Motor and household appliance

Abstract

The present application discloses a motor and a household appliance, wherein the motor comprises a stator assembly (100), a rotor assembly (200), and insulating pieces (300). The rotor assembly (200) rotates around a rotation axis (0); the stator assembly (100) comprises a stator iron core (110) and two insulating frames (127, 128) connected to two ends of the stator iron core (110) along the rotation axis (0); the stator iron core (110) comprises a yoke portion (111) and a plurality of stator teeth (112); the yoke portion (111) surrounds the rotor assembly (200); the stator teeth (112) are arranged along the inner periphery of the yoke portion (111) and arranged at intervals along the circumference of the rotor assembly (200); a winding slot (130) is formed between every two circumferentially adjacent stator teeth (112); and two ends of each insulating piece (300) along the rotation axis (0) are respectively connected to the insulating frames (127, 128), and the insulating pieces (300) are further arranged along the inner peripheries of the winding slots (130).

Description

Motors and household appliances

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to Chinese patent application number 202410230837.9, filed on February 29, 2024, entitled “Motors and Household Appliances”. The entire contents of the above patent application are incorporated by reference into this application. Technical Field

[0003] The present application relates to the field of motor technology, and in particular to a motor and a household appliance. Background Art

[0004] In the related art, the stator assembly of a motor generally includes a stator core, an insulating frame, and windings. The two insulating frames located at both ends of the stator core are installed using a plug-in method. The plug-in walls of the two insulating frames are inserted into the winding slots of the stator core. The two insulating frames are positioned and installed by the abutting plug-in walls, and an insulating layer is formed in the winding slots, so that the windings can meet the electrical insulation requirements after being wound around the insulating frames. However, the thick plug-in walls of the insulating frames reduce the area of ​​the winding slots, resulting in a reduction in the winding volume of the windings, which cannot meet the design requirements of miniaturized, high-power models. Summary of the Invention

[0005] The present application aims to at least partially solve one of the technical problems existing in the prior art. To this end, the present application proposes a motor and a household appliance having the motor.

[0006] The motor according to the first embodiment of the present application includes a rotor assembly, a stator assembly and an insulating sheet. The rotor assembly rotates around a rotation axis. The stator assembly includes a stator core, two insulating frames connected to the stator core at both ends along the rotation axis, and the stator core includes a yoke and a plurality of stator teeth. The yoke is arranged around the outside of the rotor assembly, and the plurality of stator teeth are arranged around the inside of the yoke and spaced apart along the circumference of the rotor assembly; along the circumference, a winding slot is formed between two adjacent stator teeth. The insulating sheet is connected to the two insulating frames at both ends along the rotation axis, and the insulating sheet is arranged around the inner side of the winding slot.

[0007] According to some embodiments of the present application, a sink groove is provided at at least one end of the stator core along the direction of the rotation axis. The sink groove is located at the end of the winding groove and arranged around the inner side of the winding groove. The insulating frame is fixedly connected to the sink groove.

[0008] According to some embodiments of the present application, the insulating frame includes a base and a wall connected to a portion of the outer edge of the base, the base is connected to the end of the stator core, the wall is arranged in the sink, and the insulating sheet is fixedly connected to the wall.

[0009] According to some embodiments of the present application, a first clamping portion is provided on the inner side of the wall portion, and a second clamping portion cooperating with the first clamping portion is provided on the side wall of the sink.

[0010] According to some embodiments of the present application, a positioning column is provided on the inner side of the base, and the stator core is provided with a positioning hole that cooperates with the positioning column.

[0011] According to some embodiments of the present application, the base and the end of the stator core are fixedly connected by fasteners.

[0012] According to some embodiments of the present application, along the circumferential direction, the maximum thickness of the wall portion is less than or equal to the minimum width of the sink.

[0013] According to some embodiments of the present application, along the direction of the rotation axis, the maximum depth of the sink is L1, and the maximum height of the stator core is L0, satisfying:

[0014] According to some embodiments of the present application, the maximum height of the insulating sheet along the direction of the rotation axis is L 11 , the maximum height of the stator core is L0, satisfying: 1≤L 11 / L0≤2.

[0015] According to some embodiments of the present application, the stator core includes a plurality of stator punchings stacked along the direction of the rotation axis, two of the plurality of stator punchings are respectively a first punching and a second punching, and along the inner circumference of the winding slot, at least a portion of the side wall of the first punching toward the winding slot is recessed inward relative to the side wall corresponding to the second punching.

[0016] According to some embodiments of the present application, the thickness of the insulating sheet is d; the stator core includes a plurality of stator punchings stacked along the direction of the rotation axis, and the maximum thickness of the stator punchings is t1; the rotor assembly includes a rotor core and a plurality of permanent magnets, the rotor core includes a plurality of core units arranged around the rotation axis, and mounting grooves are formed between adjacent core units, and a plurality of permanent magnets are respectively installed in the corresponding mounting grooves, and the core unit includes a plurality of rotor punchings stacked along the direction of the rotation axis, and the maximum thickness of the rotor punchings is t2; the maximum outer diameter of the stator core is D1, and the minimum inner diameter of the stator core is D2; the maximum outer diameter of the rotor core is D3, and the minimum inner diameter of the rotor core is D4; satisfying:

[0017] According to some embodiments of the present application, the rotor assembly includes a rotor core and a plurality of permanent magnets, wherein the rotor core includes a plurality of core units arranged around the rotation axis, and mounting slots are formed between adjacent core units, and the plurality of permanent magnets are respectively mounted in corresponding mounting slots; along the circumference of the rotor assembly, the maximum width of the permanent magnet is W mag Along the radial direction of the rotor assembly, the minimum width of the mounting groove away from the rotation axis is so1, and the minimum width of the mounting groove close to the rotation axis is so2, satisfying: 0.5≤so1 / W mag ≤0.6, and 0.5≤so2 / W mag ≤0.6.

[0018] According to some embodiments of the present application, the minimum width so1 of the installation groove at one end away from the rotation axis and the minimum width so2 of the installation groove at one end close to the rotation axis satisfy: 0.9≤so1 / so2≤1.

[0019] The household appliance according to the embodiment of the second aspect of the present application includes the motor described in the above embodiment.

[0020] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become obvious from the description below, or will be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present application is further described below with reference to the accompanying drawings and embodiments, wherein:

[0022] FIG1 is a schematic structural diagram of a motor according to an embodiment of the present application;

[0023] FIG2 is a simplified schematic diagram of the motor shown in FIG1 ;

[0024] FIG3 is an enlarged view of a portion of the stator core and the rotor core in FIG1 , showing two stator teeth and one rotor punching;

[0025] FIG4 is a schematic structural diagram of a stator core in an initial state according to another embodiment of the present application;

[0026] FIG5 is a schematic structural diagram of a stator assembly according to another embodiment of the present application, wherein the windings are not shown;

[0027] FIG6 is an exploded view of the stator assembly shown in FIG5 ;

[0028] FIG7 is an enlarged view of a portion of the structure of a stator assembly according to another embodiment of the present application;

[0029] FIG8 is an enlarged view of a portion of the structure of a stator core according to another embodiment of the present application, showing two stator teeth;

[0030] FIG9 is a cross-sectional view of a stator assembly according to another embodiment of the present application;

[0031] FIG10 is an enlarged view of a portion of the structure of a stator core according to another embodiment of the present application, showing a stator tooth;

[0032] FIG11 is a cross-sectional view of a stator assembly according to another embodiment of the present application, showing the stator teeth shown in FIG10 and an insulating frame mated therewith;

[0033] FIG12 is an enlarged view of a portion of the structure of a stator core according to another embodiment of the present application, showing a stator tooth;

[0034] FIG13 is a cross-sectional view of a stator assembly according to another embodiment of the present application, showing the stator teeth shown in FIG12 and an insulating frame mated therewith;

[0035] FIG14 is a second insulating frame according to an embodiment of the present application;

[0036] FIG15 is a first insulating frame according to an embodiment of the present application;

[0037] FIG16 is a second insulating frame according to another embodiment of the present application;

[0038] FIG17 is a first insulating frame according to another embodiment of the present application;

[0039] FIG18 is an enlarged view of a portion of the structure of a rotor assembly according to an embodiment of the present application, showing two core units and permanent magnets;

[0040] FIG19 is an enlarged view of a portion of the structure of a rotor assembly according to an embodiment of the present application, showing two core units.

[0041] Reference numerals: stator assembly 100; stator core 110; yoke 111; first yoke 1111; second yoke 1112; stator tooth 112; tooth 113; first side wall 1131; second side wall 1132; tooth top 114; tooth shoe 1141; first tooth shoe 1142; second tooth shoe 1143; protrusion 115; groove 116; welding feature 117; latch hole 118; positioning hole 119; insulation frame 120; base 121; wall 122; first wall 1221; second wall 1222; third wall 1223; first chamfer 1224; thinning structure 1225; Snap 123; first boss 124; second boss 125; limiting groove 126; second notch 1261; second chamfer 1262; first insulating frame 127; second insulating frame 128; positioning post 129; winding groove 130; first notch 131; groove bottom 132; recess 140; first recess 141; second recess 142; first section 143; second section 144; third section 145; winding 150; rotor assembly 200; rotor core 210; core unit 211; first protrusion 212; second protrusion 213; magnetic bridge 214; permanent magnet 220; first chamfered surface 221; second chamfered surface 222; third chamfered surface 223; mounting slot 230; insulating sheet 300; rotation axis O. DETAILED DESCRIPTION

[0042] The following describes in detail embodiments of the present application. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present application and are not to be construed as limiting the present application.

