Slot wedge and motor provided with same

Abstract

The present application discloses a slot wedge and a motor. The slot wedge comprises an insulating main body and pole shoes; one or more pole shoes are arranged on one side or two opposite sides of the insulating main body; an outer side wall of each pole shoe is fixedly connected to a slot side wall of each open slot of an iron core or a positioning portion arranged at the opening of each open slot; and an inner side wall of each pole shoe is fixedly connected to the insulating main body to cut off magnetic communication between the inner side wall of each pole shoe and each open slot. Slots of the iron core of the present application are of an open slot structure, and the coil inserting space is large, such that coil inserting of a winding of the iron core is facilitated, and the process difficulty of iron core slotting is reduced; pole shoes of slot wedges are matched with the open slots of the iron core, such that the effect of semi-open slots can be achieved, and the electromagnetic performance of the iron core can be improved; the pole shoes on two sides are separated by the insulating main body, such that an eddy current caused by communication of the pole shoes on the two sides can be avoided, and the motor efficiency is prevented from being affected; the insulating main body is provided on the side of the pole shoes close to the bottoms of the open slots, so as to achieve an insulating effect; the pole shoes are fixed by the insulating main body, such that the overall rigidity of the slot wedges can be increased, and the insulating main body can limit the winding.

Description

A slot wedge and a motor having the same

[0001] This application claims priority to two Chinese patent applications, filed with the Patent Office of China on October 26, 2022, with application number 202211316978.X, and with the invention name “A composite slot wedge and a motor having the same”, and filed with the Patent Office of China on October 26, 2022, with application number 202211316730.3, and with the invention name “A slot wedge and a motor having the same”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the technical field of motors, and in particular to a slot wedge and a motor having the same. Background Art

[0003] The iron core in a motor is an important component of the motor's magnetic circuit. The iron core slots used to store the windings in the motor include three structures: open slots, semi-open slots, and closed slots. Among them, the closed slot structure is rarely used in the iron core. The open slot structure has the advantage of facilitating winding assembly, but the motor's electromagnetic performance is poor, and the lack of pole shoes increases the motor's air gap harmonics, increasing motor losses and reducing motor performance and efficiency. The semi-open slot structure is equipped with pole shoes and has the advantage of better electromagnetic performance of the iron core, but the semi-open slot structure is more difficult to assembly, and it is difficult to use flat copper wire or formed coils made of flat copper wire.

[0004] Semi-open slots and open slots are often paired with slot wedges. Traditional slot wedges are divided into insulating slot wedges and magnetic slot wedges. Insulating slot wedges are generally used to secure windings in semi-open slots, while magnetic slot wedges are generally used to secure windings in open slots. However, the small slot opening of semi-open slots makes winding unwinding difficult. When open slots are combined with magnetic slot wedges, the magnetic slot wedges can fulfill the role of pole shoes, but they also generate eddy currents, causing stator temperatures to rise. If the magnetic slot wedges are disconnected, the slot opening of the open slot is disconnected, the eddy currents generated by the magnetic slot wedges are reduced, but the magnetic slot wedges' ability to retain the windings is reduced.

[0005] Therefore, how to reduce the difficulty of offline while ensuring electromagnetic performance has become a technical problem that needs to be solved urgently by those skilled in the art.

[0006] Summary of the Invention

[0007] The purpose of this application is to provide a slot wedge and a motor having the same, so as to solve the problems raised in the above background technology.

[0008] To achieve the above objectives, the present application provides a slot wedge in a first aspect, comprising:

[0009] Insulation body;

[0010] One or more pole shoes are provided on one side or two opposite sides of the insulating body, and the outer side wall of the pole shoe is fixedly connected to the slot side wall on the adjacent side of the opening slot of the iron core; the inner side wall of the pole shoe is fixedly connected to the insulating body to cut off the magnetic connection between the inner side wall of the pole shoe and the opening slot.

[0011] Optionally, a groove is provided on one side or two opposite sides of the insulating body, and the pole shoe is installed on the groove; the side wall of the pole shoe connected to the side wall of the open groove is the outer wall of the pole shoe, and the side wall of the pole shoe connected to the side wall of the groove is the inner wall of the pole shoe.

[0012] Optionally, the insulating body includes a connected insulating body portion and an insulating bottom; the insulating body portion is located between the pole shoe and the slot side wall on the far side of the opening slot, and the insulating bottom is located on the side of the pole shoe close to the bottom of the opening slot.

[0013] Optionally, the inner wall of the insulating bottom forming the groove wall is a first groove wall; in the direction from the insulating bottom to the insulating main body, the first groove wall is inclined in a direction away from the open groove bottom.

[0014] Optionally, the insulating body further includes an insulating top portion connected to the insulating body portion, and the insulating top portion is located on the other side of the pole shoe facing away from the bottom of the open slot.

[0015] Optionally, the insulating body further includes insulating ends which are blocked at two ends in the length direction of the pole shoe to isolate the magnetic connection between the pole shoe ends and the open slot.

[0016] Optionally, a first protrusion extending outward is provided on the outer side of the pole shoe, and a clamping groove is provided on the side wall of the opening groove, and the first protrusion is clamped with the clamping groove; the cross-sectional shape of the first protrusion is the same as the cross-sectional shape of the clamping groove.

[0017] Optionally, a second protrusion is provided on the insulating end portion corresponding to the first protrusion, and a cross-sectional shape of the second protrusion is the same as that of the first protrusion.

