Stator core assembly and electric machine

Abstract

This utility model discloses a stator core assembly and a motor. The stator core assembly includes a core body and a connector. The core body has a first side, and the connector is welded to the first side. The connector also includes a main body and a flange. The main body has a connection structure for detachable engagement with a housing. The flange is located at the axial end of the main body near the first side and has a second side facing away from the core body, which is used as a contact surface for welding electrodes. In this utility model, the connector is welded to the core body, avoiding the need for holes in the core body. This method also ensures high welding reliability and strong connection. The connector allows for detachable installation of the core body onto the housing, facilitating core maintenance. Furthermore, the flange prevents direct contact between the welding electrodes and the core body during welding, reducing the adverse effects of welding heat on the core performance.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, specifically to a stator core assembly and a motor. Background Technology

[0002] In existing axial flux motors, there are various processes for connecting and fixing the iron core to the housing. These include bolting, bonding, press-fitting, and welding. Bolting requires drilling screw holes on the fixing surface of the iron core, which must avoid gaps in the iron core and can potentially negatively impact its performance. Bonding strength is significantly affected by ambient temperature and humidity, making reliability uncertain. Press-fitting requires high machining precision and makes core disassembly difficult, hindering maintenance. Welding typically involves directly welding the iron core to the housing, which is difficult to disassemble, and the welding heat can negatively affect the iron core's performance. Utility Model Content

[0003] To address the aforementioned technical problems, the main objective of this utility model is to provide a stator core assembly and motor that offers reliable connection strength, minimizes impact on core performance, and is easy to disassemble and maintain, thereby improving product qualification rate and reliability.

[0004] To achieve the above objectives, this utility model proposes a stator core assembly, comprising:

[0005] The core has a first side and a second side arranged opposite each other in the axial direction, the second side being oriented toward the air gap; and

[0006] A connector is welded to the first side. The connector includes a main body and a flange. The main body is provided with a connection structure for detachable engagement with the housing. The flange is located at one end of the main body near the first side in the axial direction. The flange has a first side facing the core and a second side facing away from the core. Solder is filled between the first side and the first side. The second side is set as a welding electrode contact surface.

[0007] Optionally, before welding, the first surface of the connector is provided with a plurality of welding protrusions, the plurality of welding protrusions are distributed at intervals along the circumference, and the plurality of welding protrusions constitute the solder.

[0008] Optionally, the protrusion height of each welding protrusion relative to the first surface is h, and the axial dimension of the flange portion is H, where H is greater than or equal to 2.5h and less than or equal to 3h; and / or,

[0009] Each of the aforementioned welding protrusions is arranged in a tapering frustoconical shape in the direction away from the first surface; and / or,

[0010] The number of welding bumps is 3.

[0011] Optionally, the main body is configured as a column, the diameter of the main body is d, and the diameter of the flange is D, where D is greater than or equal to 1.3d and less than or equal to 1.7d.

[0012] Optionally, the main body is configured as a column, and the connecting structure is an internally threaded hole facing the housing; or,

[0013] The main body is configured as a column, and the connecting structure is an external thread provided on the outer periphery of the main body.

[0014] Optionally, multiple connectors are provided, and the multiple connectors are distributed at intervals along the circumference of the core on the first side.

[0015] To achieve the above objectives, this utility model proposes a motor, comprising:

[0016] chassis;

[0017] Stator core assembly, wherein the stator core assembly is as described above; and,

[0018] A connecting fitting is disposed on the housing, and the connecting fitting cooperates with the connecting fitting in the stator core assembly so that the stator core assembly is detachably connected and fixed to the housing.

[0019] Optionally, the housing is provided with a clearance hole, the clearance hole having a first end penetrating the inner side of the housing and a second end facing the outer side of the housing, the connector being inserted into the clearance hole at least partially from the first end, and the connecting fitting being inserted into the clearance hole from the second end and connected and fitted with the connector within the clearance hole.

[0020] Optionally, the inner circumference of the clearance hole is formed with a stepped surface facing the first end, and the stepped surface presses against the second surface.

[0021] Optionally, the main body is columnar, the connecting structure is an internally threaded hole facing the housing, the connecting fitting is a bolt, and the housing is also provided with a countersunk hole that passes through the outside of the housing. The countersunk hole is connected to the second end of the clearance hole, and the bolt passes through the countersunk hole and is screwed into the internally threaded hole.

