A stator assembly for an oil pump motor

Abstract

The application discloses a kind of stator assembly of oil pump motor, including stator core and motor shell, the number of stator core is multiple, multiple stator core is connected by connecting bridge to form stator group;Stator group is straight row type, and the stator core on the two ends is located and is provided with mutually matched positioning structure;Stator group is bent and is rounded by connecting bridge, and positioning structure is used to enhance the integrity of stator group after rounding;Stator group is installed in motor shell, and motor shell and stator group are provided with mutually matched limiting structure.The application has beneficial effects: the stator core head and tail are connected to make straight row structure, which can further improve the flexibility of winding (horizontal or vertical winding), the cable is wound on the stator core in straight row state, and then it is rounded, which effectively improves the winding space, increases the slot fill rate, and can ensure that the utility model has the characteristics of convenient winding, high slot fill rate, high automation degree and the like.

Description

Technical Field

[0001] This application relates to the field of engineering machinery and new energy vehicle parts technology, and in particular to a stator assembly of an oil pump motor. Background Technology

[0002] With the continuous development of technology, electronic oil pumps have begun to be widely used in automobiles, industry, and shipbuilding. An oil pump motor generally includes a stator assembly and a rotor assembly. Electromagnetic induction is generated by winding coils on the stator assembly, driving the magnetic rotor assembly to rotate. In existing technologies, the stator assembly is generally a directly machined coil structure, which makes subsequent winding difficult. Furthermore, the slot width needs to accommodate the wire passage, resulting in a relatively large design and limited slot fill factor.

[0003] Traditional stator assembly designs suffer from insufficient slot fill factor (typically 40%–50%), resulting in low power density in oil pump motors. Furthermore, in most oil pump motors, the stator and motor housing are assembled using adhesive or heat-shrink fitting, leaving the stator constantly immersed in hot oil, which poses a risk of failure. Additionally, the loose arrangement of the coiled and then wound cables makes them prone to insulation wear under prolonged vibration. Therefore, it is necessary to improve the existing stator assembly. Utility Model Content

[0004] One objective of this application is to provide a stator assembly for an oil pump motor that can solve at least one of the defects in the aforementioned background art.

[0005] To achieve at least one of the above objectives, the technical solution adopted in this application is as follows: a stator assembly for an oil pump motor, comprising a stator core and a motor housing, wherein there are multiple stator cores connected by connecting bridges to form a stator group; the stator group is of a straight-line type, wherein the stator cores at the first and last ends are provided with mutually cooperating positioning structures; the stator group is bent and rolled into a circle by connecting bridges, and the positioning structures are used to enhance the stability of the stator group after rolling; the stator group is installed in the motor housing, and the motor housing and the stator group are provided with mutually cooperating limiting structures.

[0006] By connecting the stator core end to end in a straight line structure as described above, the flexibility of winding can be further improved (horizontal or vertical winding is possible). In the straight line state, the cable is wound onto the stator core and then rolled into a circle, which effectively increases the winding space and increases the slot fill factor. The positioning structure can ensure that the rolled stator assembly has high stability to prevent the stator assembly from unraveling under its own elastic force.

[0007] Preferably, the stator core is provided with connecting portions, winding teeth, and protrusions in sequence. The connecting portions are arc-shaped, and the connecting bridge is disposed between two adjacent connecting portions. After the stator assembly is rolled into a circle, the adjacent two protrusions cooperate to form a slot. With this arrangement, the cable can be directly wound onto the winding teeth, and the connecting portions and protrusions on both sides of the winding teeth can play a limiting role, further improving the stability of cable winding; the protrusions can greatly reduce the width of the slot after the stator assembly is rolled into a circle.

[0008] Preferably, the connecting bridge is arc-shaped, and the included angle between the inclined surfaces corresponding to two adjacent connecting parts is 30°. This design allows the stator assembly to be rolled into a circle after being arranged in a straight line, making the overall curvature closer to a circle, which is more conducive to subsequent installation; setting the included angle between the inclined surfaces corresponding to two connecting parts to 30° ensures that the stator assembly has sufficient rolling space while minimizing the width of the slot.

[0009] Preferably, the angle between the winding teeth and the protrusion is 122.5°, and the width of the slot is no greater than 0.4mm. This configuration effectively reduces cable stress concentration and increases slot fill factor.

