In-line insert injection molding stator

Abstract

The utility model discloses an in-line insert injection molding stator, which comprises a stator iron core and a stator framework arranged outside the stator iron core in an injection molding manner, and is characterized in that the stator iron core comprises a stator yoke, stator teeth positioned inside the stator yoke and tooth boots for connecting the stator yoke and the stator teeth; a supporting groove extending to the surface of the tooth boot is formed in the stator framework at one axial end of the tooth boot, and the supporting groove and the stator framework are integrally formed through occupation of an injection mold. According to the utility model, the supporting grooves are integrally formed when the stator framework is subjected to injection molding, and at the supporting grooves, an injection mold can provide stable support for the stator iron core, thereby resisting impact of injection molding pressure on stator teeth, and preventing tooth parts of the stator iron core from being bent and deformed.

Description

TECHNICAL FIELD

[0001] The utility model relates to motor technical field especially relates to a inline insert injection molding stator. BACKGROUND

[0002] In the prior art, in order to better prevent the stator core from directly contacting moisture, dust and other pollutants in the external environment, avoid the insulation performance of motor components from being reduced, prevent the surface of the stator core from being corroded, deformed or damaged, the stator skeleton is usually injected in the inner slot of the stator core by the way of integral injection molding, and plastic sealing is carried out after the winding and terminal are installed to form the injection molding stator.

[0003] The existing injection molding stator has the following problems:

[0004] 1. In the traditional injection molding process, the injection mold is a simple columnar structure, the shape of the end part is the same as the shape of the stator core, and there is a gap between the injection mold and the end part of the stator core during injection molding, the injection material fills the gap between the two to form the stator skeleton, but during the injection molding process, the injection material fills the inner slot of the stator under the high pressure in the mold, which will generate a large pressure on the tooth part of the stator core. The stator core has no structural support, and if the injection pressure is not properly controlled, the tooth part of the stator core will be bent, causing the tooth part to be deformed and protrude from the stator skeleton and be exposed. The deformation of the tooth part of the stator core affects the electromagnetic performance and running stability of the motor, thereby increasing the product failure rate.

[0005] 2. The stator core is the basic structure of the stator, providing a magnetic flux path, the coil winding is the key part of the motor to generate electromagnetic force, and the stator skeleton is used to fix and protect the coil winding to ensure that it will not be damaged during operation. The high-pressure injection material during injection will directly impact the coil winding, and the enameled wire will be pushed out of the insulation skeleton, causing breakage. Therefore, the end part of some stator skeletons is provided with a baffle for surrounding a wire passing groove, such as the wire passing groove formed between the outer baffle and the inner baffle in patent No. CN113949190B, but the prior art does not design the details of the wire passing groove. In fact, whether the wire passing groove can play a shockproof role also depends on whether the size design of the wire passing groove is reasonable. If the size of the wire passing groove is too large, the enameled wire will sway in the wire passing groove, increasing the risk of wear and breakage. And the wire passing groove that is too small cannot provide enough support and protection for the enameled wire. During the injection molding process, if the size of the wire passing groove is insufficient, the pressure generated during injection molding may still push the enameled wire out of the stator skeleton, causing serious damage. In addition, the size of the wire passing groove will also affect the manufacturing process and production cost of the motor.

[0006] 3. During the stator assembly winding process, the enameled wire winds from one winding slot to another, supported by a crossover structure located at the wire-passing end of the stator assembly, such as the positioning post in patent number CN202111241099.0. However, in actual use, the enameled wire is often squeezed by the positioning post, causing wear or even breakage. This is due to the unreasonable design of the shape of the positioning post and its contact position with the enameled wire. The current method is to avoid winding the enameled wire too tightly, which causes unnecessary displacement of the enameled wire due to the vibration of the winding machinery. This can cause the enameled wire to accidentally deviate from its intended trajectory and fall into adjacent or other winding slots, interrupting the production process and requiring manual intervention for correction. Moreover, it can easily cause confusion in the winding structure, increasing the risk of short circuits and seriously reducing the efficiency and stability of automated winding operations, thus hindering the realization of efficient automated production.

[0007] 4. To meet the demands of high-power motors for higher torque and speed, the stator core stack height is often relatively large. A stator frame is first formed using injection molding, and then the stator core is completely encased in it. While this injection molding process significantly improves the safety and lifespan of the stator core, the injection molding material mainly flows from one end of the stator tooth surface to the other. Due to the limited thickness of the stator frame, the injection molding material may not cover all the areas it flows through, easily leading to incomplete injection molding.

[0008] 5. In current manufacturing technology, the stator winding process uses automatic stator winding equipment. During the operation of the automatic stator winding equipment, the in-line stator needs to be placed into the fixture of the automatic winding equipment. The existing fixture directly clamps both ends of the stator core or both ends of the stator frame. Since the ends are flat structures, the clamping may become loose, affecting subsequent winding operations and leading to winding failure or a decrease in product quality. Utility Model Content

[0009] In order to solve at least one of the technical problems mentioned in the background art, the present invention provides an inline insert injection molded stator to solve the above problems.

[0010] The technical solution adopted by this utility model to solve its technical problem is: an in-line insert injection molded stator, including a stator core and a stator frame injection molded outside the stator core. The stator core includes a stator yoke, stator teeth located inside the stator yoke, and a toothed shoe connecting the stator yoke and the stator teeth. The stator frame located at one axial end of the toothed shoe has a support groove extending to the surface of the toothed shoe. The support groove is integrally formed with the stator frame by the placement of the injection mold.

[0011] In an optional embodiment of this utility model, the support groove is located close to the stator teeth.

[0012] In the optional embodiment of the utility model, the depth of the support groove is greater than or equal to 0.25mm.

[0013] In the optional embodiment of the utility model, the depth of the support groove is less than or equal to 10.9mm.

[0014] In the optional embodiment of the utility model, the surface of the stator framework at one end of the stator yoke axis is provided with a wire separation plate and a wire protection plate, the wire separation plate is located on the radial inner side of the wire protection plate, and a wire protection groove is formed between the wire separation plate and the wire protection plate, the ratio of the radial width of the wire protection groove to the diameter of the enameled wire is 1~1.2, and the ratio of the axial height of the wire protection groove to the diameter of the enameled wire is 1.2~2.6.

