CN112186915A

CN112186915A - Stator assembly

Info

Publication number: CN112186915A
Application number: CN202011144538.1A
Authority: CN
Inventors: 万锦; 陶加山
Original assignee: Jiangsu Jinfeng Electrical Co ltd
Current assignee: Jiangsu Jinfeng Electrical Co ltd
Priority date: 2020-10-22
Filing date: 2020-10-22
Publication date: 2021-01-05

Abstract

The invention discloses a stator assembly, and belongs to the technical field of motor equipment. This stator module includes stator core and the stator winding of package on stator core, and stator core is formed by a plurality of stator punching piles up the lamination, and the stator punching includes yoke portion, tooth portion and sets up the tooth boots at the tooth tail end, and a plurality of tooth portions just form the punching sheet groove along the circumference evenly distributed of yoke portion between two adjacent tooth portions, and the tooth side is formed with the bulge to the protruding in the punching sheet groove. The invention can obtain proper magnetic field distribution of the tooth part, obtain more average magnetic flux density, simultaneously improve the slot fullness rate of the punching sheet slot, improve the power density of the motor, simultaneously reduce the coil inserting difficulty during winding and improve the production efficiency.

Description

Stator assembly

Technical Field

The invention belongs to the technical field of motor equipment, and particularly relates to a stator assembly.

Background

The stator is a stationary part of the motor, the stator generally comprises three parts of a stator core, a stator winding and a base, the stator winding is wound on the stator core to form a rotating magnetic field to drive the rotor to move, the existing motor is divided into an 'outer rotor' motor and an 'inner rotor' motor according to different rotor positions, the 'outer rotor' refers to the rotor rotating outside the stator, the 'inner rotor' refers to the rotor rotating inside the stator, the stator cores of the two motors are generally formed by laminating stator punching sheets, the stator punching sheets comprise tooth parts and yoke parts, the stator winding is generally wound on the tooth parts of the stator punching sheets, the existing tooth part structure is generally divided into 'parallel teeth' and 'non-parallel teeth', the two different structural designs are that the parallel teeth refer to the same upper and lower sizes of the tooth parts to form a structure with two parallel sides of the tooth parts, the non-parallel teeth refer to the different upper and lower, the two sides of the groove are parallel. The structure of the stator punching sheet has great influence on the whole volume and the output power of the motor, and along with the continuous development of the society, the stator punching sheet has urgent requirements on improving the power density of the motor, reducing the current density, reducing the temperature rise and improving the motor efficiency.

In the existing stator punching structure, because the cross section of the rotary motor is circular, when the stator punching adopts a structural design of non-parallel teeth, the sizes of the top and the bottom of the tooth part of the punching are inconsistent, and the magnetic flux density of a magnetic line of force in the teeth is inconsistent, so that the motor efficiency is low, and the electromagnetic noise is high; when the stator punching sheet is designed by adopting a parallel tooth structure, the widths of the tooth parts are consistent, the space of the slots formed among the tooth parts is larger, the upper and lower widths are inconsistent, when the stator winding adopts a copper wire for parallel winding and coil off, the slot area is not fully utilized, the slot fullness rate is not high, the temperature rise and the magnetic leakage coefficient of the motor are increased, the service life and the reliability of the motor are reduced, if the magnetic load is improved by increasing the magnetic flux by increasing the using amount of the winding, the inconvenience of the overload capacity of the motor is ensured, and the production cost of the motor is increased by the method for reducing the temperature rise of the motor.

Disclosure of Invention

The technical problem is as follows: aiming at the problems in the prior art, the invention aims to solve the technical problems of low motor efficiency, low slot filling rate, high motor temperature rise and the like caused by the existing stator punching structure and stator winding design.

The technical scheme is as follows: in order to solve the above problems, the present invention adopts the following technical solutions.

The utility model provides a stator module, is in including stator core and winding dress stator winding on the stator core, stator core is piled up the lamination by a plurality of stator punching and forms, the stator punching includes yoke portion, tooth portion and sets up the tooth boots of tooth portion tail end, and is a plurality of the tooth portion just follows the circumference evenly distributed of yoke portion forms the punching groove between two adjacent tooth portions, the tooth portion side to the protruding bulge that is formed with in the punching groove.

