Insulation framework, motor stator assembly and motor

Abstract

The utility model provides an insulating framework, a motor stator assembly and a motor, and the insulating framework comprises a first insulating baffle plate and a second insulating baffle plate which are respectively disposed on the end surfaces of two opposite sides of a stator iron core, and a plurality of insulating support plates disposed between the first insulating baffle plate and the second insulating baffle plate. The first insulation baffle is provided with first tooth portion blocking pieces corresponding to the end face positions of all stator teeth of the stator core, the second insulation baffle is provided with second tooth portion blocking pieces corresponding to the end face positions of all the stator teeth of the stator core, and an insulation supporting plate is supported between at least part of the first tooth portion blocking pieces and the second tooth portion blocking pieces. And the non-deformability of the insulating support plate is higher than that of the first insulating baffle plate and the second insulating baffle plate. According to the utility model, the generation of iron core tooth part stress and the reduction of tooth part sheet layer spacing caused by winding of the winding are avoided, the insulation performance between the tooth part sheet layers is ensured, and the magnetic performance after the stator winding is wound on the stator iron core is ensured to be at a better level.

Description

Insulating frame, motor stator assembly and motor Technical Field

[0001] This utility model belongs to the field of motor design technology, specifically relating to an insulating frame, a motor stator assembly, and a motor. Background Technology

[0002] Motor losses mainly include iron losses and copper losses. Iron losses are generated by the iron core, while copper losses are generated by the windings. Currently, iron cores are generally manufactured by punching and shearing single pieces of non-oriented electrical steel and then riveting or welding them together. These processes all introduce residual stress into the iron core, which increases iron losses and reduces its permeability, indirectly leading to increased copper losses. To eliminate this negative impact, the industry generally uses annealing to remove the residual stress generated during core manufacturing.

[0003] However, for motors that mainly use concentrated windings, such as permanent magnet synchronous motors and DC motors, the winding process will generate a large axial pressure on the teeth of key parts of the stator core's magnetic circuit. This will cause stress on the teeth and reduce the interlaminar spacing of the teeth. Especially after the stator core has undergone stress-relief annealing, the insulation coating will be damaged, which will lead to a significant decrease in the interlaminar insulation performance of the stator core teeth. Ultimately, this will result in a significant reduction in the magnetic properties of the annealed stator core after winding.

[0004] Existing patents cannot reduce the pressure exerted by concentrated windings on the stator core teeth. For example, Chinese Patent Publication No. CN204696822U discloses a DC motor rotor insulating end plate. This insulating end plate has a winding slot and tooth profile structure, which can cover both sides of the tooth cross-section and one side of the tooth end face of the rotor core. However, since the other side of the tooth end face is not covered, this insulating end plate has difficulty affecting the axial force on the core teeth. Furthermore, when the pressure generated by the winding is large, the contact area between the winding and the winding slot of the insulating end plate may be damaged. Chinese Patent Publication No. C Invention patent N105356632A discloses a core body made of soft magnetic composite material and an insulating part of plastic material that is injection molded and covers the entire surface of the core. However, when the insulating part is cooled in a molten state, it will shrink in volume, that is, the insulating part itself will exert pressure on the entire surface of the core, including axial pressure on the core teeth. Chinese utility model patent CN206932089U discloses a thermally conductive plastic insulating frame for a stator or rotor with a high thermal conductivity. The insulating frame is also injection molded and covers the core teeth, which will also exert axial pressure on the core teeth. Summary of the Invention

[0005] Therefore, this utility model provides an insulating frame, a motor stator assembly, and a motor, which can overcome the technical problem in related technologies that the insulating frame used in the iron core cannot resist the axial pressure generated during the concentrated winding process, causing stress to be generated in the iron core teeth and reducing the interlamellar spacing of the teeth, resulting in a significant decrease in the interlamellar insulation performance and a significant decrease in magnetic properties after winding.