[0015] In the optional embodiment of the utility model, a wire passing groove is formed between the stator framework and the wire separation plate at the tooth end surface of the stator, the ratio of the radial width of the wire passing groove to the radial width of the wire protection groove is 2~8, and the ratio of the axial height of the wire passing groove to the axial height of the wire protection groove is 2~8.

[0016] In the optional embodiment of the utility model, the in-line insert injection stator is composed of a plurality of stator monomers, the axial one end of each stator monomer is provided with a positioning clamping groove matched with the positioning plate of the clamp in the winding equipment, the axial other end of each stator monomer protrudes in the axial direction and has a positioning clamping block, and the arc-shaped two sides of the end portion of each stator monomer are respectively provided with one positioning clamping block, when the stator monomers are in a straight arrangement state, the two positioning clamping blocks on the adjacent stator monomers are close to each other to form a positioning assembly for clamping of the clamping jaw of the clamp in the winding equipment.

[0017] In the optional embodiment of the utility model, the positioning clamping groove comprises a limiting groove and a limiting hole located on the radial outer side of the limiting groove, the groove width a of the limiting groove is greater than the hole diameter b of the limiting hole, and the positioning plate of the clamp passes through the limiting hole and abuts against the surface of the limiting groove.

[0018] In the optional embodiment of the utility model, the in-line insert injection stator is composed of a plurality of stator monomers, a first vertical column and a second vertical column are located at the wire passing end of the adjacent two stator monomers, a wire passing groove is formed between the first vertical column and the second vertical column and the wire separation plate on the stator monomer, the first vertical column and the second vertical column have a first surface arranged opposite to each other and spliced with each other, the first vertical column comprises a first top corner located at the radial outer end of the first surface and a second top corner located at the radial outer end of the side away from the first surface.

[0019] The second vertical column comprises a third top corner located at the radial outer end of the first surface and a fourth top corner located at the radial outer end of the side away from the first surface; and the radial maximum dimension of the second vertical column is located at the third top corner.

[0020] The first upright column is located radially inside a line connecting the second top corner and the third top corner, and the second upright column is located radially inside a line connecting the third top corner and the fourth top corner; the first top corner, the second top corner, the third top corner and the fourth top corner are all provided with chamfers; and the enameled wire abuts against at least two of the first top corner, the second top corner, the third top corner and the fourth top corner during winding.

[0021] In the optional embodiment of the utility model, still include the terminal of one end of stator framework and the plastic sealing body of the integral plastic sealing of stator core, stator framework and terminal, the stator yoke outer circumferential surface has the material guide groove extending to the both ends of stator yoke along the axial direction, the injection molding material of stator yoke is filled to form the material guide body at the material guide groove, the outer surface of material guide body has the long groove extending along the axial direction, the plastic sealing body fills the long groove.

[0022] The utility model discloses the beneficial effect is:

[0023] (1) the utility model discloses when injection molding stator framework, the support groove is integrally formed, at the support groove, the injection mold can provide stable support for the stator core, resist the impact of injection pressure on the stator tooth, prevent the tooth of stator core from being bent and deformed.

[0024] (2) the utility model discloses the depth of support groove can be accurately controlled the thickness of stator framework after injection molding, and then realize the effective control of creepage distance.

[0025] (3) the utility model discloses the size of wire protection groove is reasonably designed according to the size of enameled wire, so that the wire protection groove can not only prevent the impact on enameled wire, but also avoid rubbing the surface of enameled wire, ensure the integrity and stability of winding, and improve the reliability and durability of motor.

[0026] (4) the utility model discloses that stator clamping groove and stator clamping block are arranged at the both ends of stator monomer respectively, and the stator clamping groove and the stator clamping block can play the positioning and fixing role, cooperate with the clamp of automatic winding machine in winding operation, realize more accurate positioning, and reduce production time. ACCURACY

[0027] The utility model will be further explained in connection with the drawings and examples.

[0028] Figure 1 It is the perspective view of the specific embodiment of the in-line insert injection molded stator of the utility model;

[0029] Figure 2 It is the perspective view of the in-line insert injection molded stator before plastic sealing of the utility model;

[0030] Figure 3 It is the perspective view of the stator core of injection molding stator framework;

[0031] Figure 4 It is the injection mold solid drawing of the utility model;

[0032] Figure 5 It is the position relation schematic view of injection mold and stator core when the utility model injection stator framework,

[0033] Figure 6 It is the partial schematic view of the in-line state before winding of the stator monomer of the utility model,

[0034] Figure 7 It is the plan view of the stator core in the stator monomer of the utility model,

[0035] Figure 8 It is the axial sectional view of the stator monomer of the utility model (only shows the wire protection structure),

[0036] Figure 9 It is the side view of the stator core in the stator monomer of the utility model,

[0037] Figure 10 It is the schematic view of the crossover structure of the utility model,

[0038] Figure 11 It is the position schematic view of the enameled wire and crossover structure in the first wire passing form of the utility model,

[0039] Figure 12 It is the position schematic view of the enameled wire and crossover structure in the third wire passing form of the utility model,

[0040] Figure 13 It is the position schematic view of the enameled wire and crossover structure in the second wire passing form of the utility model,

[0041] Figure 14 It is the cooperation schematic view of the in-line insert injection stator and clamp of the utility model,

[0042] Figure 15 It is Figure 14 the enlarged view of g in the utility model,

[0043] Figure 16 It is the cross-sectional schematic view of the stator monomer in the utility model,

[0044] Figure 17 It is the end face partial sectional view of the in-line insert injection stator of the utility model,

[0045] Figure 18 It is the structure schematic view of the material guide body in the utility model.

