CN114204702A - Armature assembly and motor with same - Google Patents

Abstract

The invention relates to an armature assembly and a motor with the same, wherein the armature assembly comprises an iron core, an upper insulation framework, a lower insulation framework, an excitation winding coil and a power supply outgoing line, wherein the iron core, the upper insulation framework, the lower insulation framework, the excitation winding coil and a first injection molding material are subjected to injection molding to form a first injection molding insert; the primary injection molding insert is made of a secondary injection molding material to form a final armature assembly through secondary injection molding, and a plurality of clearance grooves D are formed in the notch position of the iron core during secondary injection molding. Compared with the prior art, the invention has the advantages of high production yield, stable manufacturing process, higher long-term running reliability of the motor and the like.

Description

Armature assembly and motor with same

Technical Field

The present invention relates to an electric motor, and more particularly, to an armature assembly and an electric motor having the same.

Background

The armature assembly is a component of the motor which is provided with a coil, and the coil moves relative to the magnetic field; in the process of realizing the interconversion of mechanical energy and electric energy by the motor, the motor plays a key role and a part with a pivot role, an armature assembly of the injection molding motor forms a motor structure supporting part in an injection molding mode, but the injection molding motor has a common problem, the armature assembly needs to be used as an insert of an injection molding process and is placed in an injection mold for plastic coating, an armature winding is in direct contact with an injection molding material in the injection molding process and is influenced by high temperature, and on the other hand, the huge impact force generated by the flow of the injection molding material directly acts on an enameled wire. The winding enameled wire is used as an important component of electromagnetic conversion of a motor, has certain special requirements, and easily causes the problems of turn-to-turn breakdown of a coil, wire breakage of the enameled wire, leakage of the enameled wire and the like in a plastic coating process.

By searching Chinese patent publication No. CN215071864U, a motor winding component and an injection molding motor with the winding component are disclosed, wherein a low-pressure injection molding part is used as intermediate transition, and due to the characteristics of high fluidity and low injection molding temperature, the injection molding pressure and the injection molding temperature can be reduced, the enameled wire can be effectively protected, and the requirements on the enameled wire material and the insulating layer can be reduced. The low-pressure injection molding part is used as intermediate transition, and due to the characteristics of high fluidity and low injection molding temperature, the injection molding pressure and the injection molding temperature can be reduced, the enameled wire can be effectively protected, and the requirements on the enameled wire material and the insulating layer can be reduced. However, in the actual manufacturing process of the prior patent, it is found that the hardness of the first plastic-coated material is low, the second injection molding process causes the material subjected to the first injection molding to deform and generate internal stress, after the motor part is subjected to the second injection molding, the internal stress of the first injection molding material in the inner cavity of the motor part is released and the material deforms and expands, after the expansion, the size of the inner cavity of the motor part is reduced, the roundness is increased, the deformation concentricity of the rabbets at the two ends of the iron core is increased, and the problem that the motor is blocked during operation is caused.

Disclosure of Invention

The present invention is directed to an armature assembly and a motor having the same, which overcome the above-mentioned disadvantages of the prior art.

The purpose of the invention can be realized by the following technical scheme:

according to one aspect of the invention, an armature assembly is provided, which comprises an iron core, an upper insulating framework, a lower insulating framework, an excitation winding coil and a power supply outgoing line, wherein the iron core, the upper insulating framework, the lower insulating framework, the excitation winding coil and a first injection molding material are subjected to injection molding to form a first injection molding insert; the primary injection molding insert is made of a secondary injection molding material to form a final armature assembly through secondary injection molding, and a plurality of clearance grooves D are formed in the notch position of the iron core during secondary injection molding.

As a preferable technical scheme, the first injection molding material is PA thermoplastic particle polyamide, and the second injection molding material is engineering plastic.

As a preferable technical scheme, the inner diameter phi D1 of the first injection molding insert is more than or equal to the inner diameter phi D2 of the notch of the iron core, and the outer diameter phi D3 of the first injection molding insert is less than or equal to the outer diameter phi D4 of the insulating framework.

As a preferable technical scheme, the first injection molding insert is provided with a groove A with the width of 0.5mm-2mm and the length of 0.3-3 mm.

As a preferred technical scheme, a groove B is formed in the winding end part of one side, provided with the outgoing line, of the excitation winding coil, and the groove B is connected with an inner cavity of the first injection molding insert in the radial direction;

and the groove C is arranged at the winding end part on one side of the non-outgoing line of the excitation winding coil and penetrates through the inner cavity and the periphery of the primary injection molding insert in the radial direction.

As a preferable technical scheme, the thickness of the covering layer of the secondary injection molding material is more than or equal to 0.5mm, and the outer surface of the primary injection molding material is wrapped and covered.

As a preferable technical scheme, the diameter Φ D5 of the void-avoiding groove D is greater than the inner diameter Φ D6 of the iron core, the difference between the two is preferably 0.1-1mm, the center of the void-avoiding groove D is aligned with the center of the notch of the iron core, the width of the void-avoiding groove D is the same as the notch of the iron core, and the length of the void-avoiding groove D is the same as the height of the iron core.

As a preferred technical scheme, during the second injection molding, two circular matching rabbets including a front end cover rabbets E and a rear end cover rabbets F are formed on two sides of the iron core; and a plurality of grooves are formed in the front end cover seam allowance E and the rear end cover seam allowance F.

Preferably, in the second injection molding, the center of a notch groove E1 on the front end cap notch E is aligned with the center of a core notch, the width of the notch groove E1 is the same as that of the core notch, the height of the notch groove E1 penetrates through the core, and the depth of the notch groove E1 is the same as that of the core notch;

the center of a spigot groove F1 on the spigot F of the rear end cover is aligned with the center of a notch of the iron core, the width of the spigot groove F1 is the same as that of the notch of the iron core, the height of the spigot groove F1 penetrates through the iron core, and the depth of the spigot groove F1 is the same as that of the notch of the iron core.

According to another aspect of the present invention, there is provided an electric machine having an armature assembly, the electric machine including the armature assembly.

Compared with the prior art, the invention has the following advantages:

1) according to the invention, the clearance groove is arranged at the notch position of the motor iron core, the strength of the rabbets at the two ends of the iron core is improved, the concentricity of the motor is ensured, the motor is prevented from being locked in the operation, and the reliability of the motor is improved;

2) the material used in the first injection molding is PA thermoplastic particle polyamide, the injection molding flowability is good, the melt viscosity is less than or equal to 10000mpa.s, the injection molding pressure is low and is 1/10 times of the injection molding pressure of engineering plastics and is 5-40kgf/cm2, the injection molding temperature is lower than the engineering plastics, the actual injection molding temperature of a charging barrel is less than or equal to 250 ℃, based on the characteristics, the injection molding process parameters are in the acceptable pressure and temperature range of a winding coil, and the damage such as wire breakage, enameled wire surface insulating layer damage and the like to a winding cannot be caused in the injection molding process;

