Modular stator assembly and motor using same

Abstract

This invention relates to a modular stator assembly. The modular stator assembly includes a plurality of stator tooth modules. The plurality of stator tooth modules are arranged around a central axis, and each of the plurality of stator tooth modules includes a first tooth block, a second tooth block, an assembly member, and a winding. The first tooth block is adjacent to the central axis and has a first winding cross-section perpendicular to the central axis. The second tooth block is radially disposed opposite to the first tooth block along the central axis and is farther away from the central axis than the first tooth block. The second tooth block has a second winding cross-section perpendicular to the central axis. The first area of ​​the first winding cross-section is smaller than the second area of ​​the second winding cross-section. The assembly member radially connects the first tooth block and the second tooth block along the central axis. The winding is wound around the periphery of the first tooth block, the second tooth block, and the assembly member.

Claims

1. A modular stator assembly comprising a plurality of stator tooth modules arranged around a central axis, each of the plurality of stator tooth modules comprising: a first tooth block adjacent to the central axis and having a first winding cross section perpendicular to the central axis; a second tooth block radially corresponding to the first tooth block along the central axis and located further away from the central axis than the first tooth block, and having a second winding cross section perpendicular to the central axis, wherein a first area of ​​the first winding cross section is smaller than a second area of ​​the second winding cross section; a set of fasteners radially connected to the first tooth block and the second tooth block along the central axis; and a winding wound around the periphery of the first tooth block, the second tooth block, and the set of fasteners.

2. The modular stator assembly as claimed in claim 1, wherein each of the plurality of stator tooth modules further includes a third tooth block, wherein the third tooth block and the second tooth block are radially corresponding to each other along the central axis, and the second tooth block is disposed between the first tooth block and the third tooth block, and the third tooth block has a third winding cross section perpendicular to the central axis, wherein the second area of ​​the second winding cross section is smaller than the third area of ​​the third winding cross section, and the winding is wound around the periphery of the first tooth block, the second tooth block, the third tooth block and the assembly of fasteners.

3. The modular stator assembly as claimed in claim 2, wherein the first tooth block includes a first side surface and a second side surface, the first side surface being adjacent to the central axis, and the first side surface and the second side surface being opposite sides of the first tooth block along the central axis, wherein the second tooth block includes a third side surface and a fourth side surface, wherein the third side surface is adjacent to or fitted with the second side surface, and the third side surface and the fourth side surface being opposite sides of the second tooth block along the central axis, wherein the third tooth block includes a fifth side surface and a sixth side surface, wherein the fifth side surface is adjacent to or fitted with the fourth side surface, and the fifth side surface and the sixth side surface being opposite sides of the third tooth block along the central axis, wherein a portion of the winding is disposed on the periphery of the first side surface and the sixth side surface.

4. The modular stator assembly as claimed in claim 2, wherein the first winding section has a first width, the second winding section has a second width, and the third winding section has a third width, wherein the first width, the second width, and the third width are respectively radially perpendicular to the central axis, and the first width is smaller than the second width, and the second width is smaller than the third width.

5. The modular stator assembly as claimed in claim 3, wherein the first tooth block includes a first top end portion, a first bottom end portion, and a first body portion, wherein the first top end portion and the first bottom end portion are opposite ends of the first tooth block along the axial direction of the central axis, and the first body portion is connected between the first top end portion and the first bottom end portion; wherein the second tooth block includes a second top end portion, a second bottom end portion, and a second body portion, wherein the second top end portion and the second bottom end portion are opposite ends of the second tooth block along the axial direction of the central axis, and the second body portion is connected between the second top end portion and the second bottom end portion; wherein the third tooth block includes a third top end portion, a third bottom end portion, and a third body portion, wherein the third top end portion and the third bottom end portion are opposite ends of the third tooth block along the axial direction of the central axis, and the third body portion is connected between the third top end portion and the third bottom end portion.

6. The modular stator assembly as described in claim 5, wherein the first tooth block includes a plurality of first upper extensions and a plurality of first lower extensions, the plurality of first upper extensions being disposed on two opposite sides of the first top end portion, and the plurality of first lower extensions being disposed on two opposite sides of the first bottom end portion, wherein the plurality of first upper extensions extend outwardly from the two opposite sides of the first top end portion along the circumferential direction of the central axis and protrude relative to the two opposite sides of the first body portion, and the plurality of first lower extensions extend outwardly from the two opposite sides of the first top end portion along the circumferential direction of the central axis and protrude relative to the two opposite sides of the first body portion, and the plurality of first lower extensions extend outwardly from the two opposite sides of the first bottom end portion along the circumferential direction of the central axis. The spindle extends circumferentially outward from two opposite sides of the first bottom end portion and protrudes relative to two opposite sides of the first body portion. The second toothed block includes a plurality of second upper extensions and a plurality of second lower extensions. The plurality of second upper extensions are disposed on two opposite sides of the second top end portion, and the plurality of second lower extensions are disposed on two opposite sides of the second bottom end portion. The plurality of second upper extensions extend circumferentially from the two opposite sides of the second top end portion along the central axis and protrude relative to the second body portion. On the two opposite sides of the second body portion, the plurality of second lower extension portions extend outward from the two opposite sides of the second bottom end portion along the circumferential direction of the central axis, and protrude relative to the two opposite sides of the second body portion. The third tooth block includes a plurality of third upper extension portions and a plurality of third lower extension portions. The plurality of third upper extension portions are disposed on the two opposite sides of the third top end portion, and the plurality of third lower extension portions are disposed on the two opposite sides of the third bottom end portion. The plurality of third upper extension portions extend outward from the two opposite sides of the third top end portion along the circumferential direction of the central axis. The two opposite sides of the end extend outward and protrude relative to the two opposite sides of the third body. The plurality of third lower extension portions extend outward from the two opposite sides of the third bottom end along the circumferential direction of the central axis and protrude relative to the two opposite sides of the third body. The winding is wound around one of the first tooth block, the second tooth block, the third tooth block and the set of fasteners. A portion of the winding is disposed in a winding area formed by the first body, the second body, the third body, the first side and the sixth side.