[0046] In the figure, 1, stator core, 101, stator yoke, 102, stator tooth, 103, tooth shoe, 2, stator framework, 201, winding part, 202, winding slot, 3, support slot, 4, injection mold, 5, protruding part, 6, stator monomer, 7, terminal, 8, plastic package, 9, wire passing end, 10, terminal end, 11, winding, 12, enameled wire, 13, wire separation plate, 14, wire protection plate, 15, wire protection slot, 16, wire passing slot, 17, clamping jaw, 18, positioning plate, 1801, T-shaped plate, 19, positioning clamping groove, 1901, limiting slot, 1902, limiting hole, 1903, opening, 20, positioning clamping block, 21, positioning assembly, 22, wire passing structure, 23, wire passing slot, 24, first surface, 25, first vertical column, 26, second vertical column, 27, first stator monomer, 28, second stator monomer, 29, first wire passing slot, 30, second wire passing slot, 31, first top corner, 32, second top corner, 33, third top corner, 34, fourth top corner, 35, material guiding slot, 36, material guiding body, 37, long slot, 38, injection material. DETAILED DESCRIPTION

[0047] The embodiments of the present application are described in detail below, examples of which are shown in the drawings, wherein the same or similar notations represent the same or similar elements having the same or similar functions throughout. The embodiments described below by reference to the drawings are exemplary only, and are used only for explaining the present application, and cannot be understood as limiting the present application.

[0048] The stator assembly generally comprises a stator core 1, a terminal 7, a stator framework 2 injected on the outside of the stator core 1, and a plastic package 8 integrally plasticizing the stator core 1, the stator framework 2 and the terminal 7, the stator core 1 comprises a stator yoke 101, a stator tooth 102 inside the stator yoke 101 and a tooth shoe 103 connecting the stator yoke 101 and the stator tooth 102. One end of the stator assembly is a wire passing end 9, the other end is a terminal end 10 for mounting the terminal 7, the stator framework 2 is provided with a winding 11 (for example, three phases), the winding 11 is passed from one end of the stator framework 2 away from the terminal 7 (the wire passing end 9) and connected with the terminal 7, and finally the above structure is covered to form an insert injection stator by an injection process.

[0049] For the inline insert injection stator, the structure before winding is as shown in Figure 6 , comprising a plurality of stator monomers 6 arranged in a straight line and connected in sequence, the structure of each stator monomer 6 is the same, which is composed of a stator core 1, a stator framework 2 and a plastic package 8, after winding, the stator teeth 102 of adjacent stator monomers 6 are tightened to form Figure 2 and Figure 3The columnar structure is shown. The stator core 1 of each stator unit 6 forms the stator core 1 of the entire stator assembly. Similarly, the stator frame 2 of each stator unit 6 forms the stator frame 2 of the entire stator assembly, and the encapsulation body 8 of each stator unit 6 forms the encapsulation body 8 of the entire stator assembly.

[0050] Example 1

[0051] like Figures 1-3 As shown, an inline insert injection molded stator includes a stator core 1 and a stator frame 2 injection molded outside the stator core 1. The stator core 1 includes a stator yoke 101, stator teeth 102 located inside the stator yoke 101, and a toothed shoe 103 connecting the stator yoke 101 and the stator teeth 102. The stator frame 2 located at one axial end of the toothed shoe 103 has a support groove 3 extending to the surface of the toothed shoe 103. The support groove 3 is integrally formed with the stator frame 2 by the placement of the injection mold 4.

[0052] Since the support groove 3 needs to be formed by the injection mold 4, the injection mold 4 used in this invention has an additional protrusion at the position opposite the toothed shoe 103 compared to the traditional injection mold 4. Figure 4 and Figure 5 As shown, during injection molding, the protruding part 5 contacts the toothed shoe 103, where no injection molding material 38 passes, thus forming a support groove 3. The solid structure of the stator frame 2 is formed around the protruding part 5. This protruding structure can provide stable support for the teeth of the stator core 1 during the injection molding process, resisting the impact of injection molding pressure on the teeth and preventing tooth deformation.

[0053] In a preferred embodiment, the support groove 3 is located close to the stator tooth 102, that is, away from the stator yoke 101, so as to maximize the supporting effect of the protruding part 5 and effectively provide support for the tooth.

[0054] The support groove 3 can be in the shape of a cube, cylinder, frustum, prism or other custom shape.

[0055] Example 2

[0056] To ensure a tight fit between the protrusion 5 and the stator core 1, and to effectively support the stator core 1, the depth of the support groove 3 needs to be precisely controlled. Furthermore, the stator frame 2 supports and fixes the stator core 1, and its thickness indirectly affects the creepage distance. During injection molding, the protrusion 5 determines the thickness of the injection molding material 38 in the stator frame 2 region. Adjusting the depth of the support groove 3 (i.e., the height of the protrusion 5) allows for precise control of the thickness of the stator frame 2 after injection molding, thereby achieving effective control of the creepage distance.

[0057] For motors operating at 380V, the minimum creepage distance is 0.25mm, and the thickness of the stator frame 2 must be ≥0.25mm. If the thickness of the stator frame 2 is less than the minimum creepage distance, electrical breakdown is likely to occur, leading to motor damage. Therefore, the depth of the support groove 3 must not be less than the minimum value, i.e., the depth of the support groove 3 must be greater than or equal to 0.25mm.

[0058] The upper limit of the creepage distance is 10.9mm, and the thickness of the stator frame 2 is ≤10.9mm. If the stator frame 2 is too thick, it will increase heat resistance, increase the volume of the stator, and increase the difficulty of internal assembly of the motor. Therefore, the depth of the support groove 3 should not be too high, that is, the depth of the support groove 3 is less than or equal to 10.9mm.

[0059] Line protection structure:

[0060] Example 3

[0061] like Figure 7 As shown, the stator frame 2 is wrapped around the stator core 1. The stator frame 2 forms a winding portion 201 at the toothed shoe 103. The grooves on both sides of the winding portion 201 are winding grooves 202. The enameled wire 12 passes through the winding grooves 202 and is wound onto the winding portion 201. When the enameled wire 12 winds from the winding groove 202 inside one stator yoke 101 to the winding groove 202 inside another stator yoke 101, the enameled wire 12 needs to pass through the surface of the stator frame 2 at the end of the stator yoke 101. This surface is the wire-passing end 9. This embodiment addresses the second problem in the background art by making the following improvement based on the above embodiment: the wire-passing end 9 is provided with a wire-passing protection structure to prevent the enameled wire 12 from being ejected from the stator frame 2 by the pressure during injection molding. The wire-passing protection structure is described below with reference to specific embodiments.