[0043] In the description of this application, it should be understood that descriptions involving orientation, such as the orientation or positional relationship indicated by up, down, etc., are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0044] In the description of this application, "a plurality" refers to more than two. The use of "first" or "second" is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of technical features indicated, or implicitly indicating the order of the technical features indicated.

[0045] In the description of this application, unless otherwise clearly defined, terms such as setting, installing, and connecting should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in this application based on the specific content of the technical solution.

[0046] Motors are essential components in household appliances. Examples include the motor that drives the fan in air conditioners, the motor assembly inside compressors, and the motors in washing machines and dishwashers. With the development of the household appliance industry, miniaturization and high power have become the trends in the development of new-generation motors.

[0047] A motor generally includes a stator assembly and a rotor assembly. The rotor assembly rotates about the motor's axis of rotation, and the stator assembly is arranged around the axis of rotation. Under the influence of an electromagnetic field, the rotor assembly can rotate relative to the stator assembly, thereby driving the load connected to the motor's output terminal to rotate. It will be understood that in one embodiment, the stator assembly is configured to be arranged around the outside of the rotor assembly, resulting in an inner rotor motor; in another embodiment, the stator assembly is configured to be arranged around the inside of the rotor assembly, resulting in an outer rotor motor.

[0048] To facilitate understanding of the solutions of the embodiments of the present application, an inner rotor motor is used as an example for explanation below.

[0049] As shown in Figure 1, the motor of the embodiment of the present application includes a stator assembly 100 and a rotor assembly 200. The rotor assembly 200 includes a rotating shaft, the central axis of the rotating shaft coincides with the rotation axis O of the motor, and the stator assembly 100 is arranged around the outer side of the rotor assembly 200. In order to improve the stability and reliability of the motor, the rotor assembly 200 and the stator assembly 100 are generally separately overmolded before being assembled. As shown in Figures 1 and 2, the rotor assembly 200 includes a rotor core 210, a plurality of permanent magnets 220 and a rotating shaft. The rotor core 210 is provided with a plurality of mounting slots 230. The plurality of permanent magnets 220 are mounted one-to-one in the corresponding mounting slots 230. The rotating shaft is mounted inside the rotor core 210. The assembled rotor core 210, the plurality of permanent magnets 220 and the rotating shaft are connected by an integrated injection molding process, which is the overmolding treatment of the rotor assembly 200. The stator assembly 100 includes a stator core 110, an insulating frame 120, and windings 150. The assembled stator core 110, insulating frame 120, and windings 150 are connected via an integrated injection molding process, which is known as the overmolding treatment of the stator assembly 100. It should be noted that the overmolding treatment of the stator assembly 100 generally simultaneously forms a portion of the motor housing, thereby facilitating rapid assembly with the rotor assembly 200. After the overmolding treatment, both the rotor assembly 200 and the stator assembly 100 can achieve a more stable structure, making it less likely for internal components to separate, thereby improving the stability of the connection between the components.

[0050] 2, 3, and 8, in an embodiment of the motor of the present application, a stator core 110 is arranged circumferentially about a rotation axis O. The stator core 110 includes a yoke 111 and a plurality of stator teeth 112. The yoke 111 is arranged around the outside of the rotor assembly 200, and the plurality of stator teeth 112 are disposed around the inside of the yoke 111. The plurality of stator teeth 112 are spaced apart circumferentially. In the radial direction of the stator core 110, the plurality of stator teeth 112 are spaced apart from the rotor assembly 200 on the side facing away from the yoke 111. Each stator tooth 112 includes a tooth portion 113 and a tooth tip 114. One end of each tooth portion 113 is connected to the yoke 111, and the other end of each tooth portion 113 is connected to the tooth tip 114. The tooth tips 114 are spaced apart from the rotor assembly 200. As shown in FIG3, an air gap is formed between the tooth tip 114 and the rotor assembly 200. This air gap is non-uniform along the circumference, thereby improving the performance of the motor. To achieve a non-uniform air gap, the motor in one embodiment of the present application configures the outer contour of the rotor core 210 as a multi-segment line, or configures the outer contour of the rotor core 210 as an arc whose center does not coincide with the rotation axis O. As an alternative embodiment, the motor can also configure the gap between each tooth tip 114 and the rotor assembly 200 to be different, or configure the inner contour of at least one tooth tip 114 on the side facing the rotor assembly 200 to be a multi-segment line or an arc whose center does not coincide with the rotation axis O, thereby varying the gap between the tooth tip 114 and the rotor assembly 200 in the circumferential direction.

[0051] 1 and 2 , the stator core 110 is provided with a plurality of winding slots 130, which are spaced apart circumferentially about the rotation axis O. Each winding slot 130 is formed by two adjacent stator teeth 112 and a portion of the yoke 111 connected between the two stator teeth 112. A gap is provided between two circumferentially adjacent stator teeth 112 on a side close to the rotor assembly 200. The gap is formed as a first notch 131 of the winding slot 130. The provision of the first notch 131 facilitates winding the winding 150 around the stator teeth 112. It is understood that the stator core 110 of the embodiment of the present application initially adopts a linearly arranged structure (such as the strip-shaped stator core 110 shown in FIG. 4 ), so that the winding slot 130 between the two stator teeth 112 can be opened in the initial state, that is, the first notch 131 of the winding slot 130 is opened, which facilitates the entry of the enameled wire into the winding slot 130 during winding, thereby improving the winding efficiency. After the stator core 110 is wound, the stator core 110 in the initial state is synthesized into a full circle (i.e., a ring-shaped stator core 110, as shown in FIG6 ). In addition, the installation method of this embodiment does not require the width of the winding needle to be reserved, and the limited space can be maximized to wind more enameled wire, thereby improving the slot fill rate, thereby achieving the goal of high-power and miniaturized motors.

[0052] As shown in Figure 4 , the stator assembly 100 of an embodiment of the present application utilizes a linear arrangement followed by a circular bend. The stator core 110 has a bend or chain-type fitting portion located midway between two stator teeth 112. The bend or chain-type fitting portion can be located on a yoke 111 between the two stator teeth 112. During assembly, the bend or chain-type fitting portion can be bent from the bar-shaped stator core 110 into a fully circular stator core 110. Therefore, the bend or chain-type fitting portion ensures the accuracy of the relative position of the two stator teeth 112 after rotation and ensures the integrity of the connection.

[0053] As shown in Figure 4, the stator core 110 in a bar-shaped state has a protrusion 115 on one side along the length direction and a groove 116 on the other side. The protrusion 115 and the groove 116 can fit tightly together after the stator core 110 is rounded. The stator core 110 is positioned in a circular position through the cooperation between the protrusion 115 and the groove 116, ensuring the accuracy of the relative position of the first and last stator teeth 112 along the length direction of the stator core 110. In the embodiment of the present application, the outer contour of the protrusion 115 is a cylindrical surface, and the inner contour of the groove 116 is a cylindrical surface that cooperates with the protrusion 115.

[0054] As shown in Figure 4 , to ensure the overall stability of the stator core 110 after being assembled, the stator core 110 in its strip-shaped state has welding features 117 on both sides along its length. These welding features 117 are generally protrusions 115 and are used to enhance the stability of the weld when the two ends of the stator core 110 need to be welded during the assembly process.

[0055] 5, 6 and 7, the insulating frame 120 of the motor according to the embodiment of the present application has various structural forms. The insulating frame 120 of the first embodiment of the present application is configured to be composed of a plurality of independent and detachable first insulating frames 127, and a plurality of independent and detachable second insulating frames 128. Along the direction of the rotation axis O, the upper end and the lower end of each stator tooth 112 are respectively installed with the first insulating frame 127 and the second insulating frame 128, the upper end of the stator core 110 is installed with a plurality of first insulating frames 127 that are circumferentially enclosed in a circle, and the lower end of the stator core 110 is installed with a plurality of second insulating frames 128 that are enclosed in a circle.

[0056] Furthermore, the insulating frame 120 of the second embodiment of the present application is configured to be composed of a plurality of independent third insulating frames arranged sequentially along the circumference. Each third insulating frame includes two insulating portions connected to the upper and lower ends of the same stator tooth 112, and a connecting portion connecting the two insulating portions. A third insulating frame is mounted corresponding to each stator tooth 112. For example, the third insulating frame of this embodiment includes the first insulating frame 127 and the second insulating frame 128 of the above-described embodiment, as well as a connecting portion connecting the first insulating frame 127 and the second insulating frame 128.

[0057] As alternative implementations, the insulating frame 120 in three other embodiments of the present application is configured to consist of two integral structures, a fourth insulating frame and a fifth insulating frame. For example, the fourth insulating frame in this embodiment comprises a plurality of first insulating frames 127 from the above embodiment, formed as a single unit, and the fifth insulating frame comprises a plurality of second insulating frames 128 from the above embodiment, formed as a single unit. Along the direction of the rotation axis O, the fourth insulating frame (integrated structure) is mounted on the upper end of the stator core 110, while the fifth insulating frame (integrated structure) is mounted on the lower end of the stator core 110.

[0058] To facilitate understanding of the solutions of the embodiments of the present application, the following description will be made by taking the first insulating frame 127 and the second insulating frame 128 of the first embodiment as an example.

