Energy-saving motor

Abstract

This utility model discloses an energy-saving motor, including a motor housing, rotor, stator, winding assembly, and insulating frame. The rotor and stator are disposed within the inner cavity of the motor housing, the insulating frame is mounted on the stator, and the winding assembly is wound around the insulating frame. The stator has 12 stator slots, which are trapezoidal slots. This utility model reduces the input current, resulting in reduced power consumption and heat generation under the same operating conditions and time. The measured efficiency (EFF%) of the motor is improved, indicating reduced energy consumption and a more energy-efficient effect. Furthermore, this utility model reduces the amount of silicon steel sheets and copper wire used, simplifying the manufacturing process.

Description

Technical Field

[0001] This utility model belongs to the field of motor technology, specifically relating to energy-saving motors. Background Technology

[0002] Multi-pole permanent magnet synchronous motors use permanent magnets for excitation, which simplifies the motor structure, reduces processing and assembly costs, and eliminates the slip rings and brushes that are prone to problems, thus improving the reliability of motor operation. Furthermore, since no excitation current is required, there is no excitation loss, which improves the efficiency and power density of the motor. Permanent magnet synchronous motors are composed of components such as stator, rotor, and end covers, and the stator magnetic field has multiple poles.

[0003] Currently, traditional motors (such as induction motors and permanent magnet synchronous motors) typically employ a stator design with a large number of slots, such as 48 slots or more. While this multi-slot structure provides better magnetomotive force waveforms in terms of electromagnetic performance, it also has the following technical drawbacks: (1) More stator slots require more silicon steel sheets and copper wires, leading to increased material costs. (2) The increased number of slots complicates stator stamping, winding, and embedding processes, extending processing time and reducing production efficiency. (3) The end windings of a 48-slot motor are longer, resulting in a significant reduction in resistance. (4) 48-slot motors exhibit significant slot leakage flux and end leakage flux, reducing motor efficiency. Utility Model Content

[0004] The purpose of this utility model is to solve the above-mentioned technical problems existing in the prior art and to provide an energy-saving motor.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] An energy-saving motor includes a motor housing, a rotor, a stator, a winding assembly, and an insulating frame. The rotor and stator are located inside the motor housing, the insulating frame is mounted on the stator, and the winding assembly is wound on the insulating frame. The stator is characterized by having 12 stator slots, the slot opening width of which is less than 1 mm.

[0007] Furthermore, the stator includes stator units, which are formed by splicing 12 stator units together. Each stator unit includes a yoke, a toothed part, and an arc-shaped part. The toothed part is located between the yoke and the arc-shaped part, and a stator slot is formed between the yoke, the toothed part, and the toothed part.

[0008] Furthermore, the side of the yoke is provided with a limiting protrusion, and the other side of the yoke is provided with a limiting groove. When two adjacent stator units are spliced ​​together, the limiting protrusion is embedded in the limiting groove.

[0009] Furthermore, a connecting part is provided between the yoke and the limiting protrusion, and a limiting opening is formed between the yoke, the limiting protrusion, and the connecting part. A locking part is provided between the yoke and the limiting groove, and a connecting opening is provided between the locking parts. The locking part and the limiting opening are matched, and the connecting part and the connecting opening are matched. When two adjacent stator units are spliced, the limiting protrusion is installed into the limiting groove from top to bottom.

[0010] Furthermore, both the outer surface of the connecting surface two and the inner surface of the limiting groove are arc surfaces.

[0011] Furthermore, the stator slots are trapezoidal slots.

[0012] Furthermore, the insulating frame includes an insulating frame body for winding the wire group. The insulating frame body extends to form a protrusion, an arc-shaped portion is installed at the protrusion located on the inner side, and a yoke portion is installed at the protrusion located on the outer side. The protrusion and the insulating frame body form a groove, and the wire group is embedded in the groove.

[0013] Furthermore, the inner protrusion is provided with a mounting surface, and the angle between the mounting surface and the outer surface of the insulating frame body is greater than 90°. The wire group is wound between the mounting surface and the outer surface of the insulating frame body.

[0014] Furthermore, the protrusion on the inner side has an installation opening, and the arc-shaped part is embedded in the installation opening.

[0015] Furthermore, the outer protrusion is provided with a limiting part, and the yoke is limited between the two limiting parts.

[0016] This utility model, by adopting the above-mentioned technical solution, has the following beneficial effects:

[0017] The existing motor has an input current of 6.887A, an input voltage of 363.8V, an input power of 4122W, a speed of 1456r / min, a torque of 25.12 N·m, and an output power of 3829W. At this time, the EFF% (efficiency) is 92.9%.

