Modular assembled stator and electric machine

Abstract

The application relates to the field of micro motors, in particular to a modular assembled stator and motor. The modular assembled stator comprises a ring-shaped yoke part and a plurality of independent stator pole units. Each stator pole unit comprises a pole shoe part and a pole body part. The pole shoe part is in a T-shaped structure and is used for defining an air gap between the stator and a rotor. The pole body part extends radially outward from the pole shoe part and is used for connecting with the ring-shaped yoke part and constructing a magnetic circuit. A winding is pre-wound on the pole shoe part of each stator pole unit, thereby forming a stator pole sub-module with winding. The application realizes externalization and automation of the winding process by decomposing the stator into sub-modules which can be independently wound, and provides a feasible solution for manufacturing of micro and slender motors.

Description

Technical Field

[0001] This application relates to the field of micro motors, and in particular to a modular assembly stator and motor. Background Technology

[0002] In the field of modern micro-motor technology, especially in the manufacturing of micro-motors with ultra-thin, long shaft structures (such as motors for certain medical catheters and precision instrument drives), the stator winding process remains a core and challenging aspect. Currently, the industry-standard manufacturing method treats the stator core as a single unit, then uses automated winding equipment to directly wind enameled copper wire into the slots of the core. This traditional process has become a relatively mature solution for conventional micro-motors with compact structures and short axial lengths, meeting the basic requirements for mass production.

[0003] However, when the axial dimension of the motor is significantly larger than its radial dimension, exhibiting a structure with a very high elongation-to-diameter ratio, the limitations of the aforementioned traditional processes become glaringly apparent. The fundamental reason is that the winding machine head (including the wire nozzle, tensioner, and other components) needs to be aligned with the teeth of the iron core at extremely close range and perform precise reciprocating wire-laying motion. For slender iron cores with a large depth-to-diameter ratio, the internal tooth space becomes exceptionally narrow, making it impossible for a standard winding machine head to effectively reach or approach the target winding area. Even with specially designed extended needle nozzles, the excessively long cantilever and insufficient rigidity can cause severe vibrations during high-speed winding, seriously damaging the neatness of the wire layup and even leading to wire breakage. Furthermore, the slender iron core itself has low mechanical rigidity, making it prone to bending or deformation due to the tension of the enameled wire and the clamping force during winding. This minute deformation further deteriorates the consistency of the winding space, ultimately causing a series of quality problems such as inaccurate turn count, insulation damage, and even short circuits between turns, resulting in low product yield and high production costs.

[0004] Therefore, the existing direct winding method has essentially become the main technical bottleneck restricting the research and development and mass production of ultra-slender micro motors. Utility Model Content

[0005] To address the issues of limited space, low yield, and high manufacturing difficulty in existing micro-motor stator winding processes, this application provides a modular assembly stator and motor that achieves standardization and efficiency in the winding process through structural innovation and process optimization.

[0006] The modular assembled stator of this application includes:

[0007] A ring-shaped yoke;

[0008] Multiple independent stator pole units, each stator pole unit includes a pole shoe portion and a pole body portion. The pole shoe portion has a T-shaped structure and is used to define the air gap between the pole and the rotor. The pole body portion extends radially outward from the pole shoe portion and is used to connect with the annular yoke portion and form a magnetic circuit.

[0009] Each of the stator pole units has a pre-wound winding on its pole shoe portion, forming a stator pole module with windings.

[0010] The multiple stator pole modules are assembled along the circumference of the annular yoke, so that the outer end face of each pole body fits against the inner circumferential wall of the yoke, and are fixed by bonding, welding or mechanical snap-fitting to form a complete stator core.

[0011] Furthermore, the stator also includes an insulating frame disposed between each pole shoe and the winding, the insulating frame being a split or integral structure for achieving electrical isolation.

[0012] This application also provides an electric motor, including a modularly assembled stator as described above, a rotor inserted into the modularly assembled stator, and an electric motor housing that houses the stator.

[0013] The technical advantages of this application are mainly reflected in the following aspects:

[0014] Optimized winding process: By independently winding each stator pole unit in an open space, the winding process is not limited by the overall structure of the stator, and standard automated winding equipment can be used, which significantly improves winding accuracy and slot fill factor.

[0015] Product quality improvement: It avoids the problem of enameled wire damage caused by direct winding in narrow and deep holes, effectively reduces the risk of inter-turn short circuits, and improves product consistency and reliability;

[0016] Improved production efficiency: Modular design supports parallel production and assembly, significantly shortening the production cycle and facilitating large-scale manufacturing;

[0017] Wide range of applications: Especially suitable for miniaturized and slender motors with a large disparity between axial length and radial dimension.