[0006] To address the aforementioned problems, this utility model provides an insulating frame, comprising a first insulating baffle and a second insulating baffle respectively located on opposite end faces of a stator core, and a plurality of insulating support plates located between the first insulating baffle and the second insulating baffle. The first insulating baffle has a first toothed baffle corresponding to the end face position of each stator tooth of the stator core, and the second insulating baffle has a second toothed baffle corresponding to the end face position of each stator tooth of the stator core. At least a portion of the first toothed baffle and the second toothed baffle are supported by the insulating support plates, and the deformation resistance of the insulating support plates is higher than that of the first insulating baffle and the second insulating baffle.

[0007] In some embodiments, the mechanical strength of the insulating support plate is higher than that of the first insulating baffle and the second insulating baffle; and / or, an insulating support plate is provided on each of the circumferential sides of each stator tooth.

[0008] In some embodiments, the insulating support plate is made of ceramic material; and / or, the first insulating baffle and / or the second insulating baffle is made of insulating plastic.

[0009] In some embodiments, the ceramic material is one of silicon dioxide, aluminum oxide, or zirconium dioxide; and / or, the insulating plastic is one of polybutylene terephthalate, glass fiber reinforced polybutylene terephthalate, polyethylene terephthalate, glass fiber reinforced polyethylene terephthalate, polyhexamethylene adipamide, or glass fiber reinforced polyhexamethylene adipamide.

[0010] In some embodiments, the insulating support plate is detachably connected to the first insulating baffle, and the insulating support plate is detachably connected to the second insulating baffle.

[0011] In some embodiments, the end of the insulating support plate is detachably connected to the first toothed baffle and the second toothed baffle through a convex-concave mating structure.

[0012] In some embodiments, the concave-convex mating structure includes a protrusion formed on the side of the first toothed baffle and the second toothed baffle near the stator core and a groove formed on the end of the insulating support plate, wherein the protrusion and the groove are fitted together.

[0013] In some embodiments, the cross-sections of the protrusion and the groove are triangular or rectangular; and / or, a clearance groove is formed on the end face of the stator tooth that mates with the insulating support plate, and the concave-convex mating structure is located within the clearance groove.

[0014] In some embodiments, the support length of the insulating support plate is h, and the design stack thickness of the stator core is T, T≤h≤T+0.01nt, where t is the thickness of a single lamination of the stacked stator core, and n is the number of laminations.

[0015] This utility model also provides a motor stator assembly, including the above-mentioned insulating frame.

[0016] This utility model also provides an electric motor, including the above-described motor stator assembly.

[0017] The insulating frame, motor stator assembly, and motor provided by this utility model have the following beneficial effects:

[0018] Setting an insulating support plate with higher resistance to deformation between the first insulating baffle and the second insulating baffle can effectively resist the axial force generated when the stator winding is wound on the stator teeth of the stator core, preventing the axial force from axially compressing and deforming the stator core. This effectively eliminates the generation of stress in the core teeth and the reduction of the tooth lamination spacing caused by the winding, ensuring the insulation performance between the tooth laminations, and thus ensuring that the magnetic properties of the stator core after winding the stator winding are at a better level, thereby reducing motor losses and improving motor efficiency. Attached Figure Description

[0019] To more clearly illustrate the embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0020] Figure 1 is a three-dimensional structural diagram of the insulating frame in an embodiment of the present invention (in a disassembled state);

[0021] Figure 2 is a magnified view of part A in Figure 1;

[0022] Figure 3 is a magnified view of part B in Figure 1;

[0023] Figure 4 is an axial projection schematic diagram of the stator core assembled with the insulating frame in an embodiment of this utility model.

[0024] Figure 5 is a cross-sectional view of AA in Figure 4;

[0025] Figure 6 is a cross-sectional view of BB in Figure 5;

[0026] Figure 7 is a cross-sectional view of the stator teeth and insulating skeleton of the stator core after being wound around the stator winding in an embodiment of the present invention.

