A kind of flat wire stator assembly and motor for robot motor
By using a split core structure and direct PCB board welding of the coil, the complexity of manufacturing and maintainability of traditional flat wire stators are solved, achieving efficient winding, uniform air gap and high reliability, making it suitable for high-frequency motors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHEJIANG FANGDE ROBOT JOINT TECH CO LTD
- Filing Date
- 2025-06-25
- Publication Date
- 2026-06-26
AI Technical Summary
Traditional flat wire stators suffer from problems such as complex manufacturing processes, poor maintainability, insufficient positioning accuracy, weak mechanical strength, and complex electrical connections, and are prone to loosening, especially under high-speed rotation conditions.
It adopts a split core structure, including a core yoke ring and an independent single-tooth core block, which are fixed by end pressure rings. The coil is directly soldered to the PCB board and treated with insulation coating and potting layer.
It improves winding efficiency and consistency, ensures air gap uniformity, reduces maintenance costs, enhances electrical reliability and power density, reduces electromagnetic interference, and is suitable for high-frequency motors.
Smart Images
Figure CN224418522U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of motor structure technology, and in particular relates to a vertically wound flat wire stator assembly and motor for robot motors. Background Technology
[0002] In the field of motor stator manufacturing, flat wire winding technology has gradually become the preferred solution for high power density motors due to its advantages such as high slot fill factor, excellent heat dissipation, and low loss. However, traditional flat wire stators usually adopt an integral iron core structure, which has the following inherent defects: 1. Complex manufacturing process: The integral iron core requires vertical winding of flat wires in a narrow tooth space, which requires extremely high precision of the winding equipment and is very easy to cause insulation damage due to the rigidity of the wire; 2. Poor maintainability: When a single tooth coil is damaged, the entire winding needs to be disassembled, resulting in high maintenance costs.
[0003] To improve manufacturing efficiency, existing technologies have proposed segmented stator designs, but these generally suffer from problems such as insufficient positioning accuracy (leading to uneven air gaps), weak mechanical strength (prone to tooth displacement), and complex electrical connections (chaotic multi-coil leads). For example, segmented teeth are usually fixed by adhesive or bolts, which are prone to loosening under high-speed rotation; the coil ends need to be manually soldered to multiple independent terminals, resulting in low wiring reliability and large space requirements. Utility Model Content
[0004] To address the aforementioned technical problems, the first objective of this invention is to provide a vertically wound flat wire stator assembly for robot motors. This stator assembly facilitates independent winding, has a robust structure, and offers improved performance. The second objective of this invention is to provide a motor employing the aforementioned vertically wound flat wire stator assembly.
[0005] To achieve the first objective mentioned above, this utility model adopts the following technical solution:
[0006] A vertically wound flat wire stator assembly for a robot motor includes an iron core and a winding. The iron core includes an iron core yoke ring and an iron core tooth assembly. The iron core tooth assembly includes multiple single-tooth independent iron core blocks arranged at equal intervals along the circumference, and end pressure rings are fixed to both ends of the multiple single-tooth independent iron core blocks. The iron core yoke ring is inserted and fixed to the inner circumference of the multiple single-tooth independent iron core blocks. The winding includes a coil and a PCB board. A coil is wound on each single-tooth independent iron core block, and both ends of each coil are soldered to the PCB board. Lead wires are also provided on the PCB board.
[0007] As a preferred embodiment, the single-tooth independent iron core block is T-shaped with the large end facing outward and the small end facing inward. A V-shaped positioning protrusion A is also provided at the end near the center. Multiple V-shaped slots extending axially are provided on the outer wall of the iron core yoke ring. The single-tooth independent iron core block is fixed by the cooperation of the V-shaped positioning protrusion A and the V-shaped slot.
[0008] As a preferred embodiment, the end pressure ring includes an outer connecting ring and a radial extension. The outer connecting ring connects multiple radial extensions into a whole piece, and the radial extension covers the single-tooth independent iron core block. The inner end of the radial extension is also provided with a V-shaped positioning protrusion B, which is also inserted and fixed with the V-shaped groove of the iron core yoke ring.
[0009] As a preferred embodiment, the iron core is further provided with an insulating coating layer, the thickness of which is 0.1 to 0.2 mm.
[0010] As a preferred embodiment, the insulating coating layer includes an end face coating layer coated at both ends of the iron core, and an inter-tooth groove coating layer coated in the winding groove formed by the iron core yoke ring and the iron core tooth assembly.
[0011] As a preferred embodiment, the space between the coil and the iron core, as well as the portion of the coil exposed above the iron core, is encapsulated with a potting layer.
[0012] As a preferred option, both ends of all coils are soldered to the PCB board, forming two rings of solder joints on the PCB board. Connecting wires are pre-installed on the PCB board, so that adjacent solder joints of the inner ring are connected, and the corresponding phase ends of the outer ring are connected by cross wires.
