A frameless torque motor manufacturing method

Abstract

The application discloses a frameless torque motor manufacturing method and belongs to the technical field of motor production. The method comprises the following steps: S1, a plurality of blocks are assembled into a stator by using an assembling device; the assembling device comprises a first limiting unit, a second limiting unit and a pushing block mechanism; the blocks are locked by a locking part after sliding into an arc-shaped guiding part; the pushing block mechanism clamps the next block on the locked block; the above steps are repeated to assemble the blocks into a semi-ring structure; two semi-ring structures are close to each other under the action of a linear driving part and are spliced into a ring-shaped stator; S2, a circuit board is welded on the stator; S3, the circuit board and the stator are plastic encapsulated; and S4, a rotor is placed in the stator. The blocks are semi-automatically assembled by the assembling device; an operator only needs to put the blocks in turn, and the pushing block mechanism completes the clamping action, thereby saving time and effort; and the arc-shaped guiding part always provides support for the block group during the assembling process, the blocks cannot be scattered, and the assembling efficiency and stability are improved.

Description

Technical Field

[0001] This application relates to the field of motor manufacturing technology, specifically to a method for manufacturing a frameless torque motor. Background Technology

[0002] Frameless torque motors, with their compact structure, small size, and light weight, are widely used in humanoid robots. Existing frameless torque motors consist of a stator and a rotor. The stator is a modular design, composed of multiple circumferentially arranged modules. Each module includes a core, an insulating frame, and windings. The core is made of multiple laminations stacked and riveted together, the insulating frame is assembled onto the core, and the windings are wound on the insulating frame. A locking head is located on the left side of the core, and a corresponding locking slot is located on the right side.

[0003] During the assembly of the frameless torque motor, adjacent modules need to be manually snapped together using clips and slots to form a ring-shaped stator. After the stator is assembled, a ring-shaped circuit board needs to be welded to the upper side of the stator. Then, the circuit board, iron core, insulating frame, and windings are plastic-sealed together. Finally, the rotor is placed into the stator to complete the motor assembly.

[0004] The existing manual assembly method is time-consuming and labor-intensive, and the operators have a high labor intensity. In addition, the pieces have not yet formed a stable ring structure during the assembly process, making them easy to fall apart and affecting the assembly efficiency. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and propose a frameless torque motor manufacturing method that reduces manual operation and improves the installation efficiency of the motor.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A method for manufacturing a frameless torque motor, comprising the following specific steps: S1, using assembly equipment to assemble multiple modules into a stator. The assembly equipment includes a first limiting unit, a second limiting unit, and a pushing block mechanism. The first and second limiting units have the same structure, arranged in a ring array on the left and right sides of the pusher mechanism. The first limiting unit includes a linear drive section, an arc-shaped guide section, and a locking section. During assembly, the assembly block slides from its end into the arc-shaped guide section of the first limiting unit. After being locked by the locking section, the pusher mechanism clamps the next assembly block onto the block locked by the locking section. After the assembly block slides forward along the arc-shaped guide section, the "locking-clamping-sliding" steps are repeated until multiple assembly blocks are assembled into a semi-circular structure along the arc-shaped guide section. Similarly, the second limiting unit is used to assemble multiple assembly blocks into another semi-circular structure. Under the action of the linear drive section, the arc-shaped guide sections of the first and second limiting units move closer to each other, and the two semi-circular structures are assembled to form a ring stator. S2, soldering circuit boards onto the stator. S3, encapsulates the circuit board and stator. S4. Place the rotor into the stator to complete the motor manufacturing process.

[0007] Furthermore, the arc-shaped guide part includes an arc-shaped guide rail and an arc-shaped pressure plate. The arc-shaped guide rail is connected to the linear drive part, and the arc-shaped pressure plate is disposed above the arc-shaped guide rail. An arc-shaped guide groove is formed between the two. The cross-section of the arc-shaped guide groove is adapted to the assembly block, so that the assembly block can slide along the arc-shaped guide groove. The locking part includes a lifting driver. The lifting driver of the locking part drives the arc-shaped pressure plate to move up and down to realize the locking and unlocking of the assembly block.