[0018] The input current of this utility model is 6.704A, the input voltage is 371.3V, the input power is 3879W, the speed is 1454 r / min, the torque is 25.13 N·m, and its output power is 3826. At this time, the EFF% (efficiency) is 98.6%.

[0019] This invention features a stator with 12 stator slots, employing concentrated windings. Compared to the existing 48-slot windings, this design reduces end winding length, significantly lowers resistance, and decreases input current. Under the same power conditions and time, it reduces power consumption and heat generation in the motor. The measured efficiency (EFF%) of the motor is improved, and energy consumption is reduced, resulting in greater energy savings. Furthermore, this invention reduces the amount of silicon steel sheets and copper wire used, simplifying the manufacturing process. The fewer stator slots also increase the slot area, solving the problem of excessive slot fill factor. The extra space allows for better heat dissipation of the windings and reduces slot and end magnetic leakage. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings:

[0021] Figure 1 This is a schematic diagram of the structure of the energy-saving motor of this utility model;

[0022] Figure 2 This is a schematic diagram of the internal structure of this utility model;

[0023] Figure 3 This is a schematic diagram of the connection between the rotor, stator, wire assembly and insulating frame in this utility model;

[0024] Figure 4 This is a schematic diagram of the connection between the stator, wire group and insulating frame in this utility model;

[0025] Figure 5 This is a schematic diagram of the connection between the stator and the insulating frame in this utility model;

[0026] Figure 6 This is a schematic diagram of the connection between the insulating frame body and the stator unit in this utility model;

[0027] Figure 7 This is a schematic diagram of the structure of the insulating frame body in this utility model;

[0028] Figure 8 This is a schematic diagram of the stator structure in this utility model;

[0029] Figure 9 for Figure 8 The main view;

[0030] Figure 10 This is a schematic diagram of the stator unit in this utility model;

[0031] Figure 11 This is a schematic diagram of the structure of the end cap of this utility model.

[0032] In the diagram, 1-motor housing; 11-boob; 12-reinforcing rib; 13-reinforcing rib one; 14-reinforcing rib two;

[0033] 2-Rotor;

[0034] 3-Stator; 3a-Stator unit; 31-Yoke; 311-Limiting protrusion; 312-Limiting groove; 313-Connecting part; 314-Connecting port; 315-Limiting port; 316-Clamping part; 32-Toothed part; 33-Arc-shaped part; 34-Stator groove;

[0035] 4-Line group;

[0036] 5-Insulating frame; 51-Insulating frame body; 52-Protrusion; 53-Groove; 54-Mounting surface one; 55-Mounting opening; 56-Limiting part; 57-Notch. Detailed Implementation

[0037] like Figures 1 to 11 As shown, the present invention is an energy-saving motor, including a motor housing 1, a rotor 2, a stator 3, a wire assembly 4, and an insulating frame 5. The rotor 2 and the stator 3 are disposed in the inner cavity of the motor housing 1.

[0038] The motor housing 1 includes a body and end covers mounted at both ends of the body. To increase the internal cavity space, the end covers are designed as follows: Figure 11 As shown, the end cap protrudes outward to form a boss 11. The boss 11 is provided with reinforcing ribs 12, which intersect to form an end cap groove. This reduces the material used in the end cap while ensuring its strength. To increase the strength between the end cap and the boss 11, a first reinforcing rib 13 is provided between the inner side of the end cap and the inner side of the boss 11, and a second reinforcing rib 14 is provided on the inner side of the boss 11.

[0039] like Figures 8 to 10 As shown, the stator 3 of this invention is composed of 12 stator units 3a spliced ​​together. Each stator unit 3a includes an integrally formed yoke 31, a toothed portion 32, and an arc-shaped portion 33. The toothed portion 32 is located between the yoke 31 and the arc-shaped portion 33. After the 12 stator units 3a are spliced ​​together, stator slots 34 are formed between the yoke 31, the toothed portion 32, and the toothed portion 32, resulting in 12 stator slots 34 in the stator 3. The stator slots 34 are designed as trapezoidal slots, which increases the slot area and solves the problem of excessive slot fill factor. The extra space also allows for good heat dissipation of the windings. The radius R5 of the outer side of the yoke 31 is 83-84 mm, the radius R6 of the inner side of the yoke 31 is 75 mm, and the radius R7 of the inner side of the arc-shaped portion 33 is 55 mm. At this point, the maximum width L2 of the stator slot 34 is 22-23 mm, and the minimum width L3 of the stator slot 34 is 13-14 mm.