[0059] As shown in Figure 7 , a first insulating frame 127 is connected to the upper end of the stator core 110 and covers the upper end surfaces of the corresponding stator teeth 112 and the portion of the yoke 111 on either side of the stator teeth 112. A second insulating frame 128 is connected to the lower end of the stator core 110 and covers the lower end surfaces of the corresponding stator teeth 112 and the portion of the yoke 111 on either side of the stator teeth 112. Portions of the first and second insulating frames 127 and 128 extend into the winding slots 130 by a certain distance (e.g., 1 mm, 2.5 mm, 3 mm, etc.), which serves to position the first and second insulating frames 127 and 128 within the winding slots 130. Alternatively, the first and second insulating frames 127 and 128 may cover only the end surfaces of the stator core 110.

[0060] In order to achieve electrical insulation in the winding groove 130, the motor of the embodiment of the present application includes an insulating sheet 300. The insulating sheet 300 surrounds the inner side of the winding groove 130 and is fixedly connected to the winding groove 130. The thickness of the insulating sheet 300 is significantly less than the thickness of the plug-in wall of the motor in the prior art. The insulating sheet 300 can be made of insulating paper with a smaller thickness, or other thin sheet materials with insulating properties, which are not specifically limited here. The insulating sheet 300 can be fixed to the first insulating frame 127 and the second insulating frame 128 by bonding, clamping, screw connection, etc., and can also be fixed to the stator core 110, which are not specifically limited here. The insulating sheet 300 is arranged around the inner side of the winding groove 130, and an insulating sheet 300 is respectively provided in each winding groove 130. The insulating sheet 300 is in contact with the inner wall of the winding groove 130, so that during the winding 150 winding process, the insulating sheet 300 plays a role of electrical insulation between the winding 150 and the stator core 110.

[0061] As an alternative embodiment, the entire stator assembly 100 is provided with a single insulating sheet 300 and is configured to be continuously arranged in a plurality of winding slots 130. Of course, the stator assembly 100 may also be provided with multiple insulating sheets 300, each insulating sheet 300 being configured to be continuously arranged in at least two winding slots 130.

[0062] When the insulating sheet 300 is connected to the first insulating frame 127 and the second insulating frame 128 respectively along the direction of the rotation axis O, the insulating sheet 300 can be flush with the ends of the first insulating frame 127 and the second insulating frame 128, or protrude from the first insulating frame 127 and the second insulating frame 128.

[0063] The motor of the embodiment of the present application is provided with a first insulating frame 127 and a second insulating frame 128, respectively connected to the two ends of the stator core 110. The first insulating frame 127 and the second insulating frame 128 are connected by an insulating sheet 300. The insulating sheet 300 is arranged around the inner side of the winding slot 130. The winding 150 is electrically insulated from the stator core 110 by the first insulating frame 127, the second insulating frame 128, and the insulating sheet 300. Moreover, the use of the insulating sheet 300 to replace the interposed walls of the insulating frame 120 in the prior art can increase the effective area of ​​the winding slot 130. Due to the increased effective area of ​​the winding slot 130, the number of turns that can be wound on the first layer of the winding 150 near the stator teeth 112 increases, and the number of turns that can be wound on each subsequent layer also increases accordingly. Therefore, when winding the same number of turns, the length of copper wire required in this embodiment is shorter, reducing the copper consumption of the winding 150, thereby reducing copper loss and manufacturing costs. This embodiment can increase the number of turns of the winding 150 while keeping the outer dimensions of the motor unchanged, thereby maximizing the motor power.

[0064] As shown in Figures 7 and 8, in one embodiment of the present application, a sunken groove 140 is provided at both ends of the stator core 110 along the direction of the rotation axis O. The number of sunken grooves 140 is twice the number of winding slots 130. A sunken groove 140 is provided at each end of each winding slot 130, and the sunken grooves 140 are arranged around the inner side of the corresponding winding slot 130. Due to the provision of the sunken grooves 140, the first and second insulating frames 127, 128 can be fixedly connected to the corresponding sunken grooves 140. The positioning of the sunken grooves 140 further stabilizes the assembly of the first and second insulating frames 127, 128 with the stator core 110. In some embodiments, since the first and second insulating frames 127, 128 have walls 122 extending into the winding slots 130, the inclusion of the walls 122 within the sunken grooves 140 helps reduce the space occupied by the walls 122 in the winding slots 130, thereby increasing the effective area of ​​the winding slots 130. Moreover, the recessed grooves 140 are only provided at the two end portions of the winding slot 130 , that is, the width of the tooth portion 113 is reduced only at the two end portions of the stator tooth 112 , while the width of the tooth portion 113 in the middle portion of the winding slot 130 remains unchanged. Compared with directly shortening the width of the entire tooth portion 113 , this embodiment can improve the problems of narrowing of the magnetic circuit and increased magnetic saturation, thereby suppressing the degradation of motor performance.

[0065] In another embodiment of the present application, the sink groove 140 is only provided at one end of the stator core 110, and the sink groove 140 is not provided at the other end of the stator core 110. Similarly, the copper usage of the winding 150 can be reduced while the same number of turns is wound, and the number of turns of the winding 150 can be increased while the outer contour size of the motor remains unchanged, thereby achieving an increase in the motor power.

[0066] In another embodiment of the present application, along the circumferential direction, a portion of the stator teeth 112 are provided with recessed grooves 140 at both ends, while another portion of the stator teeth 112 are not provided with recessed grooves 140 at both ends. For example, recessed grooves 140 are provided only at both ends of the winding slots 130 on both sides of the stator teeth 112 where the enameled wire is wound. Therefore, the stator teeth 112 provided with recessed grooves 140 can also reduce the copper usage of the winding 150 while winding the same number of turns, and increase the number of turns of the winding 150 wound in the winding slots 130 on both sides of the stator teeth 112 while maintaining the same outer dimensions of the motor, thereby maximizing the motor power.

[0067] The embodiment of the present application is introduced by taking the example of providing a sink 140 at both ends of the winding slot 130. The first insulating frame 127 and the second insulating frame 128 each include a base 121 and a wall 122. The base 121 is connected to the end of the stator core 110, and the wall 122 is connected to the two opposite edges of the base 121. The two wall portions 122 are respectively located in two adjacent sinks 140. In two circumferentially adjacent winding slots 130, the base 121 is connected to the stator teeth 112 between the two winding slots 130 and the partial structure of the yoke 111 connected to both sides of the stator teeth 112. The wall portion 122 on one side of the base 121 is embedded in the sink 140 of one of the winding slots 130, and the wall portion 122 on the other side of the base 121 is embedded in the sink 140 of the other winding slot 130. The first insulating frame 127 and the second insulating frame 128 can be connected to the teeth 113 through the slots formed by the walls 122 on both sides. As an alternative embodiment, the wall 122 can be provided only on one side edge of the base 121, while the wall 122 is not provided on the other side edge of the base 121. This can also reduce the copper usage of the winding 150 while winding the same number of turns, and increase the number of turns of the winding 150 while keeping the outer dimensions of the motor unchanged, thereby improving the motor power.

[0068] As shown in Figure 9, in an embodiment of the present application, the insulating sheet 300 is fixedly connected to the wall portion 122. In order to meet the creepage distance requirements, the wall portions 122 of the first insulating frame 127 and the second insulating frame 128 must meet a certain overlap distance with the insulating sheet 300. Therefore, the axial dimensions of the wall portion 122 need to be designed according to the creepage distance. In an embodiment of the present application, along the axial direction, the overlap height h between the insulating sheet 300 and the first insulating frame 127 and the second insulating frame 128 is greater than or equal to 2.5 mm. The insulating sheet 300 and the first insulating frame 127 and the second insulating frame 128 referred to here all correspond to the insulating sheet 300 and the first insulating frame 127 and the second insulating frame 128 around which the winding 150 is wound. It is understandable that the length of the wall portion 122 in the axial direction can also be set to be greater than or equal to 2.5 mm to ensure the creepage distance.

[0069] The structures of the first and second insulating frames 127 and 128 are substantially the same. For ease of understanding, the following description will take the first insulating frame 127 as an example. The structure of the second insulating frame 128 can be understood with reference to the structure of the first insulating frame 127. To avoid repetition, the details will not be repeated here.

[0070] As shown in Figures 10, 11, and 14, in a motor according to one embodiment of the present application, a first latching portion is provided on the inner side of the wall portion 122, and a second latching portion is provided on the sidewall of the recessed groove 140. The first and second latching portions cooperate to securely connect the first insulating frame 127 to the stator core 110. In some embodiments, the first latching portion is a buckle 123 attached to the inner side of the wall portion 122; the second latching portion is a latching hole 118. The sidewall of the recessed groove 140 surrounds the winding groove 130 and faces the center of the winding groove 130. The engagement of the buckle 123 and the latching hole 118 in the wall portion 122 securely connects the first insulating frame 127 to the stator core 110, improving manufacturability. In some embodiments, the sidewalls of two adjacent recessed grooves 140 each have at least one latching hole 118, and the opposing sides of the two wall portions 122 each have at least one buckle 123. As an alternative embodiment, the first clamping portion and the second clamping portion may be configured as a clamping hole 118 and a clamping buckle 123 respectively.

