A T-block stator structure

Abstract

The utility model discloses a kind of T-block stator structures, it is related to the field of stator, including busbar, stator winding, plastic skeleton and T-block iron core, the stator winding includes copper wire, bridge line, the busbar includes integrated plastic-coated plate, the outer wall of the top of integrated plastic-coated plate is equipped with U-shaped welding fixed position, the outer wall of integrated plastic-coated plate is equipped with lug, the bottom of integrated plastic-coated plate is equipped with inside bucking point.The utility model discloses a kind of T-block stator structures, adopt busbar structure, omit the stator insertion protective sleeve step to avoid sleeve insertion wrong cause motor cannot normally run, and save the time of wire carding from winding top, also avoid copper wire film damage caused in the process of manual wire carding, stator adopts the integrated plastic-coated forming of plastic skeleton and T-block iron core, under the condition of meeting insulation performance, also save the insulation step of T-block iron core insertion slot, improve work efficiency.

Description

Technical Field

[0001] This utility model relates to the field of stators, and in particular to a T-block stator structure. Background Technology

[0002] Traditional integrated motor stator production has long faced challenges such as low automation, heavy reliance on manual labor, low material utilization, and high costs. With the explosive growth of the new energy vehicle industry, the market has placed extreme demands on drive motors for high power density, ultra-high efficiency, and large-scale consistent production, which traditional processes can no longer meet.

[0003] Against this backdrop, modular motor technology emerged. Its core lies in dividing the stator core into multiple modules, allowing for pre-winding and subsequent assembly. This structural innovation brings revolutionary advantages: it greatly simplifies automated production processes, significantly reduces manufacturing costs and reliance on manual labor; simultaneously, the modular design optimizes the magnetic circuit, improves power and torque density, and reduces material waste from silicon steel sheets.

[0004] Therefore, it is necessary to propose a T-block stator structure to solve the above problems. Utility Model Content

[0005] The main objective of this invention is to provide a T-block stator structure that can effectively solve the problems in the prior art.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A T-block stator structure includes a busbar, stator windings, a plastic-coated frame, and a T-block core. The stator windings include copper wires and bridging wires. The busbar includes an integral plastic-coated plate. A U-shaped welding fixing position is installed on the outer wall of the top of the integral plastic-coated plate. A protrusion is installed on the outer wall of the integral plastic-coated plate. An inner fastening point is installed on the bottom of the integral plastic-coated plate. A copper plate is installed on the top of the integral plastic-coated plate. The outer wall of the plastic-coated skeleton is provided with a bridging groove, a winding and exiting groove, and a hollow groove. The T-shaped block core includes a toothed part and an outer side of the T-shaped block. A groove is provided on one side of the outer side of the T-shaped block, and a protrusion is installed on the other side of the outer side of the T-shaped block.

[0007] Preferably, the U-shaped welding fixing position is used to weld and fix the copper wire, there are three copper plates, the copper plates are used as three-phase lines to connect with the external controller, there are three protrusions, the protrusions cooperate with the inner fastening points to install the busbar at the plastic-coated frame.

[0008] Preferably, the stator winding is composed of copper wire, with one copper wire exiting from one side of each stator winding.

[0009] Preferably, the bridging trough is used to install the bridging wire, and the winding outlet trough is used to install the copper wire.

[0010] Preferably, the dimensions of the protrusions and grooves are matched, and the plurality of T-shaped iron core blocks are formed by the protrusions and grooves mutually enclosing each other.

[0011] Preferably, the outer side of the T-shaped block is an irregular circle.

[0012] Compared with the prior art, the present invention has the following beneficial effects: This T-block stator structure, as an assembly, consists of a busbar, stator windings, a plastic-coated frame, and a T-block core. Compared to the conventional integral stator structure, this new stator structure significantly improves slot utilization. While the conventional slot fill factor is approximately 60%-65%, this product achieves around 80%-85%, resulting in a substantial increase in efficiency and power density. The busbar structure eliminates the need for the conventional step of inserting protective sleeves into the stator, preventing incorrect sleeve insertion that could malfunction the motor. It also saves time spent on winding and coiling from above, avoiding damage to the copper wire insulation during manual coiling. The stator uses an integrated plastic-coated frame and T-block core, ensuring insulation performance while eliminating the need for inserting the T-block core into the slots for insulation, thus improving work efficiency. This product can be adapted to different power requirements simply by changing the axial length, thereby meeting the needs of various customers. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is an exploded view of this utility model; Figure 3 This is a schematic diagram of the structure of the busbar of this utility model; Figure 4 This is a bottom view of the busbar of this utility model; Figure 5 This is a schematic diagram of the stator winding structure of this utility model; Figure 6 This is a schematic diagram of the structure of the plastic-coated skeleton of this utility model; Figure 7 This is a schematic diagram of the structure of the T-shaped block iron core of this utility model.

