with a suitable height.

[0184] In other examples, after the strip 24 is wound in multiple layers along its width, it is stacked longitudinally until a specified number of layers are reached. Then, multiple welds are made from top to bottom along its annular surface to weld it into a whole, forming a complete stator core 20.

[0185] like Figures 35-45 As shown, the motor 1000 according to an embodiment of the present invention includes: a support assembly 200, a rotor assembly 300 and a stator assembly 100. The stator assembly 100 and the rotor assembly 300 are disposed on the support assembly 200. By using the stator assembly 100, a stator-free motor 1000 can be formed, which can reduce the vibration and noise of the motor 1000 during operation and improve the performance of the motor 1000.

[0186] like Figures 35-38 As shown, in some embodiments, the motor 1000 further includes a conductor 80, which is disposed on the insulating frame 10 and cooperates with the stator core 20 and the support assembly 200 respectively to make the stator core 20 and the support assembly 200 conductive. Since the rotor assembly 300 is connected to the support assembly 200, by setting the conductor 80, the conductor 80 connects the stator core 20 and the support assembly 200, so that the motor 1000 achieves equipotential, which can suppress the discharge between the stator core 20 and the rotor assembly 300, prevent severe discharge from generating an arc that damages the electronic control components, and avoid excessive voltage difference causing damage to the inside of the motor 1000.

[0187] like Figure 35As shown, in some embodiments, the insulating frame 10 has a mounting hole 104, one end of the conductor 80 extends into the mounting hole 104, and the insulating frame 10 is fixedly connected to the bracket assembly 200 by a fastener 90 passing through the mounting hole 104. The fastener 90 and the conductor 80 are in contact and engaged, thereby making full use of the internal structure of the motor 1000 to realize the cooperation between the conductor 80 and other structural components, and realizing the conduction between the stator core 20 and the bracket assembly 200.

[0188] It is understandable that the stator core 20, fasteners 90, conductors 80, support assembly 200, and rotor assembly 300 are all metal parts. The conductors 80 can be made of metal materials with good elasticity, such as beryllium copper or stainless steel.

[0189] like Figure 36 and Figure 37 As shown, in some embodiments, the conductive member 80 includes a first conductive section 81, a second conductive section 82, and a third conductive section 83. The first conductive section 81 is mounted on the insulating frame 10. The second conductive section 82 and the third conductive section 83 are respectively disposed at both ends of the first conductive section 81. The second conductive section 82 extends toward the stator core 20 to be clamped between the insulating frame 10 and the stator core 20. The third conductive section 83 defines a slot 834, which is adapted to be inserted into the insulating frame 10. For example, the slot 834 is inserted into the hole of the mounting hole 104, and a portion of the third conductive section 83 extends into the mounting hole 104, thereby realizing the installation and fixation of the conductive member 80.

[0190] like Figure 37 As shown, in some embodiments, the included angle between the second conductive segment 82 and the first conductive segment 81 is α, 150°≤α≤175°, which facilitates the second conductive segment 82 to fit with the stator core 20 without hindering the assembly of the stator core 20 with the insulating frame 10.

[0191] like Figure 37 As shown, in some embodiments, the third conductive segment 83 includes a first folded edge 831, a second folded edge 832, and a third folded edge 833 connected in sequence. The first folded edge 831 is connected to the first conductive segment 81, the second folded edge 832 overlaps the edge of the mounting hole 104, and the third folded edge 833 extends into the mounting hole 104. The included angle between the third folded edge 833 and the second folded edge 832 is β, where 95°≤β≤120°.

[0192] The mounting hole 104 may have a mounting platform 173 slightly lower than the end face. The third conductive section 83 is mounted on the mounting platform 173 to avoid the installation of the conductive piece 80 affecting the assembly of other structures. The third folded edge 833 is placed in the mounting hole 104 to realize the installation of the third conductive section 83, and the conductive piece 80 is further fixed by the fastener 90 installed in the mounting hole 104.

[0193] The included angle between the third fold 833 and the second fold 832 is limited to between 95° and 120°, which allows the third fold 833 to have a good fit with the fastener 90 without hindering the insertion of the fastener 90, thus preventing the third fold 833 from affecting the overall assembly of the motor 1000. The fastener 90 can be a screw, with the screw threads or cylindrical surface elastically fitted to the conductor 80.

