Structure for improving stator slot space factor

Abstract

The utility model relates to the technical field of brushless motors, in particular to a structure for improving the slot fullness rate of a stator, the wall thickness of an insulating framework of the structure can reach 0.2 mm, compared with the existing 0.6 mm, the wall thickness is obviously reduced, the effective slot area is increased, the slot fullness rate is increased, an upper yoke insulating framework and a lower yoke insulating framework are fixed on the insulating framework in a positioning assembly assembling manner, and the structure is simple in structure and convenient to use. The assembly reliability is further ensured; comprising a stator core and an insulating framework, and the stator core is installed on the inner side wall of the insulating framework; the motor further comprises a positioning assembly, an upper yoke insulation framework and a lower yoke insulation framework, the upper yoke insulation framework is installed on the upper portion of the insulation framework, the lower yoke insulation framework is installed on the lower portion of the insulation framework, and the stator iron core is arranged on the insulation framework in a plastic coating injection molding mode. The upper yoke insulating framework and the lower yoke insulating framework are provided with positioning assemblies, and the positioning assemblies are used for reinforcing the connection among the insulating frameworks, the upper yoke insulating framework and the lower yoke insulating framework.

Description

Technical Field

[0001] This utility model relates to the technical field of brushless motors, and in particular to a structure for improving stator slot fill factor. Background Technology

[0002] Increasing the stator slot fill factor of a brushless motor can significantly improve its torque density and power density, thereby reducing the boundary size of the brushless motor and enabling it to develop towards miniaturization and integration.

[0003] The purpose of increasing the stator slot fill factor of a brushless motor is to increase the amount of winding, and to wind more enameled wire on the stator teeth of the same boundary size, thereby increasing the motor power within a limited size. There are two main directions: one is to optimize the winding wiring, and the other is to increase the effective slot area.

[0004] Currently, there are two main product structures. One involves injection molding the stator insulation frame first, then assembling it with the stator core. To ensure assemblability, the stator frame is divided into upper and lower parts, installed using an interlocking method. However, this method has the drawback of requiring a certain gap between the insulation frame and the stator core, and some warping may still exist after assembly, thus reducing the slot fill factor. The other method involves directly injection molding a layer of plastic onto the surface of the stator core through a plastic coating process. This method ensures no gap between the frame and the core. However, because the insulation layer inside the frame slot is thinner, while the plastic is thicker in the circumferential direction of the yoke, uneven shrinkage during injection molding can lead to material shortages and incomplete filling, thus limiting the design of thinner insulation layers. Currently, the typical design wall thickness is 0.6mm. Utility Model Content

[0005] To solve the above-mentioned technical problems, this utility model provides an insulating skeleton with a wall thickness of up to 0.2mm, which is significantly reduced compared to the existing 0.6mm, thereby increasing the effective slot area and slot fill factor. The upper yoke insulating skeleton and the lower yoke insulating skeleton are fixed to the insulating skeleton by means of positioning components, which further ensures the reliability of the assembly and improves the stator slot fill factor.

[0006] This utility model discloses a structure for improving stator slot fill factor, comprising a stator core and an insulating frame, with the stator core mounted on the inner wall of the insulating frame; it also includes a positioning component, an upper yoke insulating frame, and a lower yoke insulating frame. The upper yoke insulating frame is mounted on the upper part of the insulating frame, and the lower yoke insulating frame is mounted on the lower part of the insulating frame. The stator core is mounted on the insulating frame by plastic injection molding. The positioning component is provided on the upper yoke insulating frame and the lower yoke insulating frame to strengthen the connection between the insulating frame, the upper yoke insulating frame, and the lower yoke insulating frame. Since there is no thicker part of the upper yoke insulating frame between the stator core and the insulating frame, the wall thickness of the insulating frame can reach 0.2mm after injection molding, which is significantly reduced compared to the existing 0.6mm, increasing the effective slot area and thus increasing the slot fill factor. The upper yoke insulating frame and the lower yoke insulating frame are fixed to the insulating frame by the positioning component assembly, further ensuring the reliability of the assembly.

