Stator tooling to improve lead wire looseness

Abstract

This invention provides a stator fixture for improving the looseness of lead wires, comprising: a fixing part, which is cylindrical in shape, with multiple grooves for accommodating coils on one end face of the fixing part; the bottom and wall of the grooves are connected by an inclined surface or an arc surface, which is used to fit the coils; teeth are formed between adjacent grooves, which are used to insert between adjacent coils to separate them; and a positioning post, on which the fixing part is sleeved. This invention can act as a support for fixing the stator winding, flowing with the stator winding in various processes after winding, and can prevent the coil from protruding from the inner support of the stator winding, eliminating the risk of the coil protruding from the inner support and hitting the rotor, ensuring that the movable lead wires of the coil do not loosen or spring back, and preventing out-of-phase contact.

Description

Technical Field

[0001] This utility model relates to the field of permanent magnet synchronous motor manufacturing, and in particular to a stator tooling for improving lead wire loosening. Background Technology

[0002] A permanent magnet synchronous motor (PMSM) is a synchronous motor that uses permanent magnets to generate a magnetic field. The rotor speed is synchronized with the frequency of the current in the stator windings. A PMSM consists of components such as a stator, rotor, and end covers.

[0003] Currently, the BTD24V series motors generally adopt a delta-parallel winding structure in stator manufacturing. However, in actual industrial production, it has been found that this structure has significant technical defects under existing process conditions: after the stator winding assembly is completed, such as... Figure 1 As shown, the reverse coil often exhibits abnormal axial height, causing it to exceed the preset safety range of the inner support. This coil protrusion defect poses a risk of motion interference between the coil and rotor components after motor assembly, potentially leading to mechanical collisions, especially under high-speed operation. Furthermore, the coil's movable leads are prone to loosening, posing a risk of out-of-phase contact.

[0004] Production data shows that the defect rate of BTD24V stator assemblies produced using traditional processes is close to 100%, forcing manufacturers to manually inspect and repair the stators, such as through visual inspection and manual repair processes. This not only significantly increases labor costs and material waste, but also poses a risk of quality problems and potential electrical safety hazards due to tool contact during disassembly and repair, as these issues can easily damage the insulation layer of the winding enameled wire. Utility Model Content

[0005] The purpose of this utility model is to provide a stator fixture that improves the looseness of the lead wires. It can act as a support for fixing the stator windings and can move with the stator windings through various processes after winding. It can also prevent the coil from protruding from the inner support of the stator windings, eliminating the risk of the coil protruding from the inner support and hitting the rotor, ensuring that the movable lead wires of the coil do not loosen or spring back, and preventing out-of-phase contact.

[0006] To achieve the above objectives, this utility model provides a stator fixture for improving lead wire loosening, comprising:

[0007] The fixing part is cylindrical, and the end face of the fixing part facing the stator winding is provided with a plurality of grooves for accommodating coils. The bottom of the groove and the groove wall are connected by a slope or arc surface. A tooth is formed between two adjacent grooves. The tooth is used to insert between two adjacent coils to separate the two adjacent coils.

[0008] The positioning post, and the fixing part is sleeved on the positioning post.

[0009] Optionally, the positioning post is coaxial with the fixing part.

[0010] Optionally, the positioning post and the fixing part are made of plastic material.

[0011] Optionally, the groove extends through the sidewall of the fixing part.

[0012] Optionally, a plurality of the grooves are evenly distributed circumferentially on the end face of the fixing part facing the stator assembly, and the grooves correspond one-to-one with the coils.

[0013] Optionally, the fixing part and the positioning post are integrally formed.

[0014] Optionally, when the bottom of the groove and the groove wall are connected by an inclined plane, the inclined plane forms an angle of 30° to 60° with the bottom of the groove.

[0015] Optionally, the tooling includes a base, and the fixing part and the positioning post are both disposed on the base.

[0016] Optionally, the outer diameter of the base is larger than the outer diameter of the fixing part, and the central axis of the fixing part and the central axis of the positioning column are both perpendicular to the base.

