Stator, electric motor, vehicle and stator manufacturing method
Through the stator design with alternate arrangement of independent teeth and integrated teeth, combined with the insulating sleeve, the problem of difficulty in simultaneously improving the stator cylindricality and copper filling coefficient in the prior art is solved, and efficient production and low-cost manufacturing of the motor are achieved.
Patent Information
- Application Number
- PCT/IB2024/000764
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-12-29
- Filing Date
- 2024-12-27
- Publication Date
- 2025-07-03
AI Technical Summary
The prior art is difficult to increase the copper filling coefficient without affecting the stator cylinder, resulting in limited motor output power and torque.
The stator design is designed with alternate arrangement of independent teeth and integral teeth. The independent teeth can be separated and bonded to the stator profile, and coils are wound in the winding groove, combining an insulating sleeve to ensure high copper filling and high cylindricality.
It is achieved to increase the copper filling coefficient without increasing the motor size, increase the motor power and torque, reduce production costs and reduce noise and vibration.
Smart Images

Figure IB2024000764_03072025_PF_FP_ABST
Abstract
Description
[0001] Technical Field The present invention relates to the field of electric motor technology, and more specifically, to a stator for an electric motor, an electric motor including the stator, a vehicle including the motor, and a stator manufacturing method for manufacturing the stator. As is well known, the stator of an electric motor primarily comprises a stator core and stator windings. The stator core primarily comprises a generally cylindrical stator body and a plurality of stator teeth radially protruding from the stator. The individual conductors of the stator windings are wound around the stator teeth in a specific manner and located in winding slots between the stator teeth. When energized, they generate a rotating magnetic field that, when coupled with the magnetic field generated by the motor's rotor, drives the rotor to rotate. Parameters such as the stator core's cylindricity and structural strength, as well as the amount of conductor in each winding slot (also known as the copper filling factor or slot fill ratio), directly affect important performance indicators of the motor, such as output power, output torque, and cogging torque. Numerous methods exist for manufacturing stator cores, each with its own advantages, disadvantages, and limitations. For example, some processing methods that pursue high cylindricity typically use a stamping process to produce multiple toothed rings. These rings are then stacked and the teeth aligned to form the stator core. However, with this method, the winding machine's operating space is limited due to interference from the stator tooth pole shoe structure, making it impossible to wind a large amount of wire around the stator teeth. Consequently, achieving a high copper fill factor for the stator is difficult. Some processing methods that also pursue a high copper fill factor typically divide the stator core into multiple segments, winding wire around each segment separately, and finally assembling the segments into a complete stator core. However, with this method, since the stator core is assembled from individual segments, achieving high stator cylindricity is difficult without an additional clamping mechanism. Therefore, both of these processing methods are exclusive and cannot simultaneously achieve high stator cylindricity and a high copper fill factor. Therefore, there is an urgent need in the art for a technical solution that can achieve both high stator cylindricity and a high copper fill factor.SUMMARY OF THE INVENTION To address the above-mentioned problems in the prior art, the present invention provides an improved stator, comprising: a stator core comprising: a generally cylindrical, circumferentially continuous stator profile; a plurality of independent teeth and a plurality of integral teeth protruding radially from the stator profile and arranged alternately along the circumferential direction, wherein each independent tooth is detachably coupled to the stator profile, and each integral tooth is integral with the stator profile; and a stator winding comprising: a plurality of coils, wherein each coil is wound around an independent tooth, or each coil is wound around an integral tooth. According to an optional embodiment of the present invention, the stator profile has a plurality of layers, continuous and coupled together in a spiral about the axial direction, and each independent tooth and each integral tooth has a plurality of layers, stacked and coupled together in the axial direction. According to an optional embodiment of the present invention, the portion of each independent tooth protruding from the stator profile and the portion of each integral tooth protruding from the stator profile have the same cross-sectional shape. According to an optional embodiment of the present invention, each independent tooth has a fixed end facing the stator profile, and an engaging portion is provided at the fixed end. The stator profile is provided with multiple matching portions on its surface, and the engaging portion of each independent tooth engages with one of the matching portions. According to an optional embodiment of the present invention, the engaging portion of each independent tooth is a protrusion protruding from the fixed end, and each