[0062] like Figures 6-8 As shown, the wire protection structure includes a wire separator 13 and a wire guard 14. The wire separator 13 is located radially inside the wire guard 14, and a wire guard groove 15 is formed between the two. The wire guard groove 15 provides a guiding function for the enameled wire 12. During the winding process, the enameled wire 12 can be clearly wound along the path of the wire guard groove 15 from one winding groove 202 to another winding groove 202. In addition, the stator frame 2 located on the end face of the stator tooth 102 can form a wire passage groove 16 between the wire separator 13 and the wire separator 13. The wire separator 13 inside the wire guard groove 15 can support the enameled wire 12 and prevent the winding 11 in the wire passage groove 16 from mixing with the enameled wire 12 in the wire guard groove 15. The wire guard 14 outside the wire guard groove 15 can prevent the enameled wire 12 from being pushed out of the stator frame 2 when subjected to the impact of the injection molding.

[0063] The size of the wire slot 15 is directly related to the wire diameter of the enameled wire 12. If the wire slot 15 (mainly referring to the radial width of the wire slot 15) is too large, the enameled wire 12 will sway in the slot, increasing the risk of wear and breakage. If the radial width of the wire slot 15 is too small, the enameled wire 12 cannot pass through the wire slot 15. If the axial height of the wire slot 15 is too small, it cannot provide sufficient support and protection for the enameled wire 12. During the injection molding process, if the axial height of the wire slot 15 is not sufficient, the pressure generated during injection molding may cause the enameled wire 12 to be pushed out of the stator framework 2, causing serious damage. If the axial height of the wire slot 15 is too high, it will cause waste of injection molding material and inconvenience for winding. Therefore, according to the wire diameter of the enameled wire 12, the size of the wire slot 15 is specifically limited, specifically:

[0064] The ratio of the radial width of the wire slot 15 to the diameter of the enameled wire 12 is 1-1.2, so that the enameled wire 12 can pass smoothly and be compressed tightly, avoiding the enameled wire 12 from swaying in the wire slot 15 and avoiding wear. The ratio of the axial height of the wire slot 15 to the diameter of the enameled wire 12 is 1.2-2.6, which can not only protect the enameled wire 12 but also reduce material waste and facilitate winding. As shown in Figure 9 The radial width refers to the width direction size in the figure, and the axial height refers to the height direction size in the figure. The wire slot 15 is surrounded by the wire separation plate 13 and the wire protection plate 14, so the radial width of the wire slot 15 is the radial distance between the wire separation plate 13 and the wire protection plate 14, and the axial height of the wire slot 15 is the minimum height of the wire separation plate 13 and the wire protection plate 14.

[0065] Through the above size design, the enameled wire 12 can pass through the wire slot 15 safely and orderly, and can effectively prevent injection molding impact on the enameled wire 12. This protection mechanism ensures the integrity and stability of the winding 11, improves the reliability and durability of the motor. The guiding effect of the wire slot 15 reduces the complexity and error rate of winding, improves production efficiency and product quality.

[0066] Taking the diameter of the enameled wire 12 as 0.5 cm as an example, the radial width of the wire slot 15 is 0.6 cm, and the axial height is 1 cm, which can better protect the enameled wire 12. At this time, the ratio of the radial width of the wire slot 15 to the diameter of the enameled wire 12 is 6:5, and the ratio of the radial width of the wire slot 15 to the diameter of the enameled wire 12 is 2.

[0067] As shown in Figure 7 The arc-shaped end surface of the wire separation plate 13 is preferably beyond the side surface of the winding part 201, avoiding the enameled wire 12 in the wire slot 15 from contacting and rubbing with the winding 11 of the winding part 201.

[0068] The wire protection plate 14 can continuously extend in the circumferential direction, or be interrupted in the middle, as shown inFigure 7 As shown, the wire protection plate 14 has a notch in the middle, which prevents the enameled wire 12 from being knocked off by impact and also reduces weight.

[0069] Example 4

[0070] like Figure 7 As shown, since both the wire guide groove 16 and the wire guard groove 15 are winding areas, and the enameled wire 12 in the wire guard groove 15 is led out from the winding groove 202, the size of the wire guard groove 15 is related to the size of the wire guide groove 16. Considering the motor production cost and space utilization, the size of the wire guard groove 15 and the size of the wire guide groove 16 need to be designed. This embodiment further limits the size based on embodiment three, with the ratio of the radial width of the wire guide groove 16 to the radial width of the wire guard groove 15 being 2~8, and the ratio of the axial height of the wire guide groove 16 to the axial height of the wire guard groove 15 being 2~8. The radial width of the wire guide groove 16 is... Figure 9 In the dimension c, the axial height of the groove 168 is... Figure 9 The dimension d in the design helps reduce the overall size of the motor and improve space utilization.

[0071] In a preferred embodiment, the ratio of the radial width of the through groove 16 to the radial width of the guard groove 15 is equal to the ratio of the axial height of the through groove 16 to the axial height of the guard groove 15. That is, the width and height dimensions of the through groove 16 are proportionally enlarged relative to the guard groove 15, resulting in better structural symmetry and space utilization.

[0072] In this embodiment, the dimensions of the enameled wire 12 and the wire guard groove 15 are the same as in Embodiment 1. In this embodiment, the radial width c of the wire guide groove 16 is 3cm and the axial height d is 5cm. That is, the ratio of the radial width of the wire guide groove 16 to the radial width of the wire guard groove 15, and the ratio of the axial height of the wire guide groove 16 to the axial height of the wire guard groove 15 are both 5.

[0073] Example 5

[0074] Based on Embodiment 3 or Embodiment 4, the axial height of the partition plate 13 is higher than the axial height of the guard plate 14, such as... Figure 3 As shown, the winding 11 in the wire passage 16 is relatively thick, so the wire separator 13 needs to be designed to be relatively high to prevent the winding 11 in the wire passage 16 from entering the wire guard 15. The height of the wire guard 14 is relatively low, which can control the axial height of the wire guard 15.

