Split type motor stator

Abstract

The utility model relates to a split type motor stator. The split type motor stator has a coil assembly including a plurality of coil strands disposed in the split type motor stator, the split type motor stator including: a first core located on a first side of the coil assembly in a direction of a rotation axis of the coil assembly, and including a receiving groove in which the coil strands are received; the coil stranded wire is inserted into the accommodating groove; and a second core portion located on a second side of the coil assembly and coupled to the first core portion to fix a position of the coil assembly.

Description

Technical Field

[0001] The following disclosure relates to a stator included in an electric motor. Background Art

[0002] The coil winding methods used in traditional motor stators are mainly divided into hairpin winding and continuous winding. The hairpin winding method is a method in which a square copper wire coil formed into a U shape (hairpin shape) is inserted into the slot of the stator core in sequence in the axial direction, and then the ends of each coil are welded and connected. The hairpin winding method is advantageous in terms of process simplification because the process is completed by inserting the square copper wire coil between the stator shoes without pre-manufacturing the winding bundle, but it is inefficient in terms of production cost and time because it requires welding the ends of multiple square copper wire coils and then laminating the protective coating. In addition, due to the multiple welding locations, welding defects inevitably occur. In addition, in the case of the hairpin winding method, there is the following problem: the axial length of the stator becomes longer because the ends of the square copper wire coils that need to be welded protrude longer to the outside of the stator.

[0003] In addition, the continuous winding method is a method of bending a square copper wire coil without destroying the square copper wire coil, performing coil welding only at limited positions to manufacture a winding bundle, and then radially inserting the winding bundle into the slot of the stator core. The continuous winding method has the advantage of increasing the ease of assembly between the stator and the winding by allowing the pre-manufactured winding to be inserted into the stator at one time, and has advantages over the hairpin winding method in terms of production cost and time because there are no many welding areas by winding the individual winding wires to support the various positions. In addition, the continuous winding method has the advantage of reducing the axial length of the stator compared to the hairpin winding method because each winding wire is wound so that its end does not protrude to the outside of the stator. However, the continuous winding method also has problems. Since the winding bundle is inserted into the radial direction of the stator, the boot protruding from the end of the existing stator tooth will be removed, and therefore, the stator teeth remain separated from each other even after the winding bundle is inserted. As a result, the continuous winding method has the problem of low NVH performance because the empty space increases and the cogging torque fluctuation occurs accordingly.

[0004] [Related technical literature]

[0005] [Patent Document]

[0006] (Patent Document 1) Korean Patent Publication No. 10-2020-0016088 “Stator Fabricating Method for Hairpin Winding Motor”, February 14, 2020. Utility Model Content

[0007] The purpose of an embodiment of the present disclosure is to provide a split motor stator and a manufacturing method thereof, wherein the split motor stator is configured to divide the stator core into an inner core and an outer core so that the entrance of the slot into which the coil is inserted can be opened and closed to compensate for the problems of the continuous winding method, thereby having the advantages of the hairpin winding method.

[0008] More specifically, an embodiment of the present disclosure aims to provide a split motor stator, which is configured to divide the stator core into an inner core and an outer core so that the entrance of the slot into which the coil is inserted can be opened and closed, thereby reducing wasted scrap by using separate cores instead of the entire core to save material costs, eliminating welding and coating processes for the coil to improve the defect rate, and even connecting the boots to each other after the winding bundle is inserted to eliminate cogging torque fluctuations and improve NVH performance, inserting the coil into the slot with the coil in close contact to increase the coil acceptance rate and ensure a high load rate, and reducing the size of the motor to reduce the axial coil length.

[0009] In one general aspect, a split motor stator has a coil assembly, which includes a plurality of coil strands arranged in the split motor stator, the split motor stator including: a first core portion, which is located on a first side of the coil assembly in the direction of a rotation axis of the coil assembly and includes a receiving groove, and the coil strands are inserted into the receiving groove; and a second core portion, which is located on a second side of the coil assembly and is connected to the first core portion to fix the position of the coil assembly.

[0010] The first core portion may include: a first center portion, which is shaped like a hollow cylinder; and a partition wall, which protrudes in a radial direction from the outer peripheral surface of the first center portion, and the partition walls may be spaced apart from each other at regular intervals along the outer peripheral surface of the first center portion, and each receiving groove may be a space formed by the partition wall and the first center portion.

[0011] The partition walls adjacent to each other may be formed such that opposing surfaces of the partition walls are parallel.

[0012] The second core portion may include: a second center portion, which is shaped like a hollow cylinder; and a connecting protrusion, which is formed to protrude on the inner circumferential surface of the second center portion, but is formed at a position corresponding to the partition wall so that the protruding surface of the connecting protrusion contacts the protruding surface of the corresponding partition wall.