[0013] To achieve the second objective mentioned above, the present invention adopts the following technical solution:
[0014] An electric motor employing any one of the above-described vertically wound flat wire stator assemblies.
[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0016] This utility model adopts a split structure of "iron core yoke ring + independent single-tooth iron core block", and the two ends of the tooth block are fixed into a rigid component by end pressure rings, and then the yoke ring is inserted into the inner circumference of the tooth block. This structure subverts the traditional tooth-yoke integrated or bolt connection mode and has the following advantages: 1. The single tooth block can be wound independently (the coil does not need to pass through the slot), which greatly improves the efficiency and consistency of flat wire vertical winding; 2. The yoke ring and the inner circumference of the tooth block are inserted and matched to ensure the uniformity of air gap; 3. Damaged single teeth can be replaced independently, reducing maintenance costs.
[0017] In addition, each coil is directly soldered to the PCB board at both ends. The PCB board has pre-set connection lines that precisely control the phase spacing, eliminating manual soldering errors and improving electrical reliability. The PCB board integrates all leads, compresses axial space, and increases power density. Furthermore, the PCB board's neat wiring reduces electromagnetic interference and is suitable for high-frequency motor applications. Attached Figure Description
[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.
[0019] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0020] Figure 2 This is an exploded structural diagram of the present invention;
[0021] Figure 3 This is a schematic diagram of the exploded structure of the iron core of this utility model;
[0022] Figure 4 This is a schematic diagram of the structure of the single-tooth independent iron core block of this utility model;
[0023] Figure 5 This is a schematic diagram of the end pressure ring of this utility model;
[0024] Figure 6 This is a schematic diagram of the iron core yoke ring of this utility model.
[0025] The reference numerals in the accompanying drawings are as follows: 1. Core yoke ring; 11. V-groove; 2. Core tooth assembly; 21. Single-tooth independent core block; 211. V-shaped positioning protrusion A; 22. End pressure ring; 221. Outer connecting ring; 222. Radial extension; 223. V-shaped positioning protrusion B; 3. Coil; 4. PCB board; 5. Insulating coating layer; 51. End face coating layer; 52. Coating layer inside the tooth groove; 6. Lead wire. Detailed Implementation
[0026] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.
[0027] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.
[0028] Furthermore, in the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., 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, and 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. Therefore, they should not be construed as limitations on this utility model.
[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.
[0030] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0031] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.
[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments:
[0033] like Figures 1 to 6The diagram shows a vertically wound flat wire stator assembly for a robot motor, comprising an iron core and windings. The iron core includes an iron core yoke ring 1 and an iron core tooth assembly 2. The iron core tooth assembly 2 includes a plurality of single-tooth independent iron core blocks 21 arranged at equal intervals along the circumference, and end pressure rings 22 are fixed at both ends of the plurality of single-tooth independent iron core blocks 21. The iron core yoke ring 1 is inserted and fixed at the inner circumference of the plurality of single-tooth independent iron core blocks 21.
[0034] The winding includes a coil 3 and a PCB board 4. A coil 3 is wound on each single-tooth independent iron core block 21. Both ends of each coil 3 are soldered to the PCB board 4. After both ends of all coils 3 are soldered to the PCB board 4, two rings of solder joints are formed on the PCB board 4. Connecting wires are pre-installed on the PCB board 4 so that adjacent solder joints of the inner ring are connected and the corresponding phase ends of the outer ring are connected by cross wires. The PCB board 4 is also provided with lead wires 6.
[0035] The inner ring connects adjacent solder joints to achieve series connection of the same phase windings, while the outer ring connects cross wires to complete the jumper connection of each phase output terminal (such as star / delta connection). The above structure allows the winding connection to be changed (such as from 4 poles to 6 poles) simply by changing the PCB board; at the same time, the PCB routing can compress the axial space at the end and reduce the volume at the end.
[0036] like Figure 3 and Figure 4 As shown, the single-tooth independent iron core block 21 is T-shaped, with the large end facing outward and the small end facing inward. The end near the center is also provided with a V-shaped positioning protrusion A211. The outer wall of the iron core yoke ring 1 is provided with a plurality of V-shaped slots 11 extending along the axial direction. The single-tooth independent iron core block 21 is fixed by the cooperation of the V-shaped positioning protrusion A211 and the V-shaped slots 11.
[0037] The T-shaped tooth block structure (large end facing out) can increase the winding slot area, accommodate more flat wires, and improve the slot fill factor; the V-shaped positioning protrusion A and the slot opening can constrain the circumferential displacement of the single tooth independent iron core block 21, avoid displacement caused by electromagnetic vibration, and the V-shaped engagement has self-guiding properties, simplifying the automated assembly process and realizing rapid assembly.
