Stator core, plastic package stator assembly, motor and air conditioner
By introducing a transverse sliding limit structure and an insulating frame connection on the semicircular stator core segment, the problem of positional instability of the stator core during the assembly and plastic sealing process is solved, the concentricity is improved and the motor noise is reduced.
Patent Information
- Application Number
- CN202422577357.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-24
- Publication Date
- 2025-09-09
- Estimated Expiration
- 2034-10-24
AI Technical Summary
The existing semicircular stator core lacks an axial limiting structure during the assembly process, resulting in significant up-down and left-right displacement of the stator core. It is prone to radial dislocation during the injection molding process, affecting the stator concentricity and causing noise problems.
A transverse sliding limit structure is adopted, and the cooperation of the hook and the slot ensures the reliable splicing of the semicircular core segment in the middle area of the axial length. The sliding direction is consistent with the first diameter direction of the stator core. Combined with the buckle and groove connection of the insulating frame, the concentricity and stability of the stator core are enhanced.
The concentricity of the stator core during the plastic sealing process is improved, the operating noise of the motor is reduced, the axial and radial limit reliability of the stator assembly is ensured, and the deviation caused by the impact of the injection molding compound is prevented.
Smart Images
Figure CN223321833U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of motor design, and in particular relates to a stator core, a plastic-sealed stator assembly, a motor, and an air conditioner. Background Art
[0002] The PG motor used in household air conditioners is an AC plastic-encapsulated motor with thyristor speed regulation. It primarily consists of a stator assembly, a rotor assembly, a Hall element, and end caps. The stator assembly is injection-molded from a stator core, a bobbin, and enameled wire.
[0003] In the existing semicircular stator splicing structure, the two sets of semicircular stator cores arranged opposite to each other are connected to each other by a dovetail structure through axial plug-in buckling to realize the splicing connection between the two split core segments. Due to the lack of a limiting structure for the axial direction of the core, the split core segments are easily misaligned. At the same time, in order to facilitate axial splicing, the matching gap between the slots and buckles of the dovetail structure is often large (the punching sheets of the stacked core need to be punched first, and the slots and buckles are realized simultaneously during the punching process, so that the core segments are not easily misaligned). The punching sheets of the type are stacked up and down, and the assembly shape and position deviations of the slots and buckles on different punching sheets are large. In order to ensure the smooth axial clamping assembly, a large deviation size needs to be reserved when stamping each punching sheet), that is, the design is relatively loose, which makes the up and down and left and right displacement of the assembled stator core more obvious. When the stator is injection molded (also known as plastic sealing), the impact of the injection plastic will cause radial dislocation and offset of the core, resulting in poor stator concentricity, which in turn causes the corresponding motor to have more prominent noise problems during application. Utility Model Content
[0004] Therefore, the utility model provides a stator core, a plastic-sealed stator assembly, a motor, and an air conditioner, which can solve the technical problem in the prior art that the relative position of the stator core formed by splicing split core segments lacks necessary limitations, the vertical and horizontal displacement lines of the spliced stator core are relatively obvious, and especially during the plastic-sealing process of the stator core, radial dislocation and offset are easily caused by the impact of the injection molding material, thereby reducing the concentricity of the stator and causing noise.
[0005] In order to solve the above problems, the utility model provides a stator core, including two semicircular core segment splits, the assembly surfaces of the two semicircular core segment splits respectively fitted together to form a whole circle, and the assembly surfaces of the two semicircular core segment splits respectively formed a splicing by a transverse sliding limit structure, the transverse sliding limit structure is located in the middle area of the axial length of each semicircular core segment split, and the sliding insertion direction of the transverse sliding limit structure is the first diameter direction of the stator core.
[0006] In some embodiments, the lateral sliding limit structure includes a hook formed on the first side circumferential wall of the semicircular core segment split and a groove formed on the second side circumferential wall of the semicircular core segment split, and the hook protrudes from the assembly surface of the semicircular core segment split, the first side and the second side are symmetrical about the central axis of the stator core, and when the two semicircular core segment splits are spliced into the full circle, the hook body of the hook of one semicircular core segment split is embedded in the groove of the other semicircular core segment split.
[0007] In some embodiments, the hook further has a connector connected between the first side circumferential wall and the hook body, the connector protrudes radially outward from the first side circumferential wall, and the length extension direction of the hook body and the depth extension direction of the slot are both parallel to the first diameter direction, and the hook body matches the size of the slot.
