Stator frame and stator assembly

Abstract

The present disclosure relates to a stator framework and a stator assembly. The stator framework comprises a plurality of framework segments, and each framework segment comprises a yoke portion comprising a wire passing end with an end face; a wire guard plate connected to the yoke portion and arranged radially outward of the end face, and a wire passing groove for the enameled wire is arranged radially inward of the wire guard plate; wherein the adjacent wire guard plates on adjacent framework segments have an enameled wire blocking structure therebetween to prevent the enameled wire in the wire passing groove from protruding radially outward beyond the wire guard plate. By arranging the enameled wire blocking structure between the adjacent wire guard plates of adjacent framework segments, the enameled wire passing radially inward of the adjacent wire guard plates can be sufficiently blocked, so that whether in the stator framework coiling process or in the subsequent injection molding process, it can be ensured that the enameled wire will not be squeezed out of the wire guard plate, so that when the injection molding is completed, the enameled wire is protected in the wire passing groove, avoiding problems such as poor motor pressure resistance and reducing motor production yield.

Description

Technical Field

[0001] This disclosure provides a stator frame and a stator assembly. 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 enameled wires of the windings passing through the yoke of the stator frame.

[0003] A common stator frame structure includes interconnected frame blocks. The stator frame is typically a strip and is stator-rounded during stator assembly. Each frame block has a partition formed on the wire-passing end face of the yoke (which is generally perpendicular to the rotor axis) and a wire guard plate formed on the outer circumferential surface of the yoke, with a wire-passing groove formed between the wire guard plate and the partition plate for the enameled wire to pass through. An opening exists between the wire guard plates of adjacent frame blocks. When using this stator frame for automated winding, the enameled wire needs to be transferred from the wire-passing groove of one frame block to the wire-passing groove of another frame block. Passing through the wire-passing groove, the enameled wire passes through the opening between adjacent wire guard plates. After winding, the straight stator frame needs to be rounded and then injection molded. However, under injection pressure, the injection molding material can expel the enameled wire from the opening between the wire guard plates into the stator frame, potentially causing wire breakage or the enameled wire hitting the stator outer wall, resulting in poor pressure resistance.

[0004] Therefore, the art expects a solution to 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 disclosure discloses a stator frame, comprising: a plurality of frame blocks, each frame block comprising: a yoke, including a wire-passing end having an end face; a wire guard plate, connected to the yoke and disposed radially outside the end face, wherein a wire-passing groove for enameled wire is disposed radially inside the wire guard plate; wherein an enameled wire blocking structure is provided between adjacent wire guard plates on adjacent frame blocks to prevent the enameled wire located in the wire-passing groove from radially protruding outward beyond the wire guard plate.

[0007] Preferably, when the stator frame is in a straight bar state, there is a gap between adjacent wire guard plates, the wire guard plate has a height H1 relative to the end face, and the ratio of the height H1 of the wire guard plate to the width W of the gap is H1:W≥5.63, so that the gap constitutes the enameled wire blocking structure.

[0008] Preferably, the width W of the gap is ≤ 1.2 mm.

[0009] Preferably, adjacent wire guards are connected to each other by a connecting part, which constitutes the enameled wire blocking structure.

[0010] Preferably, the radial thickness D1 of the wire guard plate is greater than the radial thickness D2 of the connecting portion.

[0011] Preferably, the ratio of the radial thickness D1 of the wire guard plate to the radial thickness D2 of the connecting part is D1:D2 = 1.8~3.2.

[0012] Preferably, the radial thickness D2 of the connecting part is 0.4mm to 0.7mm.

[0013] Preferably, the connecting part is integrally injection molded with the adjacent wire guard plate.

[0014] Preferably, the height of the connecting portion relative to the end face is the same as the height H1 of the wire guard plate.

[0015] Preferably, the wire guard plate and the corresponding skeleton are integrally injection molded in separate blocks.

[0016] Preferably, the stator frame further includes: a partition plate disposed on the end face and radially inside the end face, thereby forming a wire passage groove between the partition plate and the wire guard plate, and the end face forming the bottom of the wire passage groove; wherein, the ratio H1 of the height H1 of the wire guard plate relative to the end face to the height H2 of the partition plate relative to the end face is H1:H2=0.45~0.93.

[0017] Preferably, the cable guard includes a T-shaped slot located in its middle, the T-shaped slot having a middle slot portion and a transverse slot portion located above the middle slot portion and extending across the middle slot portion.

[0018] Preferably, the lower edge of the transverse slot portion has a height H3 relative to the end face, and the ratio of the height H1 to the height H3 is H1:H3=1.30~1.35.

[0019] Preferably, the ratio of height H1 to height H3 is H1:H3 = 1.32.

[0020] Preferably, the plurality of skeleton blocks are connected together.

