Stator module and permanent magnet motor

Abstract

The utility model discloses a kind of stator module and permanent magnet motor;The stator module includes: by several sub-block windings are connected along circumference, the sub-block winding includes sub-block core and locating block, the front and rear end of the sub-block core is connected with one the locating block. The utility model is connected with one locating block in the front and rear end of sub-block core, utilize the structural design of locating block, make it can withstand greater stress, effectively dispersed the stress that sub-block core has received in splicing and operating process, to reduce the stress of sub-block core, not only improve the overall mechanical strength of stator module, also effectively improve the roundness and cylindricity of stator module after splicing, also reduce the interaction deviation between stator tooth slot and rotor magnetic pole, and then realize motor tooth slot torque significantly reduce, so that motor is more stable in operating process, vibration and noise significantly reduce, to improve the operating efficiency and service life of motor.

Description

Technical Field

[0001] This utility model relates to the field of permanent magnet motor technology, and in particular to a stator module and a permanent magnet motor. Background Technology

[0002] With the rapid development of industrial automation and intelligent manufacturing, permanent magnet synchronous servo motors are widely used in various high-precision transmission systems due to their advantages such as high efficiency, high precision, and high dynamic performance. In the design and manufacturing of permanent magnet synchronous servo motors, the design of the stator structure has a crucial impact on the overall performance of the motor.

[0003] Currently, a common stator structure is the modular design. This structure involves dividing the stator laminations into multiple modules, which are then assembled to form a complete stator. The main advantage of this design is its ease of winding and ability to effectively improve the stator slot fill factor. Increased slot fill factor means that more wires can be accommodated within the limited stator slot space, thereby enhancing the motor's output power and helping to reduce motor losses, ultimately improving the overall efficiency of the motor.

[0004] However, despite the significant advantages of modular stator structures in terms of winding and slot fill factor, some problems have also emerged in practical applications. During the manufacturing process of modular stator laminations, burrs are inevitably generated. These burrs are mainly concentrated on the mating surfaces of the laminations. When the modular stator laminations are assembled into a round shape, the burrs on the mating surfaces adversely affect the roundness and cylindricity of the stator's inner diameter after assembly. Specifically, the presence of burrs compromises the geometric accuracy of the stator's inner diameter, preventing it from achieving the ideal circular and cylindrical shape.

[0005] Such deviations in geometric precision lead to an increase in motor cogging torque. Cogging torque is an important parameter of a motor, referring to a periodic torque fluctuation generated by the interaction between the stator slots and the rotor magnetic poles. An increase in cogging torque not only affects the smoothness of motor operation but also leads to increased motor vibration and noise, reducing motor performance and lifespan, and consequently affecting the stability and reliability of the entire motor system.

[0006] In summary, while the modular stator structure offers certain advantages in terms of winding and slot fill factor, the burr problem severely affects the roundness and cylindricity of the stator's inner diameter, leading to increased cogging torque and impacting the motor's operating performance and lifespan. Therefore, effectively addressing the burr problem in modular stator structures, reducing cogging torque, and improving motor performance and reliability are current technical challenges that need to be solved in the field of permanent magnet synchronous servo motors. Utility Model Content

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide a stator module and a permanent magnet motor.

[0008] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: In a first aspect, this utility model provides a stator module, comprising: a plurality of segmented windings spliced ​​together along the circumference, wherein each segmented winding includes a segmented iron core and a positioning block, and each of the front and rear ends of the segmented iron core is connected to a positioning block.

[0009] In one specific embodiment, the segmented iron core is provided with a first positioning hole, and the positioning block is provided with a second positioning hole corresponding to the first positioning hole. The first positioning hole and the second positioning hole are fixed by bolts.

[0010] In one specific embodiment, the central angle of the segmented iron core is φ1, the central angle of the positioning block is φ2, and φ2 is greater than φ1.

[0011] In one specific embodiment, the outer diameter of the segmented iron core is the same as the outer diameter of the positioning block.

[0012] In one specific embodiment, the segmented iron core is composed of a stack of several iron core pieces.

