Electric motor stator, electric motor, and manufacturing method for electric motor stator

Abstract

Provided in the present invention is an electric motor stator, comprising a core (1), a coil (21) and an insulating member (3). The core (1) is provided with slots (1a), each slot (1a) being recessed in the radial direction of the core (1), and a protrusion (1e) being provided on one or two side walls (1b) of each slot (1a); the coil (21) is embedded into the slots (1a) via a radial opening (1d) of each slot (1a); in the radial direction of the core (1), the protrusion (1e) is arranged between the coil (21) and the radial opening (1d); and the insulating member (3) extends out from a gap between the side wall (1b) and the coil (21) and covers the protrusion (1e), and the coil (21) is fixed in the slots (1a) in an expansion manner. Further provided are an electric motor and a manufacturing method for an electric motor stator.

Description

Motor stator, motor, and method for manufacturing motor stator Technical Field

[0001] The present application relates to the field of motors, and in particular to a motor stator, a motor, and a method for manufacturing the motor stator. Background Art

[0002] Chinese invention patent application CN111801875A discloses a method for manufacturing an armature and an armature. The coil can be formed into a wave-wound shape, with the slot receiving portion inserted radially inward relative to the slot. An in-slot arrangement portion is disposed between the slot receiving portion and the inner surface of the slot. The slot receiving portion can be secured relative to the inner surface of the slot by a compressive force generated by the expansion of the in-slot arrangement portion. However, the reliability of the aforementioned securing method still leaves room for improvement.

[0003] Summary of the Invention

[0004] The present application provides a motor stator as follows, comprising: an iron core, which is provided with a narrow slot, the narrow slot being recessed along the radial direction of the iron core, and one or both side walls of the narrow slot being provided with a protrusion; a coil, which is embedded in the narrow slot through the radial opening of the narrow slot, and in the radial direction of the iron core, the protrusion is provided between the coil and the radial opening; and an insulating member, which extends from the gap between the side wall and the coil and covers the protrusion, and fixes the coil in the narrow slot in an expansion manner.

[0005] In an optional solution, the insulating member covers the top of the protrusion.

[0006] In another optional embodiment, the insulating member includes a first expansion portion and a second expansion portion adjacent to each other, the first expansion portion is arranged in the gap between the side wall and the coil, the second expansion portion covers the protrusion, and the thickness of the first expansion portion is less than the thickness of the second expansion portion.

[0007] In another optional embodiment, the insulating member is U-shaped, the coil is arranged on the inner side of the U-shape, the bottom of the U-shape is arranged in the gap between the bottom wall of the narrow slot and the coil, and the top of the U-shape extends from the gap between the side wall and the coil and covers the protrusion.

[0008] In another optional solution, the radial opening is provided with a chamfer.

[0009] In another optional solution, the chamfer is adjacent to the protrusion.

[0010] In another optional solution, the insulating member includes a foam material.

[0011] The present application also provides a motor as follows, which includes the above-mentioned motor stator.

[0012] The present application also provides a method for manufacturing the above-mentioned motor stator, comprising: positioning the insulating member in a non-expanded state in the narrow slot so that the insulating member covers the protrusion; positioning the coil in the narrow slot so that in the radial direction of the iron core, the protrusion remains between the coil and the radial opening; and changing the insulating member positioned in the narrow slot from a non-expanded state to an expanded state so that the coil positioned in the narrow slot is fixed in the narrow slot.

[0013] In one optional aspect, changing the insulating member from a non-expanded state to an expanded state includes heating the insulating member.

[0014] By adopting the above technical solution, by providing a protrusion, the protrusion can cause the portion of the insulating component extending from the gap to shift circumferentially inward, so that the insulating component can more effectively limit the radial position of the coil, thereby achieving higher reliability of the motor stator. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG1 shows a schematic diagram of a motor stator according to an embodiment of the present application, wherein an insulating member is in an expanded state.

[0016] FIG. 2 shows a partial enlarged view of the stator of the motor in FIG. 1 .

[0017] FIG3 shows a partial enlarged view of the iron core of the motor stator in FIG1 .