[0027] Figure 8 is a magnified view of point C in Figure 6;

[0028] Figure 9 is a structural schematic diagram of the first insulating baffle or the second insulating baffle and the insulating support plate in another embodiment of the present invention (in the disassembled state);

[0029] Figure 10 is a structural schematic diagram of the first insulating baffle or the second insulating baffle and the insulating support plate in another embodiment of the present invention (in the disassembled state).

[0030] The attached figures are labeled as follows:

[0031] 11. First insulating baffle; 110. Protrusion; 111. First toothed baffle; 12. Second insulating baffle; 121. Second toothed baffle; 13. Insulating support plate; 130. Groove; 14. Inner winding baffle; 15. Outer winding baffle; 100. Stator core; 101. Clearance slot; 102. Stator tooth; 103. Tooth yoke; 200. Stator winding. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present utility model or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0033] In the description of this utility model, it should be understood that the directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this utility model. The directional terms "inner" and "outer" refer to the inner and outer contours of each component itself.

[0034] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90° or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0035] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be construed as limiting the scope of protection of this utility model.

[0036] Referring to Figures 1 and 10, according to an embodiment of the present invention, an insulating frame is provided, including a first insulating baffle 11 and a second insulating baffle 12 respectively located on (i.e., assembled on) the opposite two end faces (i.e., the two axial end faces) of a stator core 100, and a plurality of insulating support plates 13 located between the first insulating baffle 11 and the second insulating baffle 12. The first insulating baffle 11 has a plurality of first toothed baffles 111 corresponding one-to-one with the end face positions of each stator tooth 102 of the stator core 100. The second insulating baffle 12 has a plurality of second toothed baffles 121 corresponding one-to-one with the end face positions of each stator tooth 102 of the stator core 100. At least a portion of the first toothed baffles 111 and the second toothed baffles 121 are supported by the insulating support plates 13, and the deformation resistance of the insulating support plates 13 is higher than that of the first insulating baffle 11 and the second insulating baffle 12.

[0037] In this technical solution, an insulating support plate 13 with higher resistance to deformation is set between the first insulating baffle 11 and the second insulating baffle 12. This can effectively resist the axial force generated when the stator winding 200 is wound at the stator teeth 102 of the stator core 100, preventing the axial force from axially compressing and deforming the stator core 100. This effectively eliminates the generation of stress in the core teeth and the reduction of the tooth layer spacing caused by the winding, ensuring the insulation performance between the tooth layers. In turn, it ensures that the magnetic properties of the stator core 100 after winding the stator winding 200 are at a better level, thereby reducing motor losses and improving motor efficiency.

[0038] In some embodiments, the mechanical strength of the insulating support plate 13 is higher than that of the first insulating baffle 11 and the second insulating baffle 12. For example, the yield strength of the insulating support plate 13 is higher than that of the two insulating baffles, so that the insulating support plate 13 can effectively resist the axial pressure generated during the winding process.

[0039] In some embodiments, an insulating support plate 13 is provided on each of the two circumferential sides of each stator tooth 102, so that each insulating support plate 13 can form uniform support in the circumferential direction of the stator core 100, ensuring that the stator core 100 does not bear the axial pressure generated by the winding in the circumferential direction of the stator core 100.

[0040] In some embodiments, the insulating support plate 13 is made of ceramic material, specifically sintered ceramic material, which can ensure that the shape and size of the insulating support plate 13 are more accurate. The aforementioned ceramic material can be, for example, one of silicon dioxide, aluminum oxide or zirconium dioxide, which has sufficient mechanical strength and excellent insulation performance. In addition, the insulating support plate 13 made of sintered ceramic material has a smooth surface, which can effectively prevent damage to the varnish film of the stator winding 200.

[0041] In a preferred embodiment, the width of the aforementioned insulating support plate 13 needs to be consistent with the width of the stator winding 200 around the side of the stator tooth 102, that is, the insulating support plate 13 can fully wrap the side of the stator tooth 102, thereby improving its insulation effect.

