Electric motor stator and manufacturing method therefor, driving electric motor, aircraft and transportation vehicle

Abstract

The present application relates to the technical field of traffic and transportation. Disclosed are an electric motor stator and a manufacturing method therefor, a driving electric motor, an aircraft and a transportation vehicle. The electric motor stator is used in a driving electric motor of an aircraft, and comprises a stator yoke, a plurality of stator teeth and a plurality of stator end plates, wherein the plurality of stator teeth are arranged at intervals in the circumferential direction of the stator yoke; the stator end plates and the stator teeth are arranged in a manner of corresponding to each other on a one-to-one basis, the stator end plates are mounted on the sides of the stator teeth away from the stator yoke, and plate surfaces of the stator end plates are connected to end surfaces of the stator teeth; and in the circumferential direction of the stator yoke, the stator end plates extend beyond the stator teeth, and the stator yoke, the stator teeth and the stator end plates enclose stator slots having openings.

Description

Motor stator and manufacturing method thereof, drive motor, aircraft, and vehicle

[0001] Priority information

[0002] This application claims priority to Chinese patent application No. 202311797720.0, filed on December 25, 2023, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the field of transportation technology, and in particular to a motor stator and a manufacturing method thereof, a drive motor, an aircraft, and a vehicle. Background Art

[0004] With the development of transportation technology, flying cars have recently emerged. Some flying cars consist of two parts: a road-based vehicle and an aircraft. The road-based vehicle can be driven on the road like a car, while the aircraft can fly when needed, using motors and other drive systems to rotate the rotors. The aircraft can also be combined with the road-based vehicle to form a complete flying car. To reduce the flight load, the aircraft in a flying car is typically lightweight. However, a light aircraft can easily affect its flight stability.

[0005] Motor stator slots generally come in two forms: open slots (Figure 1) and semi-open slots (Figure 2). Open slots simplify the process, allowing coils to be easily placed onto stator teeth from the outside of the slot toward the inside. However, they result in large cogging torque and torque ripple, and low flux utilization, significantly negatively impacting motor efficiency. Semi-open slots reduce cogging torque and torque ripple, while also increasing flux utilization and motor efficiency. However, they require more complex coil assembly and result in higher overall manufacturing costs. Summary of the Invention

[0006] The main purpose of this application is to propose a motor stator and a manufacturing method thereof, a drive motor, an aircraft, and a vehicle, aiming to reduce the cogging torque and torque fluctuation at a lower manufacturing cost.

[0007] To achieve the above-mentioned purpose, the motor stator proposed in the present application is used for a drive motor of an aircraft, and the motor stator includes a stator yoke, a plurality of stator teeth and a plurality of stator end plates, and the plurality of stator teeth are arranged at intervals along the circumferential direction of the stator yoke; the stator end plates are arranged in a one-to-one correspondence with the stator teeth, and the stator end plates are installed on the side of the stator teeth away from the stator yoke, and the plate surface of the stator end plate is connected to the end surface of the stator teeth; along the circumferential direction of the stator yoke, the stator end plates extend out of the stator teeth, and the stator yoke, the stator teeth and the stator end plates enclose a stator slot with an opening.

[0008] In one embodiment, the width direction of the stator teeth and the width direction of the stator end plate are respectively consistent with the circumferential direction of the stator yoke, and the width of the stator end plate is greater than or equal to the width of the stator teeth.

[0009] In one embodiment, a first groove is provided on the end surface of the stator tooth facing the stator end plate, and an embedded body is provided on the plate surface of the stator end plate facing the stator tooth; the embedded body is embedded in the first groove to fix the stator tooth and the stator end plate.

[0010] In one embodiment, the width direction of the first groove and the width direction of the embedded body are respectively consistent with the circumferential direction of the stator yoke; the first groove includes a first slot segment and a second slot segment, the second slot segment is arranged on the side of the first slot segment away from the stator yoke, and the width of the second slot segment is smaller than the width of the first slot segment; the embedded body includes a first embedded segment and a second embedded segment, the first embedded segment is arranged on the side of the second embedded segment away from the stator end plate, and the width of the first embedded segment is larger than the width of the second embedded segment; the second embedded segment is arranged in the second slot segment, the first embedded segment is arranged in the first slot segment, and both sides of the first embedded segment along the width direction respectively abut against the wall surface of the first slot segment.

[0011] In one embodiment, in a cross section perpendicular to the axial direction of the stator yoke, at least part of the contour of the second embedded section is set to be arc-shaped; and / or, in a cross section perpendicular to the axial direction of the stator yoke, the contour of the side of the second embedded section facing away from the stator end plate is set to be arc-shaped; and / or, in a cross section perpendicular to the axial direction of the stator yoke, the second embedded section is provided with an inclined contour section on the side facing the stator end plate, and the distance from the inclined contour section to the stator end plate increases in a direction away from the stator teeth.