[0022] The technical solution provided by this utility model has the following beneficial effects:

[0023] The stator core assembly provided by this utility model includes a core body and a connector. The core body has a first side, and the connector is welded to the first side. The connector also includes a main body and a flange. The main body has a connection structure for detachable engagement with the housing. The flange is located at the axial end of the main body near the first side. The flange has a first surface facing the core body and a second surface facing away from the core body. Solder is filled between the first side and the first surface, and the second surface is used as the contact surface for the welding electrode. The stator core assembly provided by this utility model fixes the connector and the core body by welding, ensuring reliable connection strength while avoiding opening holes in the core body, thus reducing adverse effects on core performance. The connector allows for detachable installation of the core body onto the housing, facilitating core maintenance. During welding, the electrode is applied through the second surface of the flange away from the core body, preventing direct contact between the welding electrode and the core body, reducing the adverse effects of welding heat on core performance. Therefore, this provides a stator core assembly and motor with reliable connection strength, less impact on core performance, and easy disassembly and maintenance, thereby improving product qualification rate and reliability. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings and the structures shown without creative effort.

[0025] Figure 1 A top view of an embodiment of the motor provided by this utility model;

[0026] Figure 2 for Figure 1 Sectional view at point AA;

[0027] Figure 3 for Figure 2 Partial sectional view of the middle casing;

[0028] Figure 4 for Figure 1 A three-dimensional structural diagram of the middle stator core assembly;

[0029] Figure 5 for Figure 4 Front view of the middle stator core assembly;

[0030] Figure 6 for Figure 4 Top view of the middle stator core assembly;

[0031] Figure 7 for Figure 4 A schematic diagram of the three-dimensional structure of the core;

[0032] Figure 8 for Figure 4 A three-dimensional structural diagram of the connecting component, showing the component before welding;

[0033] Figure 9 for Figure 8 A three-dimensional structural diagram of the connecting component from another perspective;

[0034] Figure 10 for Figure 8 Front view of the connecting component.

[0035] Explanation of icon numbers:

[0036] 100-Stator core assembly; 10-Core body; 11-First side; 12-Second side; 20-Connector; 21-Main body; 211-Connecting structure; 22-Flange; 221-First surface; 222-Second surface; 23-Welding protrusion; 200-Housing; 201-Allowing hole; 2011-First end; 2012-Second end; 2013-Stepped surface; 202-Counterhead hole.

[0037] The realization of the purpose, functional characteristics and excellent effects of this utility model will be further explained below in conjunction with specific embodiments and accompanying drawings. Detailed Implementation

[0038] 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. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0039] It should be noted that if the embodiments of this utility model involve directional indication, the directional indication is only used to explain the relative positional relationship and movement of each component in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0040] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0041] This utility model provides a stator core assembly 100 and a motor. Please refer to [link / reference]. Figures 1 to 3 The motor typically includes a housing 200, a rotor assembly (not shown in the figure) mounted on the housing 200, and the aforementioned stator core assembly 100. The housing 200 can be made of different materials such as aluminum alloy or cast iron, depending on the motor's heat dissipation requirements, weight requirements, and cost budget.

[0042] Please see Figures 4 to 9 The stator core assembly 100 provided by this utility model includes a core 10 and a connector 20, such as... Figures 5 to 7 As shown, the core 10 has a first side 11 and a second side 12 arranged opposite each other in the axial direction, with the second side 12 facing the air gap to ensure the normal operation of electromagnetic induction in the axial magnetic field motor. The first side 11 of the core 10 is connected and fixed to the housing 200, thereby being installed in the housing 200. The core 10 can be made of silicon steel sheets of different grades, such as low-loss, high-permeability silicon steel sheets, to meet the performance requirements of motors with different power. The core 10 is manufactured by a lamination process.

[0043] Connector 20 is welded to the first side 11, such as Figures 8 to 10 As shown, the connector 20 includes a main body 21 and a flange 22. The main body 21 is provided with a connection structure 211 for detachable engagement with the housing 200. The specific type of the connection structure 211 can be selected according to the actual situation, as long as it can achieve the connection and engagement with the housing 200. For example, it can be an internal thread or external thread adapted to the housing 200.

