Stator assembly and motor

Abstract

The utility model provides a stator assembly which is characterized by comprising a plurality of stator modules, and the stator modules together form the stator assembly in an annular shape. The stator module comprises a stator core, two end portions and a winding portion located between the two end portions are arranged in the axial direction of the stator assembly, and the size of the winding portion in the circumferential direction of the stator assembly is smaller than that of the end portions. The size of the end part in the circumferential direction is gradually increased along the radial outward direction of the stator assembly, and the side edges of the two ends of the end part in the circumferential direction are provided with protruding parts and / or concave parts; and the winding is wound on the periphery of the winding part of the stator core. Wherein the side edges of the end parts of the stator cores of every two adjacent stator modules are matched with each other, so that the protruding part of one stator module is accommodated in the concave part of the adjacent stator module, and the plurality of stator modules are encircled to form a complete annular stator assembly.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of electric machines, in particular to a stator assembly and an electric machine comprising the same. BACKGROUND

[0002] Axial flux permanent magnet synchronous motor, also known as disc type permanent magnet motor, has the advantages of compact structure, high power density and high efficiency, and its application range involves automotive systems, manufacturing systems, household appliances, power tools, aerospace and other application fields. Single stator-double rotor structure, force balance of stator and rotor has good structural stability, is one of the typical topological structures of axial flux motor which is widely used.

[0003] However, the stator core of the existing single stator-double rotor structure disc type permanent magnet motor is mostly a block structure, that is, a plurality of single stator modules are assembled into a circular stator assembly assembly. Since there is no positioning structure when the adjacent stator modules are installed, complex fixtures are required for circumferential and axial positioning, which has high requirements on the production process and low product qualification rate.

[0004] Moreover, the existing single stator core is a trapezoidal body made of silicon steel sheets stacked together. Since the trapezoidal faces are stacked together, it is difficult to ensure the axial trapezoidal face flatness. In addition, the stator is assembled together, and several or even dozens of single stator modules are assembled together, so it is more difficult to ensure the axial orientation of the induction surface flatness. Therefore, the production process and fixture of the axial flux motor block type stator core to form the stator assembly assembly are complex, and simple fixtures are difficult to meet the requirements of circumferential and axial precision, resulting in low product qualification rate.

[0005] Therefore, a structure capable of optimizing the assembly of the stator assembly is needed. CONTENT OF THE UTILITY MODEL

[0006] The purpose of the present disclosure is to at least solve the shortcomings in the prior art. The present disclosure provides a stator assembly, which is characterized by comprising a plurality of stator modules, which together form a ring-shaped stator assembly. The stator module comprises a stator core having two end portions and a winding portion located between the two end portions in the axial direction of the stator assembly, the size of the winding portion in the circumferential direction of the stator assembly is smaller than that of the end portion, the size of the end portion in the circumferential direction gradually increases in the radial outward direction of the stator assembly, and the side edges of the two ends of the end portion in the circumferential direction are provided with protruding portions and / or recessed portions; a winding is wound around the periphery of the winding portion of the stator core. Wherein, the side edges of the end portions of the stator cores of every two adjacent stator modules cooperate with each other, so that the protruding portion of one stator module is accommodated in the recessed portion of the adjacent stator module, and then the plurality of stator modules are surrounded to form a complete ring-shaped stator assembly.

[0007] For example, according to some embodiments of the present disclosure, the stator core is formed by die casting, such that the flatness of the two outermost end faces of the two end portions of the stator module in the axial direction is less than or equal to 0.03 mm, and / or the parallelism between the two end faces is less than or equal to 0.03 mm.

[0008] For example, according to some embodiments of the present disclosure, the end faces of the plurality of stator modules respectively form two annular axial induction faces at both ends of the axial direction, the flatness of each of the axial induction faces is less than or equal to 0.05 mm, and / or the parallelism between the two axial induction faces is less than or equal to 0.05 mm.

[0009] For example, according to some embodiments of the present disclosure, the end portions of the stator module are provided with two protrusions on one of the side edges and two recesses on the other of the side edges.

[0010] For example, according to some embodiments of the present disclosure, the protrusions and the recesses have complementary circular arc profiles.

[0011] For example, according to some embodiments of the present disclosure, the stator module further comprises a skeleton integrally formed to wrap the winding portion, and the end faces of the end portions of the stator core protrude in the axial direction beyond the skeleton.