[0012] In one embodiment, an adhesive layer is provided between the end surface of the stator tooth facing the stator end plate and the plate surface of the stator end plate facing the stator tooth, and the two sides of the adhesive layer respectively adhere and fix the end surface of the stator tooth and the plate surface of the stator end plate.

[0013] In one embodiment, the adhesive layer extends beyond the stator teeth along the circumferential direction of the stator yoke.

[0014] In one embodiment, the stator yoke, the stator teeth and the stator end plate are arranged in sequence from the inside to the outside, and the motor stator further includes a fixing belt; along the circumferential direction of the stator yoke, the fixing belt is wound around the outer surface of the stator end plate to fix the stator end plate on the stator teeth; and / or, a second groove is provided on the plate surface of the stator end plate facing away from the stator yoke, and the second groove is used to face the peripheral wall of the motor rotor; and / or, in a cross section perpendicular to the axial direction of the stator yoke, at least one of the stator end plates facing away from the stator yoke is provided. Part of the contour is set to be arc-shaped, and the arc-shaped contour of the stator end plate facing away from the stator yoke is used to be set parallel to the peripheral wall of the motor rotor; and / or, the stator end plate includes a protruding portion, and the protruding portion extends out of the stator tooth along the circumferential direction of the stator yoke; on a cross-section perpendicular to the axial direction of the stator yoke, the angle between the contour of the protruding portion toward the stator yoke and the side surface of the stator tooth is greater than or equal to 90 degrees; and / or, the difference between the magnetic permeability of the stator end plate and the magnetic permeability of the stator tooth is greater than or equal to zero and less than or equal to a preset value.

[0015] In one embodiment, the motor stator includes a coil sleeved outside the stator teeth, and the cross-section of the wire body of the coil is set to be rectangular;

[0016] The coil includes multiple layers of wire loops, and the wire loops are formed by bending an integrally formed wire body.

[0017] The present application also proposes a drive motor, which is used for an aircraft. The drive motor includes a motor rotor and the above-mentioned motor stator, and the peripheral wall of the motor rotor is arranged opposite to the stator end plate.

[0018] In one embodiment, along the radial direction of the stator yoke, the plate surface of the stator end plate is spaced apart from the circumferential wall of the motor rotor to form an air gap, and the width direction of the air gap is consistent with the radial direction of the stator yoke; the ratio of the width of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.3 and less than or equal to 1, and the virtual circle passes through the center of the width of the air gap; and / or the ratio of the maximum thickness of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.04 and less than or equal to 0.3, and the virtual circle passes through the center of the width of the air gap; and / or the ratio of the width of the stator end plate to the maximum thickness of the stator end plate is greater than or equal to 1.5 and less than or equal to 15.5.

[0019] In one embodiment, the ratio of the width of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.35 and less than or equal to 0.9; and / or the ratio of the maximum thickness of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.05 and less than or equal to 0.25; and / or the ratio of the width of the stator end plate to the maximum thickness of the stator end plate is greater than or equal to 1.7 and less than or equal to 15.

[0020] The present application also proposes an aircraft, which includes a cockpit, a rotor and the above-mentioned drive motor, wherein the cockpit is used for movably mounting on a road vehicle, the drive motor is mounted on the cockpit, and the drive motor is transmission-connected to the rotor to drive the rotor to rotate.

[0021] The present application also proposes a vehicle, which includes a road vehicle and the above-mentioned aircraft.

[0022] The present application also proposes a method for manufacturing a motor stator, the method comprising the following steps performed in sequence:

[0023] forming the stator yoke and stator teeth;

[0024] Sleeving the coil onto the stator teeth along the radial direction of the stator yoke;

[0025] The plate surface of the stator end plate is connected to the end surface of the stator tooth, so that the stator end plate extends out of the stator tooth along the circumferential direction of the stator yoke.

[0026] The technical solution of the present application is to enable the stator end plate to extend the stator teeth along the circumferential direction of the stator yoke, so that the stator yoke, stator teeth and stator end plate can enclose a semi-open stator slot, and the motor stator can be used to reduce the tooth slot torque and torque fluctuation; the plate surface of the stator end plate is connected to the end face of the stator tooth, so that the coil can be installed by radial loading and other methods before installing the stator end plate, thereby reducing the difficulty of the coil assembly process; in addition, the stator end plate is relatively flat, which is conducive to increasing the radial length of the stator teeth, thereby providing a longer guide length for radial loading and other installation methods of the coil, and is also conducive to reducing the difficulty of the coil assembly process; that is, the motor stator in this solution can reduce the tooth slot torque and torque fluctuation at a lower manufacturing cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] 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 ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0028] FIG1 is a schematic cross-sectional view of an embodiment of a driving motor in the related art;

[0029] FIG2 is a schematic cross-sectional view of another embodiment of a driving motor in the related art;