[0008] Furthermore, the pusher mechanism includes a feeding mechanism, a moving seat, a rotator, a connecting rod, and a push plate. The feeding mechanism is connected to the movable base, and the push plate is rotatably mounted on the movable base via a connecting rod and driven by a rotator. In S1, when the pusher mechanism assembles the assembly block to the first or second limiting unit, the movable seat is located between the first and second limiting units. The rotator drives the push plate, which pushes the assembly block, causing it to lock onto the assembly block locked by the locking part. After the blocks on the first and second limiting units are assembled, the moving seat moves away from between the first and second limiting units under the drive of the feeding mechanism.

[0009] Furthermore, when the pusher mechanism assembles the blocks for the first or second limiting unit, the rotation center of the pusher plate of the pusher mechanism is located at the center of the corresponding arc-shaped guide.

[0010] Furthermore, in S3, BMC is used for molding.

[0011] Furthermore, the assembly includes an iron core, windings, and an insulating frame. The insulating frame is fitted onto the iron core. The outer end of the insulating frame has an outward flange along its circumference, and the inner end of the insulating frame has an inward flange along its circumference. The winding is disposed between the inward and outward flanges and wound on the insulating frame. The upper and lower sides of the outer flange, as well as the upper and lower sides of the inner flange, are both arc-shaped and coaxial with the stator. The upper side of the arc-shaped guide rail is provided with a first arc-shaped groove and a second arc-shaped groove, and the inner edge and outer edge of the arc-shaped pressure plate are respectively provided with an inner arc-shaped baffle and an outer arc-shaped baffle. When the assembly block is located in the arc-shaped guide section, the lower sides of the inner and outer flanges of the assembly block are respectively embedded in the first arc-shaped groove and the second arc-shaped groove, and the upper sides of the inner and outer flanges slide in cooperation with the outer side of the inner arc-shaped baffle and the inner side of the outer arc-shaped baffle, respectively.

[0012] Furthermore, the arc-shaped pressure plate moves downward, pressing the upper sides of the inner and outer flanges to lock the assembly.

[0013] Furthermore, under the action of the rotator, the push plate contacts the inner and outer flanges, pushing the assembly block to move towards the assembly block that is locked in place, thereby achieving the locking of the assembly block.

[0014] Furthermore, the left and right sides of the iron core are respectively provided with a locking head and a locking slot. The locking head of the iron core is inserted into the locking slot of another iron core to achieve the clamping of two adjacent blocks.

[0015] Furthermore, the front side of the upper end of the inner flange and the outer flange is provided with a notch, the rear side of the notch forms a vertical stop surface, and the front end of the arc-shaped pressure plate is provided with an end plate. When multiple blocks are assembled into a semi-circular structure along the arc-shaped guide, the stop surface of the first block abuts against the end plate, and its locking head is located outside the arc-shaped guide rail, while the locking groove of the last block is located outside the arc-shaped guide rail.

[0016] Through the above improvements, the present invention has the following beneficial effects: 1. Through the cooperation of the arc-shaped guide and the pusher mechanism in the assembly equipment, the operator only needs to put the assembly blocks into the arc-shaped guide in sequence, and the pusher mechanism completes the clamping action between the assembly blocks, which replaces manual squeezing assembly, reduces labor intensity and improves assembly efficiency; 2. During the assembly process, the arc-shaped guide provides support and limits to the assembled blocks, preventing them from falling apart and ensuring the stability of the assembly process. 3. By assembling two semi-circular structures through the first limiting unit and the second limiting unit respectively, and then bringing the two together to form a circular stator through the linear drive unit, the semi-automatic assembly operation is realized, which further improves the manufacturing efficiency. 4. The inner and outer flanges of the assembly block limit the winding on the one hand, and on the other hand, they serve as a guide structure embedded in the arc groove of the arc guide rail, so that the assembly block can only slide along the specified arc path and will not move radially, thus improving the accuracy and stability of the assembly. 5. When the arc-shaped pressure plate locks, the force is applied to the inner and outer flanges. When the push plate pushes the block, the force is also applied to the inner and outer flanges, protecting the iron core and windings from damage. Attached Figure Description

[0017] Figure 1This is a schematic diagram illustrating how the pusher mechanism, as an example, clamps the second piece onto the first piece.

[0018] Figure 2 for Figure 1 Enlarged view of point A.

[0019] Figure 3 This is a schematic diagram of the first limiting unit after the assembly of the blocks in the embodiment.

[0020] Figure 4 for Figure 3 Enlarged view of point B.