[0071] In an embodiment of the present application, the first insulating frame 127 is a plastic part, and the buckle 123 and the first insulating frame 127 are integrally injection molded. The stator core 110 includes a plurality of stator punchings stacked along the direction of the rotation axis O, and the plurality of stator punchings are connected by rivet holes to form a stator core 110 with a certain thickness. Of course, the stator punchings can also be connected by other means, such as injection molding. The stator core 110 can be punched out with stator punchings of different structures by a stamping process, and some stator punchings have notch structures of different structural sizes at the position where the clamping hole 118 is formed, so that the clamping hole 118 is formed after different stator punchings are stacked. In another embodiment, the stator core 110 is an integral structure, rather than being formed by stacking stator punchings. In this case, the clamping hole 118 can be directly processed on the surface of the stator core 110.

[0072] As shown in Figures 8 and 10 , the circumferentially oriented recessed grooves 140 on either side of the tooth portion 113 comprise a first recessed groove 141 and a second recessed groove 142. The portion of the first recessed groove 141 proximal to the tooth portion 113, and the portion of the second recessed groove 142 proximal to the tooth portion 113, each comprise a first segment 143, a second segment 144, and a third segment 145, connected in sequence. The first segment 143 of the first recessed groove 141 is located at the end of the first yoke 1111, the second segment 144 is located on one side of the end of the tooth portion 113, and the third segment 145 is located at the end of the first tooth shoe 1142. The first segment 143 of the second recessed groove 142 is located at the end of the second yoke 1112, the second segment 144 is located on the other side of the end of the tooth portion 113, and the third segment 145 is located at the end of the second tooth shoe 1143.

[0073] Along the circumference, the two walls 122 of the first insulating frame 127 are mounted in the first and second recesses 141, 142, respectively. As shown in Figures 14 and 16 , each wall 122 includes a first wall 1221, a second wall 1222, and a third wall 1223. The first wall 1221 abuts against and is located within the first section 143. The second wall 1222 abuts against and is located within the second section 144. The third wall 1223 abuts against and is located within the third section 145.

[0074] As shown in Figures 10 and 11 , in some embodiments, the second section 144 of the first recess 141 and the second section 144 of the second recess 142 are each provided with a latch hole 118, and latches 123 are respectively provided on opposing sides of the two second walls 1222. The latches 123 engage with corresponding latch holes 118, and the number of latches 123 and latch holes 118 is the same, ensuring a stable connection between the first insulating frame 127 and the end of the stator core 110. The latch holes 118 provided in the second section 144 provide space for the latches 123 of the first insulating frame 127 to connect. Furthermore, the latches 123 distributed on both sides of the teeth 113 allow for a more secure connection between the first insulating frame 127 and the stator core 110 using fewer latches 123.

[0075] 12 and 16 , in other embodiments, the first section 143 and the third section 145 of the first recessed groove 141 or the second recessed groove 142 are each provided with a latch hole 118. Circumferentially, the first wall 1221 and the third wall 1223, located on the same side of the base 121, are each provided with a latch 123. The latches 123 engage with corresponding latch holes 118, and the number of latches 123 is the same as the number of latch holes 118, ensuring a stable connection between the first insulating frame 127 and the end of the stator core 110.

[0076] For understanding purposes of FIG12 , FIG13 , and FIG16 , in other embodiments, at least one latch hole 118 is provided in the portion of the first recess 141 excluding the second section 144 and in the portion of the second recess 142 excluding the second section 144. Circumferentially, latches 123 that engage with the latch holes 118 are provided on the side of the base 121 near the first recess 141 and the side near the second recess 142, respectively. This ensures that the first insulating frame 127 is stably connected to the end of the stator core 110. For example, the connection between the first insulating frame 127 and the stator core 110 in this embodiment is one of the following:

[0077] The first type: The first section 143 of the first sink groove 141 and the third section 145 of the second sink groove 142 are respectively provided with a clamping hole 118. Along the circumferential direction, the first wall 1221 of the base 121 close to the first sink groove 141 and the third wall 1223 close to the second sink groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 at the corresponding position.

[0078] The second type: the first section 143 of the first sink groove 141 and the first section 143 of the second sink groove 142 are respectively provided with a clamping hole 118, and along the circumferential direction, the first wall 1221 of the base 121 close to the first sink groove 141 and the first wall 1221 close to the second sink groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 on the first section 143.

[0079] The third type: The third section 145 of the first sink groove 141 and the third section 145 of the second sink groove 142 are respectively provided with a locking hole 118. Along the circumferential direction, the third wall 1223 of the base 121 close to the first sink groove 141 and the third wall 1223 close to the second sink groove 142 are respectively provided with a buckle 123 that cooperates with the locking hole 118 on the third section 145.

[0080] The fourth type: the first section 143 and the third section 145 of the first groove 141, and the first section 143 and the third section 145 of the second groove 142 are respectively provided with a clamping hole 118. Along the circumferential direction, the first wall 1221 and the third wall 1223 of the base 121 close to the first groove 141, and the first wall 1221 and the third wall 1223 close to the second groove 142 are respectively provided with a buckle 123 that cooperates with the clamping hole 118 on the first section 143 and the third section 145.

[0081] It can be understood that, by adopting the above four embodiments, since the buckles 123 provided on the first wall 1221 and the third wall 1223 of the first insulating frame 127 are more easily deformed, the manufacturability can be improved.

[0082] 14 and 16 , in the first insulating frame 127 of this embodiment, the end of the wall portion 122 away from the base 121 has a first chamfer 1224 . The first chamfer 1224 is arranged on a side close to the stator core 110 , so as to facilitate the introduction of the first insulating frame 127 into the stator core 110 , thereby making the installation of the first insulating frame 127 more convenient and the manufacturability better.

[0083] As shown in Figures 14 and 15 , in one embodiment of the present application, the wall portion 122 includes a second wall 1222. Two opposing second walls 1222 are inserted into the ends of the tooth portion 113, and the second walls 1222 abut the sidewalls of the recess 140. Part of the second wall 1222 comprises a thinning structure 1225, to which the buckle 123 is attached. The thickness of the thinning structure 1225 is less than that of the rest of the wall portion 122. The placement of the buckle 123 within the thinning structure 1225 makes deformation at the buckle 123 easier, facilitating installation and improving manufacturability.

[0084] 14 and 16 , in one embodiment of the present application, the first insulating frame 127 includes a first boss 124 protruding into the winding groove 130, and the first boss 124 is connected to the base 121 or the wall 122. In order to meet the requirements of manufacturability and reliability, the first boss 124 is integrally formed with the base 121 and the wall 122. One or more first bosses 124 are provided. When there are multiple first bosses 124, the multiple first bosses 124 are spaced apart on the base 121 or the wall 122 along the direction surrounding the winding groove 130. The first boss 124 is used to limit one end of the insulating sheet 300 along the direction of the rotation axis O. When the two first insulating frames 127 at both ends of the stator core 110 along the direction of the rotation axis O are respectively provided with a first boss 124, the first bosses 124 located at both ends jointly position the axial ends of the insulating sheet 300, limit the axial movement of the insulating sheet 300, ensure the installation reliability of the insulating sheet 300, thereby facilitating the winding operation of the winding 150 and ensuring the reliability of the electrical insulation of the motor.

[0085] Referring to Figures 15 and 17 , in another embodiment of the present application, the first insulating frame 127 includes a second boss 125 that protrudes into the winding groove 130 . The second boss 125 is connected to the base 121 or the wall 122 . To ensure manufacturability and reliability, the second boss 125 is integrally formed with the base 121 and the wall 122 . One or more second bosses 125 are provided. When multiple second bosses 125 are provided, the multiple second bosses 125 are spaced apart on the base 121 or the wall 122 along a direction surrounding the winding groove 130 .

[0086] Along the direction of the rotation axis O, a retaining groove 126 is provided on one side of the second boss 125 facing the other first insulating frame 127. Specifically, a second notch 1261 of the retaining groove 126 faces the insulating sheet 300, and one end of the insulating sheet 300 along the direction of the rotation axis O is connected to the retaining groove 126. It is understood that the retaining groove 126 can be formed within the second boss 125, or at the connection between the second boss 125 and the wall portion 122, and is not specifically limited here. When the two first insulating frames 127 at both ends of the stator core 110 along the direction of the rotation axis O are respectively provided with a second boss 125, the retaining grooves 126 of the second bosses 125 at both ends jointly position the axial ends of the insulating sheet 300, limiting axial movement of the insulating sheet 300 and ensuring reliable installation of the insulating sheet 300, thereby facilitating the winding operation of the winding 150 and ensuring reliable electrical insulation of the motor.

[0087] 15 and 17 , the limiting groove 126 extends through the second boss 125 in a direction surrounding the winding groove 130, so that the two side walls of the limiting groove 126 are parallel to the corresponding partial structure of the wall portion 122. It can be understood that, along the direction of the rotation axis O, the second notch 1261 of the limiting groove 126 gradually increases in a direction away from the base 121, so that the side wall of the limiting groove 126 forms a second chamfer 1262 at the position of the second notch 1261. The second chamfer 1262 can be provided on one of the two side walls of the limiting groove 126, or on both side walls at the same time. When one of the side walls of the limiting groove 126 is the outer wall of the wall portion 122, the second chamfer 1262 can also be provided on the end of the wall portion 122 away from the base 121.