[0194] Thus, by adopting a spring-loaded conductive element 80, one end of the conductive element 80 is elastically connected to the stator core 20, and the other end of the conductive element 80 is elastically connected to the fastener 90. The fastener 90 is connected to the bracket assembly 200, thereby enabling the bracket assembly 200 to conduct electricity with the stator core 20.

[0195] In addition, the rotor assembly 300 is connected to the support assembly 200 via the central shaft 202 and the bearing 303, and the stator core 20 is indirectly connected to the rotor assembly 300 to achieve equipotential.

[0196] like Figure 28 As shown, in some embodiments, the insulating frame 10 is provided with a limiting groove 171, which is used to install the conductive element 80. This not only limits the conductive element 80, but also prevents the installation of the conductive element 80 from interfering with other structural components.

[0197] like Figures 25-28 As shown, in some embodiments, the insulating frame 10 is provided with a limiting post 172, and the first conductive section 81 has a limiting hole 84. The limiting post 172 and the limiting hole 84 are inserted and matched, thereby limiting the installation of the first conductive section 81, reducing the probability of the conductive component 80 shaking and affecting other structural components, and improving the reliability of the overall structural fit.

[0198] In addition, the conductive element 80 can be further fixed to the insulating frame 10, such as by riveting or hot melting, to prevent it from loosening.

[0199] like Figure 39 and Figure 45 As shown, in some examples, the bracket assembly 200 includes a bracket body 201 and a central shaft 202. The stator assembly 100 is mounted on one side of the bracket body 201, the central shaft 202 is located on one side of the bracket body 201 and is located in the middle of the stator assembly 100, and the other side of the bracket body 201 is used to mount the electronic control board 400.

[0200] like Figure 39 and Figure 44As shown, in some examples, the rotor assembly 300 includes a rotor housing 301 and a permanent magnet 302. The rotor housing 301 includes an outer housing 3011 and an inner housing 3012. The outer housing 3011 is located on the outer periphery of the stator assembly 100. The permanent magnet 302 is disposed on the outer housing 3011. The inner housing 3012 is adapted to be inserted into the inner hole of the stator assembly 100, and the inner housing 3012 cooperates with the central shaft 202 through a bearing 303, thereby realizing the installation of the rotor assembly 300 and enabling the electrical connection between the rotor assembly 300 and the support assembly 200.

[0201] The control board 400 has screw holes, and the bracket body 201 is provided with mounting bosses 203. The control board 400 is locked onto the mounting bosses 203 by fasteners 90. Since the rotor housing 301 is connected to the central shaft 202 through the bearing 303, and the bracket body 201 is connected to the central shaft 202, they are closely connected, thereby realizing the conductive connection between the rotor assembly 300, the stator core 20, and the control board 400, so that the motor 1000 achieves equipotential and avoids damage to the control board due to excessive pressure difference.

[0202] Grounding plates and capacitors are provided around the screw holes on the upper and lower surfaces of the electronic control board 400. The electronic control board 400 is installed on the bracket assembly 200. The grounding plates are attached to the mounting boss 203. After the fasteners 90 are tightened, the grounding plates are tightly attached to the mounting boss 203, thereby enabling the bracket assembly 200 to connect with the electronic control board 400 and the capacitors and other components on the electronic control board 400.

[0203] The bracket assembly 200 is connected to the rotor assembly 300, and the bracket assembly 200 is attached to the electronic control board 400, thereby achieving equipotential within the motor 1000 and preventing damage to the electronic control board due to excessive pressure difference.

[0204] The electronic fan 2000 according to an embodiment of the present invention includes a motor 1000 according to an embodiment of the present invention, which can reduce vibration and noise during operation and improve the performance of the electronic fan 2000.

[0205] The vehicle 3000 according to an embodiment of the present invention includes a motor 1000 according to an embodiment of the present invention or an electronic fan 2000 according to an embodiment of the present invention, which can reduce vibration and noise on the vehicle, improve vehicle performance, and enhance user experience.

[0206] Other configurations and operations of the vehicle 2000 according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here. The vertical, horizontal, and front-back directions are defined as shown in the figures.

[0207] In the description of this invention, 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 not in direct contact but through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature 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.