[0030] FIG3 is a schematic structural diagram of an embodiment of a vehicle in the present application;

[0031] FIG4 is a schematic cross-sectional view of an embodiment of a drive motor in the present application;

[0032] FIG5 is a partial schematic diagram of an embodiment of a motor stator in the present application;

[0033] FIG6 is another partial schematic diagram of an embodiment of a motor stator in the present application;

[0034] FIG7 is another partial schematic diagram of an embodiment of a motor stator in the present application;

[0035] FIG8 is another partial schematic diagram of an embodiment of a drive motor in the present application;

[0036] FIG9 is another partial schematic diagram of an embodiment of a drive motor in the present application;

[0037] FIG10 is a diagram showing the magnetic field distribution of an embodiment of a driving motor in the related art;

[0038] FIG11 is a diagram showing the magnetic field distribution of an embodiment of a drive motor in the present application;

[0039] FIG12 is a torque comparison diagram of an embodiment of a drive motor in the present application;

[0040] FIG13 is a torque fluctuation comparison diagram of an embodiment of a drive motor in the present application;

[0041] FIG14 is a comparison diagram of motor efficiency of an embodiment of a drive motor in the present application;

[0042] FIG15 is a comparison diagram of the cogging torque of an embodiment of a drive motor in the present application;

[0043] FIG16 is a partial schematic diagram of another embodiment of the drive motor in the present application;

[0044] FIG17 is a partial schematic diagram of another embodiment of the drive motor in the present application;

[0045] FIG18 is a partial schematic diagram of another embodiment of the drive motor in the present application;

[0046] FIG19 is a partial schematic diagram of another embodiment of the drive motor in the present application;

[0047] FIG20 is a partial schematic diagram of another embodiment of the drive motor in the present application;

[0048] FIG21 is a schematic diagram of the steps of an embodiment of a method for manufacturing a motor stator in the present application;

[0049] FIG22 is a flow chart of an embodiment of a method for manufacturing a motor stator in the present application.

[0050] The realization of the objectives, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. Modes for Carrying Out the Invention

[0051] The following will be combined with the accompanying 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 of this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0052] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back, etc.), such directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0053] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present application, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of such features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme in which A and B are satisfied at the same time. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement it. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0054] In the related art, motor stator slots generally come in two forms: open slots (Figure 1) and semi-open slots (Figure 2). Open slots simplify the process, allowing coils to be easily placed onto stator teeth from the outside of the slot toward the inside. However, they result in large cogging torque and torque fluctuations, and low flux utilization, significantly negatively impacting motor efficiency. Semi-open slots can reduce cogging torque and torque fluctuations, while also providing higher flux utilization and motor efficiency. However, they require more complex coil assembly processes and result in higher overall manufacturing costs.

[0055] Therefore, this application proposes a motor stator designed to reduce cogging torque and torque ripple at a low manufacturing cost. This motor stator can be used in an aircraft drive motor, but it can also be used in drive motors for other devices, without limitation in this embodiment. The following uses the motor stator's use in an aircraft drive motor as an example to explain its structure.

[0056] Referring to Figures 3 and 4 , the motor stator is suitable for use in an aircraft, such as a flying car, that can form an integrated structure with a road-based vehicle 500. Specifically, the flying car comprises the road-based vehicle 500 and the aforementioned aircraft. Specifically, the aircraft may include a cabin 300, rotors 400, and a drive motor. The cabin 300 is designed to be movably mounted on the road-based vehicle 500, allowing the aircraft to be movably mounted on the road-based vehicle 500. The drive motor is mounted on the cabin 300 and is transmission-connected to the rotors 400 to drive the rotors 400 for rotation. The cabin 300 can be used to carry passengers or cargo. The drive motor comprises a motor rotor 200 and a motor stator 100. The motor rotor 200 typically contains permanent magnets. The peripheral wall of the motor rotor 200 is positioned opposite the stator end plate 130, so that the motor rotor 200 rotates when an alternating magnetic field is generated by the motor stator 100.

[0057] In a flying car, for an aircraft that is mounted on a road-moving vehicle 500, the weight is typically minimized to reduce flight loads. This translates to extremely stringent weight requirements. When the aircraft is lightweight, higher performance requirements, such as cogging torque and torque ripple, are imposed on the drive motor to minimize its adverse effects on the aircraft's flight stability. The drive motor on an aircraft is relatively large. For example, when the stator teeth are spaced apart from the circumferential wall of the motor rotor to form an air gap, the diameter of a virtual circle passing through the center of the air gap typically ranges from 150 to 350 mm (millimeter), and the maximum diameter can reach 1000 mm. Therefore, for an aircraft drive motor, if the stator slots are semi-open slots, the coil assembly process is relatively complex. For example, hairpin-shaped wires must be inserted axially into the stator slots one by one, and then the hairpins must be bent and welded. This results in a complex manufacturing process and high overall manufacturing costs.