matching portion is a groove recessed from the surface of the stator profile. According to an optional embodiment of the present invention, the fixed end of each independent tooth has a portion connected to the engaging portion and a portion in contact with the stator profile. According to an optional embodiment of the present invention, the entire fixed end of each independent tooth is connected to the engaging portion. According to an optional embodiment of the present invention, each independent tooth also has a pole shoe portion at the end opposite the fixed end. The stator further includes multiple insulating sleeves, each insulating sleeve being mounted on the independent tooth between the pole shoe portion and the engaging portion of the independent tooth and having a first pair of legs and a second pair of legs spaced apart from each other. The coil is wound around the insulating sleeve between the first pair of legs and the second pair of legs.According to an optional embodiment of the present invention, the first pair of legs have portions shaped to conform to the pole shoe portion and in contact with the pole shoe portion, and the second pair of legs have portions shaped to conform to the stator morphology and in contact with the stator morphology. Similarly, to address the aforementioned problems in the prior art, the present invention further provides an improved motor comprising a stator as described herein and a rotor coupled to the stator. Also, to address the aforementioned problems in the prior art, the present invention further provides an improved vehicle comprising wheels, a motor as described herein, and a transmission mechanism for transmitting motion between the motor and the wheels. Also, to address the aforementioned problems in the prior art, the present invention further provides an improved stator manufacturing method for manufacturing the stator as described herein, comprising the following steps:
[0002] S100: Cutting the soft magnetic sheet into strips;
[0003] S200: punching the soft magnetic sheet to form a top piece extending along a length direction and a plurality of integrated teeth protruding from the top piece along a width direction;
[0004] S300: Winding the top sheet around an axial direction perpendicular to both the length direction and the width direction, so that the top sheet is spirally continuous around the axial direction to form a stator top sheet of the stator, and aligning the integral tooth sheets of each layer along the axial direction to form each integral tooth of the stator;
[0005] S400: punching the material punched out from the soft magnetic sheet in step S200 to form independent tooth pieces, and stacking a plurality of independent tooth pieces together to form each independent tooth of the stator;
[0006] S500: Winding a coil on each independent tooth or each integrated tooth;
[0007] S600: Combine each independent tooth to the stator profile. According to an optional embodiment of the present invention, step S300 is to: wind the profile in such a manner that each integral tooth piece is located outside the profile; and / or step S500 is to: sleeve an insulating sleeve on each independent tooth and wind a coil on the insulating sleeve. According to an optional embodiment of the present invention, step S300 is to: combine each layer of the profile to form the stator profile of the stator, and combine each aligned integral tooth piece to form each integral tooth of the stator. The present invention can be embodied as an illustrative embodiment in the accompanying drawings. However, it should be noted that the drawings are merely schematic, and any changes conceivable under the teachings of the present invention should be deemed to be included within the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate exemplary embodiments of the present invention. These drawings should not be construed as necessarily limiting the scope of the present invention. FIG. 1 is a schematic cross-sectional view of a stator according to one embodiment of the present invention; FIG. 2a is a schematic, partially enlarged view of the stator shown in FIG. 1; FIG. 2b is a schematic, partially enlarged view of the stator shown in FIG. 1 after the individual teeth have been removed; FIG. 3 is a schematic, partially enlarged view of a stator according to another embodiment of the present invention; FIG. 4 is a schematic, partially enlarged view of a stator according to yet another embodiment of the present invention; FIG. 5 is a schematic front view of a punching sheet used to manufacture a stator according to a stator manufacturing method according to the present invention; and FIG. 6 is a schematic, perspective view of a punching sheet used to manufacture a stator according to a stator manufacturing method according to the present invention. Further features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings. Exemplary embodiments of the present invention are shown in the drawings, and the drawings are not necessarily drawn to scale. However, the present invention may be embodied in many different forms and should not be construed as necessarily limited to the exemplary embodiments disclosed herein. Rather, these exemplary embodiments are provided solely to illustrate the present invention and convey the spirit and substance of the present invention to those skilled in the art.The present invention aims to provide an improved stator for a motor. The novel design of this stator enables a high copper filling factor (also known as slot fill ratio) in each winding slot of its