[0018] Optionally, the pole shoe is provided on one side of the insulating body, and the other side of the insulating body facing away from the pole shoe is fixedly connected to the other side wall of the open slot.

[0019] Optionally, a third protrusion is provided on the other side of the insulating body facing away from the pole shoe, and the third protrusion is clamped and fixed to the other side wall of the open slot.

[0020] Optionally, the pole shoes are provided on opposite sides of the insulating body, and the insulating body separates the pole shoes located on the opposite sides of the insulating body.

[0021] To achieve the above-mentioned purpose, the second aspect of the present application provides a slot wedge, comprising:

[0022] Insulation body;

[0023] One or more pole shoes, each of which is provided on one side or two opposite sides of the insulating body;

[0024] A positioning portion is provided at the opening of the open slot of the iron core, and the outer side wall of the pole shoe is fixed to the positioning portion by bonding with magnetic adhesive; and the insulating body cuts off the magnetic connection between the inner side wall of the pole shoe and the open slot.

[0025] Optionally, a groove for installing the pole shoe is provided on the outer wall of the insulating body, and the inner wall of the pole shoe is in contact with the groove wall of the groove; the insulating body includes an insulating body portion located between the pole shoe and the groove side wall of the opening groove away from the positioning portion, and an insulating bottom portion connected to the insulating body portion and located on the side of the pole shoe close to the bottom of the opening groove.

[0026] Optionally, one end of the insulating bottom away from the insulating main body is in contact with the side wall of the open slot to cut off the magnetic connection between the inner side wall of the pole shoe and the open slot.

[0027] Optionally, the outer side wall of the pole shoe is coplanar with the outer side wall of the insulating body.

[0028] Optionally, the inner side wall of the groove wall formed by the insulating bottom is a first groove wall; in the direction from the insulating bottom to the insulating main body, the first groove wall is inclined in a direction away from the open groove bottom.

[0029] Optionally, the surface of the pole shoe facing away from the bottom of the open slot is coplanar with the end surface of the iron core where the open slot is provided.

[0030] Optionally, the insulating body further includes an insulating top portion connected to the insulating body portion, and the insulating top portion is located on the other side of the pole shoe facing away from the bottom of the open slot.

[0031] Optionally, an inner wall surface of the insulating top portion corresponding to the groove is perpendicular to an inner wall surface of the insulating main body portion corresponding to the groove.

[0032] Optionally, the insulating body further includes insulating ends blocking the two ends of the pole shoe in the length direction.

[0033] Optionally, the positioning portion is a V-shaped groove, and the outer side wall of the pole shoe is adapted to the shape of the groove wall of the positioning portion.

[0034] Optionally, the pole shoe is provided on one side of the insulating body, and the other side of the insulating body facing away from the pole shoe is fixedly connected to the other side wall of the open slot.

[0035] Optionally, the pole shoes are provided on opposite sides of the insulating body, and the insulating body separates the pole shoes located on the opposite sides of the insulating body.

[0036] To achieve the above-mentioned purpose, the third aspect of the present application further provides a motor, comprising: an iron core, wherein a plurality of open slots are evenly distributed on the iron core, wherein the open slots are arranged in a one-to-one correspondence with the slot wedges, and the slot wedges are the slot wedges described above.

[0037] Optionally, the front and rear ends of the insulating body extend out of the opening slot respectively.

[0038] In summary, the technical effects and advantages of this application are:

[0039] 1. In the present application, the core slot is an open slot structure with a large space for unloading the wire, which is convenient for unloading the core winding; the pole shoe of the slot wedge cooperates with the open slot of the iron core to play the role of a semi-open slot, which can improve the electromagnetic performance of the iron core; in addition, when pole shoes are provided on both sides of the opposite sides of the insulating body, the pole shoes on both sides are separated by the insulating body, which can avoid the connection between the pole shoes on both sides to generate eddy currents and avoid affecting the efficiency of the motor; an insulating bottom is provided on the side of the pole shoe close to the bottom of the open slot to play an insulating role, and the pole shoe is fixed by the insulating body, which can increase the overall stiffness of the slot wedge, and the insulating body can limit the winding.

[0040] 2. In the present application, the pole shoes and the positioning part can also be bonded by magnetic conductive adhesive, which is simple to install and has a fixed installation position; the pole shoes on both sides are separated by an insulating body, which can avoid the connection between the pole shoes on both sides to generate eddy currents and avoid affecting the motor efficiency.

[0041] 3. In the present application, the inner wall of the groove formed by the insulating bottom is the first groove wall. The force applied by the insulating bottom to the pole shoe includes a supporting force in the direction away from the groove bottom of the open groove and a pressure directed outward toward the groove wall of the open groove. Since the pole shoe is clamped with the groove wall of the open groove, the outward pressure of the insulating bottom on the pole shoe can increase the interaction force between the groove wall of the open groove and the pole shoe, thereby improving the connection stability between the pole shoe and the open groove.

[0042] 4. In the present application, the force applied to the pole shoe by the first groove wall inclined at the bottom of the insulation includes a supporting force in the direction away from the bottom of the open groove and a pressure directed outward toward the groove wall of the positioning portion. The outward pressure of the first groove wall on the pole shoe can increase the interaction force between the groove wall of the positioning portion and the pole shoe, thereby improving the bonding stability between the pole shoe and the positioning portion.

[0043] 5. In the present application, the insulating top of the pole shoe on the side away from the bottom of the open slot can further enhance the slot wedge stiffness, so that the slot wedge can withstand greater force, and the insulating top, insulating main body and insulating bottom cooperate with each other to jointly cover the pole shoe, which can prevent the pole shoe from being deformed by the magnetic force of the permanent magnet.