[0021] Figure 5 This is a schematic diagram illustrating the principle of assembling the blocks one by one in the first limiting unit under the action of the pushing mechanism.

[0022] Figure 6 This is a schematic diagram showing the principle of assembling the second limit unit one by one under the action of the push block mechanism after the first limit unit assembly operation is completed.

[0023] Figure 7 This is a schematic diagram showing the assembly of the annular stator completed after the first and second limiting units are assembled and joined together.

[0024] Figure 8 This is a schematic diagram of a tile in an embodiment.

[0025] Figure 9 This is an exploded view of the puzzle pieces used in an example.

[0026] Figure 10 This is a schematic diagram of the stator after the circuit board has been soldered.

[0027] In the diagram: 1-block, 2-stator, 3-first limiting unit, 4-second limiting unit, 5-push block mechanism, 6-linear drive unit, 7-circuit board, 8-arc guide rail, 9-arc pressure plate, 10-lifting driver, 11-feeding mechanism, 12-moving seat, 13-rotator, 14-connecting rod, 15-push plate, 16-iron core, 17-winding, 18-insulating frame, 19-outer flange, 20-inner flange, 21-first arc groove, 22-second arc groove, 23-inner arc baffle, 24-outer arc baffle, 25-clamp head, 26-clamp slot, 27-stop surface, 28-end plate. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0030] like Figures 1 to 10 This embodiment provides a method for manufacturing a frameless torque motor, including the following steps: S1, using assembly equipment to assemble multiple modules 1 into stator 2; S2, solder circuit board 7 onto stator 2; S3, encapsulate circuit board 7 and stator 2; S4, place the rotor into stator 2 to complete the motor manufacturing.

[0031] The following section provides a detailed explanation of each step, taking into account the specific structure and working process of the assembly equipment.

[0032] The assembly equipment includes a first limiting unit 3, a second limiting unit 4, and a pushing mechanism 5. The first limiting unit 3 and the second limiting unit 4 have the same structure and are arranged in a circular array on the left and right sides of the pushing mechanism 5.

[0033] The first limiting unit 3 includes a linear drive unit 6, an arc-shaped guide unit, and a locking unit. The linear drive unit 6 drives the arc-shaped guide unit to move in the left-right direction. A high-precision linear motor or servo cylinder is preferably used to ensure the accuracy and stability of the movement. The arc-shaped guide unit provides guidance and sliding support for the assembly block 1. Its radius is adapted to the radius of the stator 2 to be manufactured, and its arc is slightly less than 180 degrees, allowing both ends of the assembled semi-annular structure to protrude beyond the ends of the arc-shaped guide unit, facilitating subsequent docking with the other semi-annular structure. Both ends of the arc-shaped guide unit are open, facing the direction of the second limiting unit 4, allowing the assembly block 1 to slide in from either end of the arc-shaped guide unit.

[0034] In one implementation, the arc-shaped guide section includes an arc-shaped guide rail 8 and an arc-shaped pressure plate 9. The arc-shaped guide rail 8 is connected to the linear drive section 6, and a first arc-shaped groove 21 and a second arc-shaped groove 22 are provided on the upper side of the arc-shaped guide rail 8. The arc-shaped pressure plate 9 is positioned above the arc-shaped guide rail 8 and is parallel to the arc-shaped guide rail 8, forming an arc-shaped guide groove between the two. Both the arc-shaped guide rail and the arc-shaped pressure plate 9 are semi-circular, with an arc angle slightly less than 180 degrees. The cross-section of the arc-shaped guide groove is adapted to the assembly block 1, allowing the assembly block 1 to slide stably along the arc-shaped path within the arc-shaped guide groove. An inner arc-shaped baffle 23 is provided on the inner edge of the arc-shaped pressure plate 9, and an outer arc-shaped baffle 24 is provided on the outer edge.