[0021] This disclosure also provides a stator assembly including the stator frame as described above.

[0022] By setting an enameled wire blocking structure between adjacent wire guard plates of adjacent frame segments, the enameled wire passing radially inward from the adjacent wire guard plates can be adequately blocked. This ensures that the enameled wire will not be squeezed out of the wire guard plates during both the stator frame rolling process and the subsequent injection molding process. As a result, when the injection molding is completed, the enameled wire is protected in the wire groove, avoiding problems such as poor motor withstand voltage and reduced motor production yield. Attached Figure Description

[0023] Figure 1 This is a partial perspective view of a stator frame in a straight bar state according to a preferred embodiment of the present disclosure;

[0024] Figure 2 According to Figure 1 A partial top view of the stator frame in a straight bar state according to a preferred embodiment, with the winding enameled wire already wound on the frame;

[0025] Figure 3 According to Figure 1 A partial top view of the pre-rolled stator frame of a preferred embodiment;

[0026] Figure 4 According to Figure 1 A schematic diagram of the gap between the wire guard plates and the related structure of the wire guard plates in a preferred embodiment;

[0027] Figure 5 This is a schematic diagram of the T-slot on the stator frame according to the present disclosure;

[0028] Figure 6 This is a partial perspective view of a stator frame in a straight bar state according to another preferred embodiment of the present disclosure;

[0029] Figure 7 According to Figure 6 A partial top view of the stator frame in a straight bar state according to another preferred embodiment;

[0030] Figure 8 According to Figure 6 A partial top view of a stator frame that has been rolled into a circle, according to another preferred embodiment. Detailed Implementation

[0031] 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.

[0032] 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.

[0033] 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.

[0034] To address the aforementioned problems, this disclosure proposes a stator frame that optimizes the structure at the yoke of the stator frame blocks, ensuring that even if the enameled wire in the wire groove passes between adjacent frame blocks, the enameled wire will not be squeezed out between adjacent frame blocks by the injection molding pressure during the subsequent injection molding stage.

[0035] Preferred embodiments according to this disclosure will now be described with reference to the accompanying drawings. It should be understood that the radial, axial, and circumferential directions of each frame segment are aligned with the radial, axial, and circumferential directions of the motor rotor. Although the drawings show a stator frame in a generally straight bar configuration, the radial direction R and axial direction X of individual frame segments are... Figure 2 As shown, the X-direction is perpendicular to the drawing surface, while the circumferential direction (unmarked) coincides with the circumferential direction of the arc-shaped surfaces of the skeleton blocks. Furthermore... Figure 3 and 8 The image shows the state after the stator has been rolled into a circle.

[0036] A stator frame according to this disclosure includes: a plurality of frame blocks, and each frame block includes: a yoke 1, including a wire-passing end having an end face 10; a wire guard plate 3, connected to the yoke 1 and disposed radially outward of the end face 10, with a wire-passing groove for enameled wire 4 provided radially inward of the wire guard plate 3. An enameled wire blocking structure is provided between adjacent wire guard plates 3 on adjacent frame blocks to prevent the enameled wire 4 located in the wire-passing groove from protruding radially outward beyond the wire guard plate 3. It should be understood that in the preferred embodiment shown in the drawings, the plurality of frame blocks can be connected to each other in any suitable manner, but according to other preferred embodiments not shown, the plurality of frame blocks may not be connected to each other.

[0037] By setting an enameled wire blocking structure between adjacent wire guard plates of adjacent frame segments, the enameled wire passing radially inward from the adjacent wire guard plates can be adequately blocked. This ensures that the enameled wire will not be squeezed out of the wire guard plates during both the stator frame rolling process and the subsequent injection molding process. As a result, when the injection molding is completed, the enameled wire is protected in the wire groove, avoiding problems such as poor motor withstand voltage and reduced motor production yield.

[0038] The stator frame according to different embodiments of the present disclosure will now be described with reference to different examples.

[0039] Figure 1-4 A first embodiment according to the present disclosure is shown. In this embodiment, when the stator frame is in a straight state (i.e., before the rolling process), there is a gap G between adjacent guard plates 3 (e.g., ...). Figure 1-3 As shown), the wire guard plate 3 has a height H1 relative to the end face 10 (as shown). Figure 4 As shown), and the ratio of the height H1 of the wire guard plate 3 to the width W of the gap G, H1:W ≥ 5.63, thus the gap G with this structure constitutes the enameled wire blocking structure as described above.