Further, the cross section of the protruding part is rectangular or trapezoidal.

Further, the protruding portion is disposed on at least one of two sides of the tooth portion, and the number of the protruding portions on the side where the protruding portion is disposed is more than one.

Furthermore, the number of the punching grooves is 6N, and N is a positive integer.

Further, the stator winding includes a plurality of coils.

Further, the coil includes a first coil wound on the projecting portion and a second coil wound on the remaining portion of the tooth portion except the projecting portion.

Furthermore, the cross section of the wire of the coil is rectangular.

Further, the cross-sectional area of the wire of the first coil is different from the cross-sectional area of the wire of the second coil.

Further, the first coil includes a plurality of sub-coils, and the second coil includes a plurality of sub-coils.

Furthermore, the stator punching sheet is an integrated silicon steel sheet or is formed by spirally winding a toothed steel belt.

Has the advantages that: compared with the prior art, the stator core laminated by the stator punching sheets becomes a novel stator core structure which gives consideration to both tooth magnetic field distribution and space utilization in a groove by arranging the convex parts on the tooth parts of the stator punching sheets, and rectangular wires with different wire diameters are matched for winding the coil and the stator winding, so that the stator component can select proper convex part design and wire gauge and distribution combination design of the winding coil according to the actual performance requirement of the motor; has the following advantages: 1. compared with the existing stator punching sheet tooth part design, the magnetic field distribution of the tooth part can be obtained properly, the more even magnetic flux density is obtained, the slot fullness rate of the punching sheet slot is improved by matching with the rectangular lead, the power density of the motor is improved, the coil inserting difficulty during winding is reduced, and the production efficiency is improved; 2. the design of the convex part and the rectangular winding leads the whole motor to have smaller volume under the same power condition, the production cost is reduced, the internal heat conduction and the heat dissipation performance are improved, and the performance and the service life of the motor are improved; 3. unnecessary clearance reduction of inside, the whole lightweight of motor, miniaturization make the electromagnetic noise reduce, the notch size that reduces simultaneously effectively reduces tooth's socket moment, further reduces motor electromagnetic noise.

Drawings

FIG. 1 is a schematic cross-sectional view of a first embodiment of a stator assembly of the present invention;

FIG. 2 is a schematic structural diagram of the stator lamination of FIG. 1;

FIG. 3 is a schematic view of a first tooth arrangement of the present invention;

FIG. 4 is a schematic view of a second tooth arrangement of the present invention;

FIG. 5 is a schematic view of a third tooth construction of the present invention;

FIG. 6 is a schematic view of a fourth tooth configuration of the present invention;

FIG. 7 is a schematic view of a fifth tooth arrangement of the present invention;

FIG. 8 is a schematic view of a sixth tooth construction of the present invention;

fig. 9 is a schematic structural view of a stator lamination in a second embodiment of the stator assembly of the present invention;

FIG. 10 is a graph showing a comparison of the groove fill factor of a rectangular line and the groove fill factor of a circular line;

FIG. 11 is a graph of efficiency of an example motor using rectangular wire;

FIG. 12 is a graph of output power of an exemplary motor employing a rectangular wire motor;

FIG. 13 is a graph of efficiency of an example motor using a round wire motor;

FIG. 14 is a graph of output power for an example motor using a round wire motor.

Detailed Description

The invention will be further elucidated with reference to the drawing.