[0035] The locking mechanism includes a lifting actuator 10. The lifting actuator 10 can be a cylinder or an electric push rod, used to drive the arc-shaped pressure plate 9 to move up and down, thereby locking and unlocking the assembly block 1. When the lifting actuator 10 drives the arc-shaped pressure plate 9 downwards, the arc-shaped pressure plate 9 presses the assembly block 1 against the arc-shaped guide rail 8, achieving locking. When the lifting actuator 10 drives the arc-shaped pressure plate 9 upwards, a small gap is formed between the arc-shaped pressure plate 9 and the upper side of the assembly block 1, allowing the assembly block 1 to slide along the arc-shaped guide groove. This small gap also prevents the assembly block 1 from shifting up and down, ensuring stability during the sliding process. The thickness at the end of the arc-shaped pressure plate 9 is less than the thickness of the rest. After the arc-shaped pressure plate presses the assembly block, a new assembly block can still slide into the end of the arc-shaped guide groove. After the assembly block slides in, there is still a small gap allowing it to slide back and forth, facilitating the pusher mechanism to engage the assembly block with the previously pressed assembly block. That is, in this embodiment, the arc-shaped pressure plate is configured to press down the previous piece, but not to press down the next piece, and only to serve a guiding function.

[0036] Furthermore, in this embodiment, the modular unit 1 is the basic component of the modular stator, including an iron core 16, a winding 17, and an insulating frame 18. The iron core 16 is formed by stacking and riveting multiple laminations. The insulating frame 18 is fitted onto the iron core 16, and the two can be fixed by snap-fit ​​or interference fit. The outer end of the insulating frame 18 has an outer flange 19 along the circumferential direction, and the inner end has an inner flange 20 along the circumferential direction. The winding 17 is located between the inner flange 20 and the outer flange 19, and is wound on the insulating frame 18. The upper and lower sides of the outer flange 19 and the upper and lower sides of the inner flange 20 are both arc-shaped and coaxial with the stator 2. The outer flange 19 and the inner flange 20 serve two purposes: firstly, they limit the axial movement of the winding 17, preventing it from shifting on the insulating frame 18; secondly, the outer flange 19 and the inner flange 20 form two arc-shaped guide rib structures on the upper and lower sides of the assembly 1, which cooperate with the arc-shaped guide rail 8 and the arc-shaped pressure plate 9 to achieve precise guidance and stable support of the assembly 1 in the arc-shaped guide section.

[0037] The iron core 16 has a locking head 25 and a locking slot 26 on its left and right sides, respectively. Two adjacent panels 1 are locked together by locking the locking head 25 of one panel 1 into the locking slot 26 of the other panel 1. This locking structure allows the panels 1 to be quickly assembled and maintain a stable connection.

[0038] When assembly piece 1 is located in the arc-shaped guide section, the lower sides of the inner flange 20 and the outer flange 19 of assembly piece 1 are respectively embedded in the first arc-shaped groove 21 and the second arc-shaped groove 22 on the arc-shaped guide rail 8, and the upper sides of the inner flange 20 and the outer flange 19 are respectively in sliding engagement with the outer side of the inner arc-shaped baffle 23 and the inner side of the outer arc-shaped baffle 24 of the arc-shaped pressure plate 9. This engagement relationship ensures that assembly piece 1 can only slide along the specified arc-shaped path without radial movement, thus guaranteeing assembly accuracy.

[0039] As one implementation, the upper front sides of the inner flange 20 and the outer flange 19 are provided with notches, and the rear side of the notches forms a vertical stop surface 27. Here, "front side" refers to the direction in which the assembly block 1 slides along the arc-shaped guide groove. The front end of the arc-shaped pressure plate 9 is provided with an end plate 28. During the assembly of the semi-circular structure, when the first assembly block 1 entering the arc-shaped guide slides to the far end of the arc-shaped guide groove, its stop surface 27 abuts against the end plate 28. The end plate 28 prevents the assembly block 1 from continuing to move forward and coming off the end of the arc-shaped guide groove, and also plays a positioning role. At this time, the locking head 25 of the assembly block 1 is located outside the arc-shaped guide rail 8, protruding beyond the end of the arc-shaped guide, for subsequent docking with the assembly block 1 of the other semi-circular structure. Correspondingly, the locking groove 26 of the last assembly block is also located outside the arc-shaped guide rail 8.

[0040] In one implementation, the pusher mechanism 5 includes a feeding mechanism 11, a moving seat 12, a rotator 13, a connecting rod 14, and a pusher plate 15. The feeding mechanism 11 is connected to the moving seat 12 and drives the moving seat 12 to perform linear feed motion in a direction perpendicular to the linear drive unit 6. The feeding mechanism 11 can be a servo cylinder, and a guide rail structure can be provided on the lower side of the moving seat 12 to improve the stability and accuracy of the movement. The rotator 13 is connected to the pusher plate 15 via the connecting rod 14 and drives the pusher plate 15 to rotate around the rotation center. The rotator 13 can be a servo motor to improve rotational stability, and a pressure sensor is installed near the pusher plate to prevent the pusher plate from damaging the blocks. Driven by the rotator 13, the pusher plate 15 pushes the blocks 1 forward along the arc-shaped guide groove, achieving clamping between the blocks 1.

