Stator frame and stator assembly comprising the same

Abstract

The utility model provides a kind of stator framework and the stator assembly comprising the stator framework.Stator framework includes: multiple framework segments are connected together, and each framework segment includes: yoke portion, it has terminal end, the terminal end has end face;Terminal socket, form on end face;Stator lead exit, it is configured so that stator lead can be led out from the stator lead exit to above end face;Line blocking column, form on end face, and line blocking column and terminal socket form wire passing space for stator lead to pass between it.By the utility model, stator lead from winding can be constrained in wire passing space between line blocking column and terminal socket, thereby avoid the problem that stator lead cannot be close to terminal socket and appear loose, even suspended, further improve the problem of poor pressure resistance, stator lead breakage even broken line in subsequent injection molding link, greatly improve the product yield of stator assembly.

Description

Technical Field

[0001] This utility model relates to a stator frame and a stator assembly including the stator frame. Background Technology

[0002] An electric motor typically consists of a stator and a rotor. The stator typically includes a stator frame with a yoke and teeth, with windings wound on the stator teeth, and the leads (enameled wires) of the windings inserted into terminal sockets on the terminal ends of the yoke via plugs.

[0003] Currently, some stator frame designs facilitate automated winding. Ideally, after winding, the enameled wire leading from the winding should run snugly against the outer wall of the terminal socket. However, in actual automated winding processes, it has been found that... Figure 5 As shown, the enameled wire 8 may become loose and suspended when passing through the outer wall of the terminal socket 9, and the enameled wire will not be tightly attached to the outer wall of the terminal socket. During the injection molding process after winding, the loose or suspended enameled wire will be squeezed to the edge of the stator outer diameter by the molding compound under the injection pressure. At this time, the enameled wire will come into contact with the housing, causing poor motor withstand voltage. In severe cases, the enamel coating of the enameled wire will be damaged or even broken under the injection pressure, thereby increasing the product defect rate.

[0004] Therefore, the art seeks a solution that can address this problem. Utility Model Content

[0005] In response to the problems and needs mentioned above, this disclosure proposes a novel technical solution that solves the aforementioned problems and brings about other technical effects by adopting the following technical features.

[0006] This utility model proposes a stator frame, comprising: a plurality of frame segments connected together, and each frame segment comprising: a yoke having a terminal end having an end face; a terminal socket formed on the end face; a stator lead outlet configured to allow stator leads to be led out from the stator lead outlet to above the end face; and a wire stop post formed on the end face, wherein a wire passage space is formed between the wire stop post and the terminal socket for the stator leads to pass through.

[0007] Preferably, the wire-blocking post includes a base and a wire-blocking portion above the base, the base being connected to the terminal socket via a connecting portion.

[0008] Preferably, the wire-blocking post has a height; the upper surface of the connecting portion is formed as a plane parallel to the end face; the wire-blocking portion has a wire-blocking portion projection outline in the plane, and the portion of the terminal socket above the connecting portion has a terminal socket projection outline in the plane, the shortest distance is between the wire-blocking portion projection outline and the terminal socket projection outline, and the ratio of the shortest distance to the height of the wire-blocking post is 1:3-1:7.

[0009] Preferably, the stator frame further includes a fixing buckle disposed on the end face, the fixing buckle being located at the outer corner of the end face on the side of the stator lead outlet.

[0010] Preferably, the wire-blocking post has a height, the fixing buckle and the end face have a first intersection line, the wire-blocking post and the end face have a second intersection line, the first intersection line and the second intersection line have a shortest distance, and the ratio of the shortest distance to the height of the wire-blocking post is 1:1.2-1:3.

[0011] Preferably, the wire-blocking post has a height, and the wire-blocking portion has a height; and the ratio of the height of the wire-blocking portion to the height of the wire-blocking post is 1:1.2-1:3.

[0012] Preferably, the line-blocking portion is formed as a comb-tooth structure.

[0013] Preferably, the wire-blocking post has a truncated pyramidal shape or a truncated conical shape that tapers gradually from bottom to top; or the wire-blocking post has a prism shape or a cylindrical shape.

[0014] Preferably, the wire-blocking post has a height, the top of the wire-blocking portion has a maximum width, and the ratio of the maximum width to the height of the wire-blocking post is 1:1.5-1:3.5.