[0013] In one specific embodiment, the thickness of the core granules is 0.3mm-0.5mm.

[0014] In one specific embodiment, the surface of the positioning block that contacts the adjacent segmented winding is a positioning surface, and the flatness of the positioning surface is 0.015 mm.

[0015] The stator module of this invention has the following advantages compared with the prior art: By connecting a positioning block to each of the front and rear ends of the segmented iron core, the structural design of the positioning blocks enables it to withstand greater stress. This design effectively disperses the stress experienced by the segmented iron core during splicing and operation, which not only improves the overall mechanical strength of the stator module, but also effectively improves the roundness and cylindricity of the spliced ​​stator module, making its geometric accuracy higher and closer to the ideal design state. At the same time, because the stator module structure can effectively improve the roundness and cylindricity of the stator inner diameter, it reduces the interaction deviation between the stator slots and the rotor magnetic poles. This improvement can significantly reduce the cogging torque of the motor. Lower cogging torque means that the motor runs more smoothly, with significantly reduced vibration and noise, thereby improving the operating efficiency and service life of the motor, and also enhancing the stability and reliability of the entire motor system.

[0016] Secondly, this utility model embodiment provides a permanent magnet motor, including a rotor module and a stator module as described above, wherein the rotor module is disposed inside the stator module.

[0017] In one specific embodiment, the rotor module includes a rotor core, and plastic-coated magnets are connected to the outer periphery of the rotor core.

[0018] In one specific embodiment, the plastic-coated magnet includes a magnet component and an injection-molded component, the lower surface of the magnet component is connected to the rotor core, and the injection-molded component is connected to the upper surface of the magnet component.

[0019] The advantages of this permanent magnet motor compared to existing technologies are as follows: By setting a stator module and connecting a positioning block to the front and rear ends of the segmented iron core, the structural design of the positioning blocks enables them to withstand greater stress. This design effectively disperses the stress experienced by the segmented iron core during splicing and operation, not only improving the overall mechanical strength of the stator module but also effectively improving the roundness and cylindricity of the spliced ​​stator module, resulting in higher geometric accuracy and closer proximity to the ideal design state. Simultaneously, because the stator module structure effectively improves the roundness and cylindricity of the stator inner diameter, it reduces the interaction deviation between the stator slots and the rotor magnetic poles. This improvement significantly reduces the cogging torque of the motor. Lower cogging torque means smoother motor operation, significantly reduced vibration and noise, thereby improving the motor's operating efficiency and service life, while also enhancing the stability and reliability of the entire motor system.

[0020] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A three-dimensional schematic diagram of the stator module provided by this utility model; Figure 2 This is a front view schematic diagram of the stator module provided by this utility model; Figure 3 A three-dimensional schematic diagram of the segmented winding provided by this utility model; Figure 4 This is a front view schematic diagram of the segmented iron core provided by this utility model; Figure 5 A front view schematic diagram of the positioning block provided by this utility model; Figure 6 A three-dimensional schematic diagram of the permanent magnet motor provided by this utility model; Figure 7 A three-dimensional schematic diagram of the rotor module provided by this utility model; Figure 8 A cross-sectional schematic diagram of the rotor module provided by this utility model; Figure 9 A cross-sectional view of the tooling for the plastic-coated magnets provided by this utility model; Figure 10 This is a cross-sectional schematic diagram of the plastic-coated magnet provided by this utility model.

[0023] Figure label: Segmented winding 10, segmented iron core 11, first positioning hole 111, positioning block 12, second positioning hole 121, positioning surface 122, rotor module 20, rotor iron core 21, plastic-coated magnet 22, magnet part 221, injection molded part 222, first tooling part 23, second tooling part 24. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0026] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0029] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0030] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. The illustrative expressions of the above terms in this specification should not be construed as necessarily referring to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0031] See Figures 1 to 5 As shown, this utility model discloses a specific embodiment of a stator module, comprising: a plurality of segmented windings 10 spliced ​​together along the circumference, wherein each segmented winding 10 includes a segmented iron core 11 and a positioning block 12, and each of the front and rear ends of the segmented iron core 11 is connected to a positioning block 12.