[0018] This application decomposes the stator into independently wound sub-modules, realizing the externalization and automation of the winding process, and providing a practical solution for the manufacturing of micro slender motors.

[0019] The beneficial effects listed above are not exhaustive of all advantages. Other potential beneficial effects and detailed technical implementation methods will be further disclosed in the embodiments or other descriptive sections of this application. Attached Figure Description

[0020] A better understanding of various aspects of this disclosure will be achieved by reading the following detailed description in conjunction with the accompanying drawings. The positions, dimensions, and extents of the structures shown in the drawings, etc., do not always represent actual positions, dimensions, and extents. In the drawings:

[0021] Figure 1 This is a schematic diagram of the structure of one embodiment disclosed in this application.

[0022] Figure 2 This is a schematic diagram of the structure of one embodiment disclosed in this application from another perspective.

[0023] Figure 3 This is a schematic diagram of the stator pole unit in one embodiment of the present application.

[0024] Figure 4 This is a schematic diagram of the structure of an electric motor disclosed in this application, in which the motor housing has been removed. Detailed Implementation

[0025] The present disclosure will now be described with reference to the accompanying drawings, which illustrate several embodiments of the present disclosure. However, it should be understood that the present disclosure can be presented in many different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make the disclosure more complete and to fully illustrate the scope of protection of the present disclosure to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide further additional embodiments.

[0026] It should be understood that the same reference numerals denote the same elements in all the accompanying drawings. For clarity, the dimensions of certain features may be modified in the drawings.

[0027] It should be understood that the terminology used in this specification is for describing specific embodiments only and is not intended to limit this disclosure. All terms used in this specification (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. For the sake of brevity and / or clarity, techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail; however, where appropriate, such techniques, methods, and apparatus should be considered part of this specification.

[0028] Unless otherwise specified, the singular forms “a,” “the,” and “the” used in this specification include the plural forms. The terms “comprising,” “including,” and “containing” used in this specification indicate the presence of the claimed feature but do not exclude the presence of one or more other features. The term “and / or” used in this specification includes any and all combinations of one or more of the relevant listed items.

[0029] Example

[0030] See attached document Figures 1 to 3 The modular assembled stator 100 of this embodiment includes an annular yoke 1 and a plurality of stator pole units 2 evenly distributed along its circumference. Each stator pole unit 2 is composed of a pole body 201 and a pole shoe 202. The pole shoe 202 has a T-shaped structure and extends radially inward to define a uniform air gap with the rotor. The pole body 201 extends radially outward from the pole shoe 202 and is fixedly connected to the inner peripheral wall of the annular yoke 4 by bonding, welding or mechanical snap-fitting. Thus, the synergistic effect of magnetic circuit construction and electrical isolation is achieved through independent winding of each unit and subsequent assembly, while reducing production complexity and improving the overall structural strength of the stator.

[0031] Furthermore, the pole body 201 adopts a T-shaped cross-section design. The outer end of the pole body is fixed to the inner circumferential wall of the annular yoke by bonding, laser welding or snap-fit ​​mechanical connection. During operation, an alternating magnetic field is generated by the windings pre-wound on the pole body, ultimately achieving the effect of efficient assembly of the stator core and uniform distribution of the magnetic field.

[0032] Based on this, the T-shaped head of the pole shoe 202 protrudes radially inward, and the edge of the head adopts a rounded transition design. The design principle is to use the gradually expanding shape to compensate for the edge magnetic field distortion and reduce eddy current loss, thereby ensuring the uniformity of air gap magnetic flux density distribution. The pole shoe 201 and the pole body 202 are integrally formed by stamping or connected by separate bolts.

[0033] Subsequently, the insulating skeleton 3 is disposed between the pole body 201 and the winding. It adopts a split or integral structure and wraps the surface of the pole body 201. The thickness of the insulating skeleton 3 is preferably 0.2-0.5 mm and it is made of polyimide or PBT material. It is a common insulation treatment method in the prior art. Its design purpose is to achieve reliable electrical isolation between the winding and the iron core. During operation, it avoids inter-turn short circuits by preventing the enameled wire from directly contacting the pole body, and ultimately improves the insulation durability and operational safety of the product.