[0040] According to this embodiment, the wire guard plates between adjacent stator frames are not connected, but rather have a certain gap. Furthermore, considering the need for wire blocking, this disclosure further defines the specific structure of this gap, ensuring it is proportional to the height of the wire guard plate itself. This proportional relationship can be applied to set the wire blocking structure for stator frames of various sizes. Testing has verified that although there is a slight difference in the gap width before and after the stator frame is rolled, and the width after rolling is more important (since the stator is circular during injection molding), as long as the gap width meets the aforementioned proportional relationship when the stator frame is in a straight state, poor pressure resistance will be significantly reduced or even eliminated after injection molding following stator frame rolling, thereby improving production efficiency.

[0041] More preferably, for some specific stator frame structures, the width W of the gap G is ≤ 1.2 mm.

[0042] Figure 6-8 Another embodiment according to this disclosure is shown. In this embodiment, adjacent wire guard plates 3 are connected to each other by a connecting portion 30, which constitutes an enameled wire blocking structure. Compared to using a gap as an enameled wire blocking structure, connecting adjacent wire guard plates provides additional obstruction and retention for the enameled wire passing through the area between adjacent wire guard plates, and also provides a reinforcing structure for the wire guard plates. Thus, when the stator is wound, the enameled wire will adhere tightly to the connecting portion, which will support the enameled wire and prevent it from being squeezed out during injection molding. Furthermore, during subsequent injection molding, it can be ensured that the enameled wire will not be squeezed out between adjacent wire guard plates and will not cause poor pressure resistance due to contact with the stator outer wall.

[0043] More preferably, especially as Figure 7 As shown, the radial thickness D1 of the wire guard plate 3 can be greater than the radial thickness D2 of the connecting portion 30. Therefore, the relatively thin connecting portion between the wire guard plates will not cause excessive obstruction during the stator rolling process, reducing the difficulty of the stator frame rolling process while ensuring the reinforcement effect on the wire guard plates.

[0044] More preferably, the ratio of the radial thickness D1 of the guard plate 3 to the radial thickness D2 of the connecting portion 30, D1:D2, is 1.8 to 3.2. For some specific stator frame structures, the radial thickness D2 of the connecting portion 30 can be 0.4 mm to 0.7 mm, more preferably 0.65 mm. Testing has verified that a connecting portion with this thickness ratio can achieve a balance between bending stress and blocking effect, providing sufficient reinforcement, and also minimizing stress concentration at the connecting portion, further improving the lifespan of the stator frame.

[0045] Preferably, the connecting portion 30 is integrally injection molded with the adjacent wire guard plate 3. Furthermore, in this stator frame, each wire guard plate 3 can be integrally injection molded with its corresponding frame block. That is, the wire guard plate, frame block, and connecting portion are all formed by integral injection molding. It should be understood that the wire guard plate can also be formed separately and fixed to the frame block by bonding, welding, or other methods; and the connecting portion can also be connected between adjacent wire guard plates by bonding or welding.

[0046] More preferably, the height of the connecting portion 30 relative to the end face 10 is the same as the height H1 of the wire guard plate 3. This arrangement simplifies the structure of the connecting portion and the wire guard plate, thereby simplifying mold design and manufacturing. Moreover, this arrangement ensures that the connecting portion and the wire guard plate are flush, eliminating sharp edges and corners and preventing scratches on the enameled wire.

[0047] Additionally, in all the embodiments described above, the stator frame may also include a partition 2. The partition 2 is disposed on the end face 10 and radially inward of the end face 10, thereby forming the wire guide groove between the partition 2 and the wire guard plate 3, and the end face 10 forms the bottom of the wire guide groove. Figure 2-3 The top view of 7-8 shows the stator skeleton with the windings already wound, with multiple enameled wires 4 passing through each wire slot.

[0048] More preferably, the ratio H1 of the height H1 of the wire guard plate 3 relative to the end face 10 and the height H2 of the partition plate 2 relative to the end face 10 is H1:H2 = 0.45~0.93. More preferably, H1:H2 = 0.63. According to this disclosure, if the ratio of H1:H2 is less than 0.45, the height of the wire guard plate 3 is too low, and the problem of enameled wire coming off will still occur; if the ratio of H1:H2 is greater than 0.93, the height of the wire guard plate 3 is too high, which will affect the installation of the automatic winding fixture.

[0049] By setting this height relationship between the wire guard plate and the partition plate, the yoke section of the stator frame can be optimized, thus allowing the wire guide groove between the wire guard plate and the partition plate to provide more comprehensive and stable retention for the enameled wire passing through it. Even during the subsequent stator winding and injection molding processes, it can be ensured that the enameled wire is properly held in place and will not be accidentally squeezed out of the stator frame, thereby avoiding problems such as poor motor withstand voltage and reduced motor production yield, while also not adversely affecting the automatic winding operation.