[0088] To facilitate installation of the insulating sheet 300, the first insulating frame 127 of the embodiment of the present application utilizes one or more boss structures, either the first boss 124 or the second boss 125. Each first insulating frame 127 is not limited to employing a single boss structure. The first insulating frames 127 at both ends of the stator core 110 can each utilize a different boss structure to ensure secure installation of the insulating sheet 300.

[0089] 14 and 15 , in an embodiment of the present application, to improve the installation efficiency of the insulating sheet 300, the first insulating frame 127 includes a first boss 124 and a second boss 125 along the direction of the rotation axis O. Along the direction surrounding the winding groove 130, the first boss 124 is provided at one end of the first insulating frame 127 closer to the tooth top 114, and the second boss 125 is provided at the other end of the first insulating frame 127 farther from the tooth top 114. Therefore, the insulating sheet 300 can be positioned at the first notch 131 of the winding groove 130 by the limiting groove 126. Both sides of the first notch 131 of the winding groove 130 are positioned by the limiting groove 126, allowing the insulating sheet 300 to be stably connected within the winding groove 130. The second insulating frame 128 includes two first bosses 124 . Along the direction surrounding the winding groove 130 , one first boss 124 is located at one end of the second insulating frame 128 close to the tooth top 114 , and the other first boss 124 is located at one end of the second insulating frame 128 away from the tooth top 114 .

[0090] As an alternative embodiment, the first insulating frame 127 includes a first boss 124, and the second insulating frame 128 includes a second boss 125. The positions of the first boss 124 and the second boss 125 are offset or adjacent to each other along the direction around the winding groove 130, which is not specifically limited here. In another embodiment, the first insulating frame 127 and the second insulating frame 128 are both composed of the first boss 124, or both are composed of the second boss 125.

[0091] Referring to FIG. 7 , in another embodiment of the motor of the present application, a positioning post 129 is provided on the inner side of the base 121 of the insulating frame 120, and a positioning hole 119 is provided on the stator core 110 to cooperate with the positioning post 129. For example, the number of matching positioning posts 129 and positioning holes 119 can be set to one or more. When the number is set to more than one, the multiple positioning posts 129 or the multiple positioning holes 119 are spaced apart. The first insulating frame 127 is securely connected to the stator core 110 through the snap-fitting engagement of at least one positioning post 129 and the positioning hole 119. It is understood that, as an alternative embodiment, the base 121 is provided with at least one positioning hole 119, and the stator core 110 is provided with at least one positioning post 129 to cooperate with the positioning hole 119.

[0092] In another embodiment of the motor of the present application, the base 121 and the end of the stator core 110 are fixedly connected by fasteners. For example, the fasteners may be screws, rivets, or other fastening components. It is understood that the number of fasteners may be multiple, with intervals between the multiple fasteners. The specific number can be selected based on the actual product needs.

[0093] In one embodiment of the present application, along the circumferential direction, the maximum thickness of the wall portion 122 is less than or equal to the minimum width of the recessed groove 140. That is, the maximum thickness of the wall portion 122 is less than or equal to the minimum width of the recessed groove 140. Therefore, after the first insulating frame 127 is installed on the stator core 110, the wall portion 122 does not protrude into the winding groove 130, so that the first insulating frame 127 does not occupy the area of ​​the winding groove 130, thereby improving the efficiency and manufacturability of the motor.

[0094] 9 , in one embodiment of the present application, along the direction of the rotation axis O, the depths of the sunken grooves 140 at both ends of the winding slot 130 are equal, the maximum depth of the sunken groove 140 is L1 (since the depths of different slot sections of the sunken groove 140 may vary, the depth of the deepest slot section is defined as L1), the maximum height of the stator core 110 is L0 (since the height of the stator core 110 may vary, the height of the stator core 110 at its maximum height along the circumferential direction is defined as L0), and the following conditions are satisfied:

[0095] It is understood that the above parameters refer to the ratio of the height of the portion of the stator core 110 without the recess 140 to the overall height of the stator core 110. This ratio can be 0.5, 0.65, 0.7, 0.8, or 0.92, etc. Setting this ratio within a reasonable range of 0.5 to 0.92 has little effect on changes in the magnetic circuit, keeping iron and copper losses within a reasonable range and having little effect on the performance of the motor. Furthermore, it allows the insulating frame 120 to be securely installed, and the insulating frame 120 and the insulating sheet 300, when used in conjunction, can ensure electrical insulation distance and creepage distance. When this ratio is less than 0.5, the depth of the recess 140 accounts for too small a proportion of the height of the stator core 110, resulting in a narrowing of the magnetic circuit and increased iron loss, which is detrimental to the performance of the motor. When the ratio is greater than 0.92, the depth of the groove 140 accounts for too large a proportion of the height of the stator core 110 , which may result in the groove 140 at both ends of the stator core 110 being insufficient in depth to support the insulation frame 120 , making it impossible to install, and the electrical insulation distance cannot be guaranteed.

[0096] 9 , in one embodiment of the present application, along the direction of the rotation axis O, the maximum height of the insulating sheet 300 is L 11 (Since the height of the insulating sheet 300 may vary along its extension direction, the height at the maximum height of the insulating sheet 300 is defined as L 11 ), the maximum height of the stator core 110 is L0, and satisfies: 1≤L 11 / L0≤2. It can be understood that the first insulating frame 127 and the second insulating frame 128 are respectively inserted at both ends of the stator core 110, and the wall portions 122 of the first insulating frame 127 and the second insulating frame 128 are both located in the winding slot 130, so L 11 / L0 affects the creepage distance and efficiency of the motor. The ratio can be 1, 1.1, 1.2, 2, etc. 11 / L0 is set within a reasonable range of 1 to 2, which can ensure the creepage distance of the motor without affecting the efficiency of the motor. 11 When / L0 is less than 1, the insulating sheet 300 cannot completely cover the wall 122 of the first insulating frame 127 and the second insulating frame 128, and the motor creepage distance may be insufficient, resulting in insufficient safety clearance and a potential safety hazard. 11 When / L0 is greater than 2, the end of the insulating sheet 300 protruding from the stator core 110 is too high, resulting in the end of the winding 150 of the entire motor being too high. The copper consumption of the winding 150 increases, resulting in greater copper loss in the motor and lower efficiency of the motor.

[0097] Referring to FIG8 , in the embodiment of the present application, the stator core 110 includes a plurality of stator laminations stacked along the rotation axis O. To form the structure of the recessed groove 140, the stator laminations include at least two structures. In this embodiment, two of the plurality of stator laminations are first laminations and second laminations. The width of the tooth portion 113 of the first lamination is smaller than the width of the tooth portion 113 of the second lamination. Correspondingly, the width of the tooth top 114 and the yoke 111 at both ends of the tooth portion 113 are also smaller than the width of the corresponding positions of the second lamination. Therefore, first laminations are stacked at both ends of the stacked plurality of second laminations, thereby forming recessed grooves 140 at both ends of the stator core 110. It is understood that the first laminations at both ends of the second laminations can each include one or more (two, five, ten, etc.), and the number of first laminations at one end of the second lamination can be the same as or different from the number of first laminations at the other end, which is not specifically limited here. Comparing the first and second punching sheets separately, it can be seen that along the inner periphery of the winding slot 130, the sidewall of the first punching sheet facing the winding slot 130 is recessed inward relative to the corresponding sidewall of the second punching sheet. It should be noted that the sidewall of the first punching sheet referred to above may be a portion of the sidewall of the winding slot 130 or the entire sidewall of the winding slot 130. In addition, the sidewall of the first punching sheet is recessed inward relative to the corresponding sidewall of the second punching sheet. The depth of the recess along the inner periphery of the winding slot 130 can be the same or different (i.e., the depth of the recess at different locations on the sidewall is different), which is not specifically limited here. The purpose of the inward recess of the sidewall of the first punching sheet is to form a sink 140, thereby reducing the copper usage of the winding 150 for the stator tooth 112 while maintaining the same number of turns. It also increases the number of turns of the winding 150 in the winding slots 130 on both sides of the stator tooth 112 while maintaining the outer dimensions of the motor, thereby maximizing the motor power. The depth of the recess at different positions mainly depends on the thickness of the wall portion 122 of the insulating frame 120 , so the depth of the recess can be designed with reference to the thickness of the wall portion 122 .

[0098] 2 and 9 , in an embodiment of the present application, a rotor assembly 200 includes a rotor core 210 and a plurality of permanent magnets 220. The rotor core 210 includes a plurality of core units 211, each of which is fan-shaped and arranged around a rotation axis O. Mounting slots 230 are formed between adjacent core units 211, and the plurality of permanent magnets 220 are mounted in corresponding mounting slots 230. The permanent magnets 220 cooperate with the mounting slots 230 to prevent the permanent magnets 220 from being ejected during movement of the rotor assembly 200. The core units 211 include a plurality of rotor laminations stacked along the rotation axis O. The rotor laminations of each core unit 211 may be composed of one or more structures, or may have different structures, which is not specifically limited herein. The stator core 110 includes a plurality of stator laminations stacked along the rotation axis O. The plurality of stator laminations may be composed of one or more structures.

[0099] The thickness of the insulating sheet 300 is d. The insulating sheet 300 is generally made of a material of uniform thickness. If the thickness of the insulating sheet 300 is not equal at different locations, the thickness of the portion of the insulating sheet 300 located in the winding groove 130 is defined as d.