[0075] Wire winding positioning:

[0076] Example 6

[0077] like Figure 14 and Figure 15As shown, the fixture in the winding device includes a clamping jaw 17 clamped at one end of the stator monomer 6 and a positioning plate 18 outwardly extending with a plurality of T-shaped plates 1801 for contacting and positioning the other end of the stator monomer 6.

[0078] For the fifth problem in the background art, as shown in Figure 6 , Figure 7 and Figure 15 , on the basis of the above embodiment, the axial one end of each stator monomer 6 is provided with a positioning clamping groove 19 matched with the positioning plate 18, the T-shaped plate 1801 on the positioning plate 18 is clamped at the positioning clamping groove 19, the axial other end of each stator monomer 6 protrudes in the axial direction with a positioning clamping block 20, and one positioning clamping block 20 is arranged on each arc-shaped side of the end of the stator monomer 6, when the stator monomer 6 is in a straight arrangement state, the two positioning clamping blocks 20 on the adjacent stator monomers 6 are close to each other to form a positioning assembly 21 for the clamping jaw 17 of the fixture in the winding device.

[0079] First, the clamping jaw 17 of the winding device (such as an automatic winding machine) is aligned with the positioning assembly 21, the in-line insert injection molded stator (not wound and not plastic sealed) is placed in the fixture, and the positioning clamping groove 19 is tightly attached to the T-shaped plate 1801 of the fixture, and finally the clamping jaw 17 is tightened and fixed.

[0080] The positioning clamping block 20 and the positioning clamping groove 19 play a positioning and fixing role, when the in-line insert injection molded stator not wound and not plastic sealed is placed in the fixture, it can ensure accurate positioning of the in-line insert injection molded stator, reducing production time. In the subsequent winding process, it plays a fixing role, effectively preventing displacement of the in-line insert injection molded stator due to vibration, and improving production efficiency.

[0081] In this embodiment, the positioning clamping blocks 20 of two adjacent stator monomers 6 are spliced to form a positioning assembly 21, which is clamped by the same clamping jaw 17, so that the adjacent stator monomers 6 can be clamped stably at the same time, the clamping jaw 17 corresponds to the positioning assembly 21 one by one, so that all stator monomers 6 are fixed together, which can not only avoid shaking of the in-line insert injection molded stator in the winding device, but also avoid relative movement between different stator monomers 6 in the in-line insert injection molded stator.

[0082] The positioning clamping block 20 is arranged on the arc-shaped sides of the end of the stator monomer 6, the arc-shaped sides of the end of the stator monomer 6 are the two sides of the end of the stator monomer 6 in the circumferential direction, and a plurality of stator monomers 6 can form a cylindrical stator assembly, so the end face shape of the stator monomer 6 is arc-shaped. The positioning clamping block 20 is arranged on the arc-shaped sides of the end of the stator monomer 6, which takes advantage of the characteristic that the in-line insert injection molded stator is in an unfolded state when winding, at this time, the positioning clamping blocks 20 on one side of the two adjacent stator monomers 6 are close to each other.

[0083] The shape of the positioning slot 19 is designed according to the T-shaped plate 1801; it only needs to be able to hold the T-shaped plate 1801 in place. Figure 7 and Figure 15 As shown, the positioning slot 19 in this embodiment includes a limiting slot 1901 and a limiting hole 1902 located radially outside the limiting slot 1901. The slot width a of the limiting slot 1901 is greater than the hole diameter b of the limiting hole 1902. The positioning plate 18 of the fixture passes through the limiting hole 1902 and abuts against the surface of the limiting slot 1901. Specifically, the T-shaped plate 1801 on the positioning plate 18 passes through the limiting hole 1902, and the inner bottom surface of the limiting slot 1901 abuts against the end of the T-shaped plate 1801, which plays a radial limiting role on the T-shaped plate 1801, thereby realizing the positioning of one end of the stator unit 6 by the positioning plate 18.

[0084] When the positioning slot 19 is a closed annular structure, the T-shaped plate 1801 needs to be a detachable structure so that the T-shaped plate 1801 can pass through the limiting hole 1902 from the side where the limiting slot 1901 is located and connect to the main body of the positioning plate 18. However, the positioning plate 18 is usually a one-piece structure. Therefore, in this embodiment, as shown... Figure 6 As shown, the positioning slot 19 has an opening 1903 extending from the center to one side, and the positioning plate 18 of the fixture enters the limiting hole 1902 through the opening 1903.

[0085] Since the fixture is located on the outer side of the in-line insert injection molded stator, that is, on the outer side of the stator yoke 101, the positioning slot 19 and the positioning block 20 are arranged along the outer edge of the stator yoke 101 of the stator unit 6. This allows the positioning slot 19 and the positioning block 20 to be closer to the fixture. Here, the outer edge of the stator yoke 101 refers to the outer edge of the stator frame 2 corresponding to the stator yoke 101. The positioning slot 19 and the positioning block 20 are fixed on the stator frame 2.

[0086] Since the wire guide end 9 has enameled wire 12 passing through it, it does not have clamping space for the grippers 17. Therefore, in this embodiment, positioning blocks 20 are set on the terminal end 10, and the two positioning blocks 20 are located on both sides of the insertion terminal 7 opening of the stator unit 6. The positioning slot 19 is set on the wire guide end 9. The positioning slot 19 can be formed on the stator frame 2 at the end of the stator unit 6.

[0087] To ensure that the stator unit is subjected to balanced force during the winding process, it is preferable that the positioning slot 19 is located in the middle of the wire-passing end 9 of the stator unit 6 along the circumferential direction.

[0088] Example 7

[0089] like Figure 6 and Figure 7 As shown, when the wire guide plate 14 is provided on the wire guide plate 9 of the stator unit 6, the positioning slot 19 can be located on the wire guide plate 14.

[0090] In this way, the component of the wire protection plate 14 can realize two functions, the first function is to avoid the winding 11 from being knocked out of the injection molding framework when impacted by the injection molding material during the injection molding stage, and the second function is to cooperate with the T-shaped plate 1801 to position during the winding stage, so as to simplify the structure of the stator assembly and improve the space utilization of the motor.

[0091] The crossover structure 22 is arranged on the wire passing end 9 of the stator framework 2.