[0038] like Figure 5 As shown, the end pressure ring 22 includes an outer connecting ring 221 and a radial extension 222. The outer connecting ring 221 connects multiple radial extensions 222 into a whole piece, and the radial extensions 222 cover the single-tooth independent iron core block 21. The inner end of the radial extension 222 is also provided with a V-shaped positioning protrusion B223, which is also inserted and fixed to the V-shaped groove 11 of the iron core yoke ring 1. The radial extension covering the tooth block can suppress the magnetic leakage at the tooth end, reduce the loss of edge magnetic flux, and improve the uniformity of air gap magnetic flux. Moreover, the structure of the end pressure ring fixation solves the circumferential displacement problem of the split tooth block and ensures the tooth pitch accuracy.
[0039] The iron core is further provided with an insulating coating layer 5, the thickness of which is 0.1–0.2 mm. The insulating coating layer 5 includes end-face coating layers 51 coated at both ends of the iron core, and inter-tooth groove coating layers 52 coated within the winding slots formed by the iron core yoke ring 1 and the iron core tooth assembly 2. In the above structure, the end-face coating layers prevent discharge between the coil and the iron core end faces, and the inter-tooth groove coating layers prevent creepage between adjacent teeth.
[0040] The portion of coil 3 exposed above the iron core is encapsulated with a potting layer. This full encapsulation suppresses vibration and noise: the flat wire has high rigidity and easily resonates with the iron core; the potting fills the gaps, achieving damping and vibration reduction. Furthermore, the potting material (such as epoxy resin + boron nitride) has better thermal conductivity than air, directly transferring heat from the coil to the iron core and improving heat dissipation efficiency. This structure also prevents moisture / chemical media from intruding into the gaps between the flat wires.
[0041] This invention also discloses a motor employing the aforementioned vertically wound flat wire stator assembly structure. The motor of this invention is particularly suitable for applications requiring stringent power density and reliability, such as drive motors for new energy vehicles and robot joint motors.
[0042] This utility model, through its innovative architecture of a split plug-in iron core and interconnected PCB windings, simultaneously overcomes challenges in manufacturing efficiency, heat dissipation reliability, maintainability, and electromagnetic compatibility, providing a disruptive solution for high power density motors and possessing significant technological advantages.
[0043] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0044] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.
Claims
1. A flat wire stator assembly for a robot motor comprising a core and windings, characterized by: The core includes a core yoke ring (1) and a core tooth assembly (2). The core tooth assembly (2) includes multiple single-tooth independent core blocks (21) arranged equidistantly along the circumference. Each of the multiple single-tooth independent core blocks (21) has an end pressure ring (22) fixed at both ends. The core yoke ring (1) is inserted and fixed at the inner circumference of the multiple single-tooth independent core blocks (21). The winding includes a coil (3) and a PCB board (4). Each single-tooth independent core block (21) is wound with a coil (3). Each coil (3) has its two ends welded to the PCB board (4). The PCB board (4) is also provided with lead wires (6).
2. The vertically wound flat wire stator assembly for a robot motor according to claim 1, characterized in that, The single-tooth independent iron core block (21) is T-shaped with the large end facing outward and the small end facing inward. The end near the center is also provided with a V-shaped positioning protrusion A (211). The outer wall of the iron core yoke ring (1) is provided with a plurality of V-shaped slots (11) extending along the axial direction. The single-tooth independent iron core block (21) is fixed by the cooperation of the V-shaped positioning protrusion A (211) and the V-shaped slot (11).
3. A vertically wound flat wire stator assembly for a robot motor according to claim 2, characterized in that, The end pressure ring (22) includes an outer connecting ring (221) and a radial extension (222). The outer connecting ring (221) connects multiple radial extensions (222) into a whole piece, and the radial extension (222) covers the single tooth independent iron core block (21). The inner end of the radial extension (222) is also provided with a V-shaped positioning protrusion B (223). The V-shaped positioning protrusion B (223) is also inserted and fixed with the V-shaped groove (11) of the iron core yoke ring (1).
4. A vertically wound flat wire stator assembly for a robot motor according to claim 1, characterized in that, The iron core is also provided with an insulating coating layer (5), the thickness of which is 0.1 to 0.2 mm.
5. A vertically wound flat wire stator assembly for a robot motor according to claim 4, characterized in that, The insulating coating layer (5) includes an end face coating layer (51) coated on both ends of the iron core, and an inter-tooth groove coating layer (52) coated in the winding groove formed by the iron core yoke ring (1) and the iron core tooth assembly (2).
6. A vertically wound flat wire stator assembly for a robot motor according to claim 1, characterized in that, The coil (3) and the iron core, as well as the portion of the coil (3) exposed above the iron core, are all encapsulated with a potting layer.
7. A vertically wound flat wire stator assembly for a robot motor according to claim 1, characterized in that, After both ends of all coils (3) are soldered to the PCB board (4), two rings of solder joints are formed on the PCB board (4). Connecting lines are pre-installed on the PCB board (4) so that adjacent solder joints of the inner ring are connected and the corresponding phase ends of the outer ring are connected by cross lines.
8. An electric motor, characterized in that: The vertically wound flat wire stator assembly for robot motors described in any one of claims 1 to 7 is adopted.