[0010] Preferably, the positioning structure includes a welding notch and a welding protrusion. After the stator assembly is rolled into a circle, the welding protrusion extends into the welding notch. With this configuration, when the stator assembly is rolled into a circle after winding, the welding protrusion extends into the welding notch, and then the two are welded together. This effectively avoids misalignment of the rolled stator assembly and further improves the welding efficiency of the stator assembly.

[0011] Preferably, the stator assembly is concentrically arranged with the motor housing, and the limiting structure includes a groove and a boss. The groove is located on the inner side of the motor housing, and the boss is located on the outer side of the stator core. This arrangement allows the boss to be embedded into the groove during stator assembly installation, preventing misalignment when the stator assembly is pressed into the housing, reducing magnetic field asymmetry caused by uneven air gap, improving motor efficiency, and reducing vibration and noise.

[0012] Preferably, the stator assembly further includes an upper winding frame and a lower winding frame, the upper winding frame and the lower winding frame forming a toothed groove, and the stator assembly is mounted in the toothed groove. This configuration allows for flexible combination of the upper and lower winding frames, enabling them to be used with a series of motor stators of the same diameter but different heights (different power), thus saving costs and improving production efficiency.

[0013] Preferably, the thickness of the mating part of the tooth groove is 0.25 mm. This setting maximizes the effective space for winding while ensuring strength.

[0014] Preferably, the upper and lower wire frames are made of PPS + glass fiber composite material. This configuration gives the upper and lower wire frames high mechanical strength, as well as excellent oil resistance, high temperature resistance, and insulation properties.

[0015] Preferably, the stator assembly adopts a 12-slot structure, which can be used with a 10-pole rotor assembly, wherein the 10-pole rotor assembly adopts a surface-mount magnetization design. This configuration increases the number of magnetic field cycles in the 10-pole rotor assembly, reducing iron losses (eddy current and hysteresis losses) and improving efficiency at the same rotational speed; the 12-slot stator structure facilitates automated winding production, reducing manufacturing costs.

[0016] Compared with the prior art, the beneficial effects of this application are as follows:

[0017] Connecting the stator core end-to-end into a straight-line structure further enhances winding flexibility (allowing for horizontal or vertical winding). In this straight-line configuration, the cable is wound onto the stator core before being rolled, effectively increasing winding space and slot fill factor. The welded convex-concave interface design enhances the overall integrity of the rolled stator assembly through mechanical interlocking, preventing loosening or misalignment of the core laminations due to high-frequency vibration or impact, thus reducing noise and wear. Furthermore, the convex-concave interface facilitates precise lamination alignment, making it suitable for automated stacking processes (such as high-speed stamping and riveting), reducing manual intervention and improving production efficiency and consistency.

[0018] The limiting structure between the motor housing and the stator assembly effectively prevents the stator from rotating relative to the housing. The fit between the boss and the groove serves as an assembly reference, stabilizing the concentricity of the stator assembly and the housing, preventing misalignment when the stator assembly is pressed into the housing, reducing magnetic field asymmetry caused by uneven air gap, improving motor efficiency, and reducing vibration and noise. Furthermore, the upper and lower wire frame can be flexibly combined, allowing the wire frame assembly in this invention to be used with a series of motor stators of the same diameter but different heights (different power), thus saving costs and improving production efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the straight-line structure of the stator group in this application.

[0020] Figure 2 for Figure 1 A magnified structural diagram of part A in the middle.

[0021] Figure 3 This is a schematic diagram of the stator core structure in this application.

[0022] Figure 4 This is a schematic diagram of the cross-sectional structure of the stator assembly after it has been rolled into a circle in this application.

[0023] Figure 5 This is a schematic diagram of the motor housing structure in this application.

[0024] Figure 6 This is a schematic diagram of the stator assembly after it has been rolled up in this application.

[0025] Figure 7 for Figure 6 A magnified structural diagram of part B in the middle section.

[0026] Figure 8 This is a schematic diagram of the stator assembly installation structure in this application. Figure 1 .

[0027] Figure 9 This is a schematic diagram of the stator assembly installation structure in this application. Figure 2 .

[0028] Figure 10 This is a schematic diagram of the stator assembly installation structure in this application. Figure 3 .