[0041] Furthermore, the specific working process of assembling the equipment in step S1 will be explained.

[0042] First, the assembly work on the first limiting unit 3 is carried out. In the initial state, the moving seat 12 of the pusher mechanism 5 is located between the first limiting unit 3 and the second limiting unit 4, and the rotation center of the pusher plate 15 coincides with the center of the arc-shaped guide portion of the first limiting unit 3. At the same time, the arc-shaped pressure plate 9 is in a raised state driven by the lifting driver 10. At this time, the vertical distance between the arc-shaped guide grooves is slightly greater than the height of the assembly block, allowing the assembly block to slide while restricting its vertical movement.

[0043] The operator manually picks up the first piece 1 and slides it into the arc-shaped guide groove from the end of the arc-shaped guide section. The lifting drive 10 of the locking section drives the arc-shaped pressure plate 9 to move downwards. The arc-shaped pressure plate 9 presses against the upper sides of the inner flange 20 and outer flange 19 of the first piece 1, locking the first piece 1 firmly onto the arc-shaped guide rail 8. It should be noted that the locking force acts on the inner flange 20 and outer flange 19, not on the iron core 16 or winding 17, protecting the piece 1 from damage. At this time, there is still a space for one piece at the sliding end of the arc-shaped guide groove. At the same time, because the thickness of the end of the arc-shaped pressure plate is slightly thinner than the thickness of the rest, the sliding end of the arc-shaped guide groove can still slide into the next piece.

[0044] Next, the operator manually slides the second piece 1 from the end of the arc-shaped guide into the arc-shaped guide groove. The rotator 13 of the pusher mechanism 5 drives the pusher plate 15 to rotate. The pusher plate 15 contacts the inner flange 20 and outer flange 19 of the second piece 1, pushing the second piece 1 forward along the arc-shaped guide groove, locking the locking head 25 of the second piece 1 into the locking groove 26 of the first piece 1, thus completing the locking between the two pieces 1. A pressure sensor is installed on the pusher plate 15 to prevent excessive pushing force from damaging the piece 1.

[0045] The lifting actuator 10 of the locking part drives the arc-shaped pressure plate 9 to rise, releasing the locking of the piece 1. During this process, the arc-shaped pressure plate only rises a very small distance, such as 0.2mm, merely loosening the piece to allow it to slide, while continuing to guide and support it. Driven by the rotator 13, the push plate 15 of the push mechanism 5 continues to push the piece group forward, causing it to move forward a distance equal to the width of one piece, freeing up space for another piece at the sliding end of the arc-shaped guide groove. Subsequently, driven by the rotator 13, the push plate 15 retracts and resets, and the lifting actuator 10 of the locking part drives the arc-shaped pressure plate 9 to descend again to lock the piece.

[0046] Next, the operator manually slides the third piece 1 into the arc-shaped guide section from its end. The pushing mechanism 5 repeats the pushing and clamping actions to clamp the third piece 1 to the second piece 1. This process is repeated, with the "locking-clamping-sliding" steps, to assemble the pieces 1 one by one along the arc-shaped guide section. Because the arc-shaped guide section always provides support and limits to the assembled piece group, the piece group will not fall apart during assembly, ensuring the continuity and stability of the assembly process. When the pieces 1 cover the entire arc-shaped guide section, a semi-circular structure is formed. The two ends of this semi-circular structure protrude from the two ends of the arc-shaped guide section, with one end exposing the locking head 25 and the other end exposing the locking groove 26. At this point, the assembly work on the first limiting unit 3 is completed.

[0047] After the assembly work on the first limiting unit 3 is completed, the arc-shaped guide part of the first limiting unit 3 moves away from the push block mechanism 5 under the action of the linear drive part 6.