[0050] On the other hand, in order to perform subsequent automatic winding operations, an automatic winding fixture (not shown) will be installed on the yoke of the stator frame segment. Therefore, according to this disclosure and as follows Figure 5As shown, the wire guard plate 3 may include a T-shaped slot 31 located in its central part, the T-shaped slot 31 having a central slot portion 311 and a transverse slot portion 312 located above and extending across the central slot portion 311. Thus, the slot 31 can be used to engage an automatic winding fixture for subsequent automatic winding operations on the stator frame. It should be understood that from Figure 5 The partition 2 and enameled wire 4 have been removed from the left side of the skeleton to show the entire slot 31 more clearly.

[0051] Since the automatic winding fixture will be removed from the stator frame after winding, slot 31 will expose a portion of the wire passage. To prevent the enameled wire 4 from being accidentally extruded from slot 31 outside the stator frame during subsequent stator winding and injection molding, preferably, as follows: Figure 4 As shown, the lower edge 313 of the transverse slot portion 312 has a height H3 relative to the end face 10, and the ratio of height H1 to height H3, H1:H3, is 1.30 to 1.35. More preferably, the ratio of height H1 to height H3, H1:H3, is 1.32. This setting specifies the height of the lower edge 313 of the transverse slot portion 312, thereby ensuring that the enameled wire will not be extruded from the stator frame during the winding and injection molding processes without interfering with the engagement with the automatic winding fixture.

[0052] This disclosure also provides a stator assembly including the stator frame as described above.

[0053] 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 skeleton blocks, and each skeleton block includes: The yoke (1) includes a wire-passing end with an end face (10); A wire guard plate (3) is connected to the yoke (1) and is disposed on the radially outer side of the end face (10). A wire groove for the enameled wire (4) is disposed on the radially inner side of the wire guard plate (3). Among them, there is an enameled wire blocking structure between adjacent wire guard plates (3) on adjacent skeleton blocks to prevent the enameled wire (4) located in the wire groove from protruding radially outward beyond the wire guard plate (3).

2. The stator frame as described in claim 1, characterized in that, When the stator frame is in a straight state, there is a gap (G) between adjacent wire guards (3), the wire guards (3) have a height H1 relative to the end face (10), and the ratio of the height H1 of the wire guards (3) to the width W of the gap (G) is H1:W≥5.63, so that the gap (G) constitutes the enameled wire blocking structure.

3. The stator frame as described in claim 2, characterized in that, The width W of the gap (G) is ≤1.2mm.

4. The stator frame as described in claim 1, characterized in that, Adjacent wire guards (3) are connected to each other by a connecting part (30), which constitutes the enameled wire blocking structure.

5. The stator frame as described in claim 4, characterized in that, The radial thickness D1 of the wire guard plate (3) is greater than the radial thickness D2 of the connecting part (30).

6. The stator frame as described in claim 5, characterized in that, The ratio of the radial thickness D1 of the wire guard plate (3) to the radial thickness D2 of the connecting part (30) is D1:D2=1.8~3.

2.

7. The stator frame as described in claim 5, characterized in that, The radial thickness D2 of the connecting part (30) is 0.4mm~0.7mm.

8. The stator frame as described in claim 4, characterized in that, The connecting part (30) is integrally injection molded with the adjacent wire guard plate (3).

9. The stator frame as described in claim 4, characterized in that, The height of the connecting part (30) relative to the end face (10) is the same as the height H1 of the wire guard plate (3).

10. The stator frame as described in claim 1, characterized in that, The wire protection plate (3) and the corresponding skeleton are integrally injection molded in separate blocks.

11. The stator frame as described in any one of claims 1-10, characterized in that, Also includes: A partition (2) is disposed on the end face (10) and on the radially inner side of the end face (10), thereby forming a wire passage groove between the partition (2) and the wire guard plate (3), and the end face (10) forms the bottom of the wire passage groove; The ratio of the height H1 of the wire guard plate (3) relative to the end face (10) to the height H2 of the partition plate (2) relative to the end face (10) is H1:H2 = 0.45~0.

93.

12. The stator frame as described in claim 11, characterized in that, The cable guard (3) includes a T-shaped slot (31) located in its middle, the T-shaped slot (31) having a middle slot portion (311) and a transverse slot portion (312) located above the middle slot portion (311) and extending across the middle slot portion (311).

13. The stator frame as described in claim 12, characterized in that, The lower edge (313) of the transverse slot portion (312) has a height H3 relative to the end face (10), and the ratio of the height H1 to the height H3 is H1:H3=1.30~1.

35.

14. The stator frame as described in claim 13, characterized in that, The ratio of height H1 to height H3 is H1:H3 = 1.

32.

15. The stator frame as described in any one of claims 1-10, characterized in that, The multiple skeleton blocks are connected to each other.

16. A stator assembly, characterized in that, Includes the stator frame as described in any one of claims 1-15.

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