[0092] For the third problem in the background art, the utility model discloses a crossover structure 22 integrally formed on the wire passing end 9 of the stator framework 2, which is used to provide support for the transition of the enameled wire 12 between different winding grooves 202 in the stator assembly, and the enameled wire 12 is wound from the winding groove 202 of one stator monomer 6 to the winding groove 202 of another stator monomer 6 through the wire passing end 9, and is supported by the crossover structure 22 at the turning position of the enameled wire 12.

[0093] The utility model discloses a crossover structure 22 integrally formed on the wire passing end 9 of the stator framework 2. Figure 10 - The crossover structure 22 integrally formed on the wire passing end 9 of the stator framework 2. Figure 13 The crossover structure 22 is illustrated by taking the in-line insert injection molded stator as an example, and the crossover structure 22 will be described in detail below according to specific embodiments.

[0094] Embodiment eight

[0095] The crossover structure 22 includes a first column 25 and a second column 26 arranged on the wire passing end 9 of the adjacent two stator monomers 6, the first column 25 and the second column 26 form a crossover groove 23 between the wire passing end 9 and the wire separation plate 13 of the stator monomer 6, the first column 25 and the second column 26 have a first surface 24 arranged opposite to each other and spliced, for the same stator monomer 6, the first column 25 and the second column 26 are respectively located on the two sides of the circumferential direction of the end of the stator monomer 6, then for the adjacent two stator monomers 6, the first column 25 of one stator monomer 6 is arranged opposite to the second column 26 of the other stator monomer 6 and spliced to form the crossover structure 22.

[0096] As shown in the figure, the left stator monomer 6 is a first stator monomer 27, and the right stator monomer 6 is a second stator monomer 28, the first column 25 of the first stator monomer 27 and the second column 26 of the second stator monomer 28 are spliced to form the crossover structure 22. Figures 11-13 The first column 25 and the wire separation plate 13 of the first stator monomer 27 form a first crossover groove 29, and the second column 26 and the wire separation plate 13 of the second stator monomer 28 form a second crossover groove 30.

[0097] The first column 25 includes a first top corner 31 located at the radial outer end of the first surface 24 and a second top corner 32 located at the radial outer end of the side away from the first surface 24. The second column 26 includes a third top corner 33 located at the radial outer end of the first surface 24 and a fourth top corner 34 located at the radial outer end of the side away from the first surface 24; the first top corner 31, the second top corner 32, the third top corner 33 and the fourth top corner 34 are all provided with chamfers. At least two of the four top corners are relied on to support the enameled wire 12 during the winding process, the contact between the top corners reduces the contact length between the column and the enameled wire 12, thereby reducing the friction, and the adjacent two top corners in contact with the enameled wire 12 form two pulling support points to pull the enameled wire 12 between the two top corners, so that the enameled wire 12 can be pulled tight.

[0098] The pulling force of the enameled wire 12 is related to the tightness of the enameled wire 12 and the distance between the adjacent two pulling support points. The greater the distance between the pulling support points, the greater the pulling force, and the enameled wire 12 is prone to breakage at this point. Conversely, the smaller the pulling force, the greater the pulling force that the enameled wire 12 can withstand, which requires that the pulling force between any two pulling support points of the enameled wire 12 be approximately equal under the condition that the size of the column remains unchanged. To this end, the utility model realizes this technical effect through the following shape design:

[0099] The maximum radial dimension of the second column 26 is located at the third top corner 33. The first column 25 is located radially inside the line connecting the second top corner 32 and the third top corner 33, that is, the first top corner 31 is recessed relative to the third top corner 33, and the enameled wire 12 does not contact the part outside the second top corner 32 in the first column 25 during the winding process. The second column 26 is located radially inside the line connecting the third top corner 33 and the fourth top corner 34, that is, the enameled wire 12 does not contact the part outside the third top corner 33 and the fourth top corner 34 in the second column 26 during the winding process, thereby realizing point contact between the enameled wire 12 and the jumper structure 22. That is, the third top corner 33 is located at the maximum radial dimension of the entire jumper structure 22, so when the enameled wire 12 extends through the wire end 9, it will inevitably contact the third top corner 33.

[0100] In summary, when the enameled wire 12 passes through the wire end 9 and winds, it will inevitably contact the third top corner 33 and may contact the second top corner 32 and the fourth top corner 34. Since the second top corner 32 and the fourth top corner 34 are both located on the side away from the first surface 24, the distances between the second top corner 32 and the third top corner 33 and between the fourth top corner 34 and the third top corner 33 are moderate and not much different, and the pulling force of the enameled wire 12 between them is also not much different, so the enameled wire 12 can be maximally tightened to prevent displacement and falling off during the winding process.

[0101] Specifically, the enameled wire 12 is pulled tight by the jumper structure 22 through the following two pulling support points: Figures 11-13There are three types of wiring configurations between the two stator units 6 shown:

[0102] The first type is Figure 11 As shown, the wire extends directly from the first crossover groove 29 and passes through the wire-passing end 9 of the second stator unit 28 into other winding grooves 202. At this time, the enameled wire 12 is supported by the second apex 32 and the third apex 33 in the crossover structure 22. The enameled wire 12 between the second apex 32 and the third apex 33 is subjected to tensile force, which has the function of preventing it from falling off.

[0103] The second type is Figure 13 The enameled wire 12 shown is transferred between the winding slots 202 of the first stator unit 27 and the second stator unit 28 via the first crossover slot 29 and the second crossover slot 30. At this time, the enameled wire 12 is supported by the second apex 32, the third apex 33 and the fourth apex 34 in the crossover structure 22. The enameled wire 12 between the second apex 32 and the third apex 33, and between the third apex 33 and the fourth apex 34, is subjected to tensile forces, and the tensile forces are approximately equal.

[0104] The third type is Figure 12 As shown, the wire extends from the second crossover groove 30 and passes directly through the wire-passing end 9 of the first stator unit 27 into other winding grooves 202. At this time, the enameled wire 12 is supported by the fourth apex 34 and the third apex 33 in the crossover structure 22. The enameled wire 12 between the third apex 33 and the fourth apex 34 is subjected to tensile force.