[0007] Preferably, the positioning component includes multiple sets of connectors, which are respectively disposed on the outer walls of the upper yoke insulating frame and the lower yoke insulating frame, and the upper yoke insulating frame and the lower yoke insulating frame are respectively provided with annular bosses; when the upper yoke insulating frame and the lower yoke insulating frame are installed on the upper and lower sides of the insulating frame, the annular bosses on the upper yoke insulating frame and the lower yoke insulating frame fit against the upper and lower ends of the insulating frame, and at the same time, the multiple sets of connectors are respectively inserted into the interior of the insulating frame, thereby improving the assembly structure stability between the insulating frame, the upper yoke insulating frame and the lower yoke insulating frame.

[0008] Preferably, it also includes multiple sets of bosses and multiple sets of grooves. The multiple sets of bosses are respectively disposed on the outer side wall of the annular bosses of the upper yoke insulating frame and the lower yoke insulating frame, and the multiple sets of grooves are respectively disposed on the upper and lower sides of the insulating frame. After the upper yoke insulating frame and the lower yoke insulating frame are installed on the upper and lower sides of the insulating frame, the structural strength between the insulating frame, the upper yoke insulating frame and the lower yoke insulating frame is further improved by inserting the multiple sets of bosses into the multiple sets of grooves.

[0009] Preferably, the outer walls of the multiple sets of bosses are provided with ribs; this improves the bending resistance of the multiple sets of bosses, increases their strength, and also improves the interference fit between the bosses and the grooves.

[0010] Compared with the prior art, the beneficial effects of this utility model are as follows: Since there is no thicker part of the upper yoke insulating skeleton and lower yoke insulating skeleton between the stator core and the insulating skeleton, the wall thickness of the insulating skeleton after injection molding can reach 0.2mm, which is significantly reduced compared with the existing 0.6mm, thus increasing the effective slot area and thereby increasing the slot fill factor. The upper yoke insulating skeleton and lower yoke insulating skeleton are fixed on the insulating skeleton by the form of positioning component assembly, which further ensures the reliability of the assembly. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the isometric structure of this utility model;

[0012] Figure 2 This is an exploded schematic diagram of the stator core and insulating frame, etc.

[0013] Figure 3 This is a partial isometric structural diagram showing the connection between the insulating frame and the groove, etc.

[0014] Figure 4 This is a partial isometric structural diagram showing the connection between the lower yoke insulating frame and connecting parts, etc.

[0015] Figure 5 This is a partial isometric structural diagram showing the connection between the upper yoke insulating skeleton and the boss, etc.

[0016] The following labels are used in the attached diagram: 1. Stator core; 2. Insulating frame; 3. Upper yoke insulating frame; 4. Lower yoke insulating frame; 5. Connector; 6. Boss; 7. Groove. Detailed Implementation

[0017] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. This utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to make the disclosure of this utility model more thorough and complete.

[0018] Example 1

[0019] like Figures 1 to 5 As shown, this utility model discloses a structure for improving stator slot fill factor, including a stator core 1 and an insulating frame 2. The stator core 1 is mounted on the inner wall of the insulating frame 2. It also includes a positioning component, an upper yoke insulating frame 3, and a lower yoke insulating frame 4. The upper yoke insulating frame 3 is mounted on the upper part of the insulating frame 2, and the lower yoke insulating frame 4 is mounted on the lower part of the insulating frame 2. The stator core 1 is set on the insulating frame 2 by plastic injection molding. The upper yoke insulating frame 3 and the lower yoke insulating frame 4 are provided with positioning components, which are used to strengthen the connection between the insulating frame 2, the upper yoke insulating frame 3, and the lower yoke insulating frame 4.

[0020] like Figure 3 As shown, the positioning component includes multiple sets of connectors 5, which are respectively disposed on the outer side walls of the upper yoke insulating frame 3 and the lower yoke insulating frame 4, and the upper yoke insulating frame 3 and the lower yoke insulating frame 4 are respectively provided with annular bosses.