[0044] 6. In the present application, the pole shoe and the insulating body on the side away from the bottom of the open slot are coplanar, so that the surface of the pole shoe on the side away from the bottom of the open slot has no insulating body, which can avoid the insulating body on the surface of the slot wedge being higher than the end face of the iron core and affecting the size of the mechanical air gap.

[0045] 7. In the present application, the insulating body has a protective effect on both the front and rear ends of the pole shoe, which can prevent the pole shoe from being damaged during the slot wedge assembly process; the front and rear ends of the insulating body extend out of the open slot respectively, and the insulating body can also play a limiting role on the end winding outside the iron core.

[0046] 8. In this application, the inner wall surface of the groove corresponding to the insulating top is perpendicular to the inner wall surface of the groove corresponding to the insulating main body, so that the shape specifications formed by the pole shoe and the open groove are the same as the shape specifications of the existing semi-open groove, which is convenient for subsequent electromagnetic calculations. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without paying any creative work.

[0048] FIG1 is a schematic structural diagram of a slot wedge in Example 1 of the first aspect of the present application;

[0049] FIG2 is a top view of a slot wedge in Example 1 of the first aspect of the present application;

[0050] FIG3 is a cross-sectional view taken along line AA of FIG2 ;

[0051] FIG4 is a schematic diagram of the assembly of the core and the slot wedge in the first embodiment of the first aspect of the present application;

[0052] FIG5 is a second schematic diagram of the assembly of the core and the slot wedge in the first embodiment of the first aspect of the present application;

[0053] FIG6 is a schematic diagram of the structure of the opening groove in the first embodiment of the first aspect of the present application

[0054] FIG7 is a schematic diagram of the assembly of the open slot and the slot wedge in Example 1 of the first aspect of the present application;

[0055] FIG8 is a sectional view taken along line BB of FIG7 ;

[0056] FIG9 is a schematic structural diagram of a slot wedge in Example 2 of the first aspect of the present application;

[0057] FIG10 is a top view of the slot wedge in the second embodiment of the first aspect of the present application;

[0058] FIG11 is a cross-sectional view taken along line CC of FIG10 ;

[0059] FIG12 is a schematic diagram of the structure of the slot wedge in Example 3 of the first aspect of the present application;

[0060] FIG13 is a top view of the slot wedge in Example 3 of the first aspect of the present application;

[0061] FIG14 is a DD cross-sectional view of FIG13 .

[0062] FIG15 is a schematic structural diagram of a slot wedge in Example 1 of the second aspect of the present application;

[0063] FIG16 is a half-section view of the slot wedge in Example 1 of the second aspect of the present application;

[0064] FIG17 is a schematic diagram of the assembly of the iron core and the slot wedge in Example 1 of the second aspect of the present application;

[0065] FIG18 is a schematic structural diagram of an open slot in Example 1 of the second aspect of the present application;

[0066] FIG19 is a schematic diagram of the assembly of the open slot and the slot wedge in Example 1 of the second aspect of the present application;

[0067] FIG20 is a schematic structural diagram of a slot wedge in Example 2 of the second aspect of the present application;

[0068] FIG21 is a half-section view of a slot wedge in Example 2 of the second aspect of the present application;

[0069] FIG22 is a schematic diagram of the assembly of the iron core and the slot wedge in the second embodiment of the second aspect of the present application;

[0070] Figure 23 is a schematic diagram of the assembly of the open slot and the slot wedge in Example 2 of the second aspect of the present application.

[0071] In the figure: In the figure: 1. slot wedge; 2. iron core; 11. insulating body; 12. pole shoe; 110. insulating body; 111. insulating bottom; 112. insulating top; 113. connecting surface; 114. chamfered surface; 115. second protrusion; 116. third protrusion; 121. first protrusion; 21. opening slot; 211. card slot; 212. positioning portion. DETAILED DESCRIPTION

[0072] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0073] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0074] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0075] In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0076] Embodiment 1 of the first aspect

[0077] This embodiment provides a slot wedge 1, as shown in Figures 1-8, comprising an insulating body 11 and a pole shoe 12. The insulating body 11 is the backbone of the slot wedge 1. On the one hand, it is used to fix the pole shoe 12, and on the other hand, it is used to bear the force of the winding diffusion trend; the pole shoe 12 is used to connect with the slot sidewalls of the open slot 21 to form a magnetic circuit. The structure formed by the pole shoe 12 and the open slot 21 is similar to the existing semi-open slot structure. The pole shoe 12 is used to improve the electromagnetic performance of the iron core 2. Because the open slot 21 has a certain length, the insulating body 11 is in the shape of an elongated strip. Pole shoes 12 are provided on opposite sides of the insulating body 11. The outer sidewalls of the pole shoe 12 are fixedly connected to the slot sidewalls on the adjacent side of the open slot 21; the inner sidewalls of the pole shoe 12 are fixedly connected to the insulating body 11 to cut off the magnetic connection between the inner sidewalls of the pole shoe 12 and the open slot 21. Specifically, grooves for mounting the pole shoe 12 are provided on opposite sides of the insulating body 11. The sidewalls of the pole shoe 12 that connect to the sidewalls of the opening groove 21 are the outer sidewalls of the pole shoe 12, and the sidewalls of the pole shoe 12 that connect to the sidewalls of the groove are the inner sidewalls of the pole shoe 12. The opening groove 21 includes a groove bottom wall, a groove sidewall on the proximal side, and a groove sidewall on the distal side. The groove sidewall on the distal side is arranged opposite to the groove sidewall on the proximal side. The groove sidewall on the proximal side and the groove sidewall on the distal side are defined by their positions relative to the pole shoe 12. The groove sidewall on the proximal side of the opening groove 21 is a groove sidewall that is directly and fixedly connected to the outer sidewall of the pole shoe 12. When the insulating body 11 cuts off the magnetic connection between the inner side wall of the pole shoe 12 and the opening groove 21, it not only cuts off the magnetic connection between the inner side wall of the pole shoe 12 and the slot side wall on the away side of the opening groove 21, but also cuts off the magnetic connection between the inner side wall of the pole shoe 12 and the slot bottom wall of the opening groove 21 and the slot side wall on the adjacent side of the opening groove 21.