[0034] Understandably, the winding process of the winding is carried out in an open space in the independent state of the stator pole unit 2, and is completed using existing automated winding equipment. The winding parameters are preferably wire diameter of 0.1-0.5 mm and number of turns controlled at 50-300 turns. The winding tension is maintained at 5-20 cN to ensure that the winding consistency reaches more than 98%. The design principle is to avoid the limitation of narrow space by external winding, thereby ensuring winding accuracy and production efficiency. The winding is fixed to the pole body 201 by the insulating frame 3, which is used to generate an alternating magnetic field to drive the rotor to rotate after being energized.

[0035] Preferably, the inner peripheral wall of the annular yoke 4 is in close contact with the outer end face of each pole body 201, and the annular yoke 4 is a known component of the stator magnetic circuit in the prior art.

[0036] In an exemplary scenario, the assembly process first arranges each stator pole unit 2 with windings sequentially along the circumference of the annular yoke 4. The number of pole units is preferably 6-24, and the distribution uniformity error is less than 0.1 mm. Then, the outer end of the pole body 201 is made to fit against the inner wall of the annular yoke 4 by mechanical pressure of 0.5-5 MPa or positioning fixtures. Finally, it is fixed. The design principle is to shorten the production cycle by using modular parallel assembly, thereby improving manufacturing efficiency and reducing labor costs. This assembly action makes each unit form a uniform circumferential distribution on the annular yoke 4. Its function is to ensure that the coaxiality of the inner circle of the stator and the air gap consistency error do not exceed 0.05 mm, ultimately achieving low-noise operation of the motor and a power density of more than 1.5 W / cm³.

[0037] Understandably, the material of the stator pole unit 2 can be selected from amorphous alloys or nanocrystalline soft magnetic materials to further reduce high-frequency losses. Its permeability ranges from 500 to 5000 H / m, and the joint between the pole body 201 and the pole shoe 202 can be chamfered or coated to enhance mechanical strength and corrosion resistance. This is a conventional application of material optimization in the prior art.

[0038] Based on the modular assembly stator described in any of the above embodiments, this application also provides a motor. Please refer to... Figure 4 As shown, the motor mainly includes: a modular assembled stator 100 as detailed above, a rotor 200 rotatably inserted into the stator, and a motor housing (not shown in the figure) for accommodating and fixing the stator 100 and the rotor 200.

[0039] Preferably, the rotor 200 can be an inner rotor or an outer rotor structure, which includes a shaft, a rotor core, and permanent magnets or windings. These are common knowledge to those skilled in the art and will not be described in detail here. The motor housing 300 is preferably made of aluminum alloy or engineering plastic, and its interior is provided with an installation structure that matches the annular yoke for precise positioning and fixing of the modular assembled stator 100.

[0040] Understandably, due to the adoption of the aforementioned modular assembly stator, the motor described in this embodiment also inherits all of its technical advantages.

[0041] It should be noted that the description of the motor structure in this paragraph is intended to illustrate the complete device including the stator of the present invention. The specific design of the rotor and the housing is not the inventive point of this application. Those skilled in the art can make selections and adaptations based on existing technology according to actual application needs, which does not depart from the core protection scope of this application.

[0042] It is understood that in this specific embodiment, the component structure, material selection, manufacturing process or connection method not described in detail, such as the operation of well-known winding equipment, the application of standard insulating materials or conventional mechanical fixing methods, are all within the scope of well-known technology or prior art that those skilled in the art can reproduce or replace based on common sense without creative effort. Moreover, this description is only used to illustrate the principles and preferred solutions of this application and does not constitute any limitation on the scope of protection of the claims.

Claims

1. A modular, assembled stator, characterized in that, include: A ring-shaped yoke; Multiple independent stator pole units, each stator pole unit includes a pole shoe portion and a pole body portion. The pole shoe portion has a T-shaped structure and is used to define the air gap between the pole and the rotor. The pole body portion extends radially outward from the pole shoe portion and is used to connect with the annular yoke portion and form a magnetic circuit. Each of the stator pole units has a pre-wound winding on its pole shoe portion, forming a stator pole module with windings. The multiple stator pole modules are assembled along the circumference of the annular yoke, so that the outer end face of each pole body fits against the inner circumferential wall of the yoke, and are fixed by bonding, welding or mechanical snap-fitting to form a complete stator core.

2. The modular assembled stator according to claim 1, characterized in that, It also includes an insulating frame disposed between each pole shoe and the winding, the insulating frame being a split or integral structure for achieving electrical isolation.

3. An electric motor, characterized in that, include: The modular assembled stator as described in claim 1 or 2, the rotor inserted into the modular assembled stator, and the motor housing accommodating the stator.

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