stator core. For a motor consisting of this stator and its magnetically coupled rotor, for a given size, this increased copper filling factor can increase the motor's power and torque. Furthermore, for a given power, this increased copper filling factor can reduce the motor's size, thereby reducing the consumption of wire, silicon steel sheets, ferromagnetic materials, and the like, thereby lowering the production costs of the stator and motor. In particular, the novel design of the stator according to the present invention ensures a high degree of cylindricity in the stator core, thereby reducing the motor's cogging torque, noise, vibration, and other factors, and further increasing the motor's power. Furthermore, the present invention aims to provide an improved stator manufacturing method. This stator manufacturing method not only produces a stator having the advantages described above and elsewhere herein, but also reduces waste material generated during manufacturing, thereby further reducing the production costs of the stator and motor. Various optional but non-limiting embodiments of a stator and a stator manufacturing method according to the present invention are described in detail below with reference to the accompanying drawings. Referring to FIG. 1 , a schematic cross-sectional view of a stator according to an embodiment of the present invention is shown. As shown in FIG. 1 , the stator 10 includes a stator core 100 and a stator winding 200.The stator core 100 is made of a soft magnetic material such as silicon steel or soft ferrite, and includes a stator feature 110 that is generally annular or cylindrical and continuous in the circumferential direction, and stator teeth 120 that protrude radially from the stator feature 110. The stator teeth 120 include a plurality of independent teeth 121 and a plurality of integral teeth 122 that are alternately arranged in the circumferential direction. Each of the independent teeth 121 is separably coupled to the stator feature 110, while each of the integral teeth 122 is integrally coupled to the stator feature 110. In other words, each independent tooth 121 is not integrally manufactured with the stator feature 110 and can therefore be mounted on the stator feature 110 after the stator feature 110 is formed, while each integral tooth 122 is integrally manufactured with the stator feature 110. Instead of being installed on the stator pattern 110 after the stator pattern 110 is formed. In other words, after the stator pattern 110 and each integral tooth 122 are manufactured, a space for accommodating an independent tooth 121 is defined between each two adjacent integral teeth 122. In this configuration, the stator pattern 110 and each integral tooth 122 can be manufactured first, and then each independent tooth 121 can be bonded to the stator pattern 110 in a manner such that one independent tooth 121 is disposed between each two adjacent integral teeth 122. In particular, the stator pattern 110 can have a multi-layer structure that is spirally continuous and bonded together in an axial direction, and each independent tooth 121 and each integral tooth 122 can have a multi-layer structure that is stacked and bonded together in an axial direction.Continuing with FIG. 1 , the stator winding 200 includes a plurality of coils 210. Each coil 210 may be formed of a wire, such as a copper wire or a copper alloy wire, and is wound around an independent tooth 121. In other words, a coil 210 is wound around each independent tooth 121. Each coil 210 constitutes the stator winding 200. After each independent tooth 121 is coupled to the stator 110, each independent tooth 121 and an adjacent integral tooth 122 define a winding slot 130 therebetween for accommodating the coil 210. When energized, each coil 210 generates a rotating magnetic field. This rotating magnetic field, when coupled with the magnetic field generated by the rotor (e.g., the magnetic field generated by the permanent magnets or armature windings on the rotor), drives the rotor to rotate, thereby converting electrical energy into kinetic energy of the rotor. In this configuration, since each independent tooth 121 can be installed on the stator feature 110 after it is formed, during assembly, each coil 210 can be first wound around each independent tooth 121, and then each independent tooth 121 with the coil 210 wound around it can be installed on the stator feature 110. This configuration provides the winding machine with ample operating space when winding the coil 210 around the independent tooth 121, even without any obstruction. Unlike in the prior art, there is no interference from the stator teeth, especially the pole shoes, during the winding operation. This allows the winding machine to wind more turns of coil 210 around each independent tooth 121, thereby filling each winding slot 130 with more copper and achieving a higher copper fill factor. Specifically, the portion of the independent tooth 121 protruding from the stator feature 110 and the portion of the integral tooth 122 protruding from the stator feature 110 have the same cross-sectional shape and extend the same length in the axial direction. That is, the independent teeth 121 and the integral teeth 122 have substantially the same shape, which enables the independent teeth 121 and the integral teeth 122 to have substantially the same saturation magnetic flux density, which helps ensure that the magnetic flux can flow smoothly through the independent teeth 121 and the integral teeth 122 so as to couple with the magnetic field generated by the rotor.It