[0015] Preferably, the portion of the wire stop post facing the wire passage space has a chamfer or rounding, or is formed as a concave surface; and / or the portion of the terminal socket facing the wire passage space has a chamfer or rounding.

[0016] Preferably, the terminal socket has an outer wall on the stator lead outlet side, and the wire stop post is located radially outward relative to the outer wall.

[0017] This utility model also proposes a stator assembly, including the stator frame as described above.

[0018] Preferably, the stator assembly has an outer diameter, and the ratio of the outer diameter to the height of the wire stop post is 10:1-19:1.

[0019] By using the stator frame, the stator leads drawn from the windings can be constrained in the wire passage space between the wire stop post and the terminal socket, thus avoiding the problem of the stator leads not being able to fit tightly against the terminal socket and becoming loose or even suspended. This improves the problems of poor pressure resistance, stator lead damage or even breakage in the subsequent injection molding process, and greatly improves the product yield of the stator assembly. Attached Figure Description

[0020] Figure 1 This is a perspective view of a segment of the stator frame according to a preferred embodiment of the present invention;

[0021] Figure 2 This is a top view of one segment of the stator frame with the winding already wound according to a preferred embodiment of the present invention;

[0022] Figure 3 This is a partially enlarged view of one segment of the stator frame according to a preferred embodiment of the present invention;

[0023] Figure 4 This is a top view of one segment of the stator frame according to a preferred embodiment of the present invention;

[0024] Figure 5 This is a top view of a pre-wound stator skeleton in the prior art. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. The same reference numerals in the drawings represent the same components. It should be noted that the described embodiments are only some, not all, of the embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the described embodiments of this disclosure without creative effort are within the scope of protection of this disclosure.

[0026] Compared to the embodiments shown in the accompanying drawings, feasible embodiments within the scope of this disclosure may have fewer components, other components not shown in the drawings, different components, components arranged differently, or components with different connections, etc. Furthermore, two or more components in the drawings may be implemented in a single component, or a single component shown in the drawings may be implemented as multiple separate components.

[0027] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by those skilled in the art to which this disclosure pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Where the number of components is not specified, the number of components may be one or more; similarly, terms such as “a,” “the,” and “described” do not necessarily indicate a quantity limitation. Terms such as “comprising” or “including” mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. Terms such as “install,” “set,” “connect,” or “link” are not limited to physical or mechanical installation, setting, or connection, but may include electrical installation, setting, or connection, whether direct or indirect. Terms such as “upper,” “lower,” “left,” and “right” are used only to indicate the relative positional relationship of the equipment during use or as shown in the accompanying drawings; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0028] In view of the problems such as loosening and suspension of the winding as mentioned above, this utility model proposes a stator frame.

[0029] See Figure 1-4 In the preferred embodiment shown, the stator frame includes multiple frame segments connected together. These frame segments can be hinged together, for example, and can form an in-line frame. During winding (e.g., winding enameled wire), the entire frame is in an in-line state and is automatically wound after being fitted with suitable winding fixtures. After winding, the frame is rolled into a cylindrical shape to form a complete stator assembly.

[0030] Figure 1 The three skeleton segments of the stator skeleton are schematically shown. Each skeleton segment typically includes a yoke 6 and a tooth 7, and the yoke 6 also includes a terminal end 1 and a wire-passing end (not shown) located at both ends along the axial direction X. The terminal end 1 has an end face 10.

[0031] Further, see Figure 1-4 Each skeleton segment also includes: a terminal socket 2 formed on the end face 10; and a stator lead outlet 3 configured to allow stator leads (enameled wire) 31 to be led out from the stator lead outlet 3 to the top of the end face 10 (e.g., Figure 2-3 (As shown); a wire-blocking post 4 is formed on the end face 10, and a wire-passing space is formed between the wire-blocking post 4 and the terminal socket 2 for the stator lead 31 to pass through. The wire-blocking post 4 can, for example, be integrally injection molded with the entire stator frame.

[0032] Through the stator frame, the stator leads 31 drawn from the windings can be constrained within the wire-passing space between the wire-blocking post 4 and the terminal socket 2, specifically as follows: Figure 2-3 As shown, this avoids the problem of stator leads not being able to fit tightly against terminal socket 2, resulting in loosening or even suspension. This improves the problems of poor pressure resistance, stator lead damage or even breakage in subsequent injection molding processes, and greatly improves the product yield of stator assemblies.