[0008] In some embodiments, shielding protrusions are further formed on the outer circumferential wall of the semicircular core segment, and the shielding protrusions are respectively arranged corresponding to the positions of the hook and the slot, and the shielding protrusions are located at both axial ends of the hook and the slot.
[0009] In some embodiments, the semicircular core segment comprises a first segment, a second segment, and a third segment arranged in sequence along its axial direction, wherein the first segment and the third segment are both formed by stacking multiple first punching sheets, and the second segment is formed by stacking multiple second punching sheets.
[0010] In some embodiments, the axial length of the second segment is greater than the axial lengths of the first segment and the third segment respectively; and / or the axial lengths of the first segment and the third segment respectively are equal.
[0011] The utility model also provides a plastic-sealed stator assembly, comprising a stator core and an insulating frame coated on the outer wall of the stator core, wherein the stator core is the stator core described above.
[0012] In some embodiments, the insulating skeleton includes four skeleton splits, and a clip and a groove are formed on the end plate of each of the skeleton splits. The clip and the groove are respectively located on opposite sides of the end plate, and when the insulating skeleton and the stator core are assembled, the clip of one of the two skeleton splits at the same axial end of the stator core is buckled into the groove of the other one.
[0013] The present invention also provides a method for manufacturing the plastic-sealed stator assembly as described above, comprising the following steps:
[0014] Two semicircular core segment splits are manufactured, and the manufactured skeleton splits are respectively covered and connected to the semicircular core segment splits to form a first split assembly and a second split assembly respectively;
[0015] Winding stator windings on the first split component and the second split component respectively;
[0016] Sliding and plugging the first split assembly and the second split assembly wound with the stator winding along the first diameter direction into one piece, and buckling the corresponding buckles and grooves of the two skeleton splits at the same end of the semicircular iron core segment split to form a stator assembly;
[0017] The stator component is placed in an injection mold for plastic sealing to finally form the plastic-sealed stator assembly.
[0018] The utility model also provides a motor, comprising the above-mentioned plastic-sealed stator assembly.
[0019] The utility model also provides an air conditioner, comprising the above-mentioned motor.
[0020] The utility model provides a stator core, a plastic-sealed stator assembly, a motor, and an air conditioner having the following features:
[0021] Beneficial effects:
[0022] The two semicircular core segments are separated by a transverse sliding limit structure located at the assembly surface position of the two. Since the transverse sliding limit structure is located in the middle area of the axial length of the stator core, and the assembly direction of the two is a push-pull sliding direction along the first diameter of the stator core, since the sliding direction is parallel to the stacking gaps of the punching sheets of the semicircular core segments, the matching size of the transverse sliding limit structure can be smaller. In this way, after the two semicircular core segments are assembled, more reliable axial and radial limiting can be achieved, which is beneficial to prevent the stator core from being radially dislocated and offset due to the impact of the injection plastic during the subsequent plastic sealing process, thereby improving the concentricity of the stator assembly and helping to reduce the operating noise of the motor. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the embodiments or the description of the prior art. The drawings described below are merely exemplary. For those skilled in the art, other implementation drawings can be derived from the provided drawings without inventive effort.
[0024] Figure 1 This is a schematic diagram of the three-dimensional structure of the semicircular core segments in the stator core of an embodiment of the present utility model;
[0025] Figure 2 This is a schematic diagram of the three-dimensional structure of the stator core of the embodiment of the present invention, in which two semicircular core segments are separated and assembled into a full circle. The arrow in the figure indicates the direction of sliding assembly.
[0026] Figure 3 yes Figure 1 Axial projection of the first punch in the first section and the third section;
[0027] Figure 4 yes Figure 1 An axial projection of the second punch in the third section;
[0028] Figure 5 This is a schematic diagram of the three-dimensional structure of the split frame in another embodiment of the present invention;
[0029] Figure 6 This is a schematic diagram of the three-dimensional structure of the embodiment of the utility model after the semi-circular core segment is assembled separately with the frame;
[0030] Figure 7 1 is a schematic diagram of the three-dimensional structure of the stator assembly of an embodiment of the present utility model (the stator winding is not shown);
[0031] Figure 8 This is a schematic diagram of the three-dimensional structure of the stator assembly of an embodiment of the present utility model;
[0032] Figure 9 It is a schematic diagram of the three-dimensional structure of the motor according to an embodiment of the present utility model.