is worth mentioning that although in the embodiment shown in Figure 1, each coil 210 is wound on each independent tooth 121, in an embodiment not shown, each coil 210 may also be wound on each integral tooth 122, and each independent tooth 121 may be installed on the stator 110 after each coil 210 is wound on each integral tooth 122. This can also provide the winding machine with a larger operating space when winding the coil 210 on the integral tooth 122, thereby filling more copper in each winding slot 130 to achieve a higher copper filling factor. It's also worth noting that, while in the embodiment shown in FIG1 , the stator teeth 120 (i.e., the individual independent teeth 121 and the individual integrated teeth 122) are located outside the stator feature 110 and protrude from the stator feature 110 away from the center of the stator feature 110, making the stator 10 suitable for manufacturing an outer-rotor motor, in embodiments not shown, the stator teeth 120 (i.e., the individual independent teeth 121 and the individual integrated teeth 122) may also be located inside the stator feature 110 and protrude from the stator feature 110 toward the center of the stator feature 110, making the stator 10 suitable for manufacturing an inner-rotor motor. Therefore, the coil winding method and the specific type of motor do not limit the scope of protection of the present invention. Any specific embodiment that improves the copper filling factor based on the teachings of the present invention falls within the scope of protection of the present invention. Reference is made to FIG2 a and FIG2 b , which respectively show schematic partial enlarged views of the stator shown in FIG1 and the stator after the individual teeth have been removed. As shown in FIG2a , each independent tooth 121 has two opposite (opposite) ends along the radial direction, i.e., a free end intended to face the rotor and a fixed end intended to face the stator feature 110, and each independent tooth 121 is provided with a pole shoe portion 121P at the free end and a coupling portion 121E at the fixed end. As shown in FIG2b , the stator feature 110 is provided with a plurality of matching portions 110E arranged along the circumferential direction on its surface, and a matching portion 110E is provided between every two adjacent integral teeth 122.The mating portion 110E of the stator feature 110 and the engaging portion 121E of the independent tooth 121 both extend axially and have complementary shapes. This allows the engaging portion 121E to engage with the mating portion 110E by moving axially, thereby securing the independent tooth 121 to the stator feature 110 and preventing it from detaching from the stator feature 110 in other directions. In this configuration, during assembly, the independent tooth 121, with the coil 210 wound around it, can be inserted axially between two integral teeth 122 while the engaging portion 121E engages with the mating portion 110E. Specifically, as shown in Figures 2a and 2b, the engaging portion 121E can be a dovetail-shaped protrusion on the fixed end of the independent tooth 121, while the mating portion 110E can be a dovetail-shaped recessed groove recessed from the surface of the stator feature 110. The engaging portion 121E can be inserted axially into the mating portion 110E. Of course, in an embodiment not shown, the engaging portion 121E may be a dovetail-shaped groove, and the matching portion 110E may be a dovetail-shaped protrusion. Specifically, the engaging portion 121E and the matching portion 110E may also take other shapes, such as oval, circular, T-shaped, etc. As shown in Figures 2a and 2b, the engaging portion 121E protrudes from a portion of the fixed end of the independent tooth 121. In other words, a portion of the fixed end of the independent tooth 121 is connected to the engaging portion 121E, while the remaining portion abuts or contacts the surface of the stator feature 110. Specifically, the portion of the fixed end of the independent tooth 121 that contacts or abuts the surface of the stator feature 110 is shaped to conform to the surface of the stator feature 110. This configuration avoids the formation of air gaps between the fixed end of the individual tooth 121 and the surface of the stator 110 that would obstruct the flow of magnetic flux. These air gaps would reduce the cross-sectional area of the individual tooth 121 through which magnetic flux flows, thereby lowering the saturation magnetic flux density of the individual tooth 121. Referring to Figure 3 , a schematic, partially enlarged view of a stator according to another embodiment of the present invention is shown. Unlike the embodiment shown in Figures 1-2b , where the engagement portion 121E protrudes from a portion of the fixed end of the individual tooth 121, in the embodiment shown in Figure 3 , the engagement portion 121E protrudes from the entire fixed end of the individual tooth 121.That is, in the embodiment shown in Figures 1-2b, a portion of the fixed end of the independent tooth 121 is connected to the engagement portion 121E, while in the embodiment shown in Figure 3, the entire or all of the fixed end of the independent tooth 121 is connected to the engagement portion 121E. In this configuration, the entire surface of the fixed end of the independent tooth 121 is occupied by the engagement portion 121E, so that the fixed end of the independent tooth 121 no longer has a portion that engages or abuts the surface of the stator feature 110. This configuration is advantageous because, if the fixed end of the