[0078] In some implementations of this embodiment, the insulating body 11 has an overall I-shaped cross-section, comprising an integrally connected insulating body portion 110, an insulating bottom portion 111, and an insulating top portion 112. The insulating body portion 110 is located between two grooves, separating the two pole shoes 12 on opposite sides of the insulating body 11; the insulating bottom portion 111 is located on the side of the pole shoe 12 closest to the bottom of the open groove 21; and the insulating top portion 112 is located on the side of the pole shoe 12 facing away from the bottom of the open groove 21. In other implementations of this embodiment, the insulating body 11 does not include the insulating top portion 112, and the insulating body 11 has an overall I-shaped cross-section.

[0079] In this embodiment, the slots on the core are open slots 21, which provide ample space for winding, facilitate winding of the core winding, and reduce the difficulty of the core slotting process. The pole shoes 12 of the slot wedge 1 cooperate with the open slots 21 of the core 2 to function as semi-open slots, thereby improving the electromagnetic performance of the core 2. In addition, the pole shoes 12 on both sides are separated by an insulating body 11, which prevents the pole shoes 12 from communicating with each other and generating eddy currents, thereby preventing the motor efficiency from being affected. An insulating bottom 111 is provided on the side of the pole shoe 12 near the bottom of the open slot 21 to provide insulation. The pole shoe 12 is fixed by the insulating body 11, which increases the overall rigidity of the slot wedge 1, and the insulating body 11 acts as a limiter for the winding. The insulating top 112 further strengthens the rigidity of the slot wedge 1, enabling the slot wedge 1 to withstand greater forces. The insulating top 112, the insulating body 110, and the insulating bottom 111 cooperate with each other to cover the pole shoe 12, thereby preventing the pole shoe 12 from being deformed by the magnetic force of the permanent magnet.

[0080] Optionally, the inner wall of the groove formed by the insulating bottom 111 is a first groove wall. The first groove wall is inclined in a direction away from the bottom of the opening groove 21 from the insulating bottom 111 to the insulating body 110. In this embodiment, the force exerted on the pole piece 12 by the inclined insulating bottom 111 includes a supporting force away from the bottom of the opening groove 21 and a pressure directed outward toward the groove wall of the opening groove 21. Because the pole piece 12 is engaged with the groove wall of the opening groove 21, the outward pressure exerted by the insulating bottom 111 on the pole piece 12 can enhance the interaction force between the groove wall of the opening groove 21 and the pole piece 12, thereby improving the connection stability between the pole piece 12 and the opening groove 21. Optionally, the groove sidewall includes a first groove wall, a second groove wall, and a connecting surface 113. The first groove wall is the inner wall of the insulating bottom 111, the second groove wall is the inner wall of the insulating top 112, and the connecting surface 113 is the inner wall of the insulating body 110. The ends of the connecting surface 113 are respectively connected to the inner sides of the first and second groove walls. As shown in Figure 3 in this embodiment, the second slot wall is parallel to the end face of the iron core 2, the connecting surface 113 is arranged perpendicular to the second slot wall, and a chamfered surface 114 can be provided at the connection between the connecting surface 113 and the second slot wall. The first slot wall is arranged at an angle, and the inner side of the pole shoe 12 fits with the groove, so that the shape of the pole shoe 12 after matching with the open slot 21 can be the same as the shape of the existing semi-open slot, so that the subsequent electromagnetic calculation is the same as the existing calculation method, which is convenient for designers to design and select.

[0081] Specifically, the insulating body 11 also includes insulating end portions that extend along the length of the pole shoe 12. These insulating end portions protect both the front and rear ends of the pole shoe 12, preventing damage to the pole shoe 12 during assembly of the slot wedge 1 into the open slot 21. Optionally, the front and rear ends of the insulating end portions extend beyond the open slot 21, respectively, and can also serve as position limits for the end windings outside the core 2.

[0082] Specifically, the outer side of the pole shoe 12 is provided with a first protrusion 121 extending outward, and the wall of the opening slot 21 is provided with a locking groove 211. The first protrusion 121 is engaged with the locking groove 211; the cross-sectional shape of the first protrusion 121 is the same as the cross-sectional shape of the locking groove 211. The present application does not limit the specific shapes of the first protrusion 121 of the pole shoe 12 and the locking groove 211 of the opening slot 21; as long as the concave and convex parts cooperate and can serve to limit the slot wedge 1, it is sufficient.

[0083] Optionally, a second protrusion 115 is provided on the insulating end portion 112 corresponding to the first protrusion 121, and the cross-sectional shape of the second protrusion 115 is the same as the cross-sectional shape of the first protrusion 121. The second protrusion 115 protects the first protrusion 121 and prevents the first protrusion 121 from being damaged during the assembly of the slot wedge 1 into the open slot 21.

