Assembly method for motor stator structure, assembly tool, and potting mold

Abstract

The present invention provides an assembly method for a motor stator structure, an assembly tool, and a potting mold. The assembly method comprises the following steps: providing an assembly tool, the assembly tool comprising an assembly mandrel; providing a bearing assembly, and sleeving the bearing assembly to the assembly mandrel; providing a coil, and arranging the coil outside the assembly mandrel; providing a front-end connecting member and an iron core that are coaxially connected at an end portion, sleeving the front-end connecting member outside the assembly mandrel, and sleeving the iron core outside the coil; providing a potting mold, placing, in a potting cavity of the potting mold, the assembly mandrel having said components mounted thereon, and injecting encapsulation glue into the potting cavity to form an encapsulation layer, so as to encapsulate a stator assembly, the front-end connecting member, and the bearing assembly into an integral whole to form a motor stator structure; and withdrawing the assembly mandrel from the motor stator structure to complete assembly. Use of the present invention can improve the performance such as coaxiality, stability and surface flatness of the motor stator structure.

Description

A method for assembling a motor stator structure, assembly tooling, and potting mold.

[0001] Cross-referencing related applications

[0002] This patent application claims priority to Chinese Patent Application No. 202510215471.2, filed on February 26, 2025, entitled "An Assembly Method, Assembly Tooling and Encapsulation Mold for an Electric Motor Stator Structure", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to the field of motor technology, and more specifically, to a method for assembling a motor stator structure, assembly tooling, and potting mold. Background Technology

[0004] In the field of adjuvant therapy for heart failure, corresponding ventricular assist devices need to provide a high flow rate, so the motor speed is high, up to 50,000 rpm. At the same time, the device needs to be inserted from the puncture point into the expected treatment position. The outer diameter of the device needs to be as small as possible to reduce damage to the puncture point. The rigid length should be as short as possible. Clinically, it is recommended that the outer diameter should not exceed 8 mm and the rigid length should not exceed 40 mm.

[0005] The existing motors have a problem with coaxiality difference between the coil and iron core of the stator assembly and between the stator assembly and the rotor assembly, which leads to magnetic circuit imbalance and large rotational eccentricity. Under high speed, the motor is prone to excessive temperature rise and excessive motor vibration, which can damage blood vessels and blood tissues. When operating at high frequency, the lifespan is short and it is difficult to meet the clinical use needs of more than 7 days or even up to 1 month.

[0006] Therefore, based on the problems existing in the prior art, it is necessary to provide an assembly method, assembly tooling and potting mold for the motor stator structure, so as to improve the coaxiality, stability and surface flatness of the motor stator structure. Summary of the Invention

[0007] In view of this, the present invention provides an assembly method for a motor stator structure, the motor stator structure including a stator assembly, a front-end connector, and a bearing assembly, the stator assembly including at least a coil and an iron core coaxially sleeved from the inside to the outside, the stator assembly having a first end and a second end, the front-end connector being coaxially connected to the iron core at the first end, and the bearing assembly being coaxially disposed at the second end of the stator assembly, comprising the following steps:

[0008] a. Provide assembly tooling, the assembly tooling including an assembly mandrel;

[0009] b. Provide a bearing assembly, the bearing assembly including a bearing, a first protective sleeve and a second protective sleeve, the first protective sleeve and the second protective sleeve being respectively sleeved on both ends of the bearing, and sleeve the bearing assembly onto the assembly mandrel;

[0010] c. Provide a coil and sleeve the coil over the assembled mandrel;

[0011] d. Provide the front-end connector and the iron core that are coaxially connected at the ends, and sleeve the coaxially connected iron core and the front-end connector outside the assembled core rod, and make the iron core sleeve outside the coil;

[0012] e. Provide a potting mold, place the assembled mandrel with the bearing assembly, the coil, the front end connector and the iron core installed in the potting cavity of the potting mold, inject encapsulating glue into the potting cavity to form an encapsulation layer, so as to encapsulate the stator assembly, the front end connector and the bearing assembly into one piece to form the motor stator structure;

[0013] f. Remove the assembly mandrel from the motor stator structure to complete the assembly.

[0014] Optionally, the inner wall of the coil is coaxially provided with an inner sleeve. In step c, before providing the coil, the inner sleeve is provided, and the inner sleeve is sleeved outside the assembly core rod and fitted to the outer wall of the assembly core rod.

[0015] Optionally, the inner sleeve is a polymer heat-shrinkable sleeve; in step c, the inner sleeve is fitted to the outer wall of the assembled mandrel by heat shrinking.