[0058] Therefore, to reduce the torque fluctuation of the aircraft's drive motor, related technologies usually make improvements in electronic control technology. For example, by detecting the phase and amplitude of the torque fluctuation and then adding a corresponding reverse compensation current.

[0059] In order to reduce the cogging torque and torque fluctuation at a lower manufacturing cost, referring to Figures 4 and 5, the motor stator 100 in the present application includes a stator yoke 110, a plurality of stator teeth 120 and a plurality of stator end plates 130. The plurality of stator teeth 120 are arranged at intervals along the circumferential direction of the stator yoke 110, and the stator end plates 130 are arranged in a one-to-one correspondence with the stator teeth 120; wherein, the plurality of stator teeth 120 can be evenly arranged along the circumferential direction of the stator yoke 110. In addition, the stator teeth 120 and the stator yoke 110 can be integrally formed by stamping silicon steel sheets, etc., and then the integral stator teeth 120 and stator yoke 110 are formed by stacking multiple layers of silicon steel sheets. Among them, the stator end plate 130 can be understood as a relatively flat plate-like structure. Referring to Figure 5, the motor stator 100 also includes a coil 150 that is sleeved outside the stator teeth 120.

[0060] The stator end plate 130 is installed on the side of the stator teeth 120 away from the stator yoke 110. It can be understood that the stator end plate 130 and the stator teeth 120 are formed separately, and the stator end plate 130 and the stator teeth 120 are then installed and connected through a subsequent assembly process. Referring to Figure 5, the plate surface of the stator end plate 130 is connected to the end surface of the stator teeth 120, for example, by bonding, clamping, etc. Along the circumferential direction of the stator yoke 110, the stator end plate 130 extends out of the stator teeth 120, thereby forming a protruding portion 136; the stator yoke 110, the stator teeth 120 and the stator end plate 130 enclose a stator slot 101 with an opening, which can be understood as the stator yoke 110, the stator teeth 120 and the stator end plate 130 enclose a semi-open slot.

[0061] In this embodiment, by making the stator end plate 130 extend out of the stator teeth 120 in the circumferential direction of the stator yoke 110, the stator yoke 110, the stator teeth 120 and the stator end plate 130 can enclose a semi-open stator slot 101, and the motor stator 100 can be used to reduce the cogging torque and torque fluctuation; the plate surface of the stator end plate 130 is connected to the end surface of the stator teeth 120, so that the coil 150 can be installed by radial insertion or other methods before installing the stator end plate 130, thereby reducing the difficulty of the assembly process of the coil 150; in addition, the stator end plate 130 is relatively flat, which is conducive to increasing the radial length of the stator teeth 120, thereby providing a longer guide length for the radial insertion or other installation methods of the coil 150, which is also conducive to reducing the difficulty of the assembly process of the coil 150; that is, the motor stator 100 in this solution can reduce the cogging torque and torque fluctuation at a lower manufacturing cost.

[0062] In some embodiments, the cross-section of the conductor body of coil 150 is configured to be rectangular; for example, the conductor body can be a flat wire, that is, the cross-section of the conductor body is configured to be rectangular. Compared to the commonly used round wire, when the cross-section of the conductor body of coil 150 is configured to be rectangular, the coil 150 has a stronger shaping ability, that is, the coil 150 can maintain a relatively high shape accuracy. Therefore, during the process of coil 150 being radially inserted into the stator teeth 120 along the stator yoke 110, the coil 140, which has a relatively high shape accuracy, can reduce the risk of being squeezed by the stator teeth 120 and can work together with the stator teeth 120 to improve the smoothness of the guidance.

[0063] Referring to Figure 5 , the coil 150 can be configured to include multiple layers of wire loops 151, formed by bending an integrally formed conductor. When the stator end plate 130 is mounted on the stator teeth 120 after the coil 150, the wire loop 151 formed by bending the integrally formed conductor can be quickly and easily fitted onto the stator teeth 120. Compared to methods that use hairpin-like flat wires to form loops, the wire loop 151 formed by bending an integrally formed conductor can be easily formed, thereby reducing manufacturing costs.

[0064] In some embodiments, the width of the stator teeth 120 and the width of the stator end plate 130 are aligned with the circumferential direction of the stator yoke 110, and the width of the stator end plate 130 is greater than or equal to the width of the stator teeth 120. Referring to FIG. 5 , the width of the stator end plate 130 can be greater than the width of the stator teeth 120, and both ends of the stator end plate 130 extend beyond the stator teeth 120 along the circumferential direction of the stator yoke 110. Of course, the width of the stator end plate 130 can be set equal to the width of the stator teeth 120, with one end of the stator end plate 130 extending beyond the stator teeth 120 along the circumferential direction of the stator yoke 110, while the other end of the stator end plate 130 is retracted within the stator teeth 120 along the circumferential direction of the stator yoke 110. This embodiment is not limited to this.