[0033] The accompanying drawings are:
[0034] 1. Semicircular core segment split; 10. Assembly surface; 11. Buckle point; 21. Hook; 211. Hook body; 212. Connector; 22. Slot; 3. Shielding protrusion; 41. First segment; 42. Second segment; 43. Third segment; 51. First punching sheet; 52. Second punching sheet; 61. Skeleton split; 611. End plate; 612. Buckle; 613. Groove; 100. Stator core; 200. Insulation skeleton; 300. Rotor assembly. DETAILED DESCRIPTION
[0035] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.
[0036] In the description of the present invention, it needs to be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.
[0037] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90° or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.
[0038] In addition, it should be noted that the use of words such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above words have no special meaning and therefore cannot be understood as limiting the scope of protection of this utility model.
[0039] See also Figure 1 and Figure 9 As shown, according to an embodiment of the present invention, a stator core is provided, see Figure 2 As shown, it includes two semicircular core segment splits 1, and the assembly surfaces 10 respectively provided by the two semicircular core segment splits 1 are fitted together to form a full circle. The assembly surfaces 10 respectively provided by the two semicircular core segment splits 1 are spliced together by a transverse sliding limit structure (not marked in the figure), and the transverse sliding limit structure is located in the middle area of the axial length of each semicircular core segment split 1, that is, the aforementioned transverse sliding limit structure is not provided at the axial ends of the semicircular core segment split 1, and the sliding insertion direction of the transverse sliding limit structure is the first diameter direction of the stator core, and the aforementioned first diameter is, for example, Figure 2The direction indicated by the arrow in the figure is objectively the first diameter direction, that is, the push-pull-slide to the left or right along a diameter direction of the stator core.
[0040] In this technical solution, the two semicircular core segment splits 1 are connected by a transverse sliding limit structure at the assembly surface position of the two. Since the transverse sliding limit structure is located in the middle area of the axial length of the stator core, and the assembly direction of the two is the push-pull sliding direction along the first diameter of the stator core, and the sliding direction is parallel to the stacking gaps of the semicircular core segment splits 1, the matching size of the transverse sliding limit structure can be smaller. In this way, after the two semicircular core segment splits 1 are assembled, more reliable axial and radial limiting can be achieved, which is beneficial to prevent the stator core from being radially dislocated and offset due to the impact of the injection plastic during the subsequent plastic sealing process, thereby improving the concentricity of the stator assembly and helping to reduce the operating noise of the motor.
[0041] In some embodiments, see Figure 4 As shown, the lateral sliding limit structure includes a hook 21 formed on the first side circumferential wall of the semicircular core segment split 1 and a groove 22 formed on the second side circumferential wall of the semicircular core segment split 1, and the hook 21 protrudes from the assembly surface 10 of the semicircular core segment split 1, and the first side and the second side are left-right symmetrical about the central axis of the stator core. When the two semicircular core segment splits 1 are spliced into the full circle, the hook body 211 of the hook 21 of one semicircular core segment split 1 is embedded in the groove 22 of the other semicircular core segment split 1, that is, for the same semicircular core segment split 1, the aforementioned hook 21 and groove 22 thereon are respectively located on both sides of its assembly surface 10.
[0042] In this technical solution, the hook 21 is provided to protrude from one side of the assembly surface 10, and the slot 22 is located on the other side of the assembly surface 10. When the two semicircular core segment splits 1 are assembled with each other, the two semicircular core segment splits 1 are symmetrical about the central axis of the stator core. After sliding horizontally along the direction of the aforementioned first diameter into place, the hooks 21 and slots 22 respectively possessed by the two semicircular core segment splits 1 are plugged into each other to form a limit in one direction of the left and right directions, thereby completing the assembly between the two.
[0043] See further Figure 4 As shown, in some embodiments, the hook 21 further has a connector 212 connected between the first side circumferential wall and the hook body 211, the connector 212 protrudes radially outward from the first side circumferential wall, and the length extension direction of the hook body 211 and the depth extension direction of the slot 22 are both parallel to the first diameter direction, and the size of the hook body 211 matches that of the slot 22, that is, the shapes and sizes of the two are the same.
[0044] In this technical solution, the connector 212 of the hook 21 protrudes from the circumferential wall and does not occupy the area of the mating surface of the two semicircular core segment splits 1, which can ensure the uniformity of the magnetic density in the yoke ring part of the assembled stator core as much as possible.