[0032] Specifically, the stator module is composed of several segmented windings 10 spliced ​​along the circumferential direction. Each segmented winding 10 mainly consists of a segmented iron core 11 and a positioning block 12. The segmented iron core 11 is a key component constituting the stator magnetic circuit. Its shape and size are optimized according to the motor's design parameters to ensure good magnetic performance. A positioning block 12 is connected to each of the front and rear ends of the segmented iron core 11. The shape and size of the positioning block 12 are designed to fit tightly with the segmented iron core 11 to ensure the stability of the overall structure.

[0033] The primary function of the positioning block 12 is to withstand significant stress, thereby reducing the stress experienced by the segmented iron core 11 during assembly and operation. The positioning block 12 can be manufactured from high-strength materials, such as high-strength aluminum alloy, engineering plastics, or 40Cr steel, to ensure sufficient mechanical strength. The positioning block 12 is connected to the segmented iron core 11 via welding, riveting, or other reliable mechanical connection methods.

[0034] In other words, by connecting a positioning block 12 to each of the front and rear ends of the segmented iron core 11, the structural design of the positioning block 12 enables it to withstand greater stress. This design effectively disperses the stress experienced by the segmented iron core 11 during splicing and operation, not only improving the overall mechanical strength of the stator module but also effectively improving the roundness and cylindricity of the spliced ​​stator module, resulting in higher geometric accuracy and closer proximity to the ideal design state. Simultaneously, because the stator module structure effectively improves the roundness and cylindricity of the stator inner diameter, it reduces the interaction deviation between the stator slots and the rotor magnetic poles. This improvement significantly reduces the motor's cogging torque. Lower cogging torque means smoother motor operation, significantly reduced vibration and noise, thereby improving the motor's operating efficiency and service life, while also enhancing the stability and reliability of the entire motor system. Furthermore, the stator module is composed of several segmented windings 10 spliced ​​along the circumference. This segmented design makes the winding assembly process more flexible and efficient. Compared to the traditional integral stator structure, the segmented winding 10 design facilitates winding operations and better adapts to complex winding process requirements. Meanwhile, the presence of the positioning block 12 not only enhances mechanical strength, but also provides better positioning and support during the assembly process, further improving the quality and precision of the winding assembly.

[0035] See Figures 1 to 5 As shown, in one embodiment, the segmented iron core 11 is provided with a first positioning hole 111, and the positioning block 12 is provided with a second positioning hole 121 corresponding to the first positioning hole 111. The first positioning hole 111 and the second positioning hole 121 are fixed by bolts.

[0036] Specifically, the segmented iron core 11 has a first positioning hole 111, while the positioning block 12 has a corresponding second positioning hole 121. The positions and dimensions of these two positioning holes are precisely designed to ensure accurate alignment, providing a reliable connection foundation for subsequent fixing. To achieve a secure connection between the segmented iron core 11 and the positioning block 12, bolts are used for fixing. The bolts are made of 40Cr steel and have undergone heat treatment. Heat-treated 40Cr steel possesses high strength and good toughness, effectively withstanding various stresses generated during motor operation, ensuring the reliability of the connection. The bolt diameter is not less than 2mm to ensure sufficient strength. The bolt and the positioning hole are fitted with an interference fit of 0.005mm. This interference fit ensures tight contact between the bolt and the positioning hole, effectively preventing loosening, and also improving the rigidity and stability of the connection.

[0037] During the connection process, bolts are passed through the first positioning hole 111 of the segmented iron core 11 and the second positioning hole 121 of the positioning block 12, and then axially locked using nuts. To further enhance the reliability of the connection, thread-locking adhesive is applied to the nuts before tightening. The thread-locking adhesive forms an adhesive protective layer between the nut and the bolt, preventing the nut from loosening due to vibration or impact, thereby ensuring the long-term stability of the connection. After the bolt connection between the segmented iron core 11 and the positioning block 12 is completed, components such as enameled wire, slotted paper, and bobbin are assembled onto the segmented iron core 11 to form a complete segmented winding 10. The enameled wire is used to form the electrical circuit of the motor, the slotted paper is used for insulation, and the bobbin provides support for the enameled wire, ensuring the accurate shape and position of the winding.