[0065] In some embodiments, referring to Figures 5, 6, and 7, a first groove 121 is provided on the end surface of the stator tooth 120 facing the stator end plate 130, and an embedded body 131 is provided on the surface of the stator end plate 130 facing the stator tooth 120. The embedded body 131 is embedded in the first groove 121 to secure the stator tooth 120 and the stator end plate 130. In this embodiment, the embedded body 131 is embedded in the first groove 121, which facilitates the installation of the stator tooth 120 and the stator end plate 130. Furthermore, the provision of the embedded body 131 as a solid structure on the stator end plate 130 helps to improve the structural strength of the stator end plate 130.

[0066] In order to fix the stator teeth 120 and the stator end plate 130, in some embodiments, referring to Figure 6, the width direction of the first groove 121 and the width direction of the embedding body 131 are respectively consistent with the circumferential direction of the stator yoke 110; the first groove 121 includes a first slot segment 122 and a second slot segment 123, and the second slot segment 123 is arranged on the side of the first slot segment 122 away from the stator yoke 110, and the width of the second slot segment 123 is smaller than the width of the first slot segment 122. Referring to Figure 7 , the embedded body 131 includes a first embedded segment 132 and a second embedded segment 133. The first embedded segment 132 is disposed on a side of the second embedded segment 133 away from the stator end plate 130. The width of the first embedded segment 132 is greater than the width of the second embedded segment 133. The second embedded segment 133 is disposed within the second slot segment 123. The first embedded segment 132 is disposed within the first slot segment 122. Both sides of the first embedded segment 132 along the width direction abut against the wall surface of the first slot segment 122, thereby improving the connection stability between the stator teeth 120 and the stator end plate 130. The embedded body 131 can be inserted into the first slot 121 along the axial direction of the stator yoke 110, or it can be squeezed into the first slot 121 along the radial direction of the stator yoke 100. This embodiment is not limited to this.

[0067] In some embodiments, referring to FIG7 , in a cross section perpendicular to the axial direction of the stator yoke 110, at least a portion of the second embedded segment 133 has an arcuate profile to reduce the risk of the second embedded segment 133 damaging the first groove 121. Specifically, in a cross section perpendicular to the axial direction of the stator yoke 110, the side of the second embedded segment 133 facing away from the stator end plate 130 has an arcuate profile to reduce the risk of the second embedded segment 133 damaging the first groove 121 during insertion of the embedded body 131 into the first groove 121 along the radial direction of the stator yoke 100. Referring to FIG7 , the second embedded segment 133 can have a circular or elliptical cross section and be connected to the first embedded segment 132, and this embodiment is not limited thereto.

[0068] When the stator teeth 120 and the stator end plate 130 are connected by embedding the embedded body 131 into the first groove 121, in some embodiments, an adhesive layer is provided between the end surface of the stator tooth 120 facing the stator end plate 130 and the plate surface of the stator end plate 130 facing the stator tooth 120. The two sides of the adhesive layer are respectively bonded and fixed to the end surface of the stator tooth 120 and the plate surface of the stator end plate 130 to improve the connection stability between the stator tooth 120 and the stator end plate 130. In particular, the adhesive layer can also be configured to extend beyond the stator tooth 120 along the circumferential direction of the stator yoke 110 to improve the connection stability between the stator tooth 120 and the stator end plate 130 at the corners.

[0069] In the above embodiment, the difference between the magnetic permeability of the stator end plate 130 and the magnetic permeability of the stator teeth 120 is greater than or equal to zero and less than or equal to a preset value. This can be understood as the stator end plate 130 and the stator teeth 120 being made of materials with the same or similar magnetic permeabilities, so as to more centrally guide and concentrate the magnetic flux on the stator teeth 120. For example, the stator end plate 130 can be made of the same material as the stator teeth 120; of course, the stator end plate 130 can also be made of other soft magnetic materials, such as soft magnetic composite materials.

[0070] In some embodiments, referring to Figures 8 and 9 , along the radial direction of the stator yoke 110, the surface of the stator end plate 130 is spaced apart from the circumferential wall of the motor rotor 200 to form an air gap 201. The width of the air gap 201 is aligned with the radial direction of the stator yoke 110. The ratio of the width W of the stator end plate 130 to the pitch S between two adjacent stator teeth 120 on a virtual circle 202 is greater than or equal to 0.3 and less than or equal to 1, thereby further reducing cogging torque and torque ripple. The virtual circle 202 passes through the width center of the air gap 201. If the parallelism between the surface of the stator end plate 130 and the circumferential wall of the motor rotor 200 is relatively low, the width center of the air gap 201 can be determined by the average width of the air gap 201. That is, after calculating the average width, the position of the virtual circle 202 is determined using the circumferential wall of the motor rotor 200 as a positioning reference. Regarding the aforementioned pitch S, when stator teeth 120 are uniformly distributed circumferentially, pitch S is equal to the circumference of virtual circle 202 divided by the number of teeth, or the circumference of virtual circle 202 divided by the number of slots, i.e., pitch S is an arc length. The ratio of the width W of the stator end plate 130 to the pitch S between two adjacent stator teeth 120 on virtual circle 202 can be set to greater than or equal to 0.35 and less than or equal to 0.9 to further reduce cogging torque and torque ripple; for example, it can be set to greater than or equal to 0.38 and less than or equal to 0.87 to further reduce cogging torque and torque ripple.