[0208] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0209] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A stator assembly (100), characterized in that, include: An insulating frame (10) is provided with a plurality of fasteners; Stator winding (30) is wound on a plurality of the fixing members.

2. The stator assembly (100) according to claim 1, characterized in that, Multiple fasteners are disposed on the end face of the insulating frame (10), and the multiple fasteners are spaced apart circumferentially along the insulating frame (10).

3. The stator assembly (100) according to claim 1, characterized in that, The plurality of fasteners include a plurality of first fasteners (113) and a plurality of second fasteners (123). The plurality of first fasteners (113) are disposed on the first end face of the insulating frame (10), and / or the plurality of second fasteners (123) are disposed on the second end face of the insulating frame (10). The first end face and the second end face are disposed opposite to each other along the axial direction of the insulating frame (10).

4. The stator assembly (100) according to claim 3, characterized in that, The plurality of second fasteners (123) include a plurality of first sub-fasteners (1231) and a plurality of second sub-fasteners (1232), the second sub-fasteners (1232) being closer to the center of the insulating frame (10) than the first sub-fasteners (1231).

5. The stator assembly (100) according to claim 4, characterized in that, The number of the plurality of first fasteners (113) and the plurality of first sub-fasteners (1231) are the same, and the plurality of first fasteners (113) and the plurality of first sub-fasteners (1231) are at the same distance from the central axis of the insulating frame (10).

6. The stator assembly (100) according to claim 2, characterized in that, The outer peripheral wall of each of the fasteners extends obliquely toward the central axis of the insulating frame (10) in a direction away from the corresponding end face of the insulating frame (10).

7. The stator assembly (100) according to claim 6, characterized in that, The cross-sectional dimensions of each of the fasteners gradually decrease along the direction away from the corresponding end face of the insulating frame (10).

8. The stator assembly (100) according to claim 3, characterized in that, At least two of the first fixing members (113) have a plurality of winding auxiliary slots (13) for accommodating a portion of the conductors (31) of the stator winding (30).

9. The stator assembly (100) according to claim 8, characterized in that, At least two of the first fixing members (113) also include a plurality of winding guide grooves (14), which are symmetrically arranged between the two first fixing members (113).

10. The stator assembly (100) according to claim 9, characterized in that, The multiple winding guide grooves (14) and the multiple winding auxiliary grooves (13) correspond one-to-one, and the winding guide grooves (14) and the winding auxiliary grooves (13) are connected by a guide surface (15).

11. The stator assembly (100) according to claim 3, characterized in that, Also includes: The stator core (20) is defined by the insulating frame (10) which defines an installation space, and at least a portion of the stator core (20) is disposed within the installation space.

12. The stator assembly (100) according to claim 11, characterized in that, The insulating frame (10) includes a first insulating frame (11) and a second insulating frame (12), the first insulating frame (11) and the second insulating frame (12) are arranged opposite to each other to form the installation space, the first fixing member is disposed on the first insulating frame (11) and the second fixing member is disposed on the second insulating frame (12).

13. The stator assembly (100) according to claim 12, characterized in that, The first insulating frame (11) is provided with a first limiting member (112) extending toward the second insulating frame (12), the first limiting member (112) engaging with the inner circumference of the stator core (20) to restrict the radial movement of the stator core (20); and / or, The second insulating frame (12) is provided with a second limiting member (122), which extends toward the first insulating frame (11) and engages with the inner circumference of the stator core (20) to restrict the radial movement of the stator core (20).

14. The stator assembly (100) according to claim 13, characterized in that, The first limiting member (112) is provided with reinforcing ribs; and / or, the second limiting member (122) is provided with reinforcing ribs.

15. The stator assembly (100) according to claim 13, characterized in that, The first limiting member (112) is provided with a snap-fit ​​part (103), which is located on the side of the first limiting member (112) near the stator core (20) and is adapted to snap-fit ​​with the stator core.

16. The stator assembly (100) according to claim 15, characterized in that, The snap-fit ​​portion (103) is configured as a protrusion and / or a groove.

17. The stator assembly (100) according to claim 13, characterized in that, The first limiting member (112) includes a plurality of such members, which are circumferentially spaced along the first insulating frame (11); and / or, the second limiting member (122) includes a plurality of such members, which are circumferentially spaced along the second insulating frame (12).