[0105] In a preferred embodiment, such as Figure 10 As shown, the difference between the circumferential width e of the first column 25 and the circumferential width f of the second column 264 is ±0.5mm.

[0106] The first surface 24 can be an arc-shaped surface or an irregular multi-segment surface, as long as the first column 25 and the second column 26 do not interfere with each other. For an in-line insert injection molded stator, before winding, the stator assembly is unfolded into a straight state. At this time, the first column 25 and the second column 26 that make up the crossover structure 22 need to be rotated and separated. Figure 6 As shown, if the first surface 24 is an irregular surface, there may be uneven interlocking parts when the two first surfaces 24 are joined together, which will prevent them from rotating and separating. Therefore, in this embodiment, the first surface 24 is preferably a plane that extends radially. At this time, the first surface 24 is approximately in contact with the two circumferential sides of the stator unit 6.

[0107] The crossover structure 22 supports the enameled wire 12 from the inside. In an optional embodiment, the first column 25 and the second column 26 are arranged along the inner edge of the wire-passing end 9 of the stator unit 6. This can reduce the total length of the enameled wire 12 and minimize the size of the wire-passing end 9, thereby reducing the size of the stator assembly.

[0108] In the preferred embodiment, the axial end surface size of the first and second posts 25 and 26 gradually decreases from the end connecting the stator unit 6 to the end away from the stator unit 6. As shown in Figure 6 the lower end of the first and second posts 25 and 26 is connected to the wire passing end 9 of the stator unit 6, and the upper end surface size of the first and second posts 25 and 26 is smaller than the lower end surface size.

[0109] Embodiment Nine

[0110] In Embodiment Eight, the first top corner 31 in the first post 25 is recessed inside the third top corner 33 of the second post 26, and the recessed distance of the first top corner 31 is not limited, i.e. the first top corner 31 can be located radially inside the second top corner 32, at this time, the radial size of the first post 25 is smaller, and the transition between the first top corner 31 and the third top corner 33 is too large, so that the enameled wire 12 between the second top corner 32 and the third top corner 33 can be pressed to the surface of the first post 25 by the injection material during subsequent injection molding, and if the space inside the enameled wire 12 is large, the enameled wire 12 can be broken. Therefore, in this embodiment, the maximum radial size of the first post 25 is set at the first top corner 31, at this time, the recessed distance of the first top corner 31 is small, the first top corner 31 is close to the third top corner 33, and there is a relatively gentle transition slope surface between the second top corner 32 and the third top corner 33, which can reduce the deformation of the enameled wire 12 between the second top corner 32 and the third top corner 33 during injection molding.

[0111] When the wire passing end 9 of the stator unit 6 is provided with the wire protection plate 14, the wire protection plate 14 extends to the radial outside of the first and second posts 25 and 26 in the circumferential direction. At this time, the difference between the axial height of the first and second posts 25 and 26 and the axial height of the wire protection plate 14 is preferably 3mm~5mm. The size difference between the first and second posts 25 and 26 is not large, and the axial height of the wire protection plate 14 is designed to be small in order to prevent the enameled wire 12 from being unable to hang on the post during winding.

[0112] Embodiment Ten

[0113] For the fourth technical problem in the background art, the embodiment is improved as follows on the basis of the above-mentioned embodiments: As shown in Figure 17 the outer circumferential surface of the stator yoke 101 has a material guiding groove 35 extending to both ends of the stator yoke 101 in the axial direction, the injection material 38 forming the stator framework 2 is filled to form a material guiding body 36 at the material guiding groove 35, the outer surface of the material guiding body 36 has an axially extending long groove 37, and the plastic sealing body 8 fills the long groove 37. The stator framework 2 and the plastic sealing body 8 are both formed by the injection molding process, and the materials used are the same. In order to facilitate the distinction, the material forming the stator framework 2 is referred to as the injection material 38, and the material forming the plastic sealing body 8 is referred to as the plastic sealing material.

[0114] In the traditional injection molding process, the injection material 38 mainly flows from one end to the other end of the inner surface of the stator tooth 102. The utility model discloses a material guide groove 35 arranged on the stator yoke 101, so that the injection material 38 has a path through the material guide groove 35, can flow into the stator core 1 more uniformly, speeds up the filling speed of the injection material 38, and can ensure that the injection material 38 can fully fill the stator core 1 in the injection molding process, thereby improving the integrity of the stator framework 2 forming. Similarly, the arrangement of the long groove 37 in the material guide body 36 can also speed up the filling speed of the plastic sealing material, and avoid the accumulation or loss of the plastic sealing material in the filling process, thereby improving the integrity of the plastic sealing. The long groove 37 also improves the gripping force of the plastic sealing body 8 on the stator core 1, so that the stator assembly is stable and reliable when bearing high torque and high speed rotation. As shown in Figure 16 As shown in the cross-sectional view of the stator monomer 6, the stator framework 2 forms a material guide body 36 on the left side of the stator core 1, and the material guide body 36 also has a long groove 37 penetrating from top to bottom.

[0115] The patent number CN109274192B discloses a plug-in groove arranged on the outer circumferential surface of the stator core. From the appearance, the plug-in groove is very similar to the material guide groove 35 in the utility model. However, the disclosed patent does not use the integral injection molding process to process the stator assembly, but uses the plug-in groove to connect the terminal box with the stator core, and then inserts the stator framework into the stator core from both ends. Therefore, the use and application range of the material guide groove 35 in the embodiment and the plug-in groove in the disclosed patent are not the same.

[0116] The cross section of the material guide groove 35 can be rectangular, circular, trapezoidal or irregular. The cross section of the long groove 37 can be rectangular, circular or trapezoidal. The material guide body 36 is a plastic part filled between the material guide groove 35 and the long groove 37.

[0117] To ensure structural symmetry, the material guide groove 35 is preferably uniformly arranged in the circumferential direction. This uniform distribution ensures the consistency of the injection material 38 and the plastic sealing material in the filling process. In further design, the material guide groove 35 is located in the middle of the circumferential direction of the stator yoke 101 of each stator monomer 6.