[0071] In some embodiments, referring to FIG8 , the ratio of the maximum thickness T of the stator end plate 130 to the pitch S between two adjacent stator teeth 120 on the virtual circle 202 is greater than or equal to 0.05 and less than or equal to 0.25, thereby further reducing cogging torque and torque ripple. Specifically, the ratio of the maximum thickness T of the stator end plate 130 to the pitch S between two adjacent stator teeth 120 on the virtual circle 202 can be set to greater than or equal to 0.04 and less than or equal to 0.3, thereby further reducing cogging torque and torque ripple; for example, it can be set to greater than or equal to 0.06 and less than or equal to 0.2, thereby further reducing cogging torque and torque ripple.

[0072] In some embodiments, referring to FIG8 , the ratio of the width W of the stator end plate 130 to the maximum thickness T of the stator end plate 130 is greater than or equal to 1.5 and less than or equal to 15.5, thereby further reducing cogging torque and torque ripple. Specifically, the ratio of the width W of the stator end plate 130 to the maximum thickness T of the stator end plate 130 can be set to greater than or equal to 1.7 and less than or equal to 15, thereby further reducing cogging torque and torque ripple; for example, it can be set to greater than or equal to 1.9 and less than or equal to 14.5, thereby further reducing cogging torque and torque ripple.

[0073] Regarding the above embodiment, Figure 10 shows a magnetic flux distribution diagram of an embodiment of a drive motor in the related art, and Figure 11 shows a magnetic flux distribution diagram of an embodiment of the drive motor in the present application. Combining Figures 10 and 11 shows that the embodiment of the drive motor in the present application can more centrally guide and concentrate the magnetic flux onto the stator teeth 120.

[0074] Figure 12 shows a torque comparison diagram of the embodiment of the drive motor in this application. Taking the torque of the open-slot drive motor in the related art as the per-unit value, the torque relative value of the embodiment of the drive motor in this application can reach 108.7%.

[0075] Figure 13 shows a comparison of the torque fluctuations of the drive motor embodiment of the present application. Taking the peak-to-peak value of the rated torque fluctuation of the open-slot drive motor in the related art as the per-unit value, the peak-to-peak value of the rated torque fluctuation of the drive motor embodiment of the present application can be reduced to 73.8%.

[0076] Figure 14 shows a comparison of the motor efficiency of the embodiment of the drive motor in this application. Taking the motor efficiency of the open-slot drive motor in the related art as the per-unit value, the motor efficiency of the embodiment of the drive motor in this application can reach a relative value of 101%.

[0077] Figure 15 shows a comparison of the cogging torque of the embodiment of the drive motor in this application. Taking the peak-to-peak value of the no-load cogging torque of the open-slot drive motor in the related art as the per-unit value, the peak-to-peak value of the no-load cogging torque of the embodiment of the drive motor in this application can be reduced to 29.3%.

[0078] Referring to Figure 16 , in some embodiments, in a cross section perpendicular to the axial direction of the stator yoke 110, an inclined profile section 134 is provided on the side of the second embedded section 133 facing the stator end plate 130. The distance between the inclined profile section 134 and the stator end plate 130 increases as it moves away from the stator teeth 120, thereby improving the connection stability between the stator end plate 130 and the stator teeth 120. The second embedded section 133 can be configured as a trapezoidal shape, as shown in Figure 16 , where the inclined profile section 134 is a straight line. Alternatively, the second embedded section 133 can be configured as a circle, as shown in Figure 19 , where the inclined profile section 134 is an arc.

[0079] 17 , in some embodiments, a bonding layer may be provided between the end surface of the stator tooth 120 facing the stator end plate 130 and the plate surface of the stator end plate 130 facing the stator tooth 120. The two sides of the bonding layer are bonded and fixed to the end surface of the stator tooth 120 and the plate surface of the stator end plate 130, respectively, to improve the installation efficiency of the stator end plate 130 and the stator tooth 120. The bonding layer may also extend beyond the stator tooth 120 along the circumferential direction of the stator yoke 110 to improve the connection stability at the corners between the stator tooth 120 and the stator end plate 130.

[0080] 18 , in some embodiments, the stator yoke 110 , the stator teeth 120 and the stator end plate 130 are arranged sequentially from the inside to the outside, and the motor stator 100 further includes a fixing belt 140 ; ​​along the circumferential direction of the stator yoke 110 , the fixing belt 140 is wound around the outer surface of the stator end plate 130 to fix the stator end plate 130 on the stator teeth 120 to improve the installation efficiency of the stator end plate 130 and the stator teeth 120 .