[0012] For example, according to some embodiments of the present disclosure, the skeleton protrudes beyond the stator core at both ends in the radial direction, and the portions of the skeleton protruding beyond the stator core at both ends in the radial direction are respectively provided with potting openings to allow the potting material to enter the interior of the stator module.

[0013] For example, according to some embodiments of the present disclosure, the stator assembly further comprises a potting portion integrally formed to fill the gaps inside the plurality of stator modules.

[0014] For example, according to some embodiments of the present disclosure, each of the stator modules is identical.

[0015] For example, according to some embodiments of the present disclosure, the stator assembly comprises 24 stator modules.

[0016] The present disclosure also proposes an electric machine comprising the stator assembly of any of the above embodiments.

[0017] For example, according to some embodiments of the present disclosure, the electric machine is a disc-type permanent magnet electric machine, and the electric machine further comprises two rotors provided with magnetic rings, and the stator assembly comprises two annular axial induction faces at both ends in the axial direction, and each of the annular end faces is coaxially and oppositely arranged with respect to the magnetic ring of one of the rotors. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1shows a perspective view of a stator assembly according to an embodiment of the present disclosure before undergoing a potting step;

[0019] Figure 2 A perspective view showing a stator assembly according to an embodiment of the present disclosure after undergoing a potting step;

[0020] Figure 3 shows an exploded view of a single stator module according to an embodiment of the present disclosure;

[0021] Figure 4 A perspective view showing a single stator module according to an embodiment of the present disclosure;

[0022] Figure 5 An enlarged perspective view illustrating a stator core of a stator module according to an embodiment of the present disclosure is shown.

[0023] Reference numerals

[0024] 1——Stator module

[0025] 11——Stator core

[0026] 111——End

[0027] 112——Winding Department

[0028] 113 - The Bulge

[0029] 114 - concave part

[0030] 115——Side

[0031] 116——End face

[0032] 12——Winding

[0033] 13 - Skeleton

[0034] 131——Pouring port

[0035] 132——Outlet

[0036] 133——Skeleton end face

[0037] 2——Potting Department

[0038] 3——Stator assembly

[0039] 31——Axial sensing surface DETAILED DESCRIPTION

[0040] In order to make the purpose, scheme and advantages of the technical solutions of the present disclosure clearer, the technical solutions of the embodiments of the present disclosure will be described clearly and completely below in conjunction with the accompanying drawings of specific embodiments of the present disclosure. Unless otherwise specified and limited, the terms used herein have the meanings commonly understood in the art. The same reference signs in the drawings represent the same components.

[0041] In the description of the present disclosure, it should be noted that, unless otherwise explicitly specified and limited, the terms “mounting”, “connection”, “connecting” should be understood broadly, for example, can be fixed connection, can also be detachable connection, or integrally connected; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be the communication inside two elements. For those skilled in the art, the specific meanings of the above terms in the present disclosure can be understood according to the specific circumstances.

[0042] In the present disclosure, for the convenience of description, the direction of the center axis of the ring-shaped stator assembly is designated as the axial direction, the radial direction of the ring-shaped stator yoke is designated as the radial direction, and the direction around the center axis of the ring-shaped stator yoke is designated as the circumferential direction.

[0043] The present disclosure proposes a stator assembly 3 comprising a plurality of stator modules 1. For example, the number of stator modules 1 is, for example, 24 as shown in Figure 1 and Figure 2 The number of end portions in the present disclosure is not limited to 24, but can also be 6, 9, 12, 15, 18, 21, 27, 30, etc. The stator modules 1 are arranged in a circle to form a ring-shaped stator assembly 3 as shown in Figure 1 Figure 3 and Figure 4 The stator module 1 according to the present disclosure can comprise a stator core 11, windings 12 and a skeleton 13 as shown in

[0044] The stator core 11 can be composed of soft magnetic composite material (SMC material), which is integrally formed with insulating iron core powder. This technology is a net forming technology, so the material utilization rate is very high, and the stator core processing mode is die casting forming. The advantages of this process and material are that the integrally formed has good heat dissipation cooling effect, higher power density, high precision, high resistivity, low eddy current loss and iron loss, no bending, edge curling and rust problems of silicon steel sheet winding. And the stator core formed in this way is convenient for processing the protruding part 113 and the recessed part 114 described below.