18. The stator assembly (100) according to claim 12, characterized in that, The first insulating frame (11) and the second insulating frame (12) are plugged into each other.

19. The stator assembly (100) according to claim 18, characterized in that, The first insulating frame (11) has a first mounting member (114), and the second insulating frame (12) has a second mounting member (124). The first mounting member (114) and the second mounting member (124) form a column shape. The first mounting member (114) is sleeved on the second mounting member (124). The first mounting member (114) and the second mounting member (124) are provided with mounting holes (104). The mounting holes (104) are used to mount the stator assembly (100) to the motor (1000).

20. The stator assembly (100) according to claim 12, characterized in that, The first insulating frame (11) is provided with a terminal mounting groove (16). The terminal mounting groove (16) is provided with a limiting slot (161) on two opposite side walls of the first insulating frame (11) along the circumference. The conductor (31) of the stator winding (30) is adapted to extend into the terminal mounting groove (16) through the limiting slot (161).

21. The stator assembly (100) according to claim 12, characterized in that, The first insulating frame (11) is provided with a third limiting member (101) at the end near the second insulating frame (12), and / or the second insulating frame (12) is provided with a third limiting member (101) at the end facing the first insulating frame (11), the third limiting member (101) cooperating with the stator core (20) to restrict the axial movement of the stator core (20).

22. The stator assembly (100) according to claim 1, characterized in that, It also includes an insulating ring (40), which is disposed on the outer periphery of the stator core (20) and is located between the stator core (20) and the stator winding (30).

23. The stator assembly (100) according to claim 22, characterized in that, The insulating ring (40) is an elastic insulating component wrapped around the stator core (20); or, the insulating ring (40) is insulating paper or insulating tape wrapped around the stator core (20).

24. The stator assembly (100) according to any one of claims 1-23, characterized in that, Also includes: A three-phase bridge (50) includes a connecting plate (51) mounted on the insulating frame (10); one of the connecting plate (51) and the insulating frame (10) has a positioning hole (53), and the other of the connecting plate (51) and the insulating frame (10) has a positioning post (18) adapted to be inserted into the positioning hole (53).

25. The stator assembly (100) according to claim 24, characterized in that, The connecting plate (51) is perpendicular to the axial direction of the stator assembly (100).

26. An electric motor (1000), characterized in that, include: The bracket assembly (200), the rotor assembly (300), and the stator assembly (100) according to any one of claims 1-25, wherein the stator assembly (100) and the rotor assembly (300) are disposed on the bracket assembly (200).

27. The motor (1000) according to claim 26, characterized in that, It also includes a conductor (80), which is disposed on the insulating frame (10) and cooperates with the stator core (20) of the stator assembly (100) and the support assembly (200) respectively, for making the stator core (20) and the support assembly (200) conductive.

28. The motor (1000) according to claim 27, characterized in that, The conductive element (80) includes a first conductive section (81), a second conductive section (82), and a third conductive section (83). The first conductive section (81) is mounted on the insulating frame (10). The second conductive section (82) and the third conductive section (83) are respectively disposed at both ends of the first conductive section (81). The second conductive section (82) extends toward the stator core (20) to clamp between the insulating frame (10) and the stator core (20). The third conductive section (83) defines a slot (834) adapted to be inserted into the insulating frame.

29. The motor (1000) according to claim 28, characterized in that, The angle between the second conductive segment (82) and the first conductive segment (81) is α, where 150°≤α≤175°.

30. The motor (1000) according to claim 29, characterized in that, The third conductive section (83) includes a first folded edge (831), a second folded edge (832), and a third folded edge (833) connected in sequence. The first folded edge (831) is connected to the first conductive section (81). The second folded edge (832) overlaps the edge of the mounting hole (104) of the insulating frame (10). The third folded edge (833) extends into the mounting hole (104) of the insulating frame (10). The included angle between the third folded edge (833) and the second folded edge (832) is β, where 95°≤β≤120°.

31. An electronic fan (2000), characterized in that, Includes the motor (1000) according to any one of claims 26-30.

32. A vehicle (3000), characterized in that, Includes the motor (1000) according to any one of claims 26-30 or the electronic fan (2000) according to claim 31.

Images