[0013] The second core may be formed by assembling a plurality of sheets divided in a circumferential direction of the second core.

[0014] The boundary of each piece may be formed at a position not to divide the coupling protrusion.

[0015] The partition wall may include a protrusion or a groove formed on a protruding surface of the partition wall, and the protruding surface of the coupling protrusion may be formed with the protrusion or the groove corresponding to a shape of one end surface of the partition wall.

[0016] The split type motor stator may further include: a fixing member coupled to an outer peripheral surface of the second core and pressing the second core in the radial direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is an exploded view showing a split-type motor stator of the present disclosure.

[0018] Figure 2 is a top view showing a first core portion of the present disclosure.

[0019] Figure 3 is a top view showing a second core portion of the present disclosure.

[0020] Figure 4 is a partial top view showing a split-type motor stator of the present disclosure.

[0021] Figure 5 1 is a partial top view showing an embodiment of a split motor stator of the present disclosure.

[0022] Figure 6 is a flow chart showing a method of manufacturing the split motor stator of the present disclosure.

[0023] Figure 7 is a perspective view showing a split type motor stator in a step of manufacturing a core in a method of manufacturing a split type motor stator of the present disclosure.

[0024] Figure 8 is a perspective view showing the split type motor stator in the step of assembling the first core portion and the coil assembly in the method of manufacturing the split type motor stator of the present disclosure.

[0025] Fig. 9 is a flowchart showing detailed steps of the step of assembling the second core portion in the method of manufacturing the split type motor stator of the present disclosure.

[0026] Fig.10 is a perspective view of the split motor stator showing the step of assembling the second core portion.

[0027] [Detailed description of main components]

[0028] 1000: Split motor stator

[0029] 100: First core

[0030] 110: Storage groove

[0031] 120: First Central Department

[0032] 130: Partition wall

[0033] 200: Second core

[0034] 210: Second Central Section

[0035] 212: Connecting protrusion

[0036] 300: Fixed components

[0037] C: Coil assembly DETAILED DESCRIPTION

[0038] In the following, the technical spirit of the present disclosure will be described in more detail with reference to the accompanying drawings. The terms and words used in this specification and claims should not be interpreted as general meanings or dictionary meanings, but are interpreted as the meanings and concepts that meet the technical ideas of the present disclosure based on the concept that the inventor of the present utility model can appropriately define the terms in order to describe the principle of its utility model in the best mode.

[0039] In the following, reference will be made to Figure 1 The basic structure of the split-type motor stator 1000 of the present disclosure is described.

[0040] The present disclosure relates to a split motor stator 1000 having a coil assembly C, wherein the coil assembly C includes a plurality of coil strands disposed in the split motor stator. Figure 1 As shown, the split motor stator 1000 of the present disclosure includes a first core 100 and a second core 200, and the first core 100 and the second core 200 can be manufactured separately and assembled when the coil assembly C is inserted. In more detail, the first core 100 can be positioned closer to the rotating shaft or the rotor than the second core 200, that is, located on the inner side, can be positioned closer to the rotating shaft relative to the coil assembly C, and includes a receiving groove 110, and the coil strands are inserted into the receiving groove 110. In addition, the second core 200 can be positioned farther away from the rotating shaft or the rotor than the first core 100, that is, located on the outer side. More specifically, the second core 200 can be positioned away from the rotating shaft relative to the coil assembly C. The second core 200 can be connected to the first core 100 to fix the position of the coil assembly C.

[0041] In this way, in the split motor stator 1000 of the present disclosure, the first core 100 and the second core 200 can be formed separately to increase the coupling performance with the coil component C, and the coil component C is inserted into the first core 100 located on the inside, that is, the coil component C is inserted from the outside to the inside, and only the outside of the second core 200 is pressed tightly, so that most of the gap between the coil strands can be removed, and the coil size can be increased by the amount of empty space. Therefore, compared with the related art (reduction in resistance, improvement in efficiency), a higher loading rate can be ensured.

[0042] In one embodiment of the split motor stator 1000 of the present disclosure, the second core portion 200 can be formed in the shape of a hollow cylinder, and can be formed in the form of a plurality of pieces divided in the circumferential direction and assembled. In this case, the plurality of pieces constituting the second core portion 200 can be equally divided into the same size and shape. In this way, the second core portion 200 is formed by being divided into a plurality of pieces, so that even if the outermost outer diameter of the first core portion 100 and the innermost inner diameter of the second core portion 200 are designed to be the same (minimizing the gap), the first core portion 100 and the second core portion 200 can be easily connected without the need for assembly.

[0043] In the following, reference will be made to Figure 2 The first core 100 of the present disclosure is described in more detail.