As shown in fig. 1, 2 and 3, a stator assembly according to a first embodiment of the present invention includes a stator core 1 and a stator winding 3 wound on the stator core 1, the stator core 1 is formed by stacking and laminating a plurality of stator laminations 2 along an axial direction, the stator winding 3 includes a plurality of coils 5, the coils 5 are formed by winding rectangular wires (or other shaped wires), the plurality of coils 5 can be wound by wires with different wire gauges (different cross-sectional areas of the wires), the stator laminations 2 include a yoke portion 21, a tooth portion 22 and a tooth shoe 23 disposed at a tail end of the tooth portion 22, the yoke portion 21 is in a ring shape, the tooth portions 22 are uniformly distributed along a circumferential direction of the yoke portion 21 and extend outward along a radial direction (suitable for a stator lamination structure of an "outer rotor" motor), the number of the uniformly distributed tooth portions 22 is set to 12 (the number of the tooth portions 22 can be set reasonably according to a motor, a punching sheet slot 4 is formed between two adjacent tooth parts 22, a plurality of coils 5 of the stator winding 3 are positioned in the punching sheet slot 4, the number of the punching sheet slots 4 is 6N, N is a positive integer, and N is equal to 2 in figure 1 (N can be reasonably selected according to the design requirement of the motor); two side edges of the middle part of each tooth part 22 respectively protrude towards the adjacent punching sheet grooves 4 to form a protruding part 221 (the protruding part 221 can also be designed in a single side on one side edge of the two side edges of the tooth part 22, the number of the protruding parts 221 on each side edge can also be designed more than one), the cross section of the protruding part 221 is rectangular (also can be trapezoidal), a straight line on the rectangular protruding part 221 is parallel to a straight line on the side edge of the tooth part 22, in fig. 1, the main body of the tooth part 22 is designed in a 'parallel tooth' structure, that is, two side edges of the main body part of the tooth part 22 except the protruding part 221 are parallel to each other; when the main body of the tooth portion 22 is designed to be a "non-parallel tooth", that is, the vertical dimensions of the tooth portion 22 are not the same, and the two side lines of the main body portion of the tooth portion 22 are not parallel, the upper line of the rectangular protrusion 221 is parallel to the line (not shown) of the side where the protrusion is located.

As shown in fig. 2 and 3, a protrusion 221 is provided at each side of the tooth 22, the protrusion 221 is provided at the middle position of the tooth 22 and is a rectangular protrusion, the coil 5 includes a first coil 51 wound on the protrusion 221 and a second coil 52 wound on the rest part of the tooth 22 except the protrusion 221, the cross sections of the wires of the first coil 51 and the second coil 52 are rectangular, and the cross section area of the wire of the first coil 51 is different from the cross section area of the wire of the second coil 52, that is, the wire gauge adopted by the portion wound on the protrusion 221 is different from the wire gauge wound on the rest part of the tooth 22, the rectangular wire gauge diameters of the first coil 51 and the second coil 52 can be selected reasonably according to the requirement of the motor, so that the magnetic field of the stator of the motor can be distributed reasonably.

As shown in fig. 4, the difference from the first tooth structure design is that the cross section of the protrusion 221 is trapezoidal, the lower bottom edge of the trapezoidal protrusion 221 is linearly overlapped with the side edge of the tooth 22 main body, the two sides of the trapezoid are equal and are isosceles trapezoids, and the two waistlines of the trapezoid can also be arc-shaped as shown in fig. 5, so as to form a third tooth structure, which can be used as different process structures to match with wire windings with different wire gauges and different cross section shapes.

As shown in fig. 6, the position of the protruding portion 221 is set at one end of the tooth portion 22 far from the tooth shoe 23, the coil 5 includes a first coil 51 wound on the protruding portion 221 and a second coil 52 wound on the rest portion of the tooth portion 22 except the protruding portion 221, because the stator punching sheet is circular, the space in the punching sheet groove 4 is larger outwards, and the space of the protruding portion 221 is smallest in the space of the punching sheet groove 4 due to the design of the position of the protruding portion 221, at this time, the rectangular wire cross-sectional area of the first coil 51 wound on the protruding portion 221 is designed to be smaller than that of the second coil 52 wound on the rest portion.

As shown in fig. 7, the position of the protruding portion 221 is set at one end of the tooth portion 22 close to the tooth shoe 23, the coil 5 includes a first coil 51 wound on the protruding portion 221 and a second coil 52 wound on the rest portion of the tooth portion 22 except the protruding portion 221, because the stator punching sheet is circular, the space in the punching sheet groove 4 where the protruding portion 221 is located is larger as the space in the punching sheet groove 4 is larger, and the rectangular wire cross-sectional area of the first coil 51 wound on the protruding portion 221 is designed to be larger than the rectangular wire cross-sectional area of the second coil 52 wound on the rest portion.