[0045] In some embodiments, a shielding protrusion 3 is further formed on the outer circumferential wall of the semicircular core segment split 1, and the shielding protrusion 3 also protrudes from the outer circumferential wall of the semicircular core segment split 1. The shielding protrusion 3 corresponds to the position of the hook 21 and the slot 22, and the shielding protrusion 3 is located at both ends of the axial direction of the hook 21 and the slot 22. For details, see Figure 2 As shown, the aforementioned shielding protrusion 3 and the hook 21 and the slot 22 on the same side are arranged in sequence front to back along the axial direction of the stator core.
[0046] In this technical solution, by providing shielding protrusions 3 at both axial ends of the hook 21 and the slot 22, a certain support can be formed for the axial end face of the hook 21, thereby ensuring the stability and reliability of the axial relative position of the assembled stator core.
[0047] In some embodiments, the semicircular core segment split 1 includes a first segment 41, a second segment 42 and a third segment 43 arranged in sequence along its axial direction, wherein the first segment 41 and the third segment 43 are both formed by stacking multiple first punching sheets 51, and the second segment 42 is formed by stacking multiple second punching sheets 52. The aforementioned first punching sheets 51 and the second punching sheets 52 are both provided with corresponding buckle points 11, and each first punching sheet 51 and / or second punching sheet 52 is reliably stacked with each other through the corresponding buckle points 11; in a preferred embodiment, the axial length of the second segment 42 is greater than the axial length of the first segment 41 and the third segment 43 respectively, so as to ensure the axial position reliability of the stator core and improve the structural strength of the stator core after splicing; and / or the axial lengths of the first segment 41 and the third segment 43 are respectively equal, so as to ensure the consistency of the magnetic properties at the axial ends of the stator core.
[0048] According to an embodiment of the present invention, a plastic-encapsulated stator assembly is further provided, comprising a stator core 100 and an insulating frame 200 coated on the outer wall of the stator core 100. The stator core 100 is the stator core described above. In a specific embodiment, the insulating frame 200 includes four frame segments 61, each frame segment 61 having a completely identical structural design. Two of the frame segments 61 are assembled to coat the upper half of the stator core 100 from one axial end thereof, and the remaining two frame segments 61 are assembled to coat the lower half of the stator core 100 from the other axial end thereof. For details, see Figure 5As shown, a buckle 612 and a groove 613 are formed on the end plate 611 of each of the skeleton parts 61, and the buckle 612 and the groove 613 are respectively located on opposite sides of the end plate 611, and when the insulating skeleton 200 and the stator core 100 are assembled, the buckle 612 of one of the two skeleton parts 61 at the same axial end of the stator core 100 is buckled into the groove 613 of the other one. Generally speaking, each skeleton part 61 is generally made of plastic material, and the buckle 612, groove 613 and end plate 611 can be integrated into one piece, and the buckle 612 has a certain elasticity. In actual application, the skeleton split 61 covering the upper half of the stator core 100 and the skeleton split 61 covering the lower half of the stator core 100 are fitted together at their ends to form an axial connection of the stator core 100, and the two skeleton splits 61 at the same axial end of the stator core 100 are reliably connected through their respective buckles 612 and grooves 613. The stator core 100 is fixed for the second time by the insulating skeleton 200, which can further improve the stator core's ability to resist impact and displacement during the injection molding process and ensure the roundness of the stator assembly.
[0049] It is understandable that the buckle 612 and the groove 613 should completely match in shape and size to ensure the position accuracy of each frame segment 61 after assembly.
[0050] According to an embodiment of the present invention, a method for manufacturing the above-mentioned plastic-encapsulated stator assembly is also provided, comprising the following steps:
[0051] Two semicircular core segment splits 1 are manufactured, and the manufactured skeleton splits 61 are respectively covered and connected to the semicircular core segment splits 1 to form a first split assembly (not labeled in the figure) and a second split assembly (not labeled in the figure);
[0052] Winding stator windings (not shown) on the stator teeth of the first split assembly and the second split assembly respectively;
[0053] The first split assembly and the second split assembly wound with the stator winding are slidably plugged into one piece along the first diameter direction, and the corresponding buckles 612 and grooves 613 of the two skeleton splits 61 at the same end of the semicircular iron core segment split 1 are buckled together to form a stator assembly;
[0054] The stator component is placed in an injection mold for plastic sealing to finally form the plastic-sealed stator assembly.
[0055] In this technical solution, before the first split component and the second split component are assembled, the stator winding is first wound on the stator teeth of each split component, which makes winding more convenient and can significantly improve the winding slot fill rate.