[0100] The maximum thickness of the stator lamination is t1. Generally speaking, the thickness of multiple stator laminations is equal. If stator laminations of different thicknesses are used, the thickness of the stator lamination with the larger thickness is defined as t1. The maximum thickness of the rotor lamination is t2. Generally speaking, the thickness of multiple rotor laminations is equal. If rotor laminations of different thicknesses are used, the thickness of the rotor lamination with the larger thickness is defined as t2.

[0101] Since the outer wall surface of the stator core 110 is generally a non-circular surface, the inner wall surface of the stator core 110 may be a non-circular surface. In order to clearly define the outer diameter of the stator core 110, the maximum outer diameter of the stator core 110 is defined as D1, and the minimum inner diameter of the stator core 110 is defined as D2. Both D1 and D2 are diameters passing through the rotation axis O.

[0102] Since the outer wall surface of the rotor core 210 is generally a non-circular surface, the inner wall surface of the rotor core 210 may be a non-circular surface. In order to clearly define the outer diameter of the rotor core 210, the maximum outer diameter of the rotor core 210 is defined as D3, and the minimum inner diameter of the rotor core 210 is defined as D4. D3 and D4 are both diameters passing through the rotation axis O.

[0103] The motor of the embodiment of the present application satisfies:

[0104] The above parameter range reflects the relationship between the inner and outer diameter difference of the stator core 110, the inner and outer diameter difference of the rotor core 210, the thickness of the stator punching, the rotor punching and the insulating sheet 300, and the above parameter value can be 4, 8, 8.3, 10, 20, 30 or 40. It is understandable that if the inner and outer diameter difference D3-D4 of the stator core 110 is too large, the electric load of the motor will increase, the stator assembly 100 will compete with the rotor side of the motor for slot area, resulting in a decrease in magnetic load and a decrease in motor performance; if the inner and outer diameter difference D1-D2 of the rotor core 210 is too large, the stator side space of the motor will decrease, the magnetic load of the motor will increase, the electric load will decrease, and the performance of the motor will decrease.

[0105] Therefore, the difference between the inner and outer diameters of the stator core 110 and the difference between the inner and outer diameters of the rotor core 210 influence and are closely related to each other. Therefore, there is a reasonable range for the ratio between the difference between the inner and outer diameters of the stator core 110 and the difference between the inner and outer diameters of the rotor core 210, so that the performance of the motor is in a better state.

[0106] The smaller the maximum thickness t1 of the stator punching sheet, the smaller the iron loss and the higher the efficiency of the motor, but the higher the cost and the higher the manufacturing difficulty; the larger t1 is, the greater the iron loss and the lower the efficiency of the motor, but the lower the cost and the lower the manufacturing difficulty.

[0107] The smaller the maximum thickness t2 of the rotor punching, the worse the magnetic permeability and the higher the cost; the larger t2 is, the better the magnetic permeability and the lower the cost.

[0108] The thickness d of the insulating sheet 300 determines the insulation thickness. The smaller d is, the larger the slot area of ​​the winding slot 130 is, the smaller the copper loss is, and the higher the efficiency of the motor is; the larger d is, the smaller the slot area of ​​the winding slot 130 is, and the greater the copper loss is.

[0109] In summary, when the parameters of the motor of this embodiment meet the above ranges, the space between the stator assembly 100 and the rotor assembly 200 can be reasonably allocated to achieve a balance between iron loss and copper loss, as well as a balance between electrical load and magnetic load, so that the motor can obtain better performance.

[0110] In order to further improve the performance of the motor, the motor of this embodiment can further meet the following requirements:

[0111] 18 and 19 , in the embodiment of the present application, along the circumferential direction M of the rotor assembly 200 , the maximum width of the permanent magnet 220 is W. mag Generally speaking, the cross section of the permanent magnet 220 is a rectangle, so the maximum width of the permanent magnet 220 is the distance between the two long sides of the rectangle. If the cross section of the permanent magnet 220 is similar to an ellipse, the width between the two points of the permanent magnet 220 that are farthest apart along the circumferential direction is defined as W.mag .W mag The larger the value, the better the magnetic properties, but the magnetic load becomes larger, the iron loss is large, and the copper loss is small; W mag The smaller it is, the larger the magnetic conductive area becomes, the smaller the magnetic load becomes, the smaller the iron loss is, and the larger the copper loss is.

[0112] Along the radial direction N of the rotor assembly 200, the minimum width of the mounting slot 230 at the end away from the rotation axis O is so1, and the minimum width of the mounting slot 230 at the end closer to the rotation axis O is so2. In the radial direction, the end of the core unit 211 closer to the rotation axis O is provided with a first protrusion 212. The first protrusion 212 is connected to the sidewall closer to the mounting slot 230 and protrudes toward the mounting slot 230. The minimum width of the slot formed between the opposing first protrusions 212 is so1. The end of the core unit 211 farther from the rotation axis O is provided with a second protrusion 213. The second protrusion 213 is connected to the sidewall closer to the mounting slot 230 and protrudes toward the mounting slot 230. The minimum width of the slot formed between the opposing second protrusions 213 is so2.

[0113] It is understood that the larger so1 is, the smaller the magnetic flux leakage is, but the weaker the support for the permanent magnet 220 is; the smaller so1 is, the better the support for the permanent magnet 220 is, but the greater the magnetic flux leakage is. The larger so2 is, the smaller the magnetic flux leakage is, but the weaker the support for the permanent magnet 220 is; the smaller so2 is, the better the support for the permanent magnet 220 is, but the greater the magnetic flux leakage is.

[0114] In summary, so1, so2 and W mag Satisfy between: 0.5≤so1 / W mag ≤0.6, and 0.5≤so2 / W mag When the above parameter range is met, the installation structure of the permanent magnet 220 is stable and is not easily thrown out from the slots on both sides of the installation slot 230. In addition, the area ratio of the core unit 211 and the installation slot 230 is reasonable, and the performance of the motor is guaranteed.

[0115] As shown in Figure 19 , it can be understood that so1 and so2 satisfy the following: 0.9 ≤ so1 / so2 ≤ 1. Meeting this parameter range ensures radial positioning of permanent magnet 220 on both sides, further stabilizing the installation of permanent magnet 220 and rotor core 210 and improving the structural stability of rotor assembly 200. In this embodiment, so1 is preferably 3 mm, and so2 is preferably 3.15 mm.

[0116] 18 , the permanent magnet 220 of an embodiment of the present application adopts a chamfered design, i.e., the cross-section of the permanent magnet 220 is a quadrilateral, and along the radial direction N and circumferential direction M of the rotor assembly 200, the four corners of the permanent magnet 220 are cut, and the cut corners can be structures such as C angles and R angles. When it is necessary to increase the amount of permanent magnet 220, and the radial length of the permanent magnet 220 remains unchanged while the circumferential width of the permanent magnet 220 is increased, the width of the magnetic bridge 214 on the side of the rotor core 210 near the rotating shaft does not meet the manufacturability (minimum of about 0.5mm), resulting in the width of the permanent magnet 220 not being increased too much. However, after adopting the chamfered design, even if the width of the permanent magnet 220 continues to increase, the magnetic bridge 214 can still meet its manufacturability and can effectively block the permanent magnet 220 from being affected by centrifugal force and falling out of the mounting slot 230. In this embodiment, along the radial direction N of the rotor assembly 200, the maximum length of the permanent magnet 220 is L; the two inclined surfaces of the permanent magnet 220 that are separated from each other in the circumferential direction are the first chamfered surface 221 and the second chamfered surface 222. The minimum distance between the first chamfered surface 221 and the second chamfered surface 222 is X1, and the maximum distance between the first chamfered surface 221 and the second chamfered surface 222 is generally the maximum length L of the permanent magnet 220. Along the circumferential direction M of the rotor assembly 200, the maximum width of the permanent magnet 220 is W. mag The two radially opposite inclined surfaces of the permanent magnet 220 are the first chamfered surface 221 and the third chamfered surface 223. The minimum distance between the first chamfered surface 221 and the third chamfered surface 223 is Y1, and the maximum distance between the first chamfered surface 221 and the third chamfered surface 223 is generally the maximum width W of the permanent magnet 220. mag .

[0117] This embodiment satisfies: 0.5≤X1 / W mag ≤0.9, and 0.7≤Y1 / L≤0.95. For example, X1 / W mag It can be 0.5, 0.6, 0.736, 0.9, etc., and Y1 / L can be 0.7, 0.86, 0.9, 0.95, etc. When the above parameter range is met, the manufacturability of the rotor assembly 200 can be taken into account while increasing the amount of permanent magnets 220, improving the air gap flux density, improving the motor's anti-demagnetization ability, improving the motor's torque density and motor efficiency, and improving the motor's overload capacity and improving the temperature rise. It can be understood that X1 / W mag When it is less than 0.5, the amount of permanent magnet 220 is too small, the magnetic density is reduced, and the efficiency of the motor is reduced; X1 / W magWhen Y1 / L is greater than 0.9, the amount of permanent magnet 220 used is large, but the rotor high-punch equipment has difficulty punching out qualified rotor punching sheet dimensions, and the rotor assembly 200 does not meet the manufacturability requirements. Specifically, the first protrusion 212 and the second protrusion 213 provided at both ends of the rotor punching along the radial direction and used to limit the permanent magnet 220 are difficult to manufacture. In addition, when Y1 / L is less than 0.7, the amount of permanent magnet 220 used is too small to improve the motor efficiency and anti-demagnetization capability; X1 / W mag When it is greater than 0.95, the rotor high-punch equipment has difficulty in punching out qualified rotor punching sheet dimensions, and the rotor assembly 200 does not meet the manufacturability requirements. Specifically, the first protrusion 212 and the second protrusion 213 of the rotor punching sheet, which are arranged at both radial ends and used to limit the permanent magnet 220, are difficult to manufacture.