[0014] In the diagram: 1. Busbar; 2. Stator winding; 3. Plastic-coated frame; 4. T-block core; 5. U-shaped welding fixing position; 6. Protrusion; 7. Copper plate; 8. Integrated plastic-coated plate; 9. Inner fastening point; 10. Copper wire; 11. Bridge wire; 12. Bridge wire groove; 13. Winding exit groove; 15. Hollow groove; 16. Raised groove; 17. Groove; 18. Tooth; 19. Outer side of T-block. Detailed Implementation

[0015] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments. Example

[0016] like Figures 1-7 As shown, a T-shaped block stator structure includes a busbar 1, a stator winding 2, a plastic-coated frame 3, and a T-shaped block core 4. The stator winding 2 includes copper wire 10 and bridging wire 11. The busbar 1 includes an integral plastic-coated plate 8. A U-shaped welding fixing position 5 is installed on the outer wall of the top of the integral plastic-coated plate 8. A protrusion 6 is installed on the outer wall of the integral plastic-coated plate 8. An inner fastening point 9 is installed on the bottom of the integral plastic-coated plate 8. A copper plate 7 is installed on the top of the integral plastic-coated plate 8. The outer wall of the plastic-coated frame 3 has a through-hole. Bridge trough 12, winding outlet trough 13, hollow trough 15, T-shaped block iron core 4 including toothed part 18 and T-shaped block outer side 19, one side of the T-shaped block outer side 19 has a groove 17, the other side of the T-shaped block outer side 19 has a protrusion 16, U-shaped welding fixing position 5 is used to weld and fix copper wire 10, there are three copper plates 7, the copper plates 7 are used as three-phase wires to connect with external controller, there are three protrusions 6, the protrusions 6 cooperate with the inner fastening point 9 to install busbar 1 on plastic-coated frame 3 At this location, the stator winding 2 is composed of copper wire 10. A single copper wire 10 exits from one side of each stator winding 2, with a shorter length compared to conventional stator windings. This wire is used for welding to the busbar 1, eliminating the need for manual winding and coiling of the wire from above the stator winding 2, thus avoiding serious insulation problems caused by damage to the copper wire sheath during manual winding. Due to slot-pole matching issues, the winding distribution is such that adjacent coils form a group, connected by a bridging wire 11. There are six sets of wires 11, with two sets diagonally opposite each other forming one phase. The stator electrical angle is 180°. The copper wire 10 is made of AI-AI material and is resistant to 220℃, which can enable the stator to operate stably in a thermal shock environment. The bridge wire groove 12 is used to install the bridge wire 11, and the winding exit groove 13 is used to install the copper wire 10. The dimensions of the protrusion groove 16 and the groove 17 are matched. Multiple T-shaped iron cores 4 are formed by the protrusion groove 16 and the groove 17 encircling each other. The outer side of the T-shaped block 19 is an irregular circle. Example