7. The modular stator assembly as claimed in claim 2, wherein a first receiving space is formed between two adjacent first tooth blocks, a second receiving space is formed between two adjacent second tooth blocks, and a third receiving space is formed between two adjacent third tooth blocks, wherein the volumes of the first receiving space, the second receiving space, and the third receiving space are equal, and a portion of the winding is disposed in the first receiving space, the second receiving space, and the third receiving space.

8. The modular stator assembly as described in claim 2, wherein the set of fasteners includes a coupling portion, the first tooth block includes a first through hole, the second tooth block includes a second through hole, the third tooth block includes a third through hole, and the first through hole, the second through hole and the third through hole are radially aligned with each other along the central axis, wherein the coupling portion of the set of fasteners passes through the first through hole, the second through hole and the third through hole, and is tightly fitted or engaged with the first through hole, the second through hole and the third through hole.

9. The modular stator assembly as claimed in claim 8, wherein the assembly includes a plate portion connected to one end of the coupling portion and perpendicular to the coupling portion, wherein the plate portion has a first plate surface and a second plate surface opposite to each other along the radial direction of the central axis, wherein the first plate surface abuts against the first tooth block, and wherein the second plate surface is provided for a portion of the winding.

10. The modular stator assembly as claimed in claim 9, wherein the set of fasteners further includes a plurality of protrusions disposed on opposite ends of the second plate, and a portion of the winding is disposed on the second plate and located between the plurality of protrusions.

11. The modular stator assembly as claimed in claim 2, wherein the first tooth block is formed by a plurality of first silicon steel sheets stacked radially along the central axis, the second tooth block is formed by a plurality of second silicon steel sheets stacked radially along the central axis, and the third tooth block is formed by a plurality of third silicon steel sheets stacked radially along the central axis.

12. A motor comprising: a modular stator assembly including a plurality of stator tooth modules arranged around a central axis, each of the plurality of stator tooth modules including: a first tooth block adjacent to the central axis and having a first winding cross section perpendicular to the central axis; and a second tooth block radially corresponding to the first tooth block along the central axis and located further away from the central axis than the first tooth block, and having a second winding cross section perpendicular to the central axis, wherein a first area of ​​the first winding cross section is smaller than a second area of ​​the second winding cross section; A set of fasteners radially assembling the first tooth block and the second tooth block along the central axis; and a winding wound around the periphery of the first tooth block, the second tooth block, and the set of fasteners; and at least one rotor assembly arranged axially with the modular stator assembly along the central axis, wherein each of the at least one rotor assembly includes a magnetic core layer and an end cap, the magnetic core layer being disposed between the end cap and the modular stator assembly, wherein the modular stator assembly includes a first shaft hole, each of the at least one rotor assembly includes a second shaft hole, and the first shaft hole of the modular stator assembly and the second shaft hole of each of the at least one rotor assembly are aligned with each other along the central axis.

13. The motor as claimed in claim 12, wherein each of the plurality of stator tooth modules further includes a third tooth block, the third tooth block being radially corresponding to the second tooth block along the central axis, the second tooth block being disposed between the first tooth block and the third tooth block, and the third tooth block having a third winding cross section perpendicular to the central axis, wherein the second area of ​​the second winding cross section is smaller than the third area of ​​the third winding cross section, and the winding is wound around the periphery of the first tooth block, the second tooth block, the third tooth block and the set of fasteners.

14. The motor as claimed in claim 13, wherein the first winding section has a first width, the second winding section has a second width, and the third winding section has a third width, wherein the first width, the second width, and the third width are respectively radially perpendicular to the central axis, and the first width is smaller than the second width, and the second width is smaller than the third width.

15. The motor as claimed in claim 13, wherein the set of fasteners includes a coupling portion, the first tooth block includes a first through hole, the second tooth block includes a second through hole, the third tooth block includes a third through hole, and the first through hole, the second through hole and the third through hole are radially aligned with each other along the central axis, wherein the coupling portion of the set of fasteners passes through the first through hole, the second through hole and the third through hole, and is tightly fitted or engaged with the first through hole, the second through hole and the third through hole.

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