[0044] A flange 22 is located at the axial end of the main body 21 near the first side 11. The flange 22 has a first surface 221 facing the core 10 and a second surface 222 facing away from the core 10. Solder fills the space between the first side 11 and the first surface 221, and the second surface 222 is set as the contact surface for the welding electrode. In this embodiment, welding tightly bonds the connector 20 to the core 10, forming a stable integral structure. The composition of the solder can be selected as needed. The flange 22 not only provides a large contact area for welding, enhancing welding stability, but also disperses stress during motor operation, avoiding local stress concentration. More importantly, the second surface 222 of the flange 22 facing away from the core 10 is set as the contact surface for the welding electrode. That is, during the process of welding and fixing the connector 20 to the first side 11, the welding electrode applies current to the second surface 222. Based on the characteristics of the solder and the material of the connector 20, the welding current, voltage, and time parameters are adjusted to allow the solder to fully melt, achieving a stable connection between the connector 20 and the core 10. During this process, the welding electrode does not directly contact the core 10, thereby avoiding the adverse effects of high welding heat on the core performance, especially its magnetic conductivity.

[0045] There are various ways to fill the space between the first side 11 and the first surface 221 with solder. For example, solder can be applied to the first side 11 or the first surface 221 before welding. In this embodiment, to ensure product reliability and consistency, the first surface 221 of the connector 20 is pre-formed with multiple welding protrusions 23 before welding. These welding protrusions 23 are spaced apart circumferentially, thus forming the solder. In different motor designs, the number and spacing of the protrusions can be flexibly adjusted according to the size and shape of the iron core and the required connection strength. For example, in large motors, the number of protrusions is increased to improve connection strength. In small motors, the protrusion spacing is appropriately reduced to ensure welding uniformity.

[0046] During welding, the electrodes of the welding equipment contact the second surface 222 of the flange 22. Current flows through the welding protrusions 23, generating heat that rapidly melts the protrusions and fills the space between the connector 20 and the core 10, achieving a strong connection. Thus, the welding protrusions 23 allow for controllable molten material during welding and ensure uniform distribution of the solder between the first surface 221 and the first side 11, improving product reliability and consistency. The combination of the flange 22 and the welding protrusions 23 not only expands the welding interface and further enhances the connection strength between the connector 20 and the core 10, but also effectively reduces the possibility of cracks or weld failure at the weld joint, improving product quality and reliability.

[0047] Based on the above embodiments, it can be understood that the axial thickness of the flange 22 is sufficiently large to effectively separate the welding electrode and the core 10, thus protecting the core 10. However, if the flange 22 is too thick, it will lead to poor electrode welding results. Therefore, in this embodiment, as... Figure 10 As shown, the protrusion height of each welding protrusion 23 relative to the first surface 221 is h, and the axial dimension of the flange portion 22 is H, where H is greater than or equal to 2.5h and less than or equal to 3h. Within this dimensional range, a good welding effect can be ensured while effectively reducing the adverse effects of high welding heat on the performance of the core 10.

[0048] Optionally, each welding bump 23 is arranged in a tapered frustum shape in the direction away from the first surface 221. The tapered frustum shape of the bumps allows heat to be distributed more evenly in the welding bumps 23, accelerates the melting of the bumps, and improves welding efficiency.

[0049] The number of welding protrusions 23 can be selected as needed; preferably, there are three welding protrusions 23. This provides sufficient welding strength while maintaining the balance and stability of the connector 20 relative to the core 10 before welding. Furthermore, the solder distribution is more uniform, resulting in better welding performance. The above-mentioned embodiments can be implemented individually or in combination. Thus, by optimizing the welding process parameters and the structural design of the connector 20, the welding quality is greatly improved, enhancing the overall performance and reliability of the stator core assembly 100 and extending the service life of the motor.