[0042] The first insulating baffle 11 and / or the second insulating baffle 12 are made of insulating plastic, such as polybutylene terephthalate, glass fiber reinforced polybutylene terephthalate, polyethylene terephthalate, glass fiber reinforced polyethylene terephthalate, polyhexamethylene adipamide, or glass fiber reinforced polyhexamethylene adipamide. In specific manufacturing, injection molding is used to produce insulating baffles with relatively complex shapes and structures. Referring to Figure 1, the aforementioned first insulating baffle 11 and second insulating baffle 12 have inner winding baffles 14 and outer winding baffles 15 respectively at their radially inner and radially outer ends, forming a winding channel for the stator winding 200 at the axial end face of the stator core 100, ensuring the positional reliability of the stator winding 200.

[0043] In some embodiments, the insulating support plate 13 is detachably connected to the first insulating baffle 11, and the insulating support plate 13 is detachably connected to the second insulating baffle 12.

[0044] In this technical solution, the insulating support plate 13 is detachably connected between the first insulating baffle 11 and the second insulating baffle 12, so that the insulating frame in this utility model can be replaced with an insulating support plate 13 of a more suitable size according to the stacking thickness of the stator core 100, thereby improving the versatility of the insulating frame.

[0045] In some embodiments, the ends of the insulating support plate 13 are detachably connected to the first toothed baffle 111 and the second toothed baffle 121 via a convex-concave fitting structure (not shown in the figure). It is understood that the aforementioned convex-concave fitting structure includes mutually fitted protrusions 110 and grooves 130 to reliably position the toothed baffles at both ends and the insulating support plate 13 in the axial, circumferential, and radial directions of the stator core. In some embodiments, the convex-concave fitting structure includes a protrusion 110 formed on the side of the first toothed baffle 111 and the second toothed baffle 121 near the stator core 100 and a groove 130 formed at the end of the insulating support plate 13. The protrusion 110 and the groove 130 are fitted together, meaning their shapes and sizes are perfectly matched. In some embodiments, the cross-sections of the protrusion 110 and the groove 130 are triangular or rectangular.

[0046] A clearance groove 101 is formed on the end face of the stator tooth 102 that cooperates with the insulating support plate 13, and the concave-convex mating structure is located in the clearance groove 101.

[0047] In this technical solution, the avoidance grooves 101 that match the concave-convex fit structure are provided on the left and right sides of the stator tooth 102. This allows the width of the insulating support plate 13, the first tooth baffle 111, and the second tooth baffle 121 in the circumferential direction of the stator core 100 to be as small as possible, so that they can be closer to one side of the stator tooth 102. This ensures that the winding slot fill factor of the stator winding 200 is at a high level.

[0048] In some embodiments, the support length of the insulating support plate 13 is h, and the design stack thickness of the stator core 100 is T, where T≤h≤T+0.01nt, t is the thickness of a single lamination of the stator core 100, and n is the number of laminations. The units of T, t, and h are generally mm. This ensures that when the stator core 100 undergoes subsequent processing and thermal expansion causes the stack thickness to increase, the insulating support plate 13 can still play its role in supporting the axial pressure generated by the winding.

[0049] The technical solution of this utility model will be further described below with reference to specific embodiments:

[0050] The stator core 100 is formed by lamination and stacking process. The electrical steel used is 35W300 grade with a thickness of 0.35mm. The designed stack thickness is 40mm and the designed number of laminations is 112. After the stator core 100 is formed, it undergoes stress-relief annealing treatment at a temperature of 750℃ for 180min. Since the residual stress generated by lamination is partially eliminated, the stack thickness of the stator core changes to approximately 40.39mm after annealing.

[0051] The structural design of the insulating frame is shown in Figure 1. The insulating support plate 13 is made of aluminum oxide and is manufactured by powder sintering.

[0052] The first insulating baffle 11 and the second insulating baffle 12 are made of glass fiber reinforced polybutylene terephthalate and are manufactured by injection molding. It is understood that the first toothed baffle 111 and the second toothed baffle 121 are integrally formed on the aforementioned first insulating baffle 11 and second insulating baffle 12.