[0056] In some embodiments, the semicircular core segment 1 is manufactured in the following manner:
[0057] The first punching sheet 51 and the second punching sheet 52 are formed by stamping, and each of the first punching sheets 51 is stacked to form the first section 41 and the third section 43. Each of the second punching sheets 52 is stacked to form the second section 42. The first section 41, the second section 42 and the third section 43 are stacked from top to bottom along the axial direction to form a whole.
[0058] According to an embodiment of the present invention, a motor is further provided, particularly a thyristor-controlled AC plastic-encapsulated motor, comprising the aforementioned plastic-encapsulated stator assembly and rotor assembly 300. After the aforementioned plastic-encapsulated stator assembly is fabricated, the rotor assembly 300 is assembled, the Hall element and end caps are installed, and the rubber rings are installed to complete the assembly of the entire motor.
[0059] According to an embodiment of the present invention, an air conditioner is also provided, comprising the above-mentioned motor.
[0060] It is easy for those skilled in the art to understand that, under the premise of no conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.
[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention. The above description is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present invention. Such improvements and variations shall also be considered within the scope of protection of the present invention.
Claims
1. A stator core, comprising two semicircular core segments (1), wherein the assembly surfaces (10) of the two semicircular core segments (1) are respectively attached to each other to form a full circle, characterized in that: The assembly surfaces (10) respectively provided by the two semicircular core segment splits (1) are spliced together by a transverse sliding limiting structure, the transverse sliding limiting structure is located in the middle area of the axial length of each semicircular core segment split (1), and the sliding insertion direction of the transverse sliding limiting structure is the first diameter direction of the stator core.
2. The stator core according to claim 1, characterized in that The transverse sliding limiting structure comprises a hook (21) formed on the first side circumferential wall of the semicircular iron core segment split (1) and a slot (22) formed on the second side circumferential wall of the semicircular iron core segment split (1), and the hook (21) protrudes from the assembly surface (10) of the semicircular iron core segment split (1), the first side and the second side are symmetrical about the central axis of the stator iron core, and when the two semicircular iron core segment splits (1) are spliced into the full circle, the hook body (211) of the hook (21) of one semicircular iron core segment split (1) is embedded in the slot (22) of the other semicircular iron core segment split (1).
3. The stator core according to claim 2, characterized in that The hook (21) further comprises a connecting body (212) connected between the first side circumferential wall and the hook body (211), the connecting body (212) protruding from the radially outer side of the first side circumferential wall, and the length extension direction of the hook body (211) and the depth extension direction of the slot (22) are both parallel to the first diameter direction, and the size of the hook body (211) matches that of the slot (22).
4. The stator core according to claim 3, characterized in that A shielding protrusion (3) is also formed on the outer circumferential wall of the semicircular core segment split (1), and the shielding protrusion (3) is respectively arranged corresponding to the position of the hook (21) and the slot (22), and the shielding protrusion (3) is located at both ends of the axial direction of the hook (21) and the slot (22).
5. The stator core according to claim 4, characterized in that The semicircular core segment split (1) comprises a first segment (41), a second segment (42) and a third segment (43) arranged in sequence along its axial direction, wherein the first segment (41) and the third segment (43) are both formed by stacking multiple first punching sheets (51), and the second segment (42) is formed by stacking multiple second punching sheets (52).
6. The stator core according to claim 5, characterized in that The axial length of the second section (42) is greater than the axial lengths of the first section (41) and the third section (43), respectively; and / or the axial lengths of the first section (41) and the third section (43) are equal.
7. A plastic-encapsulated stator assembly, comprising a stator core (100) and an insulating frame (200) coated on the outer wall of the stator core (100), characterized in that: The stator core (100) is the stator core according to any one of claims 1 to 6.
8. The plastic-sealed stator assembly according to claim 7, characterized in that: The insulating frame (200) includes four frame segments (61), and a buckle (612) and a groove (613) are formed on the end plate (611) of each frame segment (61), and the buckle (612) and the groove (613) are respectively located on opposite sides of the end plate (611), and when the insulating frame (200) and the stator core (100) are assembled, the buckle (612) of one of the two frame segments (61) located at the same axial end of the stator core (100) is buckled into the groove (613) of the other frame segment (61).
9. A motor, characterized in that: Including the plastic-sealed stator assembly according to claim 7 or 8.
10. An air conditioner, characterized in that: Including the motor according to claim 9.