[0017] like Figures 1-7 As shown, a T-block stator structure: Busbar: The busbar is integrally molded using a copper plate and plastic coating process. The internal copper plates are arranged in unequal circles according to the wiring method. A U-shaped welding fixing position 5 is provided on the outer side, which is welded to the single lead copper wire 10 to prevent poor contact of the copper wire 10 and thus avoid three-phase imbalance. Three copper plates 7 extend from the top as three-phase lines connecting to the controller. An integral plastic-coated plate 8 is used below the copper plates to increase overall insulation. Three protrusions 6 are provided on the outermost side, which cooperate with the inner fastening points 9 to fix it to the plastic-coated frame 3. Stator winding 2: Stator winding 2 is the energy conversion channel of the motor. Its core function is to generate magnetism through energization. Its design, materials, and processes directly determine almost all key performance indicators of the motor, such as torque, speed, efficiency, power density, temperature rise, and reliability. It is one of the most crucial components in motor technology. The lead-out method of this stator winding 2 differs from the conventional stator lead-out method. A copper wire 10 leads out from the left or right side of a single stator winding 2. The lead-out length is shorter than that of a conventional stator winding. This is mainly for welding to the busbar 1 above, eliminating the need for winding and combing from above in a conventional stator winding, and avoiding serious insulation problems caused by damage to the copper wire sheath during manual winding. Due to slot-pole matching issues, the winding distribution is such that adjacent coils form a group, connected by a bridge wire 11, for a total of six groups. Two diagonally opposite groups form one phase, with a stator electrical angle of 180°. The copper wire 10 is made of AI-AI material, with a temperature resistance of 220℃, enabling the stator to operate stably and continuously in thermal shock environments. Plastic-coated frame 3: Used to support the stator copper coil and place the stator winding 2. In this application, the plastic-coated frame 3 is integrated with the T-shaped block core 4. Compared with conventional frames, it reduces the step of inserting insulating paper into the slot, improving production efficiency. In order to further improve the slot fill factor and consider the frame's resistance to winding strength, the thinnest part of the plastic-coated frame 3 is only 0.45mm thick. The plastic-coated frame 3 is provided with a bridging groove 12 and a winding exit groove 13 to ensure that the copper wire 10 is embedded in the winding exit groove 13, increasing the overall creepage distance and avoiding discharge to the T-shaped block core 4 and the plastic-coated frame 3. The center of the plastic-coated frame 3 is a hollow groove 15, which is the position of the T-shaped block core 4 during plastic coating. It is integrated with the frame by molding. T-shaped core 4: As part of the motor's magnetic circuit. To reduce eddy current and hysteresis losses caused by alternating magnetomotive force in the core, the core material is made of stacked B35A300 silicon steel sheets, connected by self-locking points. The stack height is 75mm thick, and the width of the teeth 18 is 5.61mm. The left and right sides of the T-shaped core 4 are designed with equal-sized protrusions 16 and grooves 17. Through the cooperation of the protrusions and grooves, the T-shaped core 4 can be quickly formed into a round shape. The outer side 19 of the T-shaped core is not a complete circle. The irregular circle design takes into account the need for laser welding after the stator is formed into a round shape. After laser welding, a strip column protruding from the plane will be formed. This irregular circle design ensures that the strip column does not exceed the outer diameter of the T-shaped core 4, preventing the entire stator from being unable to be installed in the housing due to the strip column formed by laser welding exceeding the outer diameter of the T-shaped core 4.

[0018] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A T-block stator structure, comprising a busbar (1), stator windings (2), a plastic-coated frame (3), and a T-block core (4), characterized in that: The stator winding (2) includes copper wire (10) and bridge wire (11). The busbar (1) includes an integral plastic-coated plate (8). The outer wall of the top of the integral plastic-coated plate (8) is equipped with a U-shaped welding fixing position (5). The outer wall of the integral plastic-coated plate (8) is equipped with a protrusion (6). The bottom of the integral plastic-coated plate (8) is equipped with an inner fastening point (9). The top of the integral plastic-coated plate (8) is equipped with a copper plate (7). The outer wall of the plastic-coated skeleton (3) is provided with a bridging groove (12), a winding outlet groove (13), and a hollow groove (15). The T-shaped block iron core (4) includes a toothed part (18) and a T-shaped block outer side (19). A groove (17) is provided on one side of the T-shaped block outer side (19), and a protrusion (16) is installed on the other side of the T-shaped block outer side (19).

2. The T-block stator structure according to claim 1, characterized in that: The U-shaped welding fixing position (5) is used to weld and fix the copper wire (10). There are three copper plates (7). The copper plates (7) are used as three-phase lines to connect with the external controller. There are three protrusions (6). The protrusions (6) cooperate with the inner fastening point (9) to install the busbar (1) at the plastic-coated frame (3).

3. A T-block stator structure according to claim 2, characterized in that: The stator winding (2) is composed of copper wire (10), with one copper wire (10) exiting from one side of a single stator winding (2).

4. A T-block stator structure according to claim 1, characterized in that: The bridge cable groove (12) is used to install the bridge cable (11), and the winding cable outlet groove (13) is used to install the copper wire (10).

5. A T-block stator structure according to claim 1, characterized in that: The dimensions of the protrusion (16) and the groove (17) are matched, and the multiple T-shaped iron cores (4) are formed by the protrusion (16) and the groove (17) surrounding each other.

6. A T-block stator structure according to claim 5, characterized in that: The outer side of the T-shaped block (19) is an irregular circle.

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