[0045] ​Through this integrated molding technology, the stator core 11 can be formed so that the flatness of its two outermost end faces 116 in the axial direction can have good precision, for example, it can be less than or equal to 0.05mm, less than or equal to 0.04mm, less than or equal to 0.03mm, less than or equal to 0.02mm, and / or the parallelism between the two end faces 116 can have good precision, for example, it can be less than or equal to 0.05mm, less than or equal to 0.04mm, less than or equal to 0.03mm, less than or equal to 0.02mm. This is conducive to improving the flatness and parallelism of the annular axial sensing surface 31 at both axial ends of the stator assembly 3 formed by the plurality of stator modules 1. However, the stator modules made of laminated silicon steel sheets in the prior art are difficult to form two end faces with such precision of flatness and parallelism.

[0046] The stator core 11 may include two end portions 111 and a winding portion 112 located between the two end portions 111. The two end portions 111 and the winding portion 112 are arranged in the axial direction, and the size of the two end portions 111 in the circumferential direction is larger than the size of the winding portion 112 in the circumferential direction. Figure 3 As shown, the stator core 11 may have an I-shaped cross-section in a plane perpendicular to the radial direction. This forms slots for winding wires to form the windings 12. Specifically, the windings 12 are wound around the periphery of the winding portion 112. If a frame 13 surrounds the winding portion 112, the windings 12 are wound around the periphery of the winding portion 112, close to the frame 13. That is, the frame 13 is disposed between the winding portion 112 and the windings 12.

[0047] Furthermore, the size of the end portion 111 in the circumferential direction may gradually increase in the radially outward direction (directed radially away from the axis of the ring), for example, Figure 3 and Figure 5 As shown, the end surface 116 of the end portion 111 may have a substantially trapezoidal shape. Thus, a plurality of stator modules 1 may surround and form a complete ring, wherein the side edges 115 of the end portion 111 of the stator core 11 of each two adjacent stator modules 1 (at both ends of the circumferential direction of the end portion 111, as shown in FIG. Figure 5 As shown) cooperate with each other, such as Figure 1 As shown, the side of the end portion 111 having a smaller circumferential dimension is located on the inner side of the ring shape, whereas the side having a larger circumferential dimension is located on the outer side of the ring shape.

[0048] And the assembly of multiple stator modules is a relatively complex process. In the prior art, when assembling, a circumferential and axial tool is needed. Without the full-range positioning of the tool, the roundness of the stator assembly and the flatness and parallelism errors of the axial induction surfaces at the two axial ends are large. After using the full-range positioning tool, especially the circumferential tool, the subsequent potting process is affected, and the potting glue cannot completely penetrate into the stator module, which affects the strength and cooling effect of the entire stator. During the potting process, due to the impact of the potting material on the stator assembly, without positioning structure between the single stator modules, the stator modules will displace, the stator assembly will deform, and the error will further increase.

[0049] In order to overcome the above-mentioned adverse defects, the side edge 115 at both ends of the end 111 in the circumferential direction of the stator core 11 is further provided with a protruding portion 113 and / or a recessed portion 114, so that when the stator modules 1 are matched with each other, the protruding portion 113 of one stator module 1 is accommodated in the recessed portion 114 of the adjacent stator module 1.

[0050] Therefore, the stator module according to the present disclosure can realize self-positioning. The self-positioning structure not only can realize convenient, fast and accurate positioning of the stator module, but also only needs a circular ring tool to press down the annular axial induction surface 31 at the two axial ends formed after the assembly of multiple stator modules, so that the axial displacement is avoided. This step is also to ensure the flatness and parallelism of the axial induction surface 31 at the two axial ends of the self-positioning stator assembly 3. In particular, the two axial induction surfaces 31 at the two axial ends in the axial direction are respectively composed of the end faces 116 of multiple stator modules 1, as shown in Figure 1 Through the above-mentioned self-positioning structure including the protruding portion 113 and the recessed portion 114 provided on the side edge 115, the flatness of the two axial induction surfaces can have good accuracy, for example, can be less than or equal to 0.07 mm, can be less than or equal to 0.06 mm, can be less than or equal to 0.05 mm, can be less than or equal to 0.04 mm, and / or the parallelism between the two axial induction surfaces can have good accuracy, for example, can be less than or equal to 0.07 mm, can be less than or equal to 0.06 mm, can be less than or equal to 0.05 mm, can be less than or equal to 0.04 mm.