[0021] In this embodiment, since there is no thicker portion of the upper yoke insulating skeleton 3 and lower yoke insulating skeleton 4 between the stator core 1 and the insulating skeleton 2, the wall thickness of the insulating skeleton 2 can reach 0.2mm after injection molding, which is significantly reduced compared to the existing 0.6mm. This increases the effective slot area and thus increases the slot fill factor. The upper yoke insulating skeleton 3 and lower yoke insulating skeleton 4 are fixed to the insulating skeleton 2 by means of positioning assembly, which further ensures the reliability of the assembly.

[0022] Example 2

[0023] Based on Example 1, such as Figure 3 As shown, the present invention provides a structure for improving stator slot fill factor, which further includes multiple sets of bosses 6 and multiple sets of grooves 7. The multiple sets of bosses 6 are respectively disposed on the outer side wall of the annular bosses of the upper yoke insulating frame 3 and the lower yoke insulating frame 4, and the multiple sets of grooves 7 are respectively disposed on the upper and lower sides of the insulating frame 2.

[0024] like Figure 3 As shown, the outer walls of the multiple sets of bosses 6 are provided with ribs;

[0025] In this embodiment, after the upper yoke insulating frame 3 and the lower yoke insulating frame 4 are installed on the upper and lower sides of the insulating frame 2, the annular bosses on the upper yoke insulating frame 3 and the lower yoke insulating frame 4 fit against the upper and lower ends of the insulating frame 2. At the same time, multiple sets of connectors 5 are respectively inserted into the interior of the insulating frame 2, thereby improving the stability of the assembly structure between the insulating frame 2, the upper yoke insulating frame 3 and the lower yoke insulating frame 4. After the upper yoke insulating frame 3 and the lower yoke insulating frame 4 are installed on the upper and lower sides of the insulating frame 2, the structural firmness between the insulating frame 2, the upper yoke insulating frame 3 and the lower yoke insulating frame 4 is further improved by inserting multiple sets of bosses 6 into multiple sets of grooves 7.

[0026] This utility model discloses a structure for improving stator slot fill factor. During operation, the stator core 1 is set on the insulating frame 2 by plastic injection molding, and the upper yoke insulating frame 3 and the lower yoke insulating frame 4 are fixed on the insulating frame 2 by positioning assembly.

[0027] The above description is only a preferred embodiment of the present 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 the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A structure for improving stator slot fill factor, comprising a stator core (1) and an insulating frame (2), wherein the stator core (1) is mounted on the inner wall of the insulating frame (2); characterized in that, It also includes a positioning component, an upper yoke insulating frame (3) and a lower yoke insulating frame (4). The upper yoke insulating frame (3) is installed on the upper part of the insulating frame (2), and the lower yoke insulating frame (4) is installed on the lower part of the insulating frame (2). The stator core (1) is set on the insulating frame (2) by plastic injection molding. The upper yoke insulating frame (3) and the lower yoke insulating frame (4) are provided with positioning components. The positioning components are used to strengthen the connection between the insulating frame (2), the upper yoke insulating frame (3) and the lower yoke insulating frame (4).

2. The structure for improving stator slot fill factor as described in claim 1, characterized in that, The positioning component includes multiple sets of connectors (5), which are respectively disposed on the outer side walls of the upper yoke insulating frame (3) and the lower yoke insulating frame (4), and the upper yoke insulating frame (3) and the lower yoke insulating frame (4) are respectively provided with annular bosses.

3. The structure for improving stator slot fill factor as described in claim 2, characterized in that, It also includes multiple sets of bosses (6) and multiple sets of grooves (7). The multiple sets of bosses (6) are respectively set on the outer side wall of the annular bosses of the upper yoke insulating frame (3) and the lower yoke insulating frame (4), and the multiple sets of grooves (7) are respectively set on the upper and lower sides of the insulating frame (2).

4. The structure for improving stator slot fill factor as described in claim 3, characterized in that, The outer walls of the multiple sets of protrusions (6) are provided with ribs.

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