[0017] Optionally, when the bottom of the groove and the groove wall are connected by an inclined surface or an arc surface, the groove is a U-shaped groove.

[0018] In summary, this utility model provides a stator fixture for improving lead wire looseness, comprising a fixing part and a positioning post. The fixing part is cylindrical, and the end face of the fixing part facing the stator winding is provided with multiple grooves for accommodating coils. The bottom of the groove and the groove wall are connected by an inclined surface or an arc surface, which is used to fit against the coil. A tooth is formed between two adjacent grooves, which is used to insert between two adjacent coils to separate the two adjacent coils. The fixing part is sleeved on the positioning post.

[0019] As configured above, the stator fixture of this invention has multiple grooves for accommodating coils. The bottom and wall of the grooves are connected by inclined or curved surfaces, which fit against the coils to ensure that the movable leads of the coils on the stator do not loosen or spring back, preventing the coils from protruding from the inner support of the stator windings. Furthermore, the teeth separate adjacent coils to prevent out-of-phase contact. In summary, the stator fixture of this invention is particularly suitable for permanent magnet synchronous motors. During production, it can act as a support for fixing the stator windings, moving with the stator windings through various processes after winding, such as lead winding, insulation treatment, and cover plate processes. It also prevents the coils from protruding from the inner support of the stator windings, eliminating the risk of the coils protruding from the inner support and hitting the rotor. This ensures that the movable leads of the coils do not loosen or spring back, preventing out-of-phase contact, effectively improving product yield, significantly reducing labor costs and material losses from rework, as well as the quality risks and potential electrical safety hazards associated with rework, and enhancing the efficiency and reliability of mass production. Attached Figure Description

[0020] Those skilled in the art will understand that the accompanying drawings are provided to better understand the present invention and do not constitute any limitation on the scope of the present invention. Wherein:

[0021] Figure 1 This is a schematic diagram of a stator winding according to an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of a stator fixture for improving loose lead wires according to an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram of a stator tooling and stator winding for improving loose lead wires according to an embodiment of the present invention;

[0024] Figure 4 This is a schematic diagram of a stator tooling for improving loose lead wires and a stator winding with a hidden lower inner support, according to an embodiment of the present invention.

[0025] The reference numerals in the attached figures are as follows:

[0026] 1-Fixing part; 11-Gear part; 2-Groove; 21-Groove bottom; 22-Groove wall; 23-Inclined surface; 3-Stator winding; 31-Coil; 32-Inner support; 4-Positioning post; 5-Base. Detailed Implementation

[0027] In this document, unless otherwise stated, the terms “upper,” “lower,” “left,” “right,” “inner,” “outer,” “front,” “back,” “top,” “bottom,” etc., are used to indicate orientation or positional relationship based on the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a characteristic orientation and operation, and therefore should not be construed as a limitation of the present invention.

[0028] The specific embodiments of this utility model will now be described in more detail with reference to the accompanying drawings. The advantages and features of this utility model will become clearer from the following description. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of this utility model.

[0029] The preferred embodiments of this utility model are given below with reference to the accompanying drawings and described in detail.

[0030] Figure 2 This is a schematic diagram of a stator fixture for improving loose lead wires according to an embodiment of the present invention. Figure 3 This is a schematic diagram of a stator fixture and stator winding for improving loose lead wires according to an embodiment of the present invention. Figure 4 This is a schematic diagram of a stator fixture for improving loose lead wires and a stator winding with a concealed lower inner support, according to an embodiment of this utility model. Please refer to... Figure 2 , Figure 3 and Figure 4 This utility model provides a stator tooling for improving lead wire loosening, which includes a base 5, a fixing part 1 and a positioning post 4, both of which are disposed on the base 5.