[0051] The radial displacement between the stator modules can be fixed by the interlocking of the protruding portion 113 and the recessed portion 114. Therefore, the assembly and processing process of the entire stator assembly 3 is simple in process and tooling, high in processing precision, and high in product qualification rate. In addition, the rigid connection between the stator modules without the above-mentioned self-positioning structure relies entirely on the connection of the potting portion 2 (to be described in detail below), while the stator modules provided with the above-mentioned self-positioning structure can not only facilitate installation, but also increase the overall rigidity of the stator.

[0052] For example, each side edge can be provided with one or more protrusions 113 and / or one or more recesses 114. For example, each side edge can be provided with one protrusion 113 and one recess 114, or, two side edges of each end portion can be provided with two protrusions 113 or two side edges of each end portion can be provided with two recesses 114 (in which case, the stator modules 1 whose two side edges are provided with protrusions 113 and the stator modules 1 whose two side edges are provided with recesses 113 are alternately arranged in sequence), or, as shown in Figure 4 , one side edge of each end portion is provided with two protrusions 113 and the other side edge is provided with a recess 114. In this way, each two pairs of cooperating side edges can have multiple pairs of cooperating protrusions 113 and recesses 114 to further enhance the strength of self-positioning achieved by the protrusions 113 and recesses 114.

[0053] Further, as shown in Figure 4 , the protrusions 113 and recesses 114 can have a circular arc shape profile that conforms to the shape, which is advantageous for the quick cooperation of adjacent stator modules 1 and ensures the connection strength. The corresponding angle of the circular arc shape can be less than 180 degrees, which can more easily achieve the positioning cooperation, because the circular arc shape with a central angle greater than 180 degrees is more difficult to cooperate and requires more time.

[0054] As shown in Figure 3 and Figure 4 , the stator module 1 can further include a skeleton 13, and the stator core 11 can be embedded in the skeleton 13, wherein the end faces 116 at both ends are exposed. The material of the skeleton 13 can be insulating plastic, and the skeleton 13 particularly surrounds the winding portion 112 and can also cover part of the two end portions 111 (exposing the end faces 116) as shown in Figure 3 , the winding 12 can be wound around the skeleton 13. The processing technology of the skeleton 13 can use the whole insert injection molding method, that is, the stator core 11 is placed in the mold, and the plastic particles are heated and melted into the mold cavity to form the skeleton 13. After processing is completed, the end faces 116 exposed at both axial ends can be slightly higher than the skeleton end face 133 of the skeleton 13, as shown in Figure 4 , to avoid interference between the skeleton end face 133 of the skeleton 13 and the tooling and the rotor (not shown). In this way, the annular axial induction surface 31 at both axial ends of the stator assembly composed of multiple stator modules 1 is exposed, which is suitable for a single-stator double-rotor motor.

[0055] And, the skeleton 13 protrudes at both ends in the radial direction beyond the stator core 11, and the portions of the skeleton 13 protruding at both ends in the radial direction beyond the stator core 11 are respectively provided with one or more notches, for example, as shown by 45, and the radial protruding portions at both ends can each be provided with a potting opening 131, and the protruding portion at one end can be provided with a wire outlet 132. The potting opening 131 functions to perform final sizing on the entire stator assembly 3 after the plurality of stator modules are assembled, and the potting glue can penetrate into the interior of each stator module through the potting opening 131 of the skeleton 13, fill the internal voids, and form an integrated potting portion 2 after the potting glue solidifies, as shown by Figure 2 which fixes the windings and ensures that the entire annular stator assembly forms a stable integrated structure, thereby enhancing the strength of the overall structure and also having good thermal conductivity. The advantage of providing one potting opening at each of the two ends of the skeleton 13 in the radial direction is that the potting speed is faster, the quality is better, and the potting is more uniform.

[0056] The wire outlet 132 allows the wires of the windings 12 to pass out for subsequent connection. Specifically, the respective windings 12 of the plurality of stator modules 1 can be coupled to each other according to actual specific applications, for example, can be connected in series or in parallel according to a certain specific rule. For example, the 24 stator modules 1 of Figure 1 1-24 can be sequentially numbered, then 1, 2, 7, 8, 13, 14, 19, and 20 can be connected in series, 3, 4, 9, 10, 15, 16, 21, and 22 can be connected in series, 5, 6, 11, 12, 17, 18, 23, and 24 can be connected in series, and finally the tail wires of the three phases connected in series can be connected in parallel.