[0016] Optionally, in step c, after applying encapsulating adhesive to the outer wall of the inner sleeve, the coil is then sleeved on the outer wall of the inner sleeve, so that the encapsulating adhesive fills the gap between the inner sleeve and the coil; then a heat-shrinkable sleeve is sleeved on the outer wall of the coil, and the heat-shrinkable sleeve makes the coil and the inner sleeve fit tightly together by heat shrinking.

[0017] Optionally, in step c, the heat shrink tubing is removed after it has been heat-shrinked and cured.

[0018] Optionally, in step c, after applying encapsulating adhesive to the outer wall of the inner sleeve, the coil is then sleeved on the outer wall of the inner sleeve, so that the encapsulating adhesive fills the gap between the inner sleeve and the coil; a clamping tool is used to clamp the coil on the outside of the coil so that the coil and the inner sleeve are tightly fitted together.

[0019] Optionally, in step d, after applying encapsulating adhesive to the outer wall of the coil, the iron core is then fitted onto the outside of the coil, so that the encapsulating adhesive fills the gap between the coil and the iron core.

[0020] Optionally, in step d, the front-end connector and the iron core are coaxially welded together at the ends, or the front-end connector and the iron core are integrally formed.

[0021] Optionally, the end of the front connector that connects to the iron core is provided with a plurality of opening slots spaced apart along the circumference; in step e, when the encapsulating adhesive is injected into the potting cavity to form an encapsulation layer, the opening slots are used to expel air.

[0022] Optionally, the assembled core rod includes a first mounting section, a second mounting section, and a third mounting section coaxially connected in sequence, with the outer diameters of the first mounting section, the second mounting section, and the third mounting section decreasing sequentially; in step c, the inner sleeve is fitted around the first mounting section near the second mounting section, and the inner sleeve is fitted against the outer wall of the first mounting section; the axial length of the inner sleeve matches the axial length of the coil.

[0023] Optionally, the assembly mandrel includes a first mounting section, a second mounting section, and a third mounting section coaxially connected in sequence, with the outer diameters of the first mounting section, the second mounting section, and the third mounting section decreasing sequentially; in step b, the bearing assembly is fitted onto the second mounting section and the third mounting section of the assembly mandrel.

[0024] Optionally, the end of the first mounting section of the assembled mandrel connecting to the second mounting section is provided with a first stepped groove that matches the first protective sleeve. When the bearing is sleeved on the second mounting section, the first protective sleeve is fitted with the first stepped groove. The end of the second protective sleeve away from the bearing is sleeved outside the third mounting section. Step c further includes: providing a protective heat-shrinkable sleeve, which is sleeved outside the first protective sleeve. After heat shrinking, one end of the protective heat-shrinkable sleeve extends to cover the first stepped groove, and the other end covers the end of the second protective sleeve near the first protective sleeve. Providing a tail connecting tube, the inner diameter of which matches the outer diameter of the third mounting section, the tail connecting tube is sleeved outside the third mounting section, and one end is inserted into the end of the second protective sleeve away from the bearing.

[0025] Based on the same inventive concept, this application also provides an assembly tooling for the assembly method of the above-mentioned motor stator structure. The assembly tooling includes an assembly mandrel, which includes a first mounting section, a second mounting section, and a third mounting section coaxially connected in sequence, with the outer diameters of the first mounting section, the second mounting section, and the third mounting section decreasing sequentially. A bearing assembly is sleeved onto the second mounting section and the third mounting section of the assembly mandrel. An inner sleeve is coaxially fitted onto the outside of the first mounting section near the second mounting section. A coil is coaxially fitted onto the outside of the inner sleeve. A coaxially connected iron core and a front-end connector are sleeved onto the outside of the first mounting section, with the iron core sleeved onto the outside of the coil. The assembly mandrel, with the bearing assembly, inner sleeve, coil, front-end connector, and iron core installed, is placed in the potting cavity of a potting mold. Encapsulating adhesive is injected into the potting cavity to form an encapsulation layer, thereby encapsulating the stator assembly, the front-end connector, and the bearing assembly into a single unit to form the motor stator structure.

[0026] Based on the same inventive concept, this application also provides a potting mold for the assembly method of the above-mentioned motor stator structure. The potting mold includes a lower mold base and an upper mold base. The top surface of the lower mold base is provided with a lower injection cavity, and the bottom surface of the upper mold base is provided with an upper injection cavity. When the upper mold base and the lower mold base are closed, the lower injection cavity and the upper injection cavity combine to form an injection cavity for accommodating an assembled mandrel with the bearing assembly, inner sleeve, coil, front end connector and iron core installed. A gap is formed between the inner wall of the injection cavity and the iron core and the bearing assembly, allowing encapsulating adhesive to be injected and filled to form an encapsulation layer, so as to encapsulate the stator assembly and the bearing assembly into one piece.