[0048] Next, the assembly work on the second limiting unit 4 is carried out. Under the action of its linear drive unit 6, the arc-shaped guide part of the second limiting unit 4 moves towards the push block mechanism 5 until the rotation center of the push plate 15 of the push block mechanism 5 coincides with the center of the arc-shaped guide part of the second limiting unit 4. Then, following the same method and steps as the assembly work of the first limiting unit 3, multiple blocks 1 are assembled along the arc-shaped guide part of the second limiting unit 4 to form another semi-circular structure. The two ends of this semi-circular structure also protrude from the two ends of the arc-shaped guide part.

[0049] After the assembly of the second limiting unit 4 is completed, the arc-shaped guide part of the second limiting unit 4 moves a certain distance away from the push block mechanism 5 under the action of the linear drive part 6. The moving seat 12 moves out from between the first limiting unit 3 and the second limiting unit 4 under the drive of the feeding mechanism 11, making room for the docking of the two semi-circular structures.

[0050] Subsequently, the linear drive units 6 of the first limiting unit 3 and the second limiting unit 4 respectively drive their respective arc-shaped guide units to move closer together. The two semi-annular structures move relative to each other with the arc-shaped guide units, and the locking head 25 at the end of one semi-annular structure aligns and engages with the locking groove 26 at the end of the other semi-annular structure. The two semi-annular structures are then joined to form a complete annular stator 2. After the docking is completed, the lifting drive 10 of the locking unit drives the arc-shaped pressure plate 9 to rise, releasing the locking on the stator 2.

[0051] After step S1 is completed, the stator 2 is stably held in the assembly equipment under the support and limiting effect of the arc-shaped guide rail 8. In step S2, the annular circuit board 7 can be placed directly above the stator 2 for welding to fix the circuit board 7 to the stator 2. Since the circuit board is a ring-shaped whole, after welding, the circuit board can support the stator, and the circuit board and the stator form an integral structure that will not fall apart after being removed from the equipment.

[0052] In step S3, after the stator with the soldered circuit board is removed from the equipment, the circuit board 7 and the stator 2 are encapsulated. As one implementation method, BMC (Bulk Molding Compound) encapsulation material is used. BMC material has good insulation properties, heat resistance, and mechanical strength, and can reliably encapsulate the circuit board 7, iron core 16, insulating frame 18, and winding 17 into a single unit, protecting the internal components from external environmental influences.

[0053] In step S4, the rotor is placed into stator 2, completing the overall manufacturing of the motor.

[0054] Using the manufacturing method described above, operators only need to place the assembly blocks 1 one by one into the arc-shaped guide section. The subsequent pressing and clamping action is completed by the pusher mechanism 5, eliminating the need for manual labor to press the assembly blocks one by one, reducing labor intensity, and improving assembly efficiency. At the same time, during the assembly process, the arc-shaped guide section always provides support and limits for the incomplete assembly blocks, preventing the assembly blocks from falling apart and ensuring the stability and reliability of the assembly process.

[0055] Furthermore, this embodiment achieves semi-automatic assembly, replacing manual pressing and clamping, saving labor intensity, and providing guiding support to prevent assembled blocks from falling apart, improving the stability and continuity of assembly. Specific timing control can be achieved by configuring a controller, which can be manually pressed to trigger the actions of the first limit unit, the second limit unit, and the pusher mechanism. For example, each time a new block slides in, the controller is manually operated to trigger the locking part and the pusher mechanism to move and reset; after the first limit unit assembly operation is completed, the controller is manually operated to trigger the linear actuators of the first and second limit units to complete the workstation switch and continue the assembly operation of the second limit unit; after the second limit unit assembly operation is completed, the controller is manually operated to trigger the feeding mechanism and the linear actuators to achieve the final annular stator docking assembly, etc.

[0056] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for manufacturing a frameless torque motor, characterized in that, The specific steps are as follows: S1, using assembly equipment to assemble multiple modules into a stator. The assembly equipment includes a first limiting unit, a second limiting unit, and a pushing block mechanism. The first and second limiting units have the same structure, arranged in a ring array on the left and right sides of the pusher mechanism. The first limiting unit includes a linear drive section, an arc-shaped guide section, and a locking section. During assembly, the assembly block slides from its end into the arc-shaped guide section of the first limiting unit. After being locked by the locking section, the pusher mechanism clamps the next assembly block onto the block locked by the locking section. After the assembly block slides forward along the arc-shaped guide section, the "locking-clamping-sliding" steps are repeated until multiple assembly blocks are assembled into a semi-circular structure along the arc-shaped guide section. Similarly, the second limiting unit is used to assemble multiple assembly blocks into another semi-circular structure. Under the action of the linear drive section, the arc-shaped guide sections of the first and second limiting units move closer to each other, and the two semi-circular structures are assembled to form a ring stator. S2, soldering circuit boards onto the stator. S3, encapsulates the circuit board and stator. S4. Place the rotor into the stator to complete the motor manufacturing process.