[0029] In the diagram: 1. Stator core; 11. Connecting part; 12. Winding teeth; 13. Protrusion; 14. Boss; 100. Stator assembly; 2. Motor housing; 21. Groove; 200. Connecting bridge; 3. Upper wire frame; 300. Slot; 4. Lower wire frame; 400. Welding protrusion; 401. Welding notch; 500. Gear groove. Detailed Implementation

[0030] The present application will be further described below with reference to specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0031] In the description of this application, it should be noted that the terms "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., which indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application 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, and should not be construed as limiting the specific protection scope of this application.

[0032] It should be noted that the terms "first," "second," etc., in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0033] The terms “comprising” and “having”, and any variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0034] One aspect of this application provides a stator assembly for an oil pump motor, such as... Figures 1-5 As shown, one preferred embodiment includes a stator core 1 and a motor housing 2. Multiple stator cores 1 are connected by connecting bridges 200 to form a stator assembly 100. The stator assembly 100 is in a straight-line configuration, with mutually cooperating positioning structures on the mating surfaces of the stator cores 1 at both ends. When the stator assembly 100 is in a straight-line configuration, the operator can wind cables onto the stator cores 1 to improve winding flexibility (horizontal or vertical winding is possible). Winding the cables onto the stator cores 1 in the straight-line configuration and then rolling them into a coil effectively increases winding space and slot fill factor. After the stator assembly 100 is rolled into a coil, the positioning structures ensure high stability, preventing the stator assembly 100 from unraveling due to its own elasticity.

[0035] Specifically, such as Figure 2 and Figure 3 As shown, the stator core 1 is sequentially provided with a connecting part 11, a winding tooth 12, and a protrusion 13. The connecting part 11 is arc-shaped to ensure that the stator assembly 100 can be rolled into a circle. A connecting bridge 200 is disposed between two adjacent connecting parts 11. When the stator assembly 100 is rolled into a circle, the two adjacent protrusions 13 cooperate to form a slot 300. The cable is wound on the winding tooth 12. The connecting parts 11 and the protrusions 13 on both sides of the winding tooth 12 can limit the cable and further improve the stability of the cable winding. In addition, the protrusions 13 can also greatly reduce the width of the slot 300 after the stator assembly 100 is rolled into a circle.

[0036] It should be understood that traditional stator windings 100 generally employ a full-circle design, which has drawbacks such as low material utilization and high winding difficulty. Furthermore, the width of the slot 300 is relatively large due to the need to accommodate the wire passage, thus limiting the slot fill factor. However, stator slotting leads to uneven air gap magnetic permeability, thereby generating harmonics; the wider the slot 300, the greater the losses and vibration noise generated by harmonics. Therefore, energy loss can be reduced by decreasing the width of the slot 300.

[0037] The stator assembly 100 in this application adopts a straight-line design, which has a high material utilization rate; the straight-line winding is flexible (it can be wound horizontally or vertically), and the straight-line winding is then rolled into a circle, which greatly reduces the width of the slot 300 and effectively increases the winding space and increases the slot fill factor.

[0038] In an embodiment, such as Figure 2 and Figure 4 As shown, the connecting bridge 200 is arc-shaped, and the connecting part 11 has inclined surfaces on both sides. The included angle between the inclined surfaces corresponding to two adjacent connecting parts 11 is θ, where θ = 30°. After the straight stator assembly 100 is rolled into a circle, the arc of the connecting bridge 200 makes the stator assembly 100 more circular overall, which is beneficial for subsequent installation. In addition, the inclined surfaces on both sides make the straight stator assembly 100 smoother when rolled into a circle, and the inclined surfaces on adjacent connecting parts 11 can fit together after the stator assembly 100 is rolled into a circle, so that the stator assembly in this application has a semi-closed groove design. Of course, in practical applications, if it is necessary to adjust the number of stator cores 1, it is also necessary to change the size of the included angle θ between the inclined surfaces corresponding to two adjacent connecting parts 11 to ensure that the stator assembly 100 can be rolled into a circle normally.