[0031] The fixing part 1 is cylindrical, and a plurality of grooves 2 for accommodating coils 31 are provided on one axial end face of the fixing part 1 (i.e., the axial end face of the cylinder). Specifically, the axial end face of the fixing part 1 facing the stator winding 3 has a plurality of grooves 2 for accommodating coils 31. Further, the plurality of grooves 2 are evenly distributed circumferentially on one axial end face of the fixing part 1, with each groove 2 corresponding to a coil 31. The grooves 2 penetrate the sidewall of the fixing part 1; preferably, the penetration direction of the grooves 2 points towards the central axis of the fixing part 1. During production, the coil 31 is placed in the groove 2, which also serves a shaping function, preventing the coil 31 from protruding from the inner support 32 of the stator winding. The bottom 21 of the groove 2 is connected to the groove wall 22 by a slope 23 or an arc surface. The slope 23 or arc surface is used to fit against the coil 31 to apply pressure to the coil 31, preventing the movable lead wire from loosening or springing back. It is understood that when the bottom 21 of the groove 2 is connected to the groove wall 22 by a slope or arc surface, the groove is a U-shaped groove. For example, when the bottom 21 of the groove 2 is connected to the wall 22 of the groove 2 by an inclined surface 23, the inclined surface 23 and the bottom 21 can form an angle of 30° to 60° (i.e., Figure 2The angle α between the inclined plane 23 and the slot bottom 21 can be, for example, 45°, but is not limited to 30° to 60°. The specific angle should be adapted according to the actual situation of the stator winding. (Refer to...) Figure 3 and Figure 4 , Figure 4 The stator windings conceal the lower inner support 32.

[0032] A tooth 11 is formed between two adjacent grooves 2. The tooth 11 is used to insert between two adjacent coils 31 to isolate them and prevent them from making out-of-phase contact. Simultaneously, the tooth 11 also serves as a guide during the placement of the stator windings 3. Preferably, the radial extension direction of the tooth 11 points towards the central axis of the fixing part 1, and the axial extension direction of the tooth 11 is parallel to the central axis of the fixing part 1. The specific thickness h of the tooth 11 is adapted to the gap within the stator slots.

[0033] The fixing part 1 is sleeved on the positioning post 4. Preferably, the positioning post 4 and the fixing part 1 are coaxial. It is understood that the positioning post 4 serves to position and guide the stator winding 3. Both the positioning post 4 and the fixing part 1 are made of plastic. It is understood that plastic is soft and can prevent damage to the stator winding 3. For example, the positioning post 4 and the fixing part 1 can be made of nylon, acetal, or other materials. In other embodiments, the positioning post 4 and the fixing part 1 can be made of other soft materials besides plastic. The end of the positioning post 4 facing away from the base 5 is rounded to prevent damage to the stator winding 3.

[0034] The fixing part 1 and the positioning post 4 can be an integrally formed structure. For example, the fixing part 1 and the positioning post 4 can be integrally formed by four-axis machining or by injection molding.

[0035] Preferably, the outer diameter of the base 5 is larger than the outer diameter of the fixing part 1, so as to improve the stability of the entire stator fixture, and the central axis of the fixing part 1 and the central axis of the positioning column 4 are both perpendicular to the base 5.

[0036] In summary, this utility model provides a stator fixture for improving lead wire loosening, comprising a base 5, a fixing part 1, and a positioning post 4. Both the fixing part 1 and the positioning post 4 are disposed on the base 5. The fixing part 1 is cylindrical, and the end face of the fixing part 1 facing the stator winding 3 is provided with multiple grooves 2 for accommodating coils 31. The bottom 21 of the groove 2 is connected to the groove wall 22 by a slope or arc surface, which is used to fit against the coil 31. A tooth 11 is formed between two adjacent grooves 2, which is used to insert between two adjacent coils 31 to separate the two adjacent coils 31. The fixing part 1 is sleeved on the positioning post 4.