[0040] like Figure 10As shown, a limiting protrusion 311 is provided on the side of the yoke 31, and a connecting portion 313 is provided between the yoke 31 and the limiting protrusion 311. The outer surface of the limiting protrusion 311 is an arc surface, and the radius R8 of the limiting protrusion 311 is 1.47 mm. A limiting opening 315 is formed between the yoke 31, the limiting protrusion 311, and the connecting portion 313. A limiting groove 312 is provided on the other side of the yoke 31. The inner surface of the limiting groove 312 is an arc surface, and the radius R9 of the limiting groove 312 is 1.50 mm. A clamping portion 316 is provided between the yoke 31 and the limiting groove 312, and a connecting port 314 is provided between the clamping portions 316. The clamping portion 316 and the limiting opening 315 are matched, and the connecting portion 313 and the connecting opening 314 are matched. When two adjacent stator units 3a are joined, the limiting protrusion 311 is embedded from top to bottom into the limiting groove 312, improving the stator assembly accuracy and stability. The clamping part 316 and the limiting opening 315 form a tight fit, preventing the stator units from separating due to electromagnetic force or vibration during motor operation. The individual joining design can reduce the slot width of the stator slot 34 (the distance between two adjacent arc-shaped parts 33). In this utility model, the slot width L1 is less than 1mm, specifically 0.9mm.

[0041] For the separately assembled stator 3, this utility model designs a corresponding insulating frame 5, such as... Figure 6 and Figure 7 As shown, it specifically includes an insulating frame body 51, which is used for winding the wire group 4. The insulating frame body 51 extends to form a protrusion 52, and the protrusion 52 and the insulating frame body 51 form a groove 53, in which the wire group 4 is embedded. An arc-shaped part 33 is installed at the inner protrusion 52, and a yoke 31 is installed at the outer protrusion 52. The outer protrusion 52 is provided with a limiting part 56, which is L-shaped and has a notch 57 to facilitate the installation of the insulating frame 5 on the stator unit 3a. The yoke 31 is limited between the two limiting parts 56, improving the insulation effect of the insulating frame 5.

[0042] The inner protrusion 52 has a mounting surface 54. The angle between the mounting surface 54 and the outer surface of the insulating frame body 51 is greater than 90°, increasing the space of the groove 53. The wire group 4 is wound between the mounting surface 54 and the outer surface of the insulating frame body 51, making it convenient to quickly wind the wire group 4 onto the assembly. The inner protrusion 52 has a mounting opening 55, and the arc-shaped part 33 is embedded in the mounting opening 55.

[0043] The stator 3 of this invention adopts a separate splicing method, dividing the original circular lamination into several equal parts, and each part is individually stacked to form a stator unit 3a. After placing the insulating frame 5, the wire group 4 is directly wound onto the splice. In this way, the wire group 4 is tight and not loose, and no additional binding and fixing is required. Moreover, the design of the separate splicing method can reduce the width of the stator slot 34. The size of the slot will affect the following aspects:

[0044] (1) Magnetic field distribution: The size of the stator slot affects the distribution of the stator wire group 4, thus affecting the magnetic field distribution of the motor. A larger slot may lead to uneven magnetic field distribution, increasing the non-uniformity of the magnetic field, thereby reducing the efficiency and performance of the motor.

[0045] (2) Magnetic field saturation: The size of the stator slot also affects the magnetic field saturation phenomenon. A larger slot may lead to aggravated magnetic field saturation, reducing the efficiency and performance of the motor. Appropriately reducing the slot size can reduce magnetic field saturation to a certain extent and improve the output power and efficiency of the motor.

[0046] (3) Efficiency and torque: There is a certain relationship between the size of the stator slot and the efficiency and torque of the motor. A larger slot may reduce the efficiency and torque density of the motor.

[0047] (4) Cogging torque: Cogging torque is generated by the interaction between the permanent magnet rotor and the stator core when the wire group 4 is not energized. Cogging torque will cause torque pulsation of the permanent magnet motor, which will lead to speed fluctuation, causing the motor to vibrate and generate noise, which will seriously affect the positioning accuracy and servo performance of the motor. Reducing the width of the stator slot can significantly reduce the cogging torque.

[0048] The individual splicing method allows wire group 4 to be directly wound onto the assembly block by machine, making wire group 4 more precise and less loose, and reducing the height of the wire coil. This reduces the cost of wire group 4 while also improving its quality. The quality of the motor wire group has a significant impact on motor performance; poor quality wire group can affect motor efficiency, power, and stability. Poor quality wire group can reduce motor efficiency, leading to power loss or even malfunction. Furthermore, poor quality motor windings can affect motor stability, reduce reliability, and increase the likelihood of failure.