[0084] This embodiment also provides a motor, as shown in FIG4 , which can be a disc motor. As shown in FIG5 , the motor can also be a radial motor. Although radial motor windings can now be wound by welding to complete the winding of the lapped winding, continuous wave windings still need to be wound using an open slot, that is, the slot wedge 1 of this embodiment is also applicable to radial motors. Specifically, as shown in FIG4-8 , the motor includes an iron core 2, and a plurality of open slots 21 are evenly distributed on the iron core 2. The open slots 21 are arranged in a one-to-one correspondence with the slot wedge 1, and the slot wedge 1 adopts the slot wedge 1 as described above. Optionally, the front and rear ends of the insulating body 11 extend out of the open slot 21 respectively. The shape and specifications formed by the pole shoe 12 in the slot wedge 1 and the open slot 21 are the same as the shape and specifications of the existing semi-open slot, which is convenient for subsequent electromagnetic calculations.

[0085] Taking a disc motor as an example for specific explanation, the iron core 2 is first rolled or stamped, and multiple open slots 21 are machined into the iron core 2. Locking grooves 211 are machined on both sides of the open slots 21 to facilitate the subsequent assembly of the slot wedge 1 and to retain the slot wedge 1, thus limiting the position of the slot wedge 1. Because the slot wedge 1 itself occupies the space in the open slot 21, the locking grooves 211 are located above the open slot 21. Optionally, the locking grooves 211 are 1-2 mm from the upper end surface of the iron core 2. This ensures that the locking grooves 211 retain the slot wedge 1 while preventing the slot wedge 1 from occupying too much space in the open slot 21.

[0086] Next, the pole shoe 12 of the slot wedge 1 is prepared. Optionally, the pole shoe 12 is partially composed of soft magnetic materials, including but not limited to silicon steel sheets and SMC (soft magnetic composite materials). The soft magnetic material is then formed by riveting the silicon steel sheets, self-bonding silicon steel sheets, sintering the soft magnetic composite materials, and other methods. The shape of the pole shoe 12, combined with the open slot 21, forms the same shape as the existing semi-open slot, facilitating electromagnetic calculations and design calculations for designers.

[0087] After the pole shoe 12 is partially formed, it is placed in a molding die, and then the composite material of the insulating body 11 is added to wrap the pole shoe 12, wherein the composite material is a material with good rigidity and insulation, including but not limited to glass fiber, etc. Subsequently, the slot wedge 1 is manufactured by molding.

[0088] This embodiment integrates the pole shoe 12 and the insulating body 11 into a single unit, without any intermixing of materials. This prevents eddy current losses caused by the soft magnetic material of the pole shoe 12 connecting to the core 2. Finally, the winding is placed into the open slot 21, and the slot wedge 1 is inserted into the slot 21, so that the first protrusion 121 of the pole shoe 12 mates with the retaining groove 211 of the slot 21, completing the final assembly. The pole shoe 12 contacts the core 2, forming a magnetic circuit that replaces the pole shoe 12 in a semi-open slot. The insulating body 11 serves as the backbone of the slot wedge 1, capable of withstanding the forces of the winding's spreading tendency.

[0089] The riveting and self-locking processes, core winding processes, and composite material molding processes involved in this technical solution are all relatively mature and relatively easy to process. This embodiment can solve problems such as winding line difficulties, increased air gap harmonics, and increased eddy currents in magnetic slot wedges at a low cost and within technical requirements.

[0090] Embodiment 2 of the first aspect

[0091] As shown in Figures 9-11, the difference between this embodiment and the first embodiment of the first aspect is that a plurality of pole shoes 12 are provided on both sides of the insulating body 11, and the number of pole shoes 12 is at least 2. In this embodiment, the number of pole shoes 12 on each side is 2, and the two pole shoes 12 on the same side are separated by the insulating body 11. Because the pole shoes 12 on the same side are separated by the insulating body 11, the insulating body 11 is made of a composite material with good rigidity and insulation. Compared with the silicon steel sheet and SMC of the pole shoes 12, the ability to resist deformation of this embodiment is stronger than that of Example 1. The other structures of this embodiment are the same as those of Example 1 of the first aspect.

[0092] Embodiment 3 of the first aspect

[0093] Some motors will use a single-sided asymmetric pole shoe 12 on the motor stator. To this end, as shown in Figures 12-14, the difference between this embodiment and the first embodiment of the first aspect is that a pole shoe 12 is provided on one side of the insulating body 11, and the number of pole shoes 12 can be arbitrary. In this embodiment, the number of pole shoes 12 is 1. A third protrusion 116 symmetrical to the first protrusion 121 is provided on the other side of the insulating body 11. During assembly, the first protrusion 121 and the third protrusion 116 are respectively connected to the card slot 211 of the opening slot 21. The other structures of this embodiment are the same as those of the first embodiment of the first aspect.