independent tooth 121 has a portion that engages the surface of the stator feature 110, as mentioned above, it is desirable to eliminate the gap between this portion and the surface of the stator feature 110 to avoid the formation of an air gap between them that would hinder the flow of magnetic flux. However, this requires machining this portion to follow the curvature of the surface of the stator feature 110, which is somewhat difficult to manufacture, and in practice, it is even difficult to completely eliminate the air gap. Therefore, the above configuration eliminates the portion of the fixed end of the independent tooth 121 that is intended to engage with the surface of the stator 110, eliminating the need for the aforementioned machining. Furthermore, compared to the aforementioned machining, manufacturing the complementary-shaped engaging portion 121E and matching portion 110E is much easier, thereby reducing the manufacturing difficulty and, consequently, the manufacturing cost of the stator 10. Referring to FIG4 , a schematic partial enlarged view of a stator according to yet another embodiment of the present invention is shown. Unlike the embodiment shown in FIG1-3 , the embodiment shown in FIG4 further includes multiple insulating sleeves 140 made of an insulating material (e.g., insulating resin, PAIVPEI plastic, etc.). Each insulating sleeve 140 is sleeved over an independent tooth 121 and positioned between the pole piece portion 121P and the engaging portion 121E of the independent tooth 121.In particular, the insulating sleeve 140 has a central portion 141 for inserting the independent tooth 121 and two pairs of legs spaced apart in the radial direction, namely, a first pair of legs 142 near the pole shoe portion 121P and a second pair of legs 143 near the engagement portion 121E, wherein each pair of legs includes two legs that protrude laterally from the central portion 141 in opposite directions, thereby defining the insulating sleeve 140 as having a substantially I-shaped cross-section, and the coil 210 is wound around the central portion 141 between the two pairs of legs. In other words, the two pairs of legs, being spaced apart in the radial direction, define two grooves therebetween for accommodating the coil 210, and the two grooves are located on either side of the central portion 141, i.e., the independent tooth 121. In this configuration, the insulating sleeve 140 can separate the coil 210 from the independent tooth 121, thereby reliably achieving insulation between the coil 210 and the independent tooth 121, and the two pairs of legs of the insulating sleeve 140 can reliably hold the coil 210, thereby achieving reliable positioning of the coil 210. In particular, the first pair of legs 142 has a first portion 142S that conforms to the shape of the pole shoe portion 121P and abuts against or contacts the pole shoe portion 121P, while the second pair of legs 143 has a second portion 143So that conforms to the shape of the stator appearance 110 and abuts against or contacts the stator appearance 110. Under this configuration, after the independent tooth 121 is assembled to the stator appearance 110, the insulating sleeve 140 will be clamped between the pole shoe portion 121P of the independent tooth 121 and the stator appearance 110, and the insulating sleeve 140 in turn helps to position the independent tooth 121, which makes it possible to promote the outer surface of the pole shoe portion 121P of each independent tooth 121 and the outer surface of the pole shoe portion 122P of each integrated tooth 122 to be positioned on the same cylindrical surface through each insulating sleeve 140, so as to achieve high cylindricity of the stator core 100, thereby reducing the cogging torque of the motor. Of course, in addition to an insulating framework such as the insulating sleeve shown in FIG4 , insulating paper (e.g., NOMEX, etc.) may be applied to the surfaces of each independent tooth 121, each integrated tooth 122, and / or the stator shell 110 in addition or as an alternative to improving insulation between the stator core 100 and the stator winding 200. Several optional but non-limiting embodiments of the stator according to the present invention have been described in detail above with reference to FIG1 to FIG4 .In particular, the present invention further provides an electric motor comprising a stator as described herein and a rotor coupled to the stator. In particular, the present invention further provides a vehicle comprising wheels, a motor as described herein, and a transmission mechanism for transmitting motion between the motor and the wheels, so that the motor can drive the wheels to rotate, thereby enabling the vehicle to travel on a ground surface. The vehicle can be a four-wheeled vehicle, a two-wheeled vehicle, or a three-wheeled vehicle. When the vehicle is a two-wheeled vehicle, the motor can be a hub motor. An optional but non-limiting embodiment of the stator manufacturing method according to the present invention will be described below with reference to Figures 5 and 6 . Figures 5 and 6 show, respectively, a schematic front view and a schematic perspective view of a lamination used to manufacture a stator according to the stator manufacturing method according to the present invention. The stator manufacturing method can produce the stator according to the present invention by the following steps, which include:
[0008] S100: Cutting a soft magnetic sheet (e.g., silicon steel sheet) into strips. As the name suggests, the length of the sheet is much greater than its width.