[0039] In this embodiment, as Figure 6 and Figure 7 As shown, the angle between the winding teeth 12 and the protrusion 13 is α, where α = 122.5°. When the cable needs to be wound, if the internal stress of the cable is too high, the stress can be released through the angle between the winding teeth 12 and the protrusion 13, thereby reducing the concentration of stress in the cable and further improving the safety of the cable. In addition, in order to reduce the loss and vibration noise generated by harmonics, the width W of the slot 300 should not exceed 0.4mm.

[0040] Understandably, after the stator assembly 100 is rolled into a circle, its shape is fixed by welding. Traditional welding methods typically involve aligning the contact surfaces on both sides of the stator assembly 100 before welding. While this welding method provides some fixation, it only welds the gaps between the surfaces and cannot withstand high tensile forces. Furthermore, the internal strength of the oil pump is considerable during operation, and long-term operation may cause the weld points to break.

[0041] To address the aforementioned problems, in some embodiments of this application, such as... Figure 6 and Figure 7As shown, the positioning structure includes a welding notch 401 and a welding protrusion 400. After the stator assembly 100 is rolled into a circle, the welding protrusion 400 can be inserted into the welding notch 401, and then the two can be welded together to effectively prevent misalignment of the rolled stator assembly 100. Compared with traditional welding methods, the welding protrusion 400 and welding notch 401 in this application can play a positioning role. Simply inserting the welding protrusion 400 into the welding notch 401 can align the stator cores 1 on both sides, effectively preventing misalignment of the rolled stator assembly 100 and further improving the welding efficiency of the stator assembly 1002. In addition, the welding protrusion 400 and welding notch 401 can also play a locking role, distributing the pressure at the welding point to improve the stability of the rolled stator assembly 100.

[0042] In addition, the design of the welding notch 401 and welding convex opening 400 enhances the integrity of the iron core through mechanical interlocking, preventing the iron core laminations from loosening or misaligning due to high-frequency vibration or impact, thereby reducing noise and wear. At the same time, the tightly interlocked laminations can reduce the air gap in the magnetic circuit, improve magnetic flux continuity, and enhance the electromagnetic efficiency of the stator. Furthermore, the concave and convex interfaces facilitate precise alignment of the laminations, making them suitable for automated stacking processes (such as high-speed stamping + riveting), reducing manual intervention, and improving production efficiency and consistency.

[0043] In this embodiment, as Figure 5 and Figure 6 As shown, in order to prevent the stator assembly 100 from rotating inside the motor housing 2, a limiting structure is provided between the motor housing 2 and the stator assembly 100. When the stator assembly 100 has a tendency to rotate, the limiting structure can block the stator assembly 100, effectively preventing the stator assembly 100 from rotating relative to the motor housing 2. This can be used as an assembly reference to ensure the concentricity of the stator and the housing.

[0044] Specifically, such as Figure 5 and Figure 6 As shown, the stator assembly 100 is concentrically arranged with the motor housing 2. The limiting structure includes a groove 21 and a boss 14. The groove 21 is located on the inner side of the motor housing 2, and the boss 14 is located on the outer side of the stator assembly 100. When installing the stator assembly 100, the boss 14 can be aligned with the groove 21 first, and then the stator assembly 100 can be placed into the motor housing 2 while ensuring that the boss 14 is embedded in the groove 21. This not only avoids misalignment of the stator assembly 100 when it is pressed into the motor housing 2, but also reduces magnetic field asymmetry caused by uneven air gap, thereby improving motor efficiency and reducing vibration noise.

[0045] In this embodiment, as Figures 8-10As shown, the stator assembly also includes an upper winding frame 3 and a lower winding frame 4. The upper winding frame 3 and the lower winding frame 4, when mated, form a toothed groove 500 between them. The stator assembly 100 is installed within the toothed groove 500, which provides a fixed and limited position for the stator assembly 100. The mating distance between the upper winding frame 3 and the lower winding frame 4 is adjustable, meaning that the combination of the upper winding frame 3 and the lower winding frame 4 is flexible, allowing it to be used with a series of motor stators of the same diameter but different heights (different power), thus saving costs and improving production efficiency.

[0046] Specifically, the thickness of the mating part of the toothed groove 500 is 0.25mm. This reasonable thickness maximizes the effective space for winding while ensuring strength. The upper wire frame 3 and the lower wire frame 4 are made of PPS + glass fiber composite material, which ensures that the upper wire frame 3 and the lower wire frame 4 have high mechanical strength, excellent oil resistance, high temperature resistance and insulation performance.