[0044] like Figure 2 As shown, the first core 100 may include a first center portion 120 in a hollow cylindrical shape and a partition wall 130 protruding in a radial direction from the outer peripheral surface of the first center portion 120. The partition walls 130 are formed to be spaced apart from each other at regular intervals along the outer peripheral surface of the first center portion 120, and the receiving groove 110 may be a space formed by the partition wall 130 and the first center portion 120 surrounding. In this case, the distance between the partition walls 130 (i.e., the width of the receiving groove 110) may be equal to the thickness of the coil strands of the coil assembly C, or may be longer than a predetermined gap length. That is, the partition wall 130 may allow the coil assembly C to be inserted and fixed in the space between the partition walls.

[0045] In this case, the partition walls 130 adjacent to each other may be formed so that the opposing surfaces are parallel. That is, the cross-sectional area of ​​the partition wall 130 may become wider as the partition wall 130 moves away from the first center portion 120, that is, as the partition wall 130 moves outward. Therefore, the shape of the receiving groove 110 for receiving the coil assembly C may be formed in the shape of a rectangular parallelepiped with one side open, and when the coil strands are stacked in the receiving groove 110 in the radial direction, each coil strand may be supported with a uniform force regardless of its position.

[0046] In the following, reference will be made to Figure 3 and Figure 4 The coupling relationship between the second core portion 200 and the first core portion 100 of the present disclosure is described in more detail.

[0047] like Figure 3 As shown, the second core 200 includes a second center portion 210 in a hollow cylindrical shape and coupling protrusions 212 protruding from an inner circumferential surface of the second center portion 210 and formed at positions corresponding to the partition walls 130. The second center portion 210 and the coupling protrusions 212 may be integrally formed.

[0048] In one embodiment of the split motor stator 1000 of the present disclosure described above, when the second core 200 is formed by assembling a plurality of sheets, the boundary of each sheet may be formed only at a position that does not divide the coupling protrusion 212. Therefore, it is possible to prevent the coupling force between the coupling protrusion 212 and the partition wall 130 from being reduced due to the boundary surface of the sheet.

[0049] like Figure 4 As shown, the coupling protrusion 212 of the second core 200 may be coupled so that the end protruding surface contacts the end protruding surface of the partition wall 130 of the first core 100. Since the second core 200 includes the protruding coupling protrusion 212, when the first core 100 and the second core 200 are coupled, the coupling position of the first core 100 and the second core 200 may be fixed. In addition, the protruding surface of the partition wall 130 may be formed with a protrusion or a groove, and the protruding surface of the coupling protrusion 212 may be formed with a protrusion or a groove to correspond to the shape of one end surface of the partition wall 130. Therefore, the coupling strength of the coupling protrusion 212 and the partition wall 130 is increased, thereby improving the structural stability of the split motor stator 1000 of the present disclosure.

[0050] In the following, reference will be made to Figure 5 The fixing member 300 of the present disclosure is described in more detail.

[0051] like Figure 5 As shown, the split motor stator 1000 of the present disclosure may further include a fixing member 300 to strengthen the coupling force between the first core portion 100 and the second core portion 200. In more detail, the fixing member 300 may be coupled to the outer peripheral surface of the second core portion 200, so that the second core portion 200 may be compressed in the radial direction. When applied as an embodiment of the split motor stator 1000 described above to a case where the second core portion 200 is formed of a plurality of sheets, the effect may be maximized. Figure 5 As shown, the fixing member 300 may be a supporting ring fitted in the outer surface of the second core 200 , or may be carbon fibers wound on the outer surface of the second core 200 .

[0052] In the following, reference will be made to Figures 6 to 10 The method of manufacturing the split type motor stator 1000 of the present disclosure is described in more detail.

[0053] like Figure 6 As shown, the present disclosure relates to a method for manufacturing a split motor stator 1000, which may include: (a) manufacturing and preparing a first core portion 100 and a second core portion 200 to be connected to each other; (b) assembling the first core portion 100 and a coil assembly C by inserting coil strands into a receiving groove 110 of the first core portion 100; and (c) assembling the first core portion 100 and the second core portion 200 to fix the position of the coil assembly C.

[0054] In more detail, Figure 7 As shown, in step (a), a first core 100 having a plurality of receiving grooves 110 and having a hollow center and a second core 200 formed to correspond to the first core 100 can be manufactured. The size of the receiving groove 110 of the first core 100 can be designed in consideration of the thickness of the coil strands of the coil assembly C.

[0055] In the subsequent step (b), if Figure 8 As shown, the coil component C manufactured by the continuous winding method can be assembled and coupled to the receiving groove 110 of the first core part 100. In this case, the coil component C can be inserted into the first core part 100 from the outside to the inside, so most of the gaps between the coil strands can be removed simply by pressing the outside of the second core part 200, and a higher load rate can be ensured compared to the prior art.