[0081] 19 , in some embodiments, a second groove 135 is provided on the plate surface of the stator end plate 130 facing away from the stator yoke 110 . The second groove 135 is used to face the peripheral wall of the motor rotor 200 to improve the motor efficiency of the drive motor.

[0082] In some embodiments, in a cross section perpendicular to the axial direction of the stator yoke 110, at least a portion of the contour of the stator end plate 130 facing away from the stator yoke 110 is set to be arc-shaped, and the arc-shaped contour of the stator end plate 130 facing away from the stator yoke 110 is used to be set parallel to the peripheral wall of the motor rotor 200 to improve the motor efficiency of the drive motor.

[0083] 20 , in some embodiments, the stator end plate 130 includes an extension portion 136 extending out of the stator teeth 120 in the circumferential direction of the stator yoke 110 ; in a cross section perpendicular to the axial direction of the stator yoke 110 , an angle A between the profile of the extension portion 136 toward the stator yoke 110 and the side surface of the stator tooth 120 is greater than or equal to 90 degrees, so as to improve the motor efficiency of the drive motor.

[0084] The present application also proposes a method for manufacturing a motor stator, referring to FIG. 21 and FIG. 22 . The method includes the following steps performed in sequence:

[0085] Step S100 , forming the stator yoke 110 and stator teeth 120 ;

[0086] Step S200: Sleeve the coil 150 onto the stator teeth 120 along the radial direction of the stator yoke 110. The coil 150 may be prefabricated. For example, the coil 150 may include a multi-layer wire loop 151 formed by bending an integrally formed wire body.

[0087] In step S300, the plate surface of the stator end plate 130 is connected to the end surface of the stator tooth 120 so that the stator end plate 130 extends out of the stator tooth 120 along the circumferential direction of the stator yoke 110; specifically, the above structure can be used to connect by means of clamping, bonding and winding of fixing belts.

[0088] The coil 150 is put onto the stator teeth 120 along the radial direction of the stator yoke 110, which is beneficial to improving the overall manufacturing efficiency of the motor stator; in addition, when the stator end plate 130 is installed on the stator teeth 120 after the coil 150, the wire loop 151 formed by bending the one-piece wire body can be put onto the stator teeth 120 more quickly; compared with the method of splicing flat wires into rings in the form of hairpins, the wire loop 151 is formed by bending the one-piece wire body, which can reduce the difficulty of forming and help reduce manufacturing costs.

[0089] It is understandable that, since the manufacturing method of the motor stator adopts all the technical solutions of all the above-mentioned motor stator embodiments, it has at least all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be described one by one here.

[0090] The above description is only a preferred embodiment of the present application and does not limit the patent scope of the present application. All equivalent structural transformations made using the contents of the present application specification and drawings under the technical concept of the present application, or direct / indirect application in other related technical fields are included in the patent protection scope of the present application.

Claims

1. A motor stator, wherein, The motor stator is for a drive motor of an aircraft, and the motor stator includes: A stator yoke; A plurality of stator teeth, and the plurality of stator teeth are arranged at intervals in the circumferential direction of the stator yoke; A plurality of stator end plates, the stator end plates are arranged in one-to-one correspondence with the stator teeth, the stator end plates are installed on a side of the stator teeth away from the stator yoke, and a plate surface of the stator end plates is connected to an end surface of the stator teeth; in the circumferential direction of the stator yoke, the stator end plates protrude from the stator teeth, and the stator yoke, the stator teeth and the stator end plates enclose to form a stator slot with an opening.

2. The motor stator according to claim 1, wherein, The width direction of the stator teeth and the width direction of the stator end plates are respectively consistent with the circumferential direction of the stator yoke, and the width of the stator end plates is greater than or equal to the width of the stator teeth.

3. The motor stator according to claim 1, wherein, A first groove is provided on an end surface of the stator teeth facing the stator end plates, and an embedding body is provided on a plate surface of the stator end plates facing the stator teeth; the embedding body is embedded into the first groove to fix the stator teeth and the stator end plates.

4. The motor stator according to claim 3, wherein, The width direction of the first groove and the width direction of the embedding body are respectively consistent with the circumferential direction of the stator yoke; the first groove includes a first groove section and a second groove section, the second groove section is arranged on a side of the first groove section away from the stator yoke, and the width of the second groove section is smaller than the width of the first groove section; the embedding body includes a first embedding section and a second embedding section, the first embedding section is arranged on a side of the second embedding section away from the stator end plates, and the width of the first embedding section is greater than the width of the second embedding section; the second embedding section is arranged in the second groove section, the first embedding section is arranged in the first groove section, and two sides of the first embedding section in the width direction respectively abut against the wall surfaces of the first groove section.