[0018] FIG. 4 is a schematic diagram illustrating a method of manufacturing the motor stator of FIG. 1 , wherein the coils and the insulating member are in a non-expanded state and positioned within the slots.

[0019] FIG5 shows a partial enlarged view of the motor stator in FIG4 , in which the jig is omitted. DETAILED DESCRIPTION

[0020] The following describes exemplary embodiments of the present application with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, and are not intended to exhaust all possible methods of the present application, nor to limit the scope of the present application.

[0021] 1 to 3 show a motor stator (hereinafter sometimes simply referred to as a stator) according to an embodiment of the present application.

[0022] 1 and 2 , the stator may include a core 1 , a winding 2 , and an insulating member 3 .

[0023] 3 , the core 1 may be provided with a plurality of slots 1a. The core 1 may be formed by stacking a plurality of laminations. The laminations may be made of soft magnetic material, for example, the laminations may be silicon steel sheets. The slots 1a may be recessed radially outward from the inner circumference of the core 1 and pass through the core 1 axially. The plurality of slots 1a may be evenly arranged in the circumferential direction C. The slots 1a may be defined by two side walls 1b and a bottom wall 1c. The two side walls 1b may be parallel to each other and arranged opposite to each other in the circumferential direction C. The bottom wall 1c may be connected between the two side walls 1b and face the radial opening 1d of the slots 1a.

[0024] Each slot 1a may be provided with two protrusions 1e and two chamfers 1f. The two protrusions 1e may be respectively provided on the two side walls 1b and arranged opposite to each other in the circumferential direction C. For example, the circumferential width D1 of the slot 1a where the protrusions 1e and the chamfers 1f are not provided may be 5.18 mm, and the minimum circumferential width D2 of the slot 1a between the two protrusions 1e may be 4.98 mm. The chamfers 1f may be provided at the edge of the radial opening 1d, and the two chamfers 1f may be adjacent to the radial inner ends of the two protrusions 1e, respectively. For example, the angle T of the chamfer 1f may be 5° to 15°, preferably 10°. Here, the angle T of the chamfer 1f refers to the angle between the side of the chamfer 1f and the side wall 1b of the slot 1a where the protrusions 1e and the chamfer 1f are not provided.

[0025] 2 , the winding 2 and the insulating member 3 can be embedded in the slot 1a. The winding 2 can include a plurality of coils 21 (or conductors). The coil 21 can be composed of a linear conductor with a rectangular cross-section (a cross-section orthogonal to the direction in which the conductor extends), that is, composed of what is commonly known as a flat wire. The coil 21 can be embedded in the slot 1a via the radial opening 1d, and the protrusion 1e can be arranged between the radial opening 1d and the coil 21. For example, the winding 2 can be a wave winding. The insulating member 3 can be an insulating paper folded into a U shape, and the coil 21 can be arranged on the inner side of the U shape, so that the iron core 1 and the coil 21 are separated by the insulating member 3. The bottom of the U shape can be arranged in the gap between the bottom wall 1c and the coil 21, and the top of the U shape can extend radially inward from the gap between the side wall 1b and the coil 21 and cover the protrusion 1e, for example, it can cover the top of the protrusion 1e.

[0026] The insulating member 3 can fix the coil 21 in the narrow slot 1a. The insulating member 3 may include a foamable thermosetting resin (an example of a foaming material), for example, an epoxy resin. By heating the insulating member 3, the insulating member 3 can be transformed from a non-expanded state with a smaller thickness to an expanded state with a larger thickness. When the insulating member 3 returns to a lower temperature, such as room temperature, the insulating member 3 can be cured and maintained in the expanded state. In the expanded state, the insulating member 3 can form two first expansion portions 31. The first expansion portion 31 can be arranged in the gap between the side wall 1b and the coil 21, and the two first expansion portions 31 can be separated by the coil 21. The first expansion portion 31 can squeeze the side wall 1b toward one circumferential side, so that the insulating member 3 can be maintained in the narrow slot 1a under the action of friction. At the same time, the first expansion portion 31 can squeeze the coil 21 toward the other circumferential side (the side opposite to the circumferential side), so that the coil 21 can be maintained between the two first expansion portions 31 under the action of friction.