[0050] Furthermore, such as Figure 10 As shown, the main body 21 is cylindrical with a diameter of d, and the flange 22 has a diameter of D, where D is greater than or equal to 1.3d and less than or equal to 1.7d. This embodiment further defines the diameter ratio between the main body 21 and the flange 22. During operation, the larger diameter flange 22 provides a larger contact surface for the welding electrode, facilitating positioning and pressure application during welding, and ensuring welding quality. During motor operation, the flange 22 can better disperse the forces from the housing 200 and the core 10, enhancing the stability of the connection between the connector 20 and the housing 200. Thus, by setting the dimensional ratio between the flange 22 and the main body 21, welding stability and connection reliability are improved, enhancing the stability and safety of the motor under various operating conditions.

[0051] Optionally, such as Figure 9As shown, the main body 21 is cylindrical, and the connecting structure 211 is an internally threaded hole facing the housing 200. Alternatively, the main body 21 is cylindrical, and the connecting structure 211 is an externally threaded hole on the outer periphery of the main body 21. For motors that require frequent disassembly and installation, the internally threaded hole combined with bolts is preferred for ease of operation. In this way, the self-locking property of the thread is used to achieve a reliable connection between the stator core assembly 100 and the housing 200, while eliminating the need to drill threaded holes in the core 10.

[0052] Correspondingly, a connecting fitting is provided on the housing 200. This connecting fitting mates with the connecting member 20 in the stator core assembly 100, allowing the stator core assembly 100 to be detachably connected and fixed to the housing 200. The connecting fitting is selected based on the connection structure 211 of the connecting member 20. For example, if the connecting member 20 has an internal threaded hole, the connecting fitting is a bolt; if the connecting member 20 has an external thread, the connecting fitting can be a nut or a structural member with internal threads. During assembly, the stator core assembly 100 is first placed into the housing 200, ensuring that the connecting member 20 is aligned with its corresponding position on the housing 200. Then, the connecting fitting is installed, and the detachable connection between the stator core assembly 100 and the housing 200 is achieved through tightening or screwing. This detachable connection between the stator core assembly 100 and the housing 200 facilitates motor maintenance, repair, and parts replacement, reduces maintenance costs, and improves the motor's service life and maintainability.

[0053] For preferred options, please refer to [link / reference]. Figures 4 to 6 Multiple connectors 20 are provided, and these connectors 20 are distributed at intervals along the circumference of the core 10 on the first side 11. In different motor applications, the number of connectors 20 can be adjusted according to the motor's operating conditions and load characteristics. For example, in motors with high vibration and high load, the number of connectors 20 can be appropriately increased to improve connection strength. In motors with low load and stable operation, the number of connectors 20 can be reduced to lower costs. During operation, the multiple connectors 20 share the force between the core 10 and the housing 200, making the connection more uniform and avoiding excessive local stress. This further enhances the strength and stability of the connection between the stator core assembly 100 and the housing 200.

[0054] Preferably, please refer to Figures 1 to 3The housing 200 has a clearance hole 201, which has a first end 2011 penetrating the inside of the housing 200 and a second end 2012 facing the outside of the housing 200. The connector 20 is inserted into the clearance hole 201 at least partially from the first end 2011, and the connecting fitting is inserted into the clearance hole 201 from the second end 2012 and engages with the connector 20 within the clearance hole 201. Specifically, the diameter and depth of the clearance hole 201 are designed according to the dimensions of the connector 20 and the connecting fitting. In this way, the clearance hole 201 provides installation space and positioning structure for the connector 20 and the connecting fitting, ensuring smooth and accurate connection. In addition, it avoids the position of the connector 20, making the motor structure more compact and smaller in size in the axial direction, so that the motor can meet the needs of more installation and use scenarios.

[0055] The shape of the clearance hole 201 can be optimized according to the shape and size of the connector 20 and the connecting mating parts. In this embodiment, the connector 20 that mates with the flange has a step provided in the clearance hole 201. Specifically, the inner circumference of the clearance hole 201 is formed with a stepped surface 2013 facing the first end 2011, and the stepped surface 2013 presses against the second surface 222. In this way, on the one hand, the first side 11 of the core 10 can be basically close to the inner side of the housing 200, making the motor structure more compact. On the other hand, when the connector 20 is inserted into the clearance hole 201, the stepped surface 2013 will automatically axially position the connector 20, limiting its displacement. This facilitates the connection operation between the connector 20 and the connecting mating parts. It also further enhances the reliability and stability of the connection between the connector 20 and the housing 200. In this way, the loosening and displacement of the connector 20 during motor operation are reduced, the risk of motor failure caused by the loosening of the connector 20 is reduced, and the service life of the motor is extended.