[0033] According to a preferred embodiment, such as Figure 3 As shown, the wire-blocking post 4 includes a base 40 and a wire-blocking portion 42 above the base 40, which are roughly as follows: Figure 3 The base 40 is connected to the terminal socket 2 via the connecting part 41. Thus, by connecting the base of the wire-blocking post 4 to the terminal socket 2, the strength of the wire-blocking post 4 is enhanced, avoiding the problems of insufficient strength and easy breakage at the base caused by a separate wire-blocking post 4. Furthermore, the connecting part 41 can support the stator lead 31 from below, preventing the stator lead 31 from being suspended in the air. Therefore, the wire-blocking post 4 can firmly hold the stator lead 31 in the wire-passing space.

[0034] Preferably, the wire-blocking post 4 can have any suitable overall shape. For example, the wire-blocking post 4 can have a truncated pyramid shape that tapers from bottom to top (e.g., Figure 1-4 (Approximately truncated square pyramid shape) or truncated cone shape. Alternatively, the guide post 4 can simply have a prism shape or a cylindrical shape.

[0035] In the preferred embodiment shown in the accompanying drawings, the wire-blocking portion 42 is integrally formed as a solid block with the entire wire-blocking post 4. However, according to a preferred embodiment not shown, the wire-blocking portion 42 can be formed as a comb-tooth structure, for example, including three to four comb teeth. This structure can give the wire-blocking portion 42 a certain degree of flexibility, avoiding excessive pressure on the stator lead 31. According to another preferred embodiment not shown, the entire wire-blocking post can be formed as a comb-tooth structure, for example, including multiple sub-wire-blocking posts, and a wire-passing space is formed between the multiple sub-wire-blocking posts and the terminal socket 2. Each sub-wire-blocking post can play the role of constraining the stator lead.

[0036] Preferably, the upper surface of the connecting portion 41 is formed as a plane parallel to the end face 10. Furthermore, since the wire-blocking post 4 can have various shapes, to ensure that the wire passage space has suitable dimensions under various conditions, this invention proposes that: the wire-blocking portion 42 has a wire-blocking portion projection outline in the plane parallel to the end face 10, and the portion of the terminal socket 2 above the connecting portion 41 has a terminal socket projection outline in the plane; the shortest distance L1 exists between the wire-blocking portion projection outline and the terminal socket projection outline (i.e., the shortest distance between any point on the wire-blocking portion projection outline and any point on the terminal socket projection outline in the plane); and the ratio of this shortest distance L1 to the height H of the wire-blocking post 4 is 1:3-1:7. Figure 3-4 As shown.

[0037] According to the inventor's tests and research, if the distance L1 is too large, the stator lead 31 cannot be tightly attached to the terminal socket 2, and there is still a risk that the stator lead 31 will be loose and suspended. If the distance L1 is too small, the stator lead 31 will not be able to smoothly enter the wire passage space during automatic winding, which may easily cause the wire to come off, or the stator lead 31 may be easily scratched when entering the wire passage space, causing damage or poor pressure resistance. Especially when L1 is smaller than the diameter of the stator lead 31, the stator lead 31 will not be able to enter the wire passage space at all, and the setting of the wire stop post 4 will be meaningless. Therefore, this utility model proposes the preferred ratio range between L1 and H as described above.

[0038] The stator frame of this invention is suitable for automatic winding operations. During automatic winding, an automatic winding fixture (not shown) is typically used to fix the stator frame to accommodate the automatic winding operation. Therefore, as... Figure 1 As shown, the stator frame according to a preferred embodiment of the present invention further includes a fixing buckle disposed on the end face 10, and typically two fixing buckles 5 and 5' are provided. One fixing buckle 5 is located at the outer corner of the end face 10 on the side of the stator lead outlet 3, and the other fixing buckle 5' is located at the outer corner of the end face 10 on the side away from the stator lead outlet 3, so as to be suitable for engagement with an automatic winding fixture.