[0118] Example eleven

[0119] In order to improve the connection strength of the injection molding material 38 and the stator core 1, and avoid the stator core 1 from being separated from the external plastic part when the stator assembly bears high torque and high-speed rotation, the width of the outer opening 1903 of the cross section of the material guide groove 35 is smaller than the inner width of the cross section of the material guide body 36 in the embodiment based on the embodiment ten, so that the stator frame 2 tightly holds the stator core 1 through the injection molding material 38 in the material guide groove 35. Meanwhile, the structure design of the material guide groove 35 also helps the injection molding material 38 stay in the material guide groove 35 and avoid overflowing out of the material guide groove 35 under the impact of the injection molding material.

[0120] As shown in Figure 17 and Figure 18 , in the embodiment, the cross section of the material guide groove 35 is trapezoidal, and the cross section of the long groove 37 is rectangular.

[0121] The size relationship between the long groove 37 and the material guide groove 35 will affect the injection molding effect. If the size of the long groove 37 is too large, the stator frame 2 will not be completely injection molded, and if the size of the long groove 37 is too small, the plastic sealing material will be gathered or missing, which will affect the smoothness of the plastic sealing surface. Therefore, in the further design, the ratio of the width of the cross section of the long groove 37 to the width of the outer opening 1903 of the cross section of the material guide body 36 is 1 / 3~2 / 3. The width refers to the horizontal direction size in Figure 18 . The ratio of the depth of the cross section of the long groove 37 to the depth of the cross section of the material guide body 36 is 1 / 4~1 / 2. The depth refers to the vertical direction size in Figure 18 .

[0122] The utility model discloses to the injection molding stator processing process exists many problems and carries out many aspects improvement, thereby improving the product quality of injection molding stator, reduces the product's bad rate.

[0123] In the description of the utility model, it is understood that the orientation or positional relationship indicated by the terms "center", "length", "width", "thickness", "left", "right", "vertical", "horizontal", "inner", "outer", "axial", "radial", "circumferential" and the like is the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the utility model and simplifying the description, and does not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the utility model.

[0124] In addition, the terms "first", "second" and the like are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0125] In the specification, the illustrative description of the terms does not necessarily refer to the same embodiment. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments in a suitable manner.

[0126] With the above ideal embodiments according to the present application as the inspiration, through the above description, relevant staff can make various changes and modifications without deviating from the technical idea of the present application. The technical scope of the present application is not limited to the content in the specification, and the technical scope must be determined according to the scope of claims.

Claims

1. An in-line insert-molded stator, characterized by: The stator core comprises a stator yoke, a stator tooth inside the stator yoke, and a tooth shoe connecting the stator yoke and the stator tooth, and a support groove extending to the surface of the tooth shoe is formed on the stator frame at the axial end of the tooth shoe, which is integrally formed with the stator frame by the occupation of the injection mold.

2. An in-line insert-molded stator according to claim 1, characterized in that: The support groove is arranged close to the stator tooth.

3. An in-line insert-molded stator according to claim 1, characterized in that: The depth of the support groove is greater than or equal to 0.25mm.

4. An in-line insert-molded stator according to claim 3, characterized in that: The depth of the support groove is less than or equal to 10.9mm.

5. The in-line insert-molded stator of claim 1, wherein: A line separation plate and a wire protection plate are arranged on the surface of the stator frame at the axial end of the stator yoke, the line separation plate is located radially inside the wire protection plate, and a wire protection groove is formed between the two, the ratio of the radial width of the wire protection groove to the diameter of the enameled wire is 1-1.2, and the ratio of the axial height of the wire protection groove to the diameter of the enameled wire is 1.2-2.

6.

6. An in-line insert-molded stator according to claim 5, characterized in that: A wire passing groove is formed between the stator frame and the line separation plate at the end surface of the stator tooth, the ratio of the radial width of the wire passing groove to the radial width of the wire protection groove is 2-8, and the ratio of the axial height of the wire passing groove to the axial height of the wire protection groove is 2-8.

7. The in-line insert-molded stator of claim 1, wherein: The in-line insert injection stator is composed of a plurality of stator monomers, each axial end of the stator monomer is provided with a positioning slot matched with the positioning plate of the clamp in the winding equipment, each axial end of the stator monomer protrudes in the axial direction, and each end of the stator monomer is provided with a positioning block on both sides of the arc, when the stator monomers are in a straight arrangement state, the two positioning blocks on the adjacent stator monomers are close to each other to form a positioning assembly for clamping by the clamping jaw of the clamp in the winding equipment.

8. An in-line insert-molded stator according to claim 7, characterized in that: The positioning slot comprises a limiting slot and a limiting hole located radially outside the limiting slot, the slot width a of the limiting slot is greater than the hole diameter b of the limiting hole, and the positioning plate of the clamp passes through the limiting hole and abuts against the surface of the limiting slot.

9. The in-line insert-molded stator of claim 5, wherein: The in-line insert injection stator is composed of a plurality of stator monomers, a first column and a second column are arranged at the wire passing end of the adjacent two stator monomers, the first column and the second column form a wire passing groove with the line separation plate on the stator monomer, the first column and the second column have a first surface arranged opposite to each other and spliced with each other, the first column comprises a first top corner located at the radial outer end of the first surface and a second top corner located at the radial outer end of the side away from the first surface; The second column comprises a third top corner located at the radial outer end of the first surface and a fourth top corner located at the radial outer end of the side away from the first surface; the maximum radial dimension of the second column is located at the third top corner; The first column is located radially inside the line connecting the second top corner and the third top corner, and the second column is located radially inside the line connecting the third top corner and the fourth top corner; a chamfer is arranged at each of the first top corner, the second top corner, the third top corner and the fourth top corner; and at least two of the first top corner, the second top corner, the third top corner and the fourth top corner are abutted by the enameled wire during winding.

10. The in-line insert-molded stator of claim 1, wherein: The application also discloses a terminal at one end of the stator framework and a plastic sealing body for sealing the stator core, the stator framework and the terminal as a whole, wherein the outer circumferential surface of the stator yoke has a material guiding groove extending to both ends of the stator yoke in the axial direction, the injection molding material constituting the stator framework is filled to form a material guiding body at the material guiding groove, the outer surface of the material guiding body has a long groove extending in the axial direction, and the plastic sealing body fills the long groove.

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