[0056] For further information, please refer to [link / reference]. Figure 3The housing 200 also has a countersunk hole 202 that passes through the outer side of the housing 200. The countersunk hole 202 connects to the second end 2012 of the clearance hole 201. The bolt passes through the countersunk hole 202 and is screwed into the internal threaded hole. In this embodiment, the bolt is passed through the countersunk hole 202 and then screwed into the internal threaded hole of the connector 20. By controlling the tightening torque, the connection is ensured to be firm. The depth and diameter of the countersunk hole 202 should be designed according to the size of the bolt head so that the bolt is flush with the surface of the housing 200 after installation. For motors that require waterproofing and dustproofing, a sealing washer can be installed in the countersunk hole 202 to improve the motor's protection performance. In this embodiment, the stator core assembly 100 and the housing 200 are firmly connected by the bolt and the internal threaded hole. The design of the countersunk hole 202 ensures the connection strength without affecting the overall appearance of the housing 200. Furthermore, the connection between the connector 20 and the connecting mating parts can be made reliable and less prone to stripping by the limiting fit between the bolt and the countersunk hole 202.

[0057] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structure made using the contents of the present utility model specification and drawings, or directly or indirectly applied to other related technical fields, are similarly included within the patent protection scope of the present utility model.

Claims

1. A stator core assembly, characterized in that, include: The core has a first side and a second side arranged opposite each other in the axial direction, the second side being oriented toward the air gap; and A connector is welded to the first side. The connector includes a main body and a flange. The main body is provided with a connection structure for detachable engagement with the housing. The flange is located at one end of the main body near the first side in the axial direction. The flange has a first side facing the core and a second side facing away from the core. Solder is filled between the first side and the first side. The second side is set as a welding electrode contact surface.

2. The stator core assembly as described in claim 1, characterized in that, Before welding, the first surface of the connector is provided with a plurality of welding protrusions, which are spaced apart along the circumference and constitute the solder.

3. The stator core assembly as described in claim 2, characterized in that, The protrusion height of each welding protrusion relative to the first surface is h, and the axial dimension of the flange portion is H, where H is greater than or equal to 2.5h and less than or equal to 3h; and / or, Each of the welding bumps is arranged in a tapered frustum shape in the direction away from the first surface; and / or, the number of the welding bumps is 3.

4. The stator core assembly as described in claim 1, characterized in that, The main body is columnar, the diameter of the main body is d, and the diameter of the flange is D, where D is greater than or equal to 1.3d and less than or equal to 1.7d.

5. The stator core assembly as described in claim 1, characterized in that, The main body is cylindrical, and the connecting structure is an internally threaded hole facing the housing; or, The main body is configured as a column, and the connecting structure is an external thread provided on the outer periphery of the main body.

6. The stator core assembly as described in any one of claims 1 to 5, characterized in that, The connector is provided in multiple ways, and the multiple connectors are distributed at intervals along the circumference of the core on the first side.

7. An electric motor, characterized in that, include: chassis; A stator core assembly, wherein the stator core assembly is the stator core assembly as described in any one of claims 1 to 6; as well as, A connecting fitting is disposed on the housing, and the connecting fitting cooperates with the connecting fitting in the stator core assembly so that the stator core assembly is detachably connected and fixed to the housing.

8. The motor as described in claim 7, characterized in that, The housing has a clearance hole, which has a first end that penetrates the inside of the housing and a second end that faces the outside of the housing. The connector is inserted into the clearance hole at least partially from the first end, and the connecting fitting is inserted into the clearance hole from the second end and is connected and fitted with the connector in the clearance hole.

9. The motor as described in claim 8, characterized in that, The inner circumference of the clearance hole is formed with a stepped surface facing the first end, and the stepped surface presses against the second surface.

10. The motor as described in claim 8, characterized in that, The main body is columnar, the connecting structure is an internally threaded hole facing the housing, the connecting fitting is a bolt, the housing is also provided with a countersunk hole that passes through the outside of the housing, the countersunk hole is connected to the second end of the clearance hole, the bolt passes through the countersunk hole and is screwed into the internally threaded hole.

Images