[0039] More preferably, such as Figure 4 As shown, there is a first phase intersection line A between the fixing clip 5 and the end face 10 on the side of the stator lead outlet 3, and a second phase intersection line B between the wire blocking post 4 and the end face 10. Although as... Figure 4The first intersecting line A and the second intersecting line B shown are straight lines. However, it should be understood that since the fixing clip 5 and the line-blocking post 4 can have any suitable shape, the first intersecting line A and the second intersecting line B also have shapes that conform to the contours of the fixing clip 5 and the line-blocking post 4, respectively, such as broken lines or curved shapes. In this case, there is a shortest distance L2 between the first intersecting line A and the second intersecting line B (i.e., the shortest distance between any point on the first intersecting line A and any point on the second intersecting line B), and the ratio of the shortest distance L2 to the height H of the line-blocking post 4 is 1:1.2-1:3.

[0040] According to the inventor's tests and research, due to the limited space on end face 10, if L2 is too large, the wire-stopping post 4 will be too small, resulting in insufficient strength of the wire-stopping post 4, making it prone to breakage during automatic winding. On the other hand, the fixing buckle 5 is used to position and fix the entire stator, including the skeleton, on the automatic winding fixture. If L2 is too small, the wire-stopping post 4 will touch or interfere with the automatic winding fixture during positioning and fixing, causing inaccurate positioning or inability to fix the stator skeleton. Therefore, this utility model proposes a preferred ratio range between L2 and H of the wire-stopping post 4 as described above.

[0041] Preferably, such as Figure 4 As shown, the top 421 of the line-blocking portion 42 has a maximum width L3. As previously mentioned, the line-blocking portion 42, along with the line-blocking post 4, can have various shapes, such as a truncated pyramid shape, a truncated cone shape, a prism shape, or a cylinder shape, as previously described. Therefore, the maximum width L3 of the top 421 is the maximum distance between any two points on the outline of the top; for example, when the top 421 has a circular shape, the maximum width L3 is the diameter of the circle. Furthermore, the ratio of the maximum width L3 to the height H of the line-blocking post 4 is 1:1.5 to 1:3.5.

[0042] Based on the inventor's testing and research, similar to the situation with L2 as described above, if L3 is too large, the wire-stopping post 4 will interfere with the automatic winding fixture, thus affecting the positioning and fixation of the stator frame on the automatic winding fixture; if L3 is too small, the wire-stopping post 4 may be too thin and lack strength, making it prone to breakage during automatic winding. Therefore, this invention proposes a preferred ratio range between the maximum width L3 and the H of the wire-stopping post 4 as described above.

[0043] Preferably, such as Figure 2 As shown, the wire-blocking part 42 may have a height h (i.e., the distance from the top 421 of the wire-blocking part 42 to the plane of the connecting part 41). The ratio of the height h of the wire-blocking part 42 to the height H of the wire-blocking post 4 may be 1:1.2-1:3.

[0044] According to the inventors' tests and research, if h is too large, the wire-blocking part 42 will be too long, reducing the strength of the wire-blocking post 4. Furthermore, the stator lead 31 will not easily fall onto the connecting part 41 when passing the wire-blocking post 4, causing the connecting part 41 to fail to support the stator lead 31, leaving it prone to suspension. If h is too small, the wire-blocking post 4 cannot fully exert its restraining effect, and in the subsequent injection molding process, the stator lead 31 will still be easily squeezed out of the wire-blocking post 4 by the injection pressure, resulting in poor pressure resistance. Therefore, this invention proposes an optimal ratio range between the height h of the wire-blocking part 42 and the height H of the wire-blocking post 4, as described above.

[0045] Preferably, the portion of the wire-blocking post 4 facing the wire passage space can be chamfered or rounded, or formed as a concave surface. This structural design is particularly suitable for wire-blocking posts that are generally in the form of a prism or truncated pyramid. Especially when formed as a concave surface, it can better adapt to the bending shape of the stator lead 31 in the wire passage space, so as to hold the stator lead 31 more securely. It is also preferred that the portion of the terminal socket 2 facing the wire passage space is chamfered or rounded. With the above structure, the sharp edges of the wire-blocking post 4 or the terminal socket 2 can be prevented from causing wear and damage to the paint of the stator lead 31.

[0046] Preferably, such as Figure 2 and 4 As shown, the terminal socket 2 has an outer wall 20 on the side of the stator lead outlet 3, and the wire-blocking post 4 is located radially (R) outward relative to the outer wall 20. In the embodiment shown in the figure, when the terminal socket 2 has a generally rectangular outline on the end face 10, the wire-blocking post 4 is located opposite the corner of the rectangular outline of the terminal socket 2, which also makes the wire passage space located exactly at the part where the stator lead needs to turn, thereby providing better constraint and support for the stator lead.