[0038] In other words, the use of 40Cr steel bolts with heat treatment and the interference fit significantly enhances the connection strength between the segmented core 11 and the positioning block 12. Simultaneously, the precise 0.005mm interference fit ensures tight contact between the bolt and the positioning hole, effectively preventing loosening and gaps. This connection method can withstand various mechanical stresses generated during motor operation, including vibration, impact, and torque, thus ensuring the stability of the stator module during long-term operation. Furthermore, the thread-locking method using thread-locking adhesive on the nuts further enhances the connection's resistance to loosening. During motor operation, especially under high dynamic response and high load conditions, the thread-locking adhesive effectively prevents the nuts from loosening due to vibration, ensuring that the connection between the segmented core 11 and the positioning block 12 remains tight at all times. This design significantly improves the motor's operational reliability and reduces the risk of failure due to loose connections. In addition, by assembling slotted paper and a frame on the segmented core 11, the motor's insulation performance is effectively improved. The insulation of the slotted paper prevents short circuits between the enameled wires, ensuring the motor's electrical performance. Meanwhile, the frame design not only provides support for the enameled wire, but also improves the heat dissipation of the motor. Good heat dissipation performance helps to reduce the operating temperature of the motor, extend the service life of the motor, and improve the overall performance of the motor.

[0039] See Figures 4 to 5 As shown, in one embodiment, the central angle of the segmented iron core 11 is φ1, and the central angle of the positioning block 12 is φ2, where φ2 is greater than φ1; the outer diameter of the segmented iron core 11 is the same as the outer diameter of the positioning block 12. The stator module is externally heat-fitted into a housing, and an interference fit is used between the housing and the stator module.

[0040] Specifically, the central angles of the segmented iron core 11 and the positioning block 12 are designed to be φ1 and φ2, respectively, with φ2 being greater than φ1. This design allows the positioning block 12 to occupy a larger circumferential angle in the assembled stator module. At the same time, the outer diameter of the segmented iron core 11 is consistent with the outer diameter of the positioning block 12, ensuring that the two can form a complete circular structure after assembly.

[0041] After the stator module is assembled, its outer side is fitted with the housing using a heat-fitting process. Heat-fitting is a common mechanical assembly method where the housing is heated to a certain temperature and quickly fitted over the stator module. Subsequent cooling causes the housing to shrink, achieving an interference fit between the housing and the stator module. This interference fit ensures a tight connection between the housing and the stator module, providing sufficient mechanical strength and stability.

[0042] Because the central angle φ2 of the positioning block 12 is slightly larger than the central angle φ1 of the segmented iron core 11, and their outer diameters are the same, the positioning block 12 can withstand most of the uneven interference force caused by the uneven expansion and contraction of the housing after heat fitting. This uneven force mainly comes from the uneven expansion and contraction that may occur during the heating and cooling process of the housing, as well as the uneven force caused by burrs on the mating surface of the segmented iron core 11. The design of the positioning block 12 enables it to effectively disperse and withstand these uneven forces, thereby protecting the segmented iron core 11 from damage.

[0043] During the splicing of the segmented windings 10, burrs may exist on the mating surfaces of the segmented cores 11, which can affect the roundness and cylindricity of the stator's inner diameter after splicing. By designing a positioning block 12 with φ2 greater than φ1, the positioning block 12 can effectively improve the difference in roundness and cylindricity of the inner diameter when the segmented windings 10 are mated. The positioning block 12 plays a buffering and corrective role during the splicing process, ensuring that the inner diameter of the stator after splicing has higher geometric accuracy.