[0009] S200: As shown in Figure 4, the soft magnetic sheet is stamped to form a plurality of integral teeth 102 extending along the length direction L and protruding from the appearance of the piece 101 along the width direction W, wherein each integral tooth piece 102 is spaced apart from the adjacent integral tooth piece 102 by the same distance;
[0010] S300: As shown in FIG5 , the yoke sheet 101 is wound about an axial direction XX, which is perpendicular to both the length direction L and the width direction W, so that the sheet 101 forms a continuous spiral about the axial direction to form the stator sheet 110. Furthermore, the integral tooth sheets 102 of each layer are aligned along the axial direction XX to form integral teeth 122 arranged about the axial direction XX and integral with the stator sheet 110. Specifically, in step S300, each layer of the sheet 101 can be joined together, for example, by welding, bonding, or the like, to form the stator sheet 110, and the aligned integral tooth sheets 102 can be joined together, for example, by welding, bonding, or the like, to form each integral tooth 122.
[0011] S400: punching the material punched out from the soft magnetic sheet in step S200 to form independent tooth pieces, and stacking a plurality of independent tooth pieces together (for example, by welding or bonding) to form each independent tooth 121;
[0012] S500: Winding a coil 210 on each independent tooth 121 or each integrated tooth 122;
[0013] S600: Each independent tooth 121 is bonded to the stator 110 to form the stator 10. It should be noted that although the above steps are described in a certain order, the order in which these steps are described does not necessarily limit the order in which they must be performed. For example, step S400 can be performed before, after, or simultaneously with step S300. After reading the foregoing, those skilled in the art will appreciate that, compared to the method of punching multiple soft magnetic rings from a soft magnetic sheet and then stacking each soft magnetic ring to form a stator morphology, the stator manufacturing method according to the present invention can significantly save soft magnetic material. This is because punching soft magnetic rings results in both the internal and external materials being treated as waste. In contrast, the stator manufacturing method according to the present invention simply punches an integral tooth segment from a soft magnetic strip, then winds the strip to form the stator morphology. The punched material is also used to form the independent teeth. Therefore, the stator manufacturing method according to the present invention not only provides a larger winding space for the winding machine but also significantly saves soft magnetic material. Furthermore, the stator profile manufactured according to the stator manufacturing method of the present invention is continuous in the circumferential direction, which helps improve the structural strength of the stator profile and makes it easier to ensure that the stator profile has a high cylindricity. This high cylindricity of the stator profile helps achieve high cylindricity of the stator core, thereby reducing the cogging torque of the motor. Specifically, step S300 involves winding the profile 101 with the integral tooth 102 positioned outside the profile 101, so that the stator 10 formed in step S600 is suitable for manufacturing an outer rotor motor. Specifically, step S500 involves placing an insulating sleeve 140 over each independent tooth 121 and winding a coil 210 around the insulating sleeve 140. The above describes in detail, with reference to the accompanying drawings, optional but non-limiting embodiments of the stator and stator manufacturing method according to the present invention. Those skilled in the art will readily appreciate that modifications and additions to the techniques and structures, as well as recombinations of features from various embodiments, without departing from the spirit and substance of the present disclosure, are to be considered within the scope of the present invention. Therefore, all modifications and supplements that can be conceived under the teachings of the present invention should be considered as part of the present invention. The scope of the present invention includes equivalent technologies known at the filing date of the present invention and equivalent technologies that have not yet been foreseen.