2. The method for manufacturing a frameless torque motor according to claim 1, characterized in that, The arc-shaped guide part includes an arc-shaped guide rail and an arc-shaped pressure plate. The arc-shaped guide rail is connected to the linear drive part, and the arc-shaped pressure plate is disposed above the arc-shaped guide rail. An arc-shaped guide groove is formed between the two. The cross-section of the arc-shaped guide groove is adapted to the assembly block, so that the assembly block can slide along the arc-shaped guide groove. The locking part includes a lifting driver. The lifting driver of the locking part drives the arc-shaped pressure plate to move up and down to realize the locking and unlocking of the assembly block.

3. The method for manufacturing a frameless torque motor according to claim 2, characterized in that, The pusher mechanism includes a feeding mechanism, a moving seat, a rotator, a connecting rod, and a push plate. The feeding mechanism is connected to the movable base, and the push plate is rotatably mounted on the movable base via a connecting rod and driven by a rotator. In S1, when the pusher mechanism assembles the assembly block to the first or second limiting unit, the movable seat is located between the first and second limiting units. The rotator drives the push plate, which pushes the assembly block, causing it to lock onto the assembly block locked by the locking part. After the blocks on the first and second limiting units are assembled, the moving seat moves away from between the first and second limiting units under the drive of the feeding mechanism.

4. The method for manufacturing a frameless torque motor according to claim 3, characterized in that, When the pusher mechanism assembles the blocks for the first or second limiting unit, the rotation center of the pusher plate is located at the center of the corresponding arc-shaped guide.

5. A method for manufacturing a frameless torque motor according to claim 1, characterized in that, In S3, BMC is used for molding.

6. A method for manufacturing a frameless torque motor according to claim 4, characterized in that, The assembly includes an iron core, windings, and an insulating frame. The insulating frame is fitted onto the iron core. The outer end of the insulating frame has an outward flange along its circumference, and the inner end of the insulating frame has an inward flange along its circumference. The winding is disposed between the inward and outward flanges and wound on the insulating frame. The upper and lower sides of the outer flange, as well as the upper and lower sides of the inner flange, are both arc-shaped and coaxial with the stator. The upper side of the arc-shaped guide rail is provided with a first arc-shaped groove and a second arc-shaped groove, and the inner edge and outer edge of the arc-shaped pressure plate are respectively provided with an inner arc-shaped baffle and an outer arc-shaped baffle. When the assembly block is located in the arc-shaped guide section, the lower sides of the inner and outer flanges of the assembly block are respectively embedded in the first arc-shaped groove and the second arc-shaped groove, and the upper sides of the inner and outer flanges slide in cooperation with the outer side of the inner arc-shaped baffle and the inner side of the outer arc-shaped baffle, respectively.

7. A method for manufacturing a frameless torque motor according to claim 6, characterized in that, The curved pressure plate moves downwards, pressing the upper sides of the inner and outer flanges to lock the pieces together.

8. A method for manufacturing a frameless torque motor according to claim 6, characterized in that, Under the action of the rotator, the push plate contacts the inner and outer flanges, pushing the assembly block to move towards the locking part, thereby locking the assembly block.

9. A method for manufacturing a frameless torque motor according to claim 6, characterized in that, The iron core is provided with a locking head and a locking slot on its left and right sides respectively. The locking head of the iron core is inserted into the locking slot of another iron core to achieve the locking of two adjacent blocks.

10. A method for manufacturing a frameless torque motor according to claim 6, characterized in that, The upper front sides of the inner and outer flanges are provided with notches, and the rear side of the notches forms a vertical stop surface. The front end of the arc-shaped pressure plate is provided with an end plate. When multiple blocks are assembled into a semi-circular structure along the arc-shaped guide, the stop surface of the first block abuts against the end plate, and its locking head is located outside the arc-shaped guide rail, while the locking groove of the last block is located outside the arc-shaped guide rail.

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