[0044] In other words, by designing a positioning block 12 with a diameter greater than φ1 and ensuring that the outer diameters of the segmented iron core 11 and the positioning block 12 are the same, the positioning block 12 can withstand most of the uneven interference force caused by the uneven expansion and contraction of the housing. This design significantly enhances the mechanical strength and stability of the stator module, ensuring that the stator module can withstand various mechanical stresses during motor operation and reducing the risk of structural damage caused by stress concentration. Furthermore, the design of the positioning block 12 not only withstands uneven forces but also buffers and corrects burrs on the mating surfaces of the segmented iron core 11 during the splicing process. This buffering and correction effectively improves the roundness and cylindricity differences of the inner diameter when the segmented windings 10 are mated, resulting in higher geometric accuracy of the spliced ​​stator inner diameter. Good roundness and cylindricity reduce cogging torque and improve the smoothness and efficiency of motor operation. Furthermore, since the positioning block 12 can improve the roundness and cylindricity of the stator inner diameter, it reduces the interaction deviation between the stator slots and the rotor magnetic poles. This reduction in deviation can reduce the cogging torque, making the motor run more smoothly, significantly reducing vibration and noise. The reduced cogging torque not only improves the operating efficiency of the motor, but also extends the service life of the motor and enhances the overall reliability of the motor system.

[0045] See Figure 3 As shown, in one embodiment, the segmented iron core 11 is composed of a stack of several iron core pieces.

[0046] Specifically, the core sheets are typically made of high-permeability silicon steel sheets or other high-performance magnetic materials to ensure good magnetic properties. The segmented core 11 is composed of several thin, stacked core sheets; this design significantly reduces eddy current losses. Eddy current losses are energy losses caused by the induction of eddy currents in the core within an alternating magnetic field. By using thin, stacked core sheets, the intensity of eddy current induction can be effectively reduced, thereby reducing eddy current losses.

[0047] In one embodiment, the thickness of the core granules is 0.3mm-0.5mm.

[0048] Specifically, the thickness of the core laminations is between 0.3mm and 0.5mm, and this thin-plate design significantly reduces eddy current losses. By using thin-plate core laminations, the induction intensity of eddy currents can be effectively reduced, thereby reducing eddy current losses. Simultaneously, due to the reduction in eddy current losses, the efficiency of the motor is significantly improved. Higher efficiency means that the motor can more effectively convert electrical energy into mechanical energy during operation, reducing energy waste, thus lowering operating costs and improving economic efficiency. Furthermore, the 0.3mm to 0.5mm thickness of the core laminations not only improves motor efficiency but also reduces material costs. The thin-plate core laminations can be efficiently manufactured using a stamping process, reducing material waste.

[0049] In one embodiment, the surface of the positioning block 12 that contacts the adjacent segmented winding 10 is a positioning surface 122, and the flatness of the positioning surface 122 is 0.015 mm.

[0050] Specifically, the surface of the positioning block 12 that contacts the adjacent segmented winding 10 is called the positioning surface 122. The flatness of the positioning surface 122 is strictly controlled within 0.015mm. This high-precision flatness requirement ensures that the positioning surface 122 can serve as a mating surface, achieving a tight fit between the segmented windings 10. During the splicing process, the tight contact between the positioning surface 122 and the mating surface of the adjacent segmented winding 10 can effectively reduce the splicing gap and improve the concentricity and cylindricity of the segmented windings 10.

[0051] Preferably, the thickness of the positioning block 12 is 5mm.

[0052] Specifically, the 5mm thick positioning block 12 is designed to ensure sufficient mechanical strength to withstand various stresses generated during motor operation, including vibration, impact, and torque. Simultaneously, the 5mm thickness of the positioning block 12 effectively reduces uneven forces during the splicing process, improving the concentricity and cylindricity of the segmented windings 10. During motor operation, the high-precision splicing structure maintains a stable magnetic field distribution, reducing non-uniformity in the magnetic circuit and thus improving the motor's operational stability.

[0053] See Figures 6 to 10 As shown, this utility model also discloses a permanent magnet motor, including a rotor module 20 and a stator module as described above, wherein the rotor module 20 is disposed inside the stator module.