[0056] In the embodiment of the split motor stator 1000 disclosed in the present invention, Fig. 9 As shown, step (c) may include (c1) assembling a plurality of sheets forming the second core portion 200 to the first core portion 100, respectively, and (c2) inserting the fixing member 300 into the outer peripheral surface of the second core portion 200 and pressing the second core portion 200 in the radial direction.

[0057] In this case, in step (c1), the sheets constituting the second core portion 200 can be divided in the circumferential direction, and can be equally divided into the same size and shape. In this way, the second core portion 200 is formed by being divided into a plurality of sheets, so that even if the outermost outer diameter of the first core portion 100 and the innermost inner diameter of the second core portion 200 are designed to be the same (minimizing the gap), the first core portion 100 and the second core portion 200 can be easily connected without the need for assembly. In addition, in step (c2), the fixing member 300 can be a support ring assembled in the outer surface of the second core portion 200, or can be a carbon fiber wrapped around the outer surface of the second core portion 200. By performing step (c), it can be finally used Fig.10The stator of the motor is configured with coils wound in the manner shown.

[0058] Furthermore, in an embodiment of the method for manufacturing the split motor stator 1000, step (a) preferably includes (a1) forming a protrusion or a groove on the protruding surface of the partition wall 130 of the first core 100, and (a2) forming a protrusion or a groove corresponding to the surface shape of one end of the partition wall 130 on the protruding surface of the coupling protrusion 212 of the second core 200. Therefore, the coupling strength of the coupling protrusion 212 and the partition wall 130 is increased, thereby improving the structural stability of the split motor stator 1000 of the present disclosure.

[0059] According to the split motor stator and manufacturing method thereof of the present disclosure constructed as described above, the stator core is divided into an inner core and an outer core so that the entrance of the slot into which the coil is inserted can be opened and closed, thereby compensating for the problems of the continuous winding method and realizing the advantages of the hairpin winding method.

[0060] More specifically, by dividing the stator core into an inner core and an outer core so that the entrance of the slot into which the coil is inserted can be opened and closed, it is possible to reduce wasted scrap by using separate cores instead of the entire core to save material costs, eliminate welding and coating processes for the coil to improve the defect rate, and even connect the boots to each other after inserting the winding bundle to eliminate cogging torque fluctuations and improve NVH performance, insert the coil into the slot with the coil in close contact to increase the coil acceptance rate and ensure a high load rate, and reduce the size of the motor to reduce the axial coil length.

[0061] The present disclosure should not be construed as being limited to the above exemplary embodiments. Without departing from the scope of the present disclosure claimed in the claims, the present disclosure can be applied to various fields and can be variously modified by those skilled in the art. Therefore, it is obvious to those skilled in the art that these changes and modifications fall within the scope of the present disclosure.

Claims

1. A split motor stator, the split motor stator having a coil assembly, the coil assembly comprising a plurality of coil strands arranged in the split motor stator, characterized in that: The split motor stator comprises: a first core portion located at a first side of the coil component in a direction of a rotation axis of the coil component and including a receiving groove into which the coil strands are inserted; and A second core portion is located at a second side of the coil component and is coupled to the first core portion to fix a position of the coil component.

2. The split motor stator according to claim 1, characterized in that: The first core comprises: a first central portion, the first central portion being in the shape of a hollow cylinder; and a partition wall protruding in a radial direction from an outer peripheral surface of the first center portion, wherein the partition walls are spaced apart from each other at regular intervals along the outer peripheral surface of the first central portion, and Each receiving groove is a space formed by surrounding the partition wall and the first central portion.

3. The split motor stator according to claim 2, characterized in that: The partition walls adjacent to each other are formed such that opposite surfaces of the partition walls are parallel.

4. The split motor stator according to claim 2, characterized in that: The second core portion comprises: a second central portion, the second central portion being in the shape of a hollow cylinder; and A coupling protrusion is formed to protrude on an inner peripheral surface of the second center portion and is formed at a corresponding partition wall of the first core portion such that a protruding surface of the coupling protrusion contacts a protruding surface of the corresponding partition wall.

5. The split motor stator according to claim 4, characterized in that: The second core is formed by assembling a plurality of sheets divided along a circumferential direction of the second core.

6. The split motor stator according to claim 5, characterized in that: The boundary of each piece is formed at a position not to divide the coupling protrusion.

7. The split motor stator according to claim 4, characterized in that: The partition wall includes a protrusion or a groove formed on the protruding surface of the partition wall, and Wherein, the protruding surface of the coupling protrusion is formed with a protrusion or a groove corresponding to the shape of one end surface of the partition wall.

8. The split motor stator according to claim 5, characterized in that: The split motor stator also includes: A fixing member is coupled to an outer peripheral surface of the second core portion and presses the second core portion in the radial direction.

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