[0037] As configured above, the stator fixture of this utility model is provided with multiple grooves 2 for accommodating coils 31, and the bottom 21 of the groove 2 is connected to the groove wall 22 by a slope 23 or an arc surface. The slope 23 or arc surface is used to fit with the coil 31 to ensure that the movable lead wire of the coil 31 on the stator does not loosen or spring back, so that the coil 31 does not protrude from the inner support 32 of the stator winding, and the teeth 11 separate two adjacent coils 31 to prevent out-of-phase contact. In summary, the stator fixture of this utility model is particularly suitable for permanent magnet synchronous motors (such as the BTD24V model, which is a delta parallel model). During the production process, it can act as a support to fix the stator winding, moving with the stator winding through various processes after winding, such as lead wire winding, insulation treatment, cover plate, etc. It can also prevent the coil 31 from protruding from the inner support 32 of the stator winding, eliminating the risk of the coil protruding from the inner support 32 and hitting the rotor, ensuring that the movable lead wire of the coil does not loosen or spring back, preventing out-of-phase contact, effectively improving product yield, greatly reducing the labor cost and material loss of rework, as well as the quality risks and potential electrical safety hazards caused by rework.

[0038] It should be noted that references to "an embodiment," "an embodiment," "a specific embodiment," "some embodiments," etc., in the specification only indicate that the described embodiment may include a specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Additionally, when a specific feature, structure, or characteristic is described in conjunction with an embodiment, whether explicitly described or not, implementing such a feature, structure, or characteristic in conjunction with other embodiments is within the knowledge of those skilled in the art.

[0039] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple, and relevant parts can be referred to the method section.

[0040] It should also be noted that although the present invention has been disclosed above with reference to preferred embodiments, these embodiments are not intended to limit the present invention. For any person skilled in the art, many possible variations and modifications can be made to the present invention without departing from the scope of the present invention, or equivalent embodiments can be modified based on the disclosed technical content. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention shall still fall within the protection scope of the present invention.

[0041] It should also be understood that, unless otherwise specified or indicated, the terms “first,” “second,” “third,” etc., in the specification are used only to distinguish the various components, elements, and steps in the specification, and not to indicate the logical or sequential relationships between the various components, elements, and steps.

[0042] Furthermore, it should be recognized that the terminology described herein is used only to describe particular embodiments and not to limit the scope of the invention. It must be noted that the singular forms “a” and “an” used herein and in the appended claims include plural bases unless the context clearly indicates otherwise. For example, a reference to “a step” or “an apparatus” means a reference to one or more steps or apparatuses, and may include secondary steps and secondary apparatuses. All conjunctions used should be understood in the broadest sense. Also, the word “or” should be understood to have the definition of logical “or” rather than logical “exclusive OR”, unless the context clearly indicates otherwise. Furthermore, implementation of the methods and / or devices in embodiments of the invention may include performing selected tasks manually, automatically, or in combination.

Claims

1. A stator tooling to improve lead wire looseness, characterized by, include: The fixing part is cylindrical, and the end face of the fixing part facing the stator winding is provided with a plurality of grooves for accommodating coils. The bottom of the groove and the groove wall are connected by a slope or arc surface. A tooth is formed between two adjacent grooves. The tooth is used to insert between two adjacent coils to separate the two adjacent coils. The positioning post, and the fixing part is sleeved on the positioning post.

2. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, The positioning post is coaxial with the fixing part.

3. The stator fixture for improving lead wire loosening as described in claim 1, characterized in that, The positioning post and the fixing part are made of plastic.

4. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, The groove extends through the side wall of the fixing part.

5. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, Multiple grooves are evenly distributed circumferentially on the end face of the fixing part facing the stator assembly, and each groove corresponds to a coil.

6. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, The fixing part and the positioning post are integrally formed.

7. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, When the bottom of the groove and the groove wall are connected by an inclined plane, the inclined plane forms an angle of 30° to 60° with the bottom of the groove.

8. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, The tooling includes a base, and the fixing part and the positioning post are both disposed on the base.

9. The stator tooling to improve lead wire looseness as defined in Claim 8 wherein, The outer diameter of the base is larger than the outer diameter of the fixing part, and the central axis of the fixing part and the central axis of the positioning column are both perpendicular to the base.

10. The stator tooling to improve lead wire looseness as defined in Claim 1 wherein, When the bottom and wall of the groove are connected by an inclined surface or an arc surface, the groove is a U-shaped groove.

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