[0054] Specifically, the rotor module 20 is disposed inside the stator module and forms the core component of the motor together with the stator module. During the overall assembly of the motor, the stator module is first fixed inside the housing, and then the rotor module 20 is installed inside the stator module. During assembly, it is essential to ensure that the air gap between the rotor module 20 and the stator module is uniform to optimize the motor's magnetic properties and operating efficiency.

[0055] In other words, by setting up a stator module and connecting a positioning block 12 to the front and rear ends of the segmented iron core 11, the structural design of the positioning block 12 enables it to withstand greater stress. This design effectively disperses the stress experienced by the segmented iron core 11 during splicing and operation, not only improving the overall mechanical strength of the stator module but also effectively improving the roundness and cylindricity of the spliced ​​stator module, making its geometric accuracy higher and closer to the ideal design state. At the same time, since the stator module structure can effectively improve the roundness and cylindricity of the stator inner diameter, it reduces the interaction deviation between the stator slots and the rotor magnetic poles. This improvement can significantly reduce the motor cogging torque. Lower cogging torque means that the motor runs more smoothly, with significantly reduced vibration and noise, thereby improving the operating efficiency and service life of the motor, and also enhancing the stability and reliability of the entire motor system.

[0056] See Figures 7 to 10 As shown, in one embodiment, the rotor module 20 includes a rotor core 21, and a plastic-coated magnet 22 is connected to the outer periphery of the rotor core 21.

[0057] Specifically, the rotor core 21 is composed of stacked silicon steel sheets with high magnetic permeability, forming the rotor's magnetic circuit. A ring of plastic-coated magnets 22 is connected to the outer periphery of the rotor core 21. This design not only enhances the mechanical strength of the magnets but also protects their surface from damage. The plastic-coated magnets 22 are made by coating the surface of permanent magnet materials (such as high-performance magnets like neodymium iron boron magnets) with plastic. The plastic coating material is typically a high-strength engineering plastic or composite material, which not only has good mechanical strength but also provides a certain degree of insulation. The plastic coating process usually involves coating the magnet surface with a layer of plastic material, and then using a heating or curing process to ensure a tight bond between the plastic material and the magnet surface. This process ensures that the plastic coating layer uniformly covers the magnet surface, forming a protective layer.

[0058] In other words, the plastic-coated magnet 22 significantly enhances the mechanical strength of the magnet by covering its surface with a layer of high-strength engineering plastic or composite material. This design effectively reduces the risk of magnet breakage due to mechanical stresses such as vibration and impact during motor operation. The plastic coating not only provides additional mechanical support but also absorbs and disperses stress to a certain extent, protecting the internal structure of the magnet from damage. Furthermore, by enhancing the mechanical strength of the magnet, the plastic-coated magnet 22 can better withstand various mechanical stresses generated during motor operation, thereby improving the reliability and service life of the motor. Under high dynamic response and high load conditions, the plastic-coated magnet 22 can maintain stable performance, reducing motor failures caused by magnet damage. In addition, the surface plastic coating of the plastic-coated magnet 22 effectively protects the magnet surface from impacts, wear, and scratches. During the manufacturing, transportation, and installation of the motor, the magnet surface is easily damaged by mechanical contact, affecting its magnetic properties. The plastic coating provides a layer of physical protection, reducing the risk of damage to the magnet surface and ensuring that the magnet maintains good magnetic properties during motor operation.

[0059] See Figures 8 to 10 As shown, in one embodiment, the plastic-coated magnet 22 includes a magnet part 221 and an injection molded part 222. The lower surface of the magnet part 221 is connected to the rotor core 21, and the injection molded part 222 is connected to the upper surface of the magnet part 221.