[0118] 2 and 3 , in a motor according to an embodiment of the present application, a first side wall 1131 and a second side wall 1132 are provided on two sides of the tooth portion 113 in the circumferential direction away from each other, and the maximum distance between the first side wall 1131 and the second side wall 1132 is W. t Since the stator core 110 of this embodiment has a sunken groove 140, the distances between the first side wall 1131 and the second side wall 1132 of different punching sheets are different. The tooth width of the punching sheet constituting the non-sunk groove 140 portion is greater than the tooth width of the punching sheet constituting the sunken groove 140 portion. Therefore, the tooth width of the punching sheet constituting the non-sunk groove 140 portion is defined as W. t The maximum outer diameter of the stator core 110 is defined as D1, and the minimum inner diameter of the stator core 110 is defined as D2. Both D1 and D2 are diameters passing through the rotation axis O. The maximum outer diameter of the rotor core 210 is defined as D3, and the minimum inner diameter of the rotor core 210 is defined as D4. Both D3 and D4 are diameters passing through the rotation axis O.

[0119] The embodiments of the present application satisfy:

[0120] The above parameter ranges reflect the relationship between the inner and outer diameter differences of the rotor assembly 200, the stator assembly 100, the tooth width, and the outer diameter of the stator core 110. These parameter values ​​can be 31.5, 40, 43.3, 45, 50, 53.5, etc. The maximum outer diameter D1 of the stator core 110 determines the outer dimensions of the stator assembly 100, the outer dimensions of the motor, and indirectly affects the outer dimensions of the rotor assembly 200. D1 is proportional to the motor volume and output capacity. t It is inversely proportional to the amount of winding 150. The larger this value is, the smaller the area of ​​the winding slot 130 is, the fewer windings 150 are accommodated, the lower the electrical load of the motor is, the greater the copper loss is, but the wider the magnetic circuit is, the lower the magnetic density is, and the smaller the iron loss is; W t The smaller the size, the larger the area of ​​winding slot 130, the greater the copper loss, but the narrower the magnetic circuit, the higher the magnetic density, and the greater the iron loss.t The effect of D1 is greater on the above parameters. 2 and W t 2 It is helpful to amplify the effects of the two parameters.

[0121] The value of D1-D2 determines the width of the stator side, affecting the capacity of winding 150 and copper loss. 1 / (D1-D2) is negatively correlated with the stator's electrical load. A larger value means smaller conductors can be accommodated and a lower electrical load. The value of D3-D4 determines the width of the rotor side and is positively correlated with the rotor's electrical load. A larger value means more permanent magnets 220 can be accommodated, increasing the magnetic flux of the permanent magnets 220 and the air gap flux density, which increases iron loss and degrades performance. Conversely, a smaller value of D3-D4 means smaller magnetic flux of the permanent magnets 220 and smaller air gap flux density, increasing copper loss and degrading performance. Therefore, the optimal value of D3-D4 must be selected, meaning it should not be too large or too small.

[0122] It should be noted that, in order to take into account both the iron loss and the copper loss of the motor, this embodiment optimizes the efficiency of the motor by limiting the above parameters to the range of 31.5 to 53.5.

[0123] 2 and 3 , in a motor according to an embodiment of the present application, the magnetic conductive area of ​​the stator core 110 is S3. The magnetic conductive area of ​​the stator core 110 is the projected area of ​​the stator core 110 along the direction of the rotation axis O. The projected area does not include the area of ​​non-magnetic parts such as injection holes and process holes, but includes the area of ​​magnetic parts such as rivet buckles.

[0124] The embodiments of the present application satisfy:

[0125] The above formula is equivalent to:

[0126] The above parameter range reflects the relationship between the magnetic conductive area of ​​the stator assembly 100 and the area of ​​the winding slot 130. The above parameter values ​​can be 35, 40, 47, 50, 55, 60, 65, etc. S4 is the area of ​​the ring formed by the inner diameter circle and the outer diameter circle of the stator core 110, so S4-S3 can be approximately equal to the area of ​​the winding 150 of the stator assembly 100, that is, the non-magnetic conductive area. The larger S3 is, the larger the magnetic conductive area is, and the lower the motor saturation is, but the smaller the amount of winding 150 is, the smaller the electrical load is, resulting in greater copper loss and lower motor efficiency. The larger S4-S3 is, the narrower the magnetic circuit of the motor is, the higher the magnetic density in the iron core magnetic circuit is, the greater the iron loss of the motor is, and the lower the efficiency is.

[0127] The maximum outer diameter D1 of the stator core 110 determines the outer dimensions of the stator assembly 100, the outer dimensions of the motor, and indirectly affects the outer dimensions of the rotor assembly 200. tThe larger the W is, the smaller the area of ​​the winding slot 130 is, the greater the copper loss is, but the wider the magnetic circuit is, the lower the magnetic density is, and the smaller the iron loss is; t The smaller it is, the larger the area of ​​the winding slot 130 is, the greater the copper loss is, but the narrower the magnetic circuit is, the higher the magnetic density is, and the greater the iron loss is. t The effect of Wt 2 It is helpful to amplify the effects of the two parameters.

[0128] It should be noted that, in order to take into account both the iron loss and the copper loss of the motor, this embodiment limits the above parameters to the range of 35 to 65, so as to maximize the efficiency of the motor.

[0129] 2 , 3 , and 18 , in a rotor assembly 200 according to one embodiment of the present application, the number of core units 211 is equal to the number of permanent magnets 220 . For example, the number of core units 211 is 10, and the number of permanent magnets 220 is also 10. Projected along the direction of the rotation axis O, the projected area of ​​the permanent magnets 220 is S1 , where S1 is the projected area of ​​a single permanent magnet 220 .

[0130] The projected area of ​​the magnetically conductive portion of the core unit 211, projected along the rotation axis O, is S2. S2 is the projected area of ​​a single core unit 211 along the rotation axis O. This projected area excludes non-magnetic portions such as injection molding holes and process holes, but includes magnetically conductive portions such as rivets. The core unit 211 includes multiple rotor laminations stacked along the rotation axis O. If rotor laminations of the same structure are used, S2 can also be defined as the projected area of ​​the magnetically conductive portion of a single rotor lamination along the rotation axis O.

[0131] The embodiments of the present application satisfy:

[0132] The above formula can be approximately equivalent to:

[0133] The above parameter range reflects the relationship between the magnetic pole area of ​​the rotor assembly 200 and the area of ​​the permanent magnet 220. The above parameter values ​​can be 38, 45, 50, 60, 70, 75, etc. NS1 is the projected area of ​​the permanent magnet 220 of the entire rotor core 210, that is, the sum of the projected areas of all permanent magnets 220; in this embodiment, the structure of each permanent magnet 220 is the same, so the projected area S1 of a single permanent magnet 220 is M times the relationship with NS1. NS2 is the magnetic pole area of ​​the entire rotor core 210, that is, the sum of the magnetic conductive areas of all core units 211; in this embodiment, the structure of each core unit 211 is the same, so the magnetic conductive area S2 of a single core unit 211 is M times the relationship with NS2. NS1 determines the volume of the permanent magnet 220. The larger this value is, the greater the amount of permanent magnet 220 used, the higher the magnetic load, the narrower the magnetic circuit, the greater the magnetic density of the rotor core 210, the deeper the saturation, the greater the iron loss, and the lower the motor efficiency; the smaller NS1 is, the smaller the amount of permanent magnet 220 used, the smaller the air gap magnetic density, the lower the magnetic load, the smaller the iron loss, and the greater the copper loss. NS2 determines the size of the rotor magnetic circuit. The larger this value is, the lower the magnetic load is, the smaller the air gap magnetic density is, resulting in a larger current at the same torque, greater copper loss, and lower motor efficiency; the smaller NS2 is, the smaller the magnetic conductive area is, the higher the magnetic load is, and the smaller the copper loss is. The maximum outer diameter D1 of the stator core 110 determines the outer contour size of the stator assembly 100, and also determines the outer dimensions of the motor, and indirectly affects the outer contour size of the rotor assembly 200. W t The larger the W is, the smaller the area of ​​the winding slot 130 is, the greater the copper loss is, but the wider the magnetic circuit is, the lower the magnetic density is, and the smaller the iron loss is; t The smaller it is, the larger the area of ​​the winding slot 130 is, the greater the copper loss is, but the narrower the magnetic circuit is, the higher the magnetic density is, and the greater the iron loss is. t The effect of Wt 2 It is helpful to amplify the effects of the two parameters.

[0134] It should be noted that, in order to take into account both the iron loss and the copper loss of the motor, this embodiment limits the above parameters to the range of 38 to 75, so as to maximize the efficiency of the motor.