[0057] In particular, the plurality of stator modules 1 included in the stator assembly 3 according to the present disclosure are completely identical, so that the stator modules 1 have interchangeability, which is beneficial to part management, simplifies assembly, and reduces costs. In the case where the stator modules 1 are identical, the included angle between the two side edges 115 of the stator module 1 can depend on the number of stator modules 1 constituting the annular stator assembly 3, i.e., the included angle = 360° / number of stator modules, for example, when the 24 stator modules shown in the figure, the included angle can be 15 degrees.

[0058] The present disclosure also proposes an electric machine including the above-mentioned stator assembly. The electric machine can be a disc-type permanent magnet electric machine, which can include two rotors (not shown), and each rotor can be provided with a magnetic ring, and the two annular axial induction surfaces 31 of the stator assembly 3 can be coaxially and oppositely arranged with the magnetic ring of one rotor.

[0059] It is to be understood that the above description is intended to be illustrative and not restrictive. For example, the above-described embodiments (and / or aspects thereof) can be used in combination with each other. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from its scope. The functions or

[0060] In the appended claims, the terms "include" and "in which" are used as the plain English equivalents of the respective terms "comprising" and "wherein." Also, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

Claims

1. A stator assembly, characterized in that: include A plurality of stator modules, together forming a stator assembly in an annular shape, the stator modules comprising The stator core has two ends along the axial direction of the stator assembly and a winding portion located between the two ends, the winding portion having a smaller size in the circumferential direction of the stator assembly than the end portions, the end portions having a size in the circumferential direction gradually increasing in the radially outward direction of the stator assembly, and the side edges of both ends of the end portions in the circumferential direction are provided with protrusions and / or recesses. The winding is wound around the outer periphery of the winding portion of the stator core, The sides of the ends of the stator cores of every two adjacent stator modules cooperate with each other so that the protrusion of one stator module is accommodated in the recess of the adjacent stator module, and the multiple stator modules are surrounded to form a complete annular stator assembly.

2. The stator assembly according to claim 1, characterized in that The stator core is die-casted so that the flatness of the two outermost end faces in the axial direction on both ends of the stator module is less than or equal to 0.03 mm, and / or the parallelism between the two end faces is less than or equal to 0.03 mm.

3. The stator assembly according to claim 2, characterized in that The end faces of the multiple stator modules respectively form two annular axial sensing surfaces at both ends of the axial direction, the flatness of each axial sensing surface is less than or equal to 0.05 mm, and / or the parallelism between the two axial sensing surfaces is less than or equal to 0.05 mm.

4. The stator assembly according to claim 1, characterized in that The end portion of the stator module is provided with two protrusions on one of the sides and two recesses on the other side.

5. The stator assembly according to claim 1, characterized in that The protrusion and the recess have arc-shaped contours that are complementary in shape.

6. The stator assembly according to claim 1, characterized in that The stator module further includes a frame that is integrally formed to wrap the winding portion, and an end surface of the end portion of the stator core protrudes from the frame in an axial direction.

7. The stator assembly according to claim 6, characterized in that Both ends of the skeleton in the radial direction protrude from the stator core. Parts of the skeleton protruding from the stator core at both ends in the radial direction are respectively provided with potting openings to allow glue to enter the interior of the stator module.

8. The stator assembly according to claim 1, wherein: Also includes The potting portion is integrally formed to fill gaps inside the plurality of stator modules.

9. The stator assembly according to any one of claims 1 to 8, characterized in that: Each stator module is identical.

10. The stator assembly according to any one of claims 1 to 8, characterized in that: The stator assembly includes 24 stator modules.

11. A motor, characterized in that: include A stator assembly according to any one of claims 1 to 10.

12. The motor according to claim 11, characterized in that The motor is a disc-type permanent magnet motor, and further comprises two rotors provided with magnetic rings. The stator assembly includes two annular axial inductive surfaces at both ends in the axial direction, and each annular end surface is coaxially and oppositely arranged with a magnetic ring of the rotor.

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