[0060] Specifically, in the production process of the plastic-coated magnet 22, a first tooling part 23 and a second tooling part 24 are required. The first tooling part 23 is made of POM plastic or aluminum alloy, possessing good mechanical and machinability properties. The first tooling part 23 has an arc-shaped groove for clearance fitting with the magnet 221. The shape of the arc-shaped groove matches the outer contour of the magnet 221, ensuring that the magnet 221 can be stably placed within the groove. One axial end of the first tooling part 23 is closed, while the other end is open, facilitating subsequent operations. The second tooling part 24 is also made of POM plastic or aluminum alloy. The second tooling part 24 is assembled onto the first tooling part 23, and its circumferential surface has threaded holes for locking the first tooling part 23, the magnet 221, and the second tooling part 24 with screws, ensuring the stability of each component during injection molding. Then, injection molding material is poured in from the open side of the first tooling part 23. The injection molding material is typically a high-strength engineering plastic or composite material with good mechanical and insulating properties. The injection molding compound forms a uniform protective layer on the upper surface of the magnet 221, and after cooling and solidification, it forms the injection molded part 222. After the injection molding compound cools and solidifies, the first tooling 23 and the second tooling 24 are removed to obtain the complete plastic-coated magnet 22. Finally, high-strength adhesive is brushed onto the bottom of the magnet 221 to ensure that the adhesive is evenly distributed, and then the plastic-coated magnet 22 is tightly and evenly attached to the outer peripheral surface of the rotor core 21.

[0061] In other words, the plastic-coated magnet 22 significantly enhances the mechanical strength of the magnet by forming a layer of injection-molded material 222 on the upper surface of the magnet part 221. Injection-molded materials typically possess high strength and good toughness, effectively reducing the risk of magnet breakage due to mechanical stresses such as vibration and impact during motor operation. The injection-molded material 222 not only provides additional mechanical support but also absorbs and disperses stress to a certain extent, protecting the internal structure of the magnet from damage. Simultaneously, by enhancing the mechanical strength of the magnet, the plastic-coated magnet 22 can better withstand various mechanical stresses generated during motor operation, thereby improving the reliability and service life of the motor. Furthermore, for non-full-pole arc coefficient magnets after plastic coating, there is no need for magnet bonding and positioning fixtures, nor is it necessary to design a positioning structure on the rotor core 21. This design reduces magnetic leakage between the magnet and the rotor core 21, improving the magnetic performance and efficiency of the motor. At the same time, by reducing magnetic leakage, the motor can more effectively convert electrical energy into mechanical energy during operation, thereby improving the motor's operating efficiency and power density.

[0062] The above embodiments are preferred implementations of this utility model. In addition, this utility model can also be implemented in other ways. Any obvious substitutions without departing from the concept of this technical solution are within the protection scope of this utility model.

Claims

1. A stator module, characterized in that, include: It is composed of several segmented windings spliced ​​together along the circumference. Each segmented winding includes a segmented iron core and a positioning block. Each of the front and rear ends of the segmented iron core is connected to a positioning block.

2. The stator module according to claim 1, characterized in that, The segmented iron core is provided with a first positioning hole, and the positioning block is provided with a second positioning hole corresponding to the first positioning hole. The first positioning hole and the second positioning hole are fixed by bolts.

3. The stator module according to claim 1, characterized in that, The central angle of the segmented iron core is φ1, the central angle of the positioning block is φ2, and φ2 is greater than φ1.

4. The stator module according to claim 1, characterized in that, The outer diameter of the segmented iron core is the same as the outer diameter of the positioning block.

5. The stator module according to claim 1, characterized in that, The segmented iron core is composed of several iron core pieces stacked together.

6. The stator module according to claim 5, characterized in that, The thickness of the iron core sheets is 0.3mm-0.5mm.

7. The stator module according to claim 1, characterized in that, The surface of the positioning block that contacts the adjacent segmented winding is the positioning surface, and the flatness of the positioning surface is 0.015mm.

8. A permanent magnet motor, characterized in that, It includes a rotor module and a stator module as described in any one of claims 1-7, wherein the rotor module is disposed inside the stator module.

9. The permanent magnet motor according to claim 8, characterized in that, The rotor module includes a rotor core, and plastic-coated magnets are connected to the outer periphery of the rotor core.

10. The permanent magnet motor according to claim 9, characterized in that, The plastic-coated magnet includes a magnet component and an injection-molded component. The lower surface of the magnet component is connected to the rotor core, and the injection-molded component is connected to the upper surface of the magnet component.

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