[0047] In this embodiment, as Figure 1 As shown, the stator assembly 100 adopts a 12-slot structure and is used in conjunction with a 10-pole rotor. This 12-slot, 10-pole configuration is a fractional-slot design, which significantly reduces torque (the periodic torque fluctuations caused by changes in magnetic reluctance when the rotor is without current). This makes the motor run more smoothly, reducing vibration and noise, making it particularly suitable for noise-sensitive automotive environments. Furthermore, the 10-pole design increases the number of magnetic field cycles, reducing iron losses (eddy current and hysteresis losses) at the same speed and improving efficiency. The multi-pole structure shortens the magnetic flux path, reduces magnetic reluctance, and enhances torque output, making it more suitable for scenarios where oil pumps require rapid response. The 12-slot stator structure facilitates automated winding production, reducing manufacturing costs.

[0048] Furthermore, the 10-pole rotor adopts a surface-mount magnetization design, which has advantages such as simple structure, low manufacturing cost, and small moment of inertia. In addition, surface-mount magnetization can also reduce air gap magnetic flux density harmonics by reasonably optimizing dimensions, slotting the rotor surface, and optimizing permanent magnet poles, making the waveform more sinusoidal, which is beneficial to improving motor performance.

[0049] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this application. Various changes and modifications can be made to this application without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

Claims

1. A stator assembly of an oil pump motor comprising a stator core (1) and a motor housing (2), characterized in that, The number of stator cores (1) is multiple, and the multiple stator cores (1) are connected by connecting bridges (200) to form a stator group (100); the stator group (100) is a straight line, wherein the stator cores (1) at the first and last ends are provided with mutually cooperating positioning structures; the stator group (100) is bent and rolled into a circle by connecting bridges (200), and the positioning structure is used to enhance the stability of the stator group (100) after rolling into a circle; the stator group (100) is installed in the motor housing (2), and the motor housing (2) and the stator group (100) are provided with mutually cooperating limiting structures.

2. The stator assembly of an oil pump motor as set forth in claim 1, wherein, The stator core (1) is provided with a connecting part (11), a winding tooth (12) and a protrusion (13) in sequence. The connecting part (11) is arc-shaped. The connecting bridge (200) is located between two adjacent connecting parts (11). After the stator assembly (100) is rolled into a circle, the two adjacent protrusions (13) cooperate to form a slot (300).

3. The stator assembly of an oil pump motor as set forth in claim 2, wherein, The connecting bridge (200) is arc-shaped, and the included angle between the inclined planes corresponding to two adjacent connecting parts (11) is 30°.

4. The stator assembly of the oil pump motor as described in claim 2, characterized in that, The angle between the winding tooth (12) and the protrusion (13) is 122.5°, and the width of the slot (300) is no greater than 0.4 mm.

5. The stator assembly of the oil pump motor as described in claim 1, characterized in that, The positioning structure includes a welding notch (401) and a welding protrusion (400). When the stator assembly (100) is rolled into a circle, the welding protrusion (400) extends into the welding notch (401).

6. The stator assembly of the oil pump motor as described in claim 1, characterized in that, The stator assembly (100) is concentrically arranged with the motor housing (2). The limiting structure includes a groove (21) and a boss (14). The groove (21) is located on the inner side of the motor housing (2), and the boss (14) is located on the outer side of the stator core (1).

7. The stator assembly of the oil pump motor as described in claim 1, characterized in that, The stator assembly further includes an upper wire frame (3) and a lower wire frame (4), the upper wire frame (3) and the lower wire frame (4) forming a toothed groove (500), and the stator assembly (100) is installed in the toothed groove (500).

8. The stator assembly of the oil pump motor as described in claim 7, characterized in that, The thickness of the mating part of the tooth groove (500) is 0.25 mm.

9. The stator assembly of the oil pump motor as described in claim 7, characterized in that, The upper frame (3) and the lower frame (4) are made of PPS+glass fiber composite material.

10. The stator assembly of the oil pump motor as described in claim 1, characterized in that, The stator assembly (100) adopts a 12-slot structure and is used in conjunction with a 10-pole rotor assembly, wherein the 10-pole rotor assembly adopts a surface-mount magnetization design.

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