[0047] This utility model also proposes a stator assembly, which includes the stator frame as described above. More preferably, as... Figure 2 As shown, the stator assembly has an outer diameter D, and the ratio of the outer diameter D to the height H of the wire-blocking post 4 is 10:1-19:1. Therefore, the wire-blocking posts on the stator frame can be set according to this ratio for stator assemblies with various outer diameters.

[0048] The exemplary embodiments of this disclosure have been described in detail above with reference to preferred embodiments. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the spirit of this disclosure, and various combinations can be made to the various technical features and structures proposed in this disclosure without exceeding the protection scope of this disclosure, which is determined by the appended claims.

Claims

1. A stator frame, characterized in that, include: Multiple skeletal segments connected together, and each skeletal segment includes: The yoke (6) has a terminal end (1) having an end face (10). Terminal socket (2) is formed on the end face (10); The stator lead outlet (3) is configured such that the stator lead (31) can be led out from the stator lead outlet (3) to the top of the end face (10); A wire stop post (4) is formed on the end face (10), and a wire passage space is formed between the wire stop post (4) and the terminal socket (2) for the stator lead (31) to pass through.

2. The stator frame as described in claim 1, characterized in that, The wire-blocking post (4) includes a base (40) and a wire-blocking portion (42) above the base (40), the base (40) being connected to the terminal socket (2) via a connecting portion (41).

3. The stator frame as described in claim 2, characterized in that, The wire-blocking post (4) has a height (H); The upper surface of the connecting part (41) is formed as a plane parallel to the end face (10); The wire-blocking part (42) has a wire-blocking part projection outline in the plane, and the portion of the terminal socket (2) above the connecting part (41) has a terminal socket projection outline in the plane. The shortest distance (L1) is between the wire-blocking part projection outline and the terminal socket projection outline, and the ratio of the shortest distance (L1) to the height (H) of the wire-blocking post (4) is 1:3-1:

7.

4. The stator frame as described in claim 1, characterized in that, It also includes a fixing buckle (5) disposed on the end face (10), the fixing buckle (5) being located at the outer corner of the end face (10) on the side of the stator lead outlet (3).

5. The stator frame as described in claim 4, characterized in that, The wire-blocking post (4) has a height (H). The fixing buckle (5) and the end face (10) have a first intersection line (A), the line blocking post (4) and the end face (10) have a second intersection line (B), the first intersection line (A) and the second intersection line (B) have a shortest distance (L2), and the ratio of the shortest distance (L2) to the height (H) of the line blocking post (4) is 1:1.2-1:

3.

6. The stator frame as described in claim 2, characterized in that, The wire-blocking post (4) has a height (H), and the wire-blocking part (42) has a height (h); and The ratio of the height (h) of the wire-blocking part (42) to the height (H) of the wire-blocking post (4) is 1:1.2-1:

3.

7. The stator frame as described in claim 2, characterized in that, The line-blocking part (42) is formed as a comb-tooth structure.

8. The stator frame as described in any one of claims 1-7, characterized in that, The wire-blocking post (4) has a truncated pyramidal shape or a truncated conical shape that tapers gradually from bottom to top; or The wire-blocking post (4) has a prism shape or a cylindrical shape.

9. The stator frame as described in any one of claims 2-3 and 6-7, characterized in that, The top (421) of the wire-blocking part (42) has a maximum width (L3), and the ratio of the maximum width (L3) to the height (H) of the wire-blocking post (4) is 1:1.5-1:3.

5.

10. The stator frame as described in any one of claims 1-7, characterized in that, The portion of the wire-blocking post (4) facing the wire-passing space has a chamfer or rounding, or is formed as a concave surface; and / or The portion of the terminal socket (2) facing the wire passage space has a chamfer or rounding.

11. The stator frame as described in any one of claims 1-7, characterized in that, The terminal socket (2) has an outer wall (20) on the side of the stator lead outlet (3), and the wire stop post (4) is located radially outward relative to the outer wall (20).

12. A stator assembly, characterized in that, Includes the stator frame as described in any one of claims 1-11.

13. The stator assembly as claimed in claim 12, characterized in that, The stator assembly has an outer diameter (D), and the ratio of the outer diameter (D) to the height (H) of the wire stop post (4) is 10:1-19:1.

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