[0053] The insulating support plate 13 is fastened together with the first toothed baffle 111 and the second toothed baffle 121 at both ends through the slot (i.e. the aforementioned groove 130) and the pin (i.e. the aforementioned protrusion 110), thereby realizing the covering of the stator tooth 102 by the insulating frame.

[0054] The concentrated winding (i.e., the aforementioned stator winding 200) is wound on the stator teeth 102 of the stator core 100, so that the axial pressure generated by the concentrated winding is shared by the insulating support plate, and the final stack thickness of the stator core is controlled to 40.20 mm.

[0055] According to an embodiment of the present invention, a motor stator assembly is also provided, including the above-described insulating frame.

[0056] According to an embodiment of the present invention, an electric motor is also provided, including the above-described motor stator assembly.

[0057] It will be readily understood by those skilled in the art that, without conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0058] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model. The above description is only a preferred embodiment of this utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this utility model, and these improvements and modifications should also be considered within the protection scope of this utility model.

Claims

1. An insulating frame, characterized in that, The system includes a first insulating baffle (11) and a second insulating baffle (12) located on opposite end faces of the stator core (100), and a plurality of insulating support plates (13) located between the first insulating baffle (11) and the second insulating baffle (12). The first insulating baffle (11) has a first tooth baffle (111) corresponding to the end face position of each stator tooth (102) of the stator core (100). The second insulating baffle (12) has a second tooth baffle (121) corresponding to the end face position of each stator tooth (102) of the stator core (100). The insulating support plates (13) are supported between at least a portion of the first tooth baffle (111) and the second tooth baffle (121), and the deformation resistance of the insulating support plates (13) is higher than that of the first insulating baffle (11) and the second insulating baffle (12).

2. The insulating frame according to claim 1, characterized in that, The mechanical strength of the insulating support plate (13) is higher than that of the first insulating baffle (11) and the second insulating baffle (12); and / or, an insulating support plate (13) is provided on each of the two circumferential sides of each stator tooth (102).

3. The insulating frame according to claim 1 or 2, characterized in that, The insulating support plate (13) is made of ceramic material; and / or, the first insulating baffle (11) and / or the second insulating baffle (12) are made of insulating plastic.

4. The insulating frame according to claim 3, characterized in that, The ceramic material is one of silicon dioxide, aluminum oxide, or zirconium dioxide; and / or the insulating plastic is one of polybutylene terephthalate, glass fiber reinforced polybutylene terephthalate, polyethylene terephthalate, glass fiber reinforced polyethylene terephthalate, polyhexamethylene adipamide, or glass fiber reinforced polyhexamethylene adipamide.

5. The insulating frame according to claim 1 or 2, characterized in that, The insulating support plate (13) is detachably connected to the first insulating baffle (11), and the insulating support plate (13) is detachably connected to the second insulating baffle (12).

6. The insulating frame according to claim 5, characterized in that, The end of the insulating support plate (13) is detachably connected to the first toothed baffle (111) and the second toothed baffle (121) through a convex-concave fit structure.

7. The insulating frame according to claim 6, characterized in that, The concave-convex mating structure includes a protrusion (110) formed on the side of the first toothed baffle (111) and the second toothed baffle (121) near the stator core (100) and a groove (130) formed at the end of the insulating support plate (13), wherein the protrusion (110) and the groove (130) are fitted together.

8. The insulating frame according to claim 7, characterized in that, The cross-sections of the protrusion (110) and the groove (130) are triangular or rectangular; and / or, a clearance groove (101) is formed on the end face of the stator tooth (102) that cooperates with the insulating support plate (13), and the concave-convex mating structure is located in the clearance groove (101).

9. The insulating frame according to claim 1, characterized in that, The support length of the insulating support plate (13) shown is h, and the design stack thickness of the stator core (100) is T, T≤h≤T+0.01nt, where t is the thickness of a single lamination of the stator core (100) stacked together, and n is the number of laminations.

10. A motor stator assembly, characterized in that, The insulating skeleton includes any one of claims 1 to 9.

11. An electric motor, characterized in that, Includes the motor stator assembly as described in claim 10.

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