[0027] The insulating member 3 can prevent the coil 21 from escaping from the narrow slot 1a. In the expanded state, the insulating member 3 can form two second expansion parts 32. The second expansion part 32 can be adjacent to the first expansion part 31 and cover the protrusion 1e, and the two second expansion parts 32 can be arranged opposite to each other in the circumferential direction C. In other words, the second expansion part 32 can be a part of the insulating member 3 that extends from the gap, that is, the top of the above-mentioned U-shape. Since the second expansion part 32 is not restricted by the gap like the first expansion part 31, the circumferential thickness of the second expansion part 32 can be greater than the circumferential thickness of the first expansion part 31, so that the circumferential spacing between the two second expansion parts 32 is less than the circumferential width of the coil 21. For example, the thickness of the entire insulating member 3 in the non-expanded state can be 0.2 mm, the thickness of the first expansion part 31 can be 0.3 mm to 0.4 mm, and the thickness of the second expansion part 32 can be 0.5 mm to 0.6 mm. In this way, the intersection of the first expansion portion 31 and the second expansion portion 32 forms a stepped structure that conforms to the shape of the coil 21, allowing the second expansion portion 32 to radially restrain the coil 21, preventing the coil 21 from escaping from the slot 1a through the radial opening 1d. Furthermore, the protrusion 1e further brings the two second expansion portions 32 closer together in the circumferential direction C, further reliably securing the second expansion portions 32 against the coil 21 in the radial direction.

[0028] 4 and 5 , a method for manufacturing a stator is described below. The method may include:

[0029] Positioning the insulating member 3 in a non-expanded state within the slot 1 a so that the insulating member 3 covers the protrusion 1 e ;

[0030] Positioning the coil 21 within the slot 1 a so that the protrusion 1 e is held between the coil 21 and the radial opening 1 d ; and

[0031] Heat the thermal insulation member 3 positioned in the slot 1a, and transform the insulation member 3 from the non-expanded state as shown in Figure 5 to the expanded state as shown in Figure 2, so that the coil 21 positioned in the slot 1a is fixed in the slot 1a. For example, the insulation member 3 can be heated at 160°C for 10 minutes.

[0032] The coil 21 can be positioned in the slot 1a by the jig 4. The jig 4 can include a support ring 41 and a plurality of positioning heads 42. The support ring 41 can be fixedly connected to the positioning heads 42, and the plurality of positioning heads 42 can be evenly arranged on the circumference C of the support ring 41. The number of slots 1a and the number of positioning heads 42 can be the same. As shown in Figure 4, when the support ring 41 is coaxially arranged with the stator, each positioning head 42 can be inserted into a slot 1a via a radial opening 1d. The positioning head 42 can push the coil 21 radially outward to ensure that the coil 21 and the protrusion 1e are radially staggered. During the heating process of the insulating member 3, the coil 21 can be confined between the bottom surface 1c and the positioning head 42, and the positioning head 42 can radially limit the coil 21. After the insulating member 3 is in the expanded state as shown in Figure 2, the positioning head 42 can slide out from the axial opening of the slot 1a, so that the jig 4 is removed from the stator.

[0033] The stator of this embodiment has at least the following advantages.

[0034] (i) By providing the protrusion 1e, the protrusion 1e can help the second expansion portion 32 to shift circumferentially inward of the slot 1a, so that the second expansion portion 32 can more effectively limit the radial position of the coil 21, thereby achieving higher reliability of the stator.

[0035] (ii) By providing the chamfer 1f, the coil 21 is easily embedded in the narrow slot under the guidance of the chamfer 1f, making the coil 21 less likely to be damaged during the assembly process, especially the insulation layer on the coil 21 less likely to be scratched, thereby further improving the reliability of the stator.

[0036] (iii) By making the chamfer 1f adjacent to the protrusion 1e, the protrusion 1e and the chamfer 1f can be compactly arranged in the radial direction, so that the stator can have a compact structure.