Claims
Claims 1. A stator, comprising: Stator core (100), the stator core (100) includes: a stator yoke (110) that is generally cylindrical and continuous in the circumferential direction; and a plurality of independent teeth (121) and a plurality of integral teeth (122) that project from the stator yoke (110) in the radial direction and are alternately arranged in the circumferential direction, wherein each independent tooth (121) is detachably coupled to the stator yoke (110), and each integral tooth (122) is integral with the stator yoke (110); and a stator winding (200), the stator winding (200) includes: a plurality of coils (210), wherein each coil (210) is wound around an independent tooth (121), or each coil (210) is wound around an integral tooth (122).
2. The stator according to claim 1, wherein, The stator yoke (110) has a multi-layer form that is helically continuous and joined together around the axial direction, and each independent tooth (121) and each integral tooth (122) respectively have a multi-layer form that is stacked and joined together along the axial direction.
3. The stator according to claim 1 or 2, wherein, The portion where each independent tooth (121) projects from the stator yoke (110) has the same cross-sectional shape as the portion where each integral tooth (122) projects from the stator yoke (110).
4. The stator according to any one of claims 1 to 3, wherein Each independent tooth (121) has a fixed end facing the stator yoke (110), and a joining portion (121E) is provided at the fixed end, and a plurality of matching portions (110E) are provided on the surface of the stator yoke (110), and the joining portion (121E) of each independent tooth (121) is joined to a matching portion (110E).
5. The stator according to claim 4, wherein, The joining portion (121E) of each independent tooth (121) is a protrusion projecting from the fixed end, and each matching portion (110E) is a groove recessed from the surface of the stator yoke (110).
6. The stator according to claim 5, wherein, The fixed end of each independent tooth (121) has a portion connected to the joining portion (121E) and a portion in contact with the stator yoke (110).
7. The stator according to claim 5, wherein, The whole of the fixed end of each independent tooth (121) is connected to the joining portion (121E).
8. The stator according to any one of claims 4-7, wherein Each independent tooth (121) is also provided with a pole shoe portion (121P) at an end opposite to the fixed end, and the stator further includes a plurality of insulating sleeves (140). Each insulating sleeve (140) is sleeved on the independent tooth (121) between the pole shoe portion (121P) and the engaging portion (121E) of an independent tooth (121), and has a first pair of legs (142) and a second pair of legs (143) spaced apart. The coil (210) is wound around the insulating sleeve (140) between the first pair of legs (142) and the second pair of legs (143).
9. The stator according to claim 8, wherein, The first pair of legs (142) has a portion shaped to conform to and in contact with the pole shoe portion (121P), and the second pair of legs (143) has a portion shaped to conform to and in contact with the stator profile (110).
10. An electric machine, comprising a stator according to any one of claims 1-9 and a rotor coupled to the stator.
11. A vehicle, comprising wheels, an electric machine according to claim 10, and a transmission mechanism for transmitting motion between the electric machine and the wheels.
12. A method for manufacturing a stator, for manufacturing a stator according to any one of claims 1-9, and comprising the following steps: S100: Cutting a soft magnetic sheet into strips; S200: Stamping the soft magnetic sheet to form a profile sheet (101) extending along the length direction and a plurality of integral tooth sheets (102) protruding from the profile sheet (101) along the width direction; S300: Winding the profile sheet (101) around an axial direction perpendicular to both the length direction and the width direction, so that the profile sheet (101) spirally continues around the axial direction to form the stator profile (110) of the stator, and aligning the integral tooth sheets (102) of each layer along the axial direction to form each integral tooth (122) of the stator; S400: Stamping the material punched from the soft magnetic sheet in step S200 to form independent tooth sheets, and stacking a plurality of independent tooth sheets together to form each independent tooth (121) of the stator; S500: Winding a coil (210) around each independent tooth (121) or each integral tooth (122); S600: Combining each independent tooth (121) to the stator profile (110).
13. The stator manufacturing method according to claim 12, wherein, Step S300 consists in winding the profile piece (101) in such a way that each integral tooth piece (102) is located outside the profile piece (101); and / or Step S500 consists in sleeving an insulating sleeve (140) on each independent tooth (121) and winding a coil (210) on the insulating sleeve (140).
14. The stator manufacturing method according to claim 12 or 13, wherein, Step S300 consists in combining each layer of the profile piece (101) together to form the stator profile (110) of the stator, and combining each aligned integral tooth piece (102) together to form each integral tooth (122) of the stator.
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