[0094] Embodiment 1 of the second aspect

[0095] This embodiment provides a slot wedge 1, as shown in Figures 15-19, comprising an insulating body 11 and a pole shoe 12. The insulating body 11 is the backbone of the slot wedge 1. It is used to fix the pole shoe 12 on one hand and to bear the force of the winding diffusion tendency on the other hand. The pole shoe 12 is used to connect with the slot wall of the open slot 21 to form a magnetic circuit. The structure formed by the pole shoe 12 and the open slot 21 is similar to the existing semi-open slot 21 structure. The pole shoe 12 is used to improve the electromagnetic performance of the iron core 2. Because the open slot 21 has a certain length, the insulating body 11 is in the shape of an elongated strip. Pole shoes 12 are provided on opposite sides of the insulating body 11. A positioning portion 212 is provided at the opening of the open slot 21. The outer wall of the pole shoe 12 is bonded to the positioning portion 212 by magnetic conductive adhesive. The insulating body 11 also cuts off the magnetic connection between the inner wall of the pole shoe 12 and the open slot 21. Specifically, a groove for mounting the pole shoe 12 is provided on the outer side wall of the insulating body 11, and the inner side wall of the pole shoe 12 is in contact with the groove wall of the groove; the insulating body 11 includes an insulating body portion 110 located between the pole shoe 12 and the groove side wall of the opening groove 21 away from the positioning portion 212, and an insulating bottom portion 111 connected to the insulating body portion 110 and located on the side of the pole shoe 12 close to the bottom of the opening groove; the pole shoes 12 on both sides are separated by the insulating body portion 110. In this embodiment, a pole shoe 12 is provided on each side of the insulating body 11. The number of pole shoes 12 provided on each side of the insulating body 11 can also be 2, 3, 4, or more, and the multiple pole shoes 12 are spaced apart on both sides of the insulating body 11 along the length direction of the insulating body 11.

[0096] In this embodiment, the slot of the core 2 is an open slot structure with a large offline space, which is convenient for offline winding of the core 2; the pole shoe 12 of the slot wedge 1 cooperates with the open slot 21 of the core 2, and can play the role of a semi-open slot 21, which can improve the electromagnetic performance of the core 2; the pole shoe 12 and the positioning part 212 are bonded by magnetic conductive glue, which is simple to install and has a fixed installation position; the pole shoes 12 on both sides are separated by the insulating main body 110, which can avoid the connection between the pole shoes 12 on both sides to generate eddy currents and avoid affecting the efficiency of the motor; the pole shoe 12 is provided with an insulating bottom 111 on the side of the slot bottom close to the open slot 21, which plays an insulating role, and the pole shoe 12 is fixed by the insulating main body 11, which can increase the overall stiffness of the slot wedge 1, and the insulating main body 11 can limit the winding.

[0097] Optionally, a groove for mounting the pole shoe 12 is provided on the sidewall of the insulating body 11. The inner sidewall of the pole shoe 12 is aligned with the groove wall, and the outer sidewall of the pole shoe 12 is coplanar with the outer sidewall of the insulating body 11. The inner sidewall of the groove wall formed by the insulating bottom 111 is a first groove wall. The first groove wall is inclined away from the bottom of the opening groove in the direction from the insulating bottom 111 to the insulating body 110. In this embodiment, the force exerted on the pole shoe 12 by the inclined first groove wall on the insulating bottom 111 includes a supporting force away from the bottom of the opening groove 21 and a pressure directed outward toward the groove wall of the positioning portion 212. The outward pressure exerted by the first groove wall on the pole shoe 12 can enhance the interaction force between the groove wall of the positioning portion 212 and the pole shoe 12, thereby improving the bonding stability between the pole shoe 12 and the positioning portion 212.

[0098] Optionally, the surface of the pole shoe 12 on the side away from the slot bottom of the open slot 21 is coplanar with the end surface of the iron core 2 where the open slot 21 is provided.

[0099] In some implementations of this embodiment, the insulating body 11 further includes an insulating top portion 112 connected to the insulating body portion 110. The insulating top portion 112 is located on the other side of the pole shoe 12, away from the bottom of the open slot. The inner wall surface of the corresponding groove of the insulating top portion 112 is perpendicular to the inner wall surface of the corresponding groove of the insulating body portion 110. The inner sidewall of the pole shoe 12 conforms to the inner walls of the corresponding grooves of the insulating body portion 110, the insulating top portion 112, and the insulating bottom portion 111. This arrangement ensures that the shape of the pole shoe 12 after mating with the open slot 21 is consistent with the shape of the existing semi-open slot 21, allowing subsequent electromagnetic calculations to be consistent with existing calculation methods, facilitating design and selection by designers. The insulating top portion 112 further strengthens the rigidity of the slot wedge 1, enabling the slot wedge 1 to withstand greater forces. Furthermore, the insulating body 11 at this location cooperates with the insulating body 11 on the side of the pole shoe 12 near the bottom of the open slot 21 to cover the pole shoe 12, preventing deformation of the pole shoe 12 due to the magnetic force of the permanent magnet. However, such a configuration would cause the insulating body 11 to be higher than the end surface of the core 2, potentially affecting the size of the mechanical air gap. In other implementations of this embodiment, the insulating body 11 may not need to have the insulating top 112, and the surface of the pole shoe 12 facing away from the bottom of the open slot 21 may be flush with the upper end surface of the insulating body 110.

[0100] Optionally, the insulating body 11 further includes insulating ends that block the length of the pole shoe 12. The insulating ends protect both the front and rear ends of the pole shoe 12, thereby preventing the pole shoe 12 from being damaged during the assembly of the slot wedge 1 into the open slot 21.

[0101] Optionally, the insulating bottom 111 extends into the open slot 21 below the positioning portion 212, and the outer side of the insulating bottom 111 fits against the slot wall of the open slot 21. The insulating bottom 111 can further improve the overall rigidity of the slot wedge 1 and increase the ability of the insulating body 11 to withstand the winding diffusion trend.