[0027] Optionally, the end of the front connector connected to the iron core is provided with multiple circumferentially spaced openings. When the front connector is placed in the filling cavity, a gap is formed between the end of the front connector connected to the iron core and the inner wall of the filling cavity. The potting mold is provided with an injection cavity, and the injection cavity is provided with an injection port communicating with the filling cavity. The injection port is located near the openings. The injection cavity allows an injection syringe to be inserted and inject encapsulating adhesive into the filling cavity from the injection port. The openings allow air to be expelled when the encapsulating adhesive is injected.

[0028] Optionally, it also includes a lead wire protection component, which is generally semi-cylindrical. The diameter of the cylinder containing the inner wall of the lead wire protection component matches the outer diameter of the third mounting section of the assembled core rod. The outer wall of the lead wire protection component is provided with at least three lead wire grooves spaced circumferentially, and the lead wire grooves are axially continuous. When the assembled core rod is placed in the lower injection cavity, the lower surface of the end of the third mounting section away from the second mounting section is fitted with the lower injection cavity, and the inner wall of the lead wire protection component is fitted with the upper surface of the end of the third mounting section away from the second mounting section. The lead wire of the coil passes through the lead wire groove.

[0029] Based on the same inventive concept, this application also provides a motor stator structure manufactured by the above-described assembly method for a motor stator structure. The motor stator structure includes a stator assembly, a front-end connector, and a bearing assembly. The stator assembly includes at least an inner sleeve, a coil, and an iron core coaxially arranged from the inside to the outside. The stator assembly has a first end and a second end. The front-end connector and the iron core are coaxially connected at the first end. The bearing assembly is coaxially disposed at the second end of the stator assembly. The front-end connector, the stator assembly, and the bearing assembly are encapsulated as a single unit by an encapsulation layer.

[0030] Compared with the prior art, the technical solutions of the embodiments of the present invention have beneficial effects.

[0031] For example, in the assembly method of the motor stator structure of the present invention, the stator assembly, the front-end connector, and the bearing assembly are all assembled based on the assembly mandrel, ensuring the coaxiality of the stator assembly, the front-end connector, and the bearing assembly. The rotor assembly is matched and installed with the bearing assembly and the front-end connector, thereby ensuring the coaxiality of the rotor assembly and the stator assembly. The coil and the iron core of the stator assembly are installed coaxially in sequence based on the assembly mandrel. The iron core is rigidly connected to the front-end connector. The coaxiality of the front-end connector, the iron core, and the mandrel is ensured by the assembly mandrel, thereby ensuring the coaxiality of the coil and the iron core. The assembly mandrel with the bearing assembly, coil, front-end connector, and iron core installed is placed in the potting cavity of the potting mold. By injecting encapsulating glue into the potting cavity to form an encapsulation layer, the stator assembly, the front-end connector, and the bearing assembly are encapsulated as one unit, ensuring the integrity and stability of the motor stator structure.

[0032] For example, an inner sleeve is provided on the inner wall of the coil. The heat shrinkage property of the inner sleeve makes it fit tightly with the assembled core rod to ensure coaxiality. The smooth property of the inner sleeve makes it easy for the assembled core rod to detach from the assembled motor stator structure.

[0033] For example, after applying encapsulating adhesive to the outer wall of the inner sleeve, the coil is then placed on the outer sleeve, allowing the encapsulating adhesive to fill the gap between the inner sleeve and the coil. Then, a heat-shrink tubing is placed over the coil to ensure a tight fit between the coil and the inner sleeve through heat shrinking. Alternatively, a clamping tool can be used to clamp the coil on the outside to ensure a tight fit between the coil and the inner sleeve, further ensuring the coaxiality and stability of the coil, while minimizing the outer diameter of the coil, thereby reducing the outer diameter of the motor. Attached Figure Description

[0034] Figure 1 is a cross-sectional view of the motor stator structure in an embodiment of the present invention;

[0035] Figure 2 is a cross-sectional view of the assembled mandrel in an embodiment of the present invention;

[0036] Figure 3 is a schematic diagram of the connection between the iron core and the front-end connector in an embodiment of the present invention;

[0037] Figure 4 is a cross-sectional view of the bearing assembly assembled to the assembly mandrel in an embodiment of the present invention;

[0038] Figure 5 is a cross-sectional view of the bearing assembly, stator assembly and front-end connector assembled onto the assembly mandrel in an embodiment of the present invention.