5. The motor stator according to claim 4, wherein, In a cross-section perpendicular to the axial direction of the stator yoke, at least part of the contour of the second embedding section is arranged as an arc; and / or, In a cross-section perpendicular to the axial direction of the stator yoke, a contour on a side of the second embedding section facing away from the stator end plates is arranged as an arc; and / or, In a cross-section perpendicular to the axial direction of the stator yoke, an inclined contour section is provided on a side of the second embedding section facing the stator end plates, and the distance from the inclined contour section to the stator end plates increases in a direction away from the stator teeth.

6. The motor stator according to any one of claims 1 to 4, wherein, An adhesive layer is provided between an end surface of the stator teeth facing the stator end plates and a plate surface of the stator end plates facing the stator teeth, and two sides of the adhesive layer are respectively adhesively fixed to the end surface of the stator teeth and the plate surface of the stator end plates.

7. The motor stator according to claim 6, wherein, In the circumferential direction of the stator yoke, the adhesive layer protrudes from the stator teeth.

8. The motor stator according to any one of claims 1 to 4, wherein, The stator yoke, the stator teeth and the stator end plates are arranged in sequence from inside to outside, and the motor stator further includes a fixing band; in the circumferential direction of the stator yoke, the fixing band is wound around an outer side surface of the stator end plates to fix the stator end plates on the stator teeth; and / or, A second groove is provided on a plate surface of the stator end plates facing away from the stator yoke, and the second groove is for facing a circumferential wall of a motor rotor; and / or, In a cross-section perpendicular to the axial direction of the stator yoke, at least part of the contour of the stator end plate facing away from the stator yoke is set to be arc-shaped, and the arc-shaped contour of the stator end plate facing away from the stator yoke is used to be arranged parallel to the peripheral wall of the motor rotor; and / or, The stator end plate includes a protruding portion that protrudes from the stator teeth in the circumferential direction of the stator yoke; in a cross-section perpendicular to the axial direction of the stator yoke, the angle between the contour of the protruding portion facing the stator yoke and the side surface of the stator teeth is greater than or equal to 90 degrees; and / or, The difference between the magnetic permeability of the stator end plate and the magnetic permeability of the stator teeth is greater than or equal to zero and less than or equal to a preset value.

9. The motor stator according to any one of claims 1 to 4, wherein, The motor stator includes a coil sleeved outside the stator teeth, and the cross-section of the wire body of the coil is set to be rectangular; The coil includes multiple layers of wire loops, and the wire loops are formed by bending a wire body integrally formed.

10. A drive motor, wherein, The driving motor is used for an aircraft, the driving motor includes a motor rotor and the motor stator according to any one of claims 1 to 9, and the peripheral wall of the motor rotor is arranged opposite to the stator end plate.

11. The drive motor according to claim 10, wherein, Along the radial direction of the stator yoke, the plate surface of the stator end plate is spaced from the peripheral wall of the motor rotor to form an air gap, and the width direction of the air gap is consistent with the radial direction of the stator yoke; The ratio of the width of the stator end plate to the pitch of two adjacent stator teeth on a virtual circle is greater than or equal to 0.3 and less than or equal to 1, and the virtual circle passes through the center of the width of the air gap; and / or, The ratio of the maximum thickness of the stator end plate to the pitch of two adjacent stator teeth on a virtual circle is greater than or equal to 0.04 and less than or equal to 0.3, and the virtual circle passes through the center of the width of the air gap; and / or, The ratio of the width of the stator end plate to the maximum thickness of the stator end plate is greater than or equal to 1.5 and less than or equal to 15.

5.

12. The drive motor according to claim 11, wherein, The ratio of the width of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.35 and less than or equal to 0.9; and / or, The ratio of the maximum thickness of the stator end plate to the pitch of two adjacent stator teeth on the virtual circle is greater than or equal to 0.05 and less than or equal to 0.25; and / or, The ratio of the width of the stator end plate to the maximum thickness of the stator end plate is greater than or equal to 1.7 and less than or equal to 15.

13. An aircraft, wherein, The aircraft includes a cockpit, a rotor, and the driving motor according to any one of claims 10 to 12. The cockpit is used for being movably installed on a road vehicle. The driving motor is installed on the cockpit, and the driving motor is in transmission connection with the rotor to drive the rotor to rotate.

14. A vehicle, wherein, The vehicle includes a road vehicle and the aircraft according to claim 13.

15. A manufacturing method of a motor stator, wherein, The manufacturing method includes the following steps executed in sequence: Form the stator yoke and stator teeth according to any one of claims 1 to 9; Along the radial direction of the stator yoke, sleeved the coil onto the stator teeth; Connect the plate surface of the stator end plate with the end surface of the stator teeth so that the stator end plate protrudes from the stator teeth in the circumferential direction of the stator yoke.

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