[0102] Optionally, the positioning portion 212 is a V-shaped groove, and the outer side surface of the pole shoe 12 is inclined outwardly in a direction away from the bottom of the opening groove 21. The outer side surface of the pole shoe 12 is fitted with the positioning portion 212. Since the V-shaped groove has two inclined limiting surfaces, the limiting surfaces can fit with the two outwardly inclined outer side surfaces of the pole shoe 12, thereby having a positioning effect on the pole shoe 12 and preventing the pole shoe 12 from moving toward the bottom of the opening groove 21. Alternatively, the positioning portion 212 can also be a rectangular groove, the width of the rectangular groove is greater than the width of the opening groove 21, the outer side surface of the pole shoe 12 is not inclined, the outer side surface of the pole shoe 12 fits with the groove wall of the rectangular groove, the rectangular groove and the opening groove 21 form a step shape, and the rectangular groove can also play a positioning role for the pole shoe 12.

[0103] This embodiment also provides a motor, as shown in Figures 17-19, comprising an iron core 2 having a plurality of open slots 21 evenly distributed thereon. The open slots 21 are arranged in a one-to-one correspondence with slot wedges 1, and the slot wedges 1 employ the same slot wedge 1 as previously described. The open slots 21 have the aforementioned structure of open slots 21 with positioning portions 212. The motor of this embodiment can be a disc motor or a radial motor. Although radial motor windings can now be welded to produce lapped windings, continuous wave windings still require the open slot method. In other words, the slot wedges 1 of this embodiment are also applicable to radial motors.

[0104] Optionally, the front and rear ends of the insulating body 11 extend out of the open slots 21 respectively; the insulating body 11 can also limit the end windings outside the iron core 2.

[0105] Taking a disc motor as an example for specific explanation, first, the iron core 2 is rolled or stamped, and a plurality of open slots 21 are processed on the iron core 2, and a positioning portion 212 is processed at the opening of the open slot 21 to facilitate the subsequent assembly of the slot wedge 1. The positioning portion 212 plays a role in connecting and positioning the pole shoe 12.

[0106] Next, the pole shoe 12 of the slot wedge 1 is prepared. Optionally, the pole shoe 12 is partially composed of soft magnetic materials, including but not limited to silicon steel sheets and SMC (soft magnetic composite materials). The soft magnetic material is then formed by riveting the silicon steel sheets, self-bonding the silicon steel sheets, or sintering the soft magnetic composite materials. The shape of the pole shoe 12, in conjunction with the open slot 21, forms the same shape as the existing semi-open slot 21, facilitating electromagnetic calculations and facilitating design calculations by designers.

[0107] After the pole shoe 12 is partially formed, it is placed in a molding die, and then the composite material of the insulating body 11 is added to wrap the pole shoe 12, wherein the composite material is a material with good rigidity and insulation, including but not limited to glass fiber, etc. Subsequently, the slot wedge 1 is manufactured by molding.

[0108] This embodiment integrates the pole shoe 12 and the insulating body 11 into a single unit, without any intermixing of materials. This prevents eddy current losses caused by the soft magnetic material of the pole shoe 12 connecting to the iron core 2. Finally, the winding is placed into the open slot 21, and the pole shoe 12 is bonded to the positioning portion 212 of the open slot 21 using magnetic adhesive to complete the final assembly. The pole shoe 12 contacts the iron core 2, forming a magnetic circuit that replaces the pole shoe 12 in the semi-open slot 21. The insulating body 11 serves as the backbone of the slot wedge 1, capable of withstanding the forces of the winding's spreading tendency.

[0109] The riveting and self-locking processes, core winding processes, and composite material molding processes involved in this technical solution are all relatively mature and relatively easy to process. This embodiment can solve problems such as winding line difficulties, increased air gap harmonics, and increased eddy currents in magnetic slot wedges at a low cost and within technical requirements.

[0110] Embodiment 2 of the second aspect

[0111] As shown in Figures 20-23, the difference between this embodiment and the first embodiment of the second aspect is that the pole shoe 12 and the insulating body 11 on the side of the slot bottom away from the open slot 21 are coplanar, which can ensure that the surface of the pole shoe 12 on the side of the slot bottom away from the open slot 21 is free of the insulating body 11, thereby preventing the insulating body 11 on the surface of the slot wedge 1 from protruding above the end face of the iron core 2 and affecting the size of the mechanical air gap. The shape of the pole shoe 12 after mating with the open slot 21 is the same as the shape of the existing semi-open slot 21, making subsequent electromagnetic calculations the same as existing calculation methods, which is convenient for designers to design and select. This embodiment does not include the third slot wall 113 of the first embodiment of the second aspect. The other structures of this embodiment are the same as those of the first embodiment of the second aspect.

[0112] Finally, it should be noted that the above are only preferred embodiments of the present application and are not intended to limit the present application. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent replacements for some of the technical features therein. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should be included in the scope of protection of the present application.

Claims

1. A slot wedge, characterized in that: include: Insulation body; One or more pole shoes, wherein the pole shoes are arranged on one side or two opposite sides of the insulating body, and the outer side wall of the pole shoe is fixedly connected to the slot side wall on the adjacent side of the opening slot of the iron core; the inner side wall of the pole shoe is fixedly connected to the insulating body to cut off the magnetic connection between the inner side wall of the pole shoe and the opening slot.