[0135] 2 and 3 , the maximum outer diameter of the stator core 110 is D1, and the minimum inner diameter of the stator core 110 is D2. The distance between the ends of two adjacent teeth 113 away from the tooth top 114 is W. slot The ends of the two adjacent teeth 113 away from the tooth top 114 are connected by the yoke 111. The side of the yoke 111 facing the winding groove 130 between the two teeth 113 is the groove bottom 132. The two ends of the groove bottom 132 along the circumferential direction are respectively connected to the ends of the two teeth 113. The groove bottom 132 is a flat surface or a multi-segment surface or an arc surface. slotIt is defined as the minimum width of the groove bottom 132 at both ends along the circumferential direction, that is, the straight-line distance between the two ends. Along the radial direction N of the rotor assembly 200, the maximum dimension of the yoke 111 is W y ;W y It is defined as the maximum thickness of the yoke 111, that is, the maximum thickness of the structure of the yoke 111 connected to the tooth 113 and the structure of the yoke 111 between adjacent teeth 113. The tooth 113 is provided with a first side wall 1131 and a second side wall 1132 on two sides facing away from each other along the circumferential direction. The maximum distance between the first side wall 1131 and the second side wall 1132 is W. t ;W t Defined as the maximum tooth width. Along the circumferential direction, the maximum width at both ends of the tooth top 114 is W tip In this embodiment, the tooth top 114 includes two tooth boots 1141, the two tooth boots 1141 protrude to both sides of the tooth portion 113 along the circumferential direction, W tip The maximum distance between the two tooth shoes 1141 of the same tooth top 114. Since the stator core 110 of this embodiment has a recessed groove 140, the distances between the two tooth shoes 1141 of different punching sheets vary. The widths at both ends of the tooth top 114 of the punching sheet that does not form the recessed groove 140 are greater than the widths at both ends of the tooth top 114 of the punching sheet that does not form the recessed groove 140. Therefore, the widths at both ends of the tooth top 114 of the punching sheet that does not form the recessed groove 140 are defined as W. tip .

[0136] In the embodiments of the present application, the following conditions are met:

[0137] Wherein, W=(D1-D2) / 2, where W is half of the difference between the inner and outer diameters of the stator core 110.

[0138] It is understandable that W slot Related to the size of the winding slot 130, W slot The larger the W is, the larger the area of ​​the winding slot 130 is, the smaller the copper loss is, the narrower the magnetic circuit is, and the greater the iron loss is; slot The smaller it is, the smaller the area of ​​the winding slot 130 is, the greater the copper loss is, the wider the magnetic circuit is, and the smaller the iron loss is.

[0139] WW y Related to the depth of the winding groove 130, WW y The larger the size, the larger the area of ​​the winding slot 130, the smaller the copper loss, but the smaller the rotor assembly 200, the smaller the magnetic load; WW y The smaller it is, the smaller the area of ​​the winding slot 130 is, and the greater the copper loss is. However, the larger the rotor assembly 200 is, the greater the magnetic load is.

[0140] W tip Related to the ability of the stator assembly 100 to collect stator-side magnetic flux, W tipThe larger the value, the larger the magnetic flux area, the greater the magnetic load, the smaller the copper loss, and the greater the iron loss; W tip The smaller it is, the smaller the magnetic flux area, the smaller the magnetic load, the greater the copper loss, and the smaller the iron loss.

[0141] W t The larger the W is, the smaller the area of ​​the winding slot 130 is, the greater the copper loss is, but the wider the magnetic circuit is, the lower the magnetic density is, and the smaller the iron loss is; t The smaller it is, the larger the area of ​​the winding slot 130 is, the smaller the copper loss is, but the narrower the magnetic circuit is, the higher the magnetic density is, and the greater the iron loss is.

[0142] It should be noted that, in order to take into account the area of ​​the winding slot 130 , the magnetic flux area, and the iron loss and copper loss, this embodiment optimizes the performance of the motor by limiting the above parameters to a range of 1 to 2.1.

[0143] A household appliance according to one embodiment of the present application includes the motor of the above embodiment. It is understood that the motor of this embodiment can be used in household appliances such as electric fans, air conditioners, dehumidifiers, refrigerators, and washing machines. As a core component of a household appliance, the motor is used to drive components such as a fan, impeller, or drum to rotate, thereby realizing the functions of the household appliance.

[0144] The household appliance of the embodiment of the present application adopts the motor of the embodiment of the first aspect. The motor is connected to the two ends of the stator core 110 respectively by setting two insulating frames 120, and the two insulating frames 120 are connected by an insulating sheet 300. The insulating sheet 300 is arranged around the inner side of the winding groove 130, and the winding 150 is electrically insulated from the stator core 110 by the insulating frame 120 and the insulating sheet 300; using the insulating sheet 300 to replace the plug-in wall of the insulating frame 120 can increase the effective area of ​​the winding groove 130, so that the winding groove 130 can accommodate a winding 150 with a larger number of turns, thereby maximizing the motor power while keeping the outer contour size of the motor unchanged.

[0145] Since the household appliance of the embodiment of the present application adopts all the technical solutions of the motor of the above embodiment, it has at least all the beneficial effects brought by the technical solutions of the above embodiment, which will not be repeated here.

[0146] Some embodiments of the present application are described in detail above in conjunction with the accompanying drawings, but the present application is not limited to the above embodiments. Various changes can be made within the scope of knowledge possessed by ordinary technicians in the relevant technical field without departing from the purpose of the present application.

Claims

1. Motor, including: a rotor assembly, rotating about a rotation axis; The stator assembly comprises a stator core and two insulating frames connected to both ends of the stator core along the rotation axis. The stator core comprises a yoke and a plurality of stator teeth. The yoke is disposed around the outside of the rotor assembly. The plurality of stator teeth are disposed around the inside of the yoke and are spaced apart along the circumference of the rotor assembly. A winding slot is formed between two adjacent stator teeth along the circumference. as well as an insulating sheet, connected to the two insulating frames at both ends along the rotation axis, the insulating sheet being arranged around the inner side of the winding groove; Wherein, along the direction of the rotation axis, at least one end of the stator core is provided with a sinking groove, the sinking groove is located at the end of the winding groove and arranged around the inner side of the winding groove, and the insulating frame is fixedly connected to the sinking groove.

2. The motor according to claim 1, wherein The insulating frame includes a base and a wall connected to a portion of the outer edge of the base. The base is connected to the end of the stator core. The wall is arranged in the sink, and the insulating sheet is fixedly connected to the wall.

3. The motor according to claim 2, wherein A first clamping portion is provided on the inner side of the wall portion, and a second clamping portion cooperating with the first clamping portion is provided on the side wall of the sink.

4. The motor according to claim 2 or 3, wherein: A positioning column is provided on the inner side of the base, and a positioning hole is provided on the stator core to match the positioning column.

5. The motor according to any one of claims 2 to 4, wherein: The base and the end of the stator core are fixedly connected by fasteners.

6. The motor according to any one of claims 2 to 5, wherein: Along the circumferential direction, the maximum thickness of the wall portion is less than or equal to the minimum width of the sink.

7. The motor according to any one of claims 1 to 6, wherein: Along the direction of the rotation axis, the maximum depth of the sink is L1, and the maximum height of the stator core is L0, satisfying:

8. The motor according to claim 1 or 7, wherein: Along the direction of the rotation axis, the maximum height of the insulating sheet is L 11 , the maximum height of the stator core is L0, satisfying: 1≤L 11 / L0≤2.

9. The motor according to any one of claims 1 to 8, wherein: The stator core includes a plurality of stator punching sheets stacked along the direction of the rotation axis, two of the plurality of stator punching sheets are respectively a first punching sheet and a second punching sheet, and along the inner circumference of the winding slot, at least a portion of the side wall of the first punching sheet toward the winding slot is recessed inward relative to the side wall corresponding to the second punching sheet.

10. The motor according to any one of claims 1 to 9, wherein: The thickness of the insulating sheet is d; The stator core includes a plurality of stator punching sheets stacked along the direction of the rotation axis, and the maximum thickness of the stator punching sheets is t1; The rotor assembly includes a rotor core and a plurality of permanent magnets. The rotor core includes a plurality of core units arranged around the rotation axis. Mounting slots are formed between adjacent core units. The plurality of permanent magnets are respectively mounted in corresponding mounting slots. The core unit includes a plurality of rotor punchings stacked along the direction of the rotation axis. The maximum thickness of the rotor punchings is t2. The maximum outer diameter of the stator core is D1, and the minimum inner diameter of the stator core is D2; and The maximum outer diameter of the rotor core is D3, and the minimum inner diameter of the rotor core is D4; satisfying:

11. The motor according to any one of claims 1 to 10, wherein: The rotor assembly includes a rotor core and a plurality of permanent magnets. The rotor core includes a plurality of core units arranged around the rotation axis. Mounting slots are formed between adjacent core units. The plurality of permanent magnets are respectively mounted in corresponding mounting slots. Along the circumference of the rotor assembly, the maximum width of the permanent magnet is W mag ;as well as Along the radial direction of the rotor assembly, the minimum width of the mounting slot at the end away from the rotation axis is so1, and the minimum width of the mounting slot at the end close to the rotation axis is so2, satisfying: 0.5≤so1 / W mag ≤0.6, and 0.5≤so2 / W mag ≤0.

6.

12. The electric machine according to claim 11, wherein The minimum width so1 of the mounting groove at one end away from the rotation axis and the minimum width so2 of the mounting groove at one end close to the rotation axis satisfy the following: 0.9≤so1 / so2≤1.

13. A household appliance comprising the motor according to any one of claims 1 to 12.

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