[0037] The present application also provides a motor comprising the above motor stator, which may also include a single rotor. The motor may be an inner rotor motor.

[0038] It should be understood that the above embodiments are merely exemplary and are not intended to limit the present application. Those skilled in the art may make various modifications and changes to the above embodiments based on the teachings of the present application without departing from the scope of the present application.

[0039] (i) The winding 2 is not limited to being a wave winding, and may be, for example, a concentric winding or other possible radially embedded winding.

[0040] (ii) The winding 2 is not limited to being composed of rectangular wires, and may be composed of, for example, round wires (linear conductors having a circular cross section), or a combination of rectangular wires and round wires.

[0041] (iii) The two side walls 1b are not limited to being provided with the protrusions 1e. For example, one of the two side walls 1b may be provided with the protrusions 1e, while the other of the two side walls 1b may not be provided with the protrusions 1e.

[0042] (iv) The two protrusions 1e are not limited to having the same shape and size, and may have different shapes and sizes, for example.

[0043] Reference Signs List 1 Iron core 1a Slot 1b Side wall 1c Bottom wall 1d Radial opening 1e Protrusion; 1f Chamfer; 2 Winding 21 Coil 3 Insulation member 31 First expansion portion 32 Second expansion portion 4 Jig 41 Support ring 42 Positioning head C Circumferential direction D1 Circumferential width D2 Circumferential width T Angle

Claims

1. A motor stator, characterized in that: include: An iron core (1) is provided with a narrow slot (1a), wherein the narrow slot (1a) is recessed along the radial direction of the iron core (1), and one or two side walls (1b) of the narrow slot (1a) are provided with a protrusion (1e); a coil (21) embedded in the slot (1a) via a radial opening (1d) of the slot (1a), wherein the protrusion (1e) is provided between the coil (21) and the radial opening (1d) in the radial direction of the iron core (1); and An insulating member (3) extends from a gap between the side wall (1b) and the coil (21) and covers the protrusion (1e), and fixes the coil (21) in the slot (1a) in an expansion manner.

2. The motor stator according to claim 1, characterized in that: The insulating member (3) covers the top of the protrusion (1e).

3. The motor stator according to claim 1, characterized in that: The insulating member (3) includes a first expansion portion (31) and a second expansion portion (32) adjacent to each other, the first expansion portion (31) being arranged in a gap between the side wall (1b) and the coil (21), the second expansion portion (32) covering the protrusion (1e), and the thickness of the first expansion portion (31) being smaller than the thickness of the second expansion portion (32).

4. The motor stator according to claim 1, characterized in that: The insulating member (3) is U-shaped, the coil (21) is arranged on the inner side of the U-shape, the bottom of the U-shape is arranged in the gap between the bottom wall (1c) of the slot (1a) and the coil (21), and the top of the U-shape extends from the gap between the side wall (1b) and the coil (21) and covers the protrusion (1e).

5. The motor stator according to any one of claims 1 to 4, characterized in that: The radial opening (1d) is provided with a chamfer (1f).

6. The motor stator according to claim 5, characterized in that: The chamfer (1f) is adjacent to the protrusion (1e).

7. The motor stator according to any one of claims 1 to 4, characterized in that: The insulating member (3) comprises a foamed material.

8. A motor comprising the motor stator according to any one of claims 1 to 7.

9. A method for manufacturing a motor stator, wherein the motor stator is the motor stator according to any one of claims 1 to 7, characterized in that: include: positioning the insulating member (3) in a non-expanded state within the slot (1a) so that the insulating member (3) covers the protrusion (1e); Positioning the coil (21) within the slot (1a) such that the protrusion (1e) is held between the coil (21) and the radial opening (1d) in the radial direction of the core (1); and The insulating member (3) positioned in the slot (1a) is transformed from a non-expanded state to an expanded state, so that the coil (21) positioned in the slot (1a) is fixed in the slot (1a).

10. The manufacturing method according to claim 9, characterized in that: Transforming the insulating member (3) from a non-expanded state to an expanded state comprises: The insulating member (3) is heated.

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