2. The slot wedge according to claim 1, characterized in that: A groove is provided on one side or two opposite sides of the insulating body, and the pole shoe is installed on the groove; the side wall of the pole shoe connected to the side wall of the opening groove is the outer side wall of the pole shoe, and the side wall of the pole shoe connected to the side wall of the groove is the inner side wall of the pole shoe.

3. The slot wedge according to claim 2, characterized in that: The insulating body includes a connected insulating body part and an insulating bottom; the insulating body part is located between the pole shoe and the slot sidewall on the far side of the open slot, and the insulating bottom is located on the side of the pole shoe close to the slot bottom of the open slot.

4. The slot wedge according to claim 3, characterized in that: The inner wall of the groove wall formed by the insulating bottom is the first groove wall; in the direction from the insulating bottom to the insulating main body, the first groove wall is inclined in a direction away from the groove bottom of the opening.

5. The slot wedge according to any one of claims 1 to 3, characterized in that: The insulating body further comprises an insulating top portion connected to the insulating body portion, and the insulating top portion is located on the other side of the pole shoe facing away from the bottom of the open slot.

6. The slot wedge according to any one of claims 1 to 5, characterized in that: A first protrusion extending outward is provided on the outer side of the pole shoe, and a clamping groove is provided on the side wall of the open groove, and the first protrusion is clamped with the clamping groove; the cross-sectional shape of the first protrusion is the same as the cross-sectional shape of the clamping groove.

7. The slot wedge according to claim 6, characterized in that: The insulating body also includes insulating ends blocking the two ends of the pole shoe in the length direction.

8. The slot wedge according to claim 7, characterized in that: The insulating end portion is provided with a second protrusion corresponding to the first protrusion, and the cross-sectional shape of the second protrusion is the same as the cross-sectional shape of the first protrusion.

9. The slot wedge according to any one of claims 1 to 8, characterized in that: The pole shoe is disposed on one side of the insulating body, and the other side of the insulating body facing away from the pole shoe is fixedly connected to the other slot side wall of the open slot.

10. The slot wedge according to claim 9, characterized in that A third protrusion is provided on the other side of the insulating body facing away from the pole shoe, and the third protrusion is clamped and fixed to the other side wall of the open slot.

11. The slot wedge according to any one of claims 1 to 8, characterized in that: The pole shoes are disposed on opposite sides of the insulating body, and the insulating body separates the pole shoes located on the opposite sides of the insulating body.

12. A slot wedge, characterized in that: include: Insulation body; One or more pole shoes, the pole shoes are arranged on one side or two opposite sides of the insulating body; A positioning portion is provided at the opening of the opening slot of the iron core, and the outer side wall of the pole shoe is fixed to the positioning portion by bonding with magnetic conductive adhesive; and The insulating body cuts off the magnetic connection between the inner side wall of the pole shoe and the open groove.

13. The slot wedge according to claim 12, characterized in that: A groove for mounting the pole shoe is provided on the outer side wall of the insulating body, and the inner side wall of the pole shoe is in contact with the groove wall of the groove; the insulating body comprises an insulating body portion located between the pole shoe and the groove side wall of the opening groove away from the positioning portion, and an insulating bottom portion connected to the insulating body portion and located on the side of the pole shoe close to the bottom of the opening groove.

14. The slot wedge according to claim 13, characterized in that One end of the insulating bottom away from the insulating main body is in contact with the slot side wall of the open slot to cut off the magnetic connection between the inner side wall of the pole shoe and the open slot.

15. The slot wedge according to claim 13, characterized in that: The outer side wall of the pole shoe is coplanar with the outer side wall of the insulating body.

16. The slot wedge according to claim 13, characterized in that: The inner side wall of the groove wall formed by the insulating bottom is the first groove wall; in the direction from the insulating bottom to the insulating main body, the first groove wall is inclined in a direction away from the open groove bottom.

17. The slot wedge according to any one of claims 12 to 16, characterized in that: The surface of the pole shoe facing away from the bottom of the open slot is coplanar with the end surface of the iron core where the open slot is provided.

18. The slot wedge according to any one of claims 13 to 16, characterized in that The insulating body further comprises an insulating top portion connected to the insulating body portion, and the insulating top portion is located on the other side of the pole shoe facing away from the bottom of the open slot.

19. The slot wedge according to claim 18, characterized in that An inner wall surface of the insulating top portion corresponding to the groove is perpendicular to an inner wall surface of the insulating main body portion corresponding to the groove.

20. The slot wedge according to any one of claims 13 to 16, characterized in that The insulating body also includes insulating ends blocking the two ends of the pole shoe in the length direction.

21. The slot wedge according to any one of claims 12 to 20, characterized in that The positioning portion is a V-shaped groove, and the outer side wall of the pole shoe is adapted to the shape of the groove wall of the positioning portion.

22. The slot wedge according to any one of claims 12 to 21, characterized in that The pole shoe is disposed on one side of the insulating body, and the other side of the insulating body facing away from the pole shoe is fixedly connected to the other slot side wall of the open slot.

23. The slot wedge according to any one of claims 12 to 21, characterized in that The pole shoes are disposed on opposite sides of the insulating body, and the insulating body separates the pole shoes located on the opposite sides of the insulating body.

24. A motor, comprising an iron core, characterized in that: The iron core is provided with a plurality of open slots, and the open slots are arranged in one-to-one correspondence with slot wedges, and the slot wedges are the slot wedges described in any one of claims 1-23.

25. The electric machine according to claim 24, characterized in that The front and rear ends of the insulating body extend out of the opening slot respectively.

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