[0039] Figure 6 is a cross-sectional view of the assembled mandrel with the bearing assembly, stator assembly and front end connector installed in the lower mold base in an embodiment of the present invention;

[0040] Figure 7 is a cross-sectional view of the motor stator assembly in the sealing mold after sealing in an embodiment of the present invention;

[0041] Figure 8 is a cross-sectional view of the motor stator assembly in the lower mold base after sealing and potting in an embodiment of the present invention;

[0042] Figure 9 is a schematic diagram of the lead wire protection component structure in an embodiment of the present invention.

[0043] In the diagram: 100-Motor stator structure; 110-Stator assembly; 111-Inner sleeve; 112-Coil; 113-Iron core; 120-Front-end connector; 121-Opening slot; 130-Bearing assembly; 131-Bearing; 132-First protective sleeve; 133-Second protective sleeve; 134-Protective heat shrink tubing; 135-Tail connector; 140-Encapsulation layer; 200-Assembled mandrel; 210-First mounting section; 211-First stepped groove; 220-Second mounting section; 230-Third mounting section; 300-Pouring mold; 310-Lower mold base; 320-Upper mold base; 330-Injection cavity; 331-Injection port; 340-Lead wire protection component; 341-Lead wire groove. Detailed Implementation

[0044] To make the objectives, features, and beneficial effects of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It is to be understood that the specific embodiments described below are merely for explaining the present invention and are not intended to limit the present invention. Furthermore, the same or similar reference numerals may be used in the drawings to refer to the same or similar elements in different embodiments, and descriptions of the same or similar elements in different embodiments, as well as descriptions of prior art elements, features, effects, etc., may be omitted.

[0045] Referring to FIG1, the motor stator structure 100 includes a stator assembly 110, a front end connector 120, and a bearing assembly 130. The stator assembly 110 includes at least a coil 112 and an iron core 113 coaxially sleeved from the inside to the outside. The stator assembly 110 has a first end and a second end. The front end connector 120 is coaxially connected to the iron core 113 at the first end, and the bearing assembly 130 is coaxially disposed at the second end of the stator assembly 110.

[0046] In some embodiments, an inner sleeve 111 is coaxially fitted to the inner wall of the coil 112.

[0047] Referring to Figures 2 to 8, this embodiment of the invention provides a method for assembling a motor stator structure.

[0048] Specifically, the assembly method includes the following steps:

[0049] a. Provide assembly tooling, which includes assembly mandrel 200;

[0050] b. Provide a bearing assembly 130, which includes a bearing 131, a first protective sleeve 132 and a second protective sleeve 133. The first protective sleeve 132 and the second protective sleeve 133 are respectively sleeved on both ends of the bearing 131. The bearing assembly 130 is sleeved onto the assembly mandrel 200.

[0051] c. Provide coil 112 and sleeve coil 112 around assembly core 200;

[0052] d. Provide a front-end connector 120 and an iron core 113 that are coaxially connected at the ends. The inner diameter of the front-end connector 120 matches the outer diameter of the first mounting section 210. The coaxially connected iron core 113 and the front-end connector 120 are sleeved outside the assembly core rod 200, and the iron core 113 is sleeved outside the coil 112.

[0053] e. Provide a potting mold 300, place the assembled mandrel 200 with the bearing assembly 130, coil 112, front end connector 120 and iron core 113 installed in the potting cavity of the potting mold 300, inject encapsulating glue into the potting cavity to form an encapsulation layer 140, so as to encapsulate the stator assembly 110, the front end connector 120 and the bearing assembly 130 into one unit to form a motor stator structure 100;

[0054] f. Remove the assembly core rod 200 from the motor stator structure 100 to complete the assembly.

[0055] In some embodiments, an inner sleeve 111 is coaxially provided on the inner wall of the coil 112. Before providing the coil 112 in step c, the inner sleeve 111 is provided and the inner sleeve 111 is sleeved on the outside of the assembly core rod 200 so that the inner sleeve 111 is fitted to the outer wall of the assembly core rod 200.

[0056] In some embodiments, the inner sleeve 111 is a polymer heat-shrinkable sleeve; in step c, the inner sleeve 111 is fitted to the outer wall of the assembly mandrel 200 by heat shrinking, ensuring the coaxiality of the inner sleeve 111 and the assembly mandrel 200.

[0057] Specifically, the inner sleeve 111 needs to have good biocompatibility, so a polymer heat-shrinkable sleeve with a thickness of 0.01mm-0.02mm can be selected; in some embodiments, the outer surface of the inner sleeve 111 can be roughened to increase the connection strength between the inner sleeve 111 and the coil 112; when a liquid channel needs to be reserved inside the motor, the inner sleeve 111 is used to isolate the solution from direct contact with the coil 112; when there is no liquid channel inside the motor, the smooth surface of the inner sleeve 111 helps the assembly core 200 to detach.

[0058] Specifically, the encapsulating adhesive is usually made of epoxy resin, but other medical adhesives can also be used.

[0059] In some embodiments, in step c, after applying encapsulating adhesive to the outer wall of the inner sleeve 111, the coil 112 is then fitted onto the outer wall of the inner sleeve 111, so that the encapsulating adhesive fills the gap between the inner sleeve 111 and the coil 112; then a heat shrink sleeve is fitted onto the outer wall of the coil 112, and the heat shrink sleeve makes the coil 112 and the inner sleeve 111 fit tightly together by heat shrinking.

[0060] In some embodiments, in step c, the heat shrink tubing is removed after heat shrinking and curing to further reduce the outer diameter.

[0061] In some embodiments, in step c, after applying encapsulating adhesive to the outer wall of the inner sleeve 111, the coil 112 is then sleeved on the outer side of the inner sleeve 111, so that the encapsulating adhesive fills the gap between the inner sleeve 111 and the coil 112; a clamping tool is used to clamp the coil 112 on the outside of the coil 112, so that the coil 112 and the inner sleeve 111 are tightly attached.

[0062] The tight fit between the coil 112 and the inner sleeve 111 can reduce the outer diameter of the coil 112, thereby reducing the outer diameter of the motor; the inner sleeve 111 and the coil 112 are filled with encapsulating glue, which can reduce the generation of internal cavities and improve structural stability.

[0063] In some embodiments, in step d, after coating the outer wall of the coil 112 with encapsulating adhesive, the iron core 113 is then sleeved on the outside of the coil 112, so that the encapsulating adhesive fills the gap between the coil 112 and the iron core 113, reducing the generation of internal cavities and improving structural stability.

[0064] In some embodiments, in step d, the front connector 120 and the iron core 113 are coaxially welded together at the ends, or the front connector 120 and the iron core 113 are integrally formed to achieve a rigid coaxial connection between the front connector 120 and the iron core 113 at the ends.

[0065] Specifically, the front-end connector 120 is rigidly connected to the iron core 113 at the end coaxially. During the assembly process, the front-end connector 120 cooperates with the first mounting section 210 of the assembly core bar 200 to ensure that the iron core 113 and the front-end connector 120 are coaxially set with the assembly core bar 200, and to ensure the coaxiality of the iron core 113 and the coil 112.

[0066] In some embodiments, the end of the front connector 120 connected to the iron core 113 is provided with a plurality of opening slots 121 spaced apart along the circumferential direction; in step e, when the encapsulating adhesive is injected into the potting cavity to form the encapsulation layer 140, the opening slots 121 are used to discharge air.

[0067] In some embodiments, the assembly core 200 includes a first mounting section 210, a second mounting section 220, and a third mounting section 230 coaxially connected in sequence, with the outer diameters of the first mounting section 210, the second mounting section 220, and the third mounting section 230 decreasing sequentially; in step c, the inner sleeve 111 is fitted outside the first mounting section 210 near the second mounting section 220, so that the inner sleeve 111 is fitted against the outer wall of the first mounting section 210; the axial length of the inner sleeve 111 matches the axial length of the coil 112.

[0068] In some embodiments, the end of the first mounting section 210 of the assembly mandrel 200 connected to the second mounting section 220 is provided with a first stepped groove 211 that matches the first protective sleeve 132. When the bearing 131 is sleeved on the second mounting section 220, the first protective sleeve 132 is fitted to the first stepped groove 211. The end of the second protective sleeve 133 away from the bearing 131 is sleeved on the third mounting section 230. Step c further includes: providing a protective heat-shrinkable sleeve 134, which is sleeved on the outside of the first protective sleeve 132. After heat shrinking, one end of the protective heat-shrinkable sleeve 134 extends to cover the first stepped groove 211, and the other end covers the end of the second protective sleeve 133 near the first protective sleeve 132; providing a tail connecting tube 135, the inner diameter of which matches the outer diameter of the third mounting section 230, the tail connecting tube 135 is sleeved on the outside of the third mounting section 230, and one end is inserted into the end of the second protective sleeve 133 away from the bearing 131.

[0069] Specifically, a ring of UV-curable adhesive is applied to the outer end of the heat-shrinkable sleeve 134 covering the first stepped groove 211 and the second protective sleeve 133 near the first protective sleeve 132 for fixation and sealing; a ring of UV-curable adhesive is applied to the outer end of the tail connecting tube 135 inserted into the second protective sleeve 133 for fixation and sealing; thus achieving external sealing protection of the bearing 131 and preventing potting adhesive from entering the interior of the bearing 131 and affecting the performance of the bearing 131.

[0070] Specifically, the outer surface of the assembly mandrel 200 undergoes surface treatment to facilitate its subsequent removal from the motor stator mechanism 100. A PTFE coating is added to the surface treatment to enhance lubrication, ensuring smooth separation of the assembly mandrel 200 from the motor stator mechanism 100 without adhesion, and maintaining a smooth and flat interior for the motor stator mechanism 100. A diamond-like carbon coating can also be added to improve the wear resistance of the assembly mandrel 200.

[0071] Referring to Figure 2, this embodiment of the invention also provides an assembly fixture for assembling a motor stator structure. The assembly fixture includes an assembly mandrel 200, which comprises a first mounting section 210, a second mounting section 220, and a third mounting section 230 coaxially connected in sequence. The outer diameters of the first mounting section 210, the second mounting section 220, and the third mounting section 230 decrease sequentially. A bearing assembly 130 is fitted onto the second mounting section 220 and the third mounting section 230 of the assembly mandrel 200. An inner sleeve 111 is coaxially fitted onto the outside of the first mounting section 210, close to the second mounting section 220. The coil 112 is coaxially fitted outside the inner sleeve 111; the coaxially connected iron core 113 and front end connector 120 are fitted outside the first mounting section 210, and the iron core 113 is fitted outside the coil 112; the assembled mandrel 200, which has the bearing assembly 130, inner sleeve 111, coil 112, front end connector 120 and iron core 113 installed, is placed in the potting cavity of the potting mold 300, and encapsulating glue is injected into the potting cavity to form an encapsulation layer 140, so as to encapsulate the stator assembly 110, the front end connector 120 and the bearing assembly 130 into a whole to form the motor stator structure 100.

[0072] Referring to Figures 6-9, this embodiment of the invention also provides a potting mold for assembling a motor stator structure. The potting mold 300 includes a lower mold base 310 and an upper mold base 320. The top surface of the lower mold base 310 is provided with a lower injection cavity, and the bottom surface of the upper mold base 320 is provided with an upper injection cavity. When the upper mold base 320 and the lower mold base 310 are closed, the lower injection cavity and the upper injection cavity are combined to form an injection cavity for accommodating the assembled mandrel 200 with the bearing assembly 130, inner sleeve 111, coil 112, front end connector 120 and iron core 113 installed. A gap is formed between the inner wall of the injection cavity and the iron core 113 and the bearing assembly 130, allowing encapsulating adhesive to be injected and filled to form an encapsulation layer 140, so as to encapsulate the stator assembly 110 and the bearing assembly 130 into one piece.

[0073] In some embodiments, the end of the front connector 120 connected to the iron core 113 is provided with a plurality of opening slots 121 spaced apart along the circumferential direction. When the front connector 120 is placed in the filling cavity, a gap is formed between the end of the front connector 120 connected to the iron core 113 and the inner wall of the filling cavity. The potting mold 300 is provided with an injection cavity 330, and the injection cavity 330 is provided with an injection port 331 communicating with the filling cavity. The injection port 331 is located near the opening slots 121. The injection cavity 330 allows an injection syringe to be inserted and inject encapsulating glue into the filling cavity from the injection port 331. The opening slots 121 discharge air when the encapsulating glue is injected.

[0074] In some embodiments, a lead wire protection member 340 is also included, which is generally semi-cylindrical. The diameter of the cylinder containing the inner wall of the lead wire protection member 340 matches the outer diameter of the third mounting section 230 of the assembled core rod 200. At least three lead wire grooves 341 are provided circumferentially on the outer wall of the lead wire protection member 340, and the lead wire grooves 341 are axially continuous. When the assembled core rod 200 is placed in the lower injection cavity, the lower surface of the end of the third mounting section 230 away from the second mounting section 220 is fitted with the lower injection cavity, and the inner wall of the lead wire protection member 340 is fitted with the upper surface of the end of the third mounting section 230 away from the second mounting section 220. The lead wire of the coil 112 passes through the lead wire grooves 341.

[0075] In a specific embodiment, the lead groove 341 can be determined according to the number and arrangement of the leads of the coil 112; the leads of the coil 112 pass through the lead groove 341 to avoid the leads being encapsulated in the encapsulation layer 140 in step f.

[0076] This invention also provides a motor stator structure manufactured by an assembly method for a motor stator structure 100. The motor stator structure 100 includes a stator assembly 110, a front-end connector 120, and a bearing assembly 130. The stator assembly 110 includes at least an inner sleeve 111, a coil 112, and an iron core 113 coaxially sleeved from the inside to the outside. The stator assembly 110 has a first end and a second end. The front-end connector 120 is coaxially connected to the iron core 113 at the first end. The bearing assembly 130 is coaxially disposed at the second end of the stator assembly 110. The front-end connector 120, the stator assembly 110, and the bearing assembly 130 are encapsulated as a whole by an encapsulation layer 140.

[0077] Finally, it should be noted that the axial, radial, and circumferential directions mentioned in the embodiments of the present invention refer to the axial, radial, and circumferential directions of the assembled mandrel 200, respectively.

[0078] Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the invention, even when only a single embodiment is described with respect to a particular feature. The feature examples provided in this disclosure are intended to be illustrative and not limiting, unless otherwise stated. In practice, one or more technical features of the dependent claims may be combined with the technical features of the independent claims as needed and where technically feasible, and may be derived from the technical features of the respective independent claims in any suitable manner rather than solely by the specific combinations listed in the claims.

[0079] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A method for assembling a motor stator structure, characterized in that, The motor stator structure includes a stator assembly, a front-end connector, and a bearing assembly. The stator assembly includes at least a coil and an iron core coaxially sleeved from the inside to the outside. The stator assembly has a first end and a second end. The front-end connector is coaxially connected to the iron core at the first end. The bearing assembly is coaxially disposed at the second end of the stator assembly. The structure includes the following steps: a. Provide assembly tooling, the assembly tooling including an assembly mandrel; b. Provide a bearing assembly, the bearing assembly including a bearing, a first protective sleeve and a second protective sleeve, the first protective sleeve and the second protective sleeve being respectively sleeved on both ends of the bearing, and sleeve the bearing assembly onto the assembly mandrel; c. Provide a coil and sleeve the coil over the assembled mandrel; d. Provide the front-end connector and the iron core that are coaxially connected at the ends, and sleeve the coaxially connected iron core and the front-end connector outside the assembled core rod, and make the iron core sleeve outside the coil; e. Provide a potting mold, place the assembled mandrel with the bearing assembly, the coil, the front end connector and the iron core installed in the potting cavity of the potting mold, inject encapsulating glue into the potting cavity to form an encapsulation layer, so as to encapsulate the stator assembly, the front end connector and the bearing assembly into one piece to form the motor stator structure; f. Remove the assembly mandrel from the motor stator structure to complete the assembly.

2. The assembly method as described in claim 1, characterized in that, The inner wall of the coil is coaxially provided with an inner sleeve. In step c, before providing the coil, the inner sleeve is provided, and the inner sleeve is sleeved on the outside of the assembly core rod and is fitted to the outer wall of the assembly core rod.

3. The assembly method as described in claim 2, characterized in that, The inner sleeve is a polymer heat-shrinkable sleeve; in step c, the inner sleeve is fitted to the outer wall of the assembled mandrel by heat shrinking.

4. The assembly method as described in claim 2, characterized in that, In step c, after applying encapsulating adhesive to the outer wall of the inner sleeve, the coil is then sleeved on the outer wall of the inner sleeve, so that the encapsulating adhesive fills the gap between the inner sleeve and the coil; then a heat-shrinkable sleeve is sleeved on the outer wall of the coil, and the heat-shrinkable sleeve makes the coil and the inner sleeve fit tightly together by heat shrinking.

5. The assembly method as described in claim 4, characterized in that, In step c, the heat shrink tubing is removed after it has been heat-shrinked and cured.

6. The assembly method as described in claim 2, characterized in that, In step c, after applying encapsulating adhesive to the outer wall of the inner sleeve, the coil is then sleeved on the outer wall of the inner sleeve, so that the encapsulating adhesive fills the gap between the inner sleeve and the coil; a clamping tool is used to clamp the coil on the outside of the coil so that the coil and the inner sleeve are tightly fitted together.

7. The assembly method as described in claim 1, characterized in that, In step d, after applying encapsulating adhesive to the outer wall of the coil, the iron core is then fitted onto the outside of the coil, so that the encapsulating adhesive fills the gap between the coil and the iron core.

8. The assembly method as described in claim 1, characterized in that, In step d, the front-end connector and the iron core are coaxially welded together at the ends, or the front-end connector and the iron core are integrally formed.

9. The assembly method as described in claim 1, characterized in that, The end of the front connector that connects to the iron core is provided with multiple opening slots spaced apart along the circumference; in step e, when the encapsulating adhesive is injected into the potting cavity to form an encapsulation layer, the opening slots are used to expel air.

10. The assembly method as described in claim 2, characterized in that, The assembled core rod includes a first mounting section, a second mounting section, and a third mounting section connected coaxially in sequence, with the outer diameters of the first mounting section, the second mounting section, and the third mounting section decreasing sequentially; in step c, the inner sleeve is fitted outside the first mounting section near the second mounting section, and the inner sleeve is fitted against the outer wall of the first mounting section; the axial length of the inner sleeve matches the axial length of the coil.

11. The assembly method as described in claim 1, characterized in that, The assembly mandrel includes a first mounting section, a second mounting section, and a third mounting section coaxially connected in sequence, with the outer diameters of the first mounting section, the second mounting section, and the third mounting section decreasing sequentially; in step b, the bearing assembly is fitted onto the second mounting section and the third mounting section of the assembly mandrel.

12. The assembly method as described in claim 11, characterized in that, The first mounting section of the assembled mandrel has a first stepped groove at the end connecting to the second mounting section, which matches the first protective sleeve. When the bearing is fitted onto the second mounting section, the first protective sleeve fits into the first stepped groove. The end of the second protective sleeve away from the bearing is fitted onto the third mounting section. Step c further includes: providing a protective heat-shrinkable sleeve, which is fitted onto the outside of the first protective sleeve. After heat shrinking, one end of the protective heat-shrinkable sleeve extends to cover the first stepped groove, and the other end covers the end of the second protective sleeve near the first protective sleeve. A tail connecting tube is provided, the inner diameter of which matches the outer diameter of the third mounting section. The tail connecting tube is fitted onto the outside of the third mounting section, and one end is inserted into the end of the second protective sleeve away from the bearing.

13. An assembly tooling for the motor stator structure according to any one of claims 1 to 12, characterized in that, The assembly includes an assembly mandrel comprising a first mounting section, a second mounting section, and a third mounting section coaxially connected in sequence, with the outer diameters of the first, second, and third mounting sections decreasing sequentially. A bearing assembly is fitted onto the second and third mounting sections of the assembly mandrel. An inner sleeve is coaxially fitted onto the outside of the first mounting section near the second mounting section. A coil is coaxially fitted onto the outside of the inner sleeve. A coaxially connected iron core and a front-end connector are fitted onto the outside of the first mounting section, with the iron core fitted onto the outside of the coil. The assembly mandrel, with the bearing assembly, inner sleeve, coil, front-end connector, and iron core installed, is placed in the injection cavity of a potting mold. Encapsulating adhesive is injected into the injection cavity to form an encapsulation layer, thereby encapsulating the stator assembly, the front-end connector, and the bearing assembly into a single unit to form the motor stator structure.

14. A potting mold for assembling the stator structure of an electric motor according to any one of claims 1 to 12, characterized in that, The device includes a lower mold base and an upper mold base. The top surface of the lower mold base is provided with a lower injection cavity, and the bottom surface of the upper mold base is provided with an upper injection cavity. When the upper mold base and the lower mold base are closed, the lower injection cavity and the upper injection cavity combine to form an injection cavity that accommodates an assembled mandrel with the bearing assembly, inner sleeve, coil, front end connector and iron core installed. A gap is formed between the inner wall of the injection cavity and the iron core and the bearing assembly, allowing encapsulating adhesive to be injected and filled to form an encapsulation layer, so as to encapsulate the stator assembly and the bearing assembly into one piece.

15. The potting mold as described in claim 14, characterized in that, The end of the front connector connected to the iron core is provided with multiple circumferentially spaced openings. When the front connector is placed in the filling cavity, a gap is formed between the end of the front connector connected to the iron core and the inner wall of the filling cavity. The potting mold is provided with an injection cavity, and the injection cavity is provided with an injection port communicating with the filling cavity. The injection port is located near the openings. The injection cavity allows an injection syringe to be inserted into the filling cavity to inject encapsulating adhesive from the injection port. The openings allow air to be expelled when the encapsulating adhesive is injected.

16. The potting mold as described in claim 14, characterized in that, It also includes a lead wire protection component, which is generally semi-cylindrical. The diameter of the cylinder containing the inner wall of the lead wire protection component matches the outer diameter of the third mounting section of the assembled core rod. The outer wall of the lead wire protection component is provided with at least three lead wire grooves spaced circumferentially, and the lead wire grooves are arranged axially. When the assembled core rod is placed in the lower injection cavity, the lower surface of the end of the third mounting section away from the second mounting section is fitted with the lower injection cavity, and the inner wall of the lead wire protection component is fitted with the upper surface of the end of the third mounting section away from the second mounting section. The lead wire of the coil passes through the lead wire groove.

17. A motor stator structure manufactured by the assembly method of the motor stator structure according to any one of claims 1 to 12, characterized in that, The device includes a stator assembly, a front-end connector, and a bearing assembly. The stator assembly includes at least an inner sleeve, a coil, and an iron core, which are coaxially arranged from the inside to the outside. The stator assembly has a first end and a second end. The front-end connector is coaxially connected to the iron core at the first end. The bearing assembly is coaxially disposed at the second end of the stator assembly. The front-end connector, the stator assembly, and the bearing assembly are encapsulated together by an encapsulation layer.

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