[0049] Compared to a single, round lamination, modular laminations reduce material waste, increase utilization, and significantly lower the cost of laminations. The modular design also makes the installation of the insulation frame 5 easier and faster, and the winding process simpler and more convenient, reducing traditional winding steps and improving efficiency.

[0050] This invention involves installing the stator 3 inside the motor housing 1 and then sealing the stator entirely with epoxy resin, providing dust and water protection. The waterproof rating reaches IP66, preventing malfunctions caused by excessive internal dust and avoiding short circuits and burnouts due to water ingress. Furthermore, the sealing process integrates the stator 3 and the motor housing 1, allowing for faster heat transfer from the stator windings to the housing. This rapid heat dissipation improves the motor's operating temperature and efficiency, leading to less energy waste and further energy conservation and emission reduction.

[0051] The existing motor has an input current of 6.887A, an input voltage of 363.8V, an input power of 4122W, a speed of 1456r / min, a torque of 25.12 N·m, and an output power of 3829W. At this time, the EFF% (efficiency) is 92.9%.

[0052] The input current of this utility model is 6.704A, the input voltage is 371.3V, the input power is 3879W, the speed is 1454 r / min, the torque is 25.13 N·m, and its output power is 3826. At this time, the EFF% (efficiency) is 98.6%.

[0053] The comparison shows that the input current of this invention is reduced, and under the same working conditions and time, the power consumption is reduced and the heat generated by the motor is reduced; the efficiency (EFF%) of the measured motor performance is improved, the energy consumption is reduced, and it has a more energy-saving effect.

[0054] The above are merely specific embodiments of this utility model, but the technical features of this utility model are not limited thereto. Any simple changes, equivalent substitutions, or modifications made based on this utility model to solve essentially the same technical problems and achieve essentially the same technical effects are all covered within the protection scope of this utility model.

Claims

1. An energy-saving motor, comprising a motor housing, a rotor, a stator, a winding assembly, and an insulating frame, wherein the rotor and the stator are disposed in the inner cavity of the motor housing, the insulating frame is mounted on the stator, and the winding assembly is wound on the insulating frame; characterized in that The stator has 12 stator slots, and the slot opening width is less than 1 mm.

2. The energy saving electric machine according to claim 1, characterized in that: The stator includes stator units, which are formed by splicing 12 stator units together. Each stator unit includes a yoke, a toothed portion, and an arc-shaped portion. The toothed portion is located between the yoke and the arc-shaped portion, and the stator slot is formed between the yoke, the toothed portion, and the toothed portion.

3. The energy saving electric machine according to claim 2, characterized in that: The side of the yoke is provided with a limiting protrusion, and the other side of the yoke is provided with a limiting groove. When two adjacent stator units are spliced ​​together, the limiting protrusion is embedded in the limiting groove.

4. The energy saving electric machine according to claim 3, characterized in that: A connecting portion is provided between the yoke and the limiting protrusion, a limiting opening is formed between the yoke, the limiting protrusion and the connecting portion, a locking portion is provided between the yoke and the limiting groove, a connecting opening is provided between the locking portions, the locking portion and the limiting opening are matched, and the connecting portion and the connecting opening are matched. When two adjacent stator units are spliced ​​together, the limiting protrusion is installed into the limiting groove from top to bottom.

5. The energy saving electric machine according to claim 4, characterized in that: Both the outer surface of the second connecting surface and the inner surface of the limiting groove are arc surfaces.

6. The energy saving electric motor as claimed in claim 2, wherein: The stator slot is a trapezoidal slot.

7. The energy saving electric motor as claimed in claim 2, wherein: The insulating skeleton includes an insulating skeleton body for winding the wire group. The insulating skeleton body extends to form a protrusion. An arc-shaped portion is installed at the protrusion located on the inner side, and a yoke portion is installed at the protrusion located on the outer side. The protrusion and the insulating skeleton body form a groove, and the wire group is embedded in the groove.

8. The energy saving electric machine according to claim 7, characterized in that: The protrusion on the inner side is provided with a mounting surface, and the angle between the mounting surface and the outer side of the insulating frame body is greater than 90°. The wire group is wound between the mounting surface and the outer side of the insulating frame body.

9. The energy efficient electric machine of claim 7, wherein: The protrusion on the inner side has a mounting opening, and the arc-shaped part is embedded in the mounting opening.

10. The energy efficient electric machine of claim 7, wherein: The outer protrusion is provided with a limiting part, and the yoke is limited between the two limiting parts.

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