The position of the protruding part 221 can also be designed at a proper tooth position according to the actual performance requirement of the motor (not only the arrangement positions of the middle part of the tooth part in fig. 3, the head end part of the tooth part in fig. 6 and the tail end part of the tooth part in fig. 7), and coils of wires with different wire gauges are matched to be used, so that the final winding obtains a proper magnetic field distribution.

As shown in fig. 8, two rectangular protrusions 221 are provided at each side of the tooth 22 (the number of the protrusions 221 may be set in multiple ways according to the requirement of magnetic field distribution), the first coil 51 wound on the protrusion 221 includes a first sub-coil 511 and a second sub-coil 512 (the number of the sub-coils corresponds to the number of the protrusions, the number of the protrusions 221 may be M, the protrusions 221 are divided into a first protrusion to an mth protrusion, the number of the sub-coils corresponds to M, the corresponding sub-coils of the first coil 51 include a first sub-coil to an mth sub-coil and are distributed correspondingly on the first protrusion to the mth protrusion, M is a positive integer, the cross-sectional areas of the rectangular wires of the first sub-coil 511 and the second sub-coil 512 are different, the second coil 52 wound on the rest part of the tooth 22 except the protrusion 221 includes a first sub-coil 521, a second sub-coil 522 and a third sub-coil 523 (the number of the sub-coils of the second coil 52 is M +1, m is the number of sub-coils), the wires of the first slave coil 521, the second slave coil 522 and the third slave coil 523 may be the same wire gauge or different wire gauges, so that the consistency of the magnetic flux density of the stator teeth is ensured, and the effective utilization of the space in the slot is ensured.

As shown in fig. 2, 3, 6, 7 and 8, due to the circular design of the stator punching sheet and the different design of the position of the protruding portion (the space in the slot is larger outwards as a whole, but the space in some slots is reduced due to the design of the protruding portion), the size of the space in the punching sheet slot 4 is different everywhere, a part with a small space in the punching sheet slot 4 is wound with a lead with a small wire gauge, and a part with a large space in the punching sheet slot 4 is wound with a lead with a large wire gauge, that is, a plurality of sub-coils of the first coil 51 and a plurality of sub-coils of the second coil 52 can be wound with leads with various wire gauges, so that the consistency of the magnetic flux density of the stator teeth can be ensured to the greatest extent, and the effective utilization of the space in the slot can be ensured.

As shown in fig. 9, the difference from the first embodiment is that the teeth 22 of the stator lamination 2 are uniformly distributed and extend inward along the circumferential direction of the yoke portion 21 (so that the stator lamination 2 of this embodiment is suitable for an electric motor with an "inner rotor" structure, and the rotor is located inside the stator), the tooth structure of the stator lamination of the second embodiment may adopt the same or corresponding structural design (i.e., the tooth structural design of fig. 3 to 8) as the structure of the first embodiment so as to achieve the same technical effect, and the design of the plurality of coils 5 of the corresponding stator winding 3 may also be the same as the first embodiment.

As shown in fig. 3 and 10, because the rectangular wire is wound to form the stator winding, the wire between the coils is in closer contact (the rectangular wire in fig. 3 and 10 is in closer contact than a common round wire), the slot filling rate is improved (the slot filling rate of the rectangular wire can reach 90%), the internal gap is reduced, the contact area between the rectangular wire flat wire and the rectangular wire flat wire is large, and the heat dissipation and heat conduction performance is better; the stator winding and the stator iron core slot are better contacted, and the heat conduction is better; the motor is very sensitive to heat dissipation and temperature, so that the heat dissipation performance is improved; the protruding design of the protruding part 221 and the coil 5 are wound by wires with different wire diameters, so that the slot filling rate can be improved, and the power density is improved; the round wire becomes the flat wire, and theoretically, under the premise that the space is not changed, the flat wire motor can improve the slot filling rate, so that stronger magnetic field intensity is generated, the motor power is equivalently increased, and under the same power, the motor is smaller in size, less in material and lower in production cost.

Under the condition that other parameter conditions are not changed, the larger the area of the punching sheet groove 4 is, the easier the coil insertion (which refers to the process of winding the stator winding by using a lead) is, the smaller the area of the punching sheet groove 4 is, the more difficult the coil insertion is, but the efficiency of the motor is reduced when the area of the punching sheet groove 4 is too large.

After the stator core and the stator winding are assembled in a set, the end part of the stator winding 3 is shortened relative to the end part of the stator winding adopting a round wire, so that copper materials are saved, and the efficiency is improved; the end of the traditional round wire motor is generally kept longer due to process problems, otherwise, the copper wire is easily damaged in the process. For a flat wire motor adopting a rectangular conducting wire to wind a winding, the winding wire adopts a hard wire, the end part can be shortened during the overall processing, compared with a round wire motor, the end part size can be reduced by 20 percent, the appearance space of the motor can be effectively reduced, the volume of the whole system can be further reduced, and the miniaturization and the light weight of the motor are realized; the electromagnetic noise of the motor is lower. The stress ratio of the wire of the motor adopting the rectangular wire is larger, the rigidity is higher, the armature has better rigidity, and the armature noise is inhibited; can get the notch size less relatively, effectively reduce tooth's socket moment, further reduce motor electromagnetic noise.

The stator punching sheet can be formed by punching sheet stitch welding (riveting) of silicon steel sheets in the traditional process, and can also be formed by a novel rolling process through a novel process of punching toothed steel strips, spiral winding, overlapping, welding and extrusion forming, so that the material utilization rate is improved.

As shown in fig. 11-14, the exemplary motor is a conventional 48V 500W brushless dc motor, and in actual use, fig. 11 is a graph of efficiency of a rectangular wire motor, which is improved by 3-5% compared to the motor using a circular shape in fig. 13; fig. 12 is a graph of the maximum output power of a motor using rectangular wires, which is improved by about 15-20% compared to the maximum output power of the motor using circular wires of fig. 14.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.

Claims

1. The utility model provides a stator module, includes stator core (1) and winds the dress and is in stator winding (3) on stator core (1), stator core (1) is piled up the lamination by a plurality of stator punching (2) and forms, its characterized in that, stator punching (2) include yoke portion (21), tooth portion (22) and set up tooth boots (23) of tooth portion (22) tail end, and is a plurality of tooth portion (22) are followed the circumference evenly distributed of yoke portion (21), form punching groove (4) between two adjacent tooth portions (22), tooth portion (22) side to the protrusion is formed with bulge (221) in punching groove (4).

2. A stator assembly according to claim 1, characterized in that the cross-section of the protrusions (221) is rectangular or trapezoidal.

3. The stator assembly according to claim 1, characterized in that the protrusions (221) are provided on at least one of both sides of the tooth (22), and the number of protrusions (221) on the side on which the protrusion (221) is provided is more than one.

4. Stator assembly according to claim 1, characterized in that the number of the punched slots (4) is 6N, N being a positive integer.

5. A stator assembly according to claim 1, characterized in that the stator winding (3) comprises a plurality of coils (5).

6. The stator assembly according to claim 5, characterized in that the coils (5) comprise a first coil (51) wound on the protrusion (221) and a second coil (52) wound on the remaining part of the tooth (22) except the protrusion (221).

7. A stator assembly according to claim 5, characterized in that the wire cross-section of the coil (5) is rectangular.

8. The stator assembly of claim 6, characterized in that the cross-sectional area of the wire of the first coil (51) is different from the cross-sectional area of the wire of the second coil (52).

9. The stator assembly of claim 6, characterized in that the first coil (51) comprises a plurality of sub-coils and the second coil (52) comprises a plurality of sub-coils.

10. The stator assembly according to claim 1, characterized in that the stator laminations (2) are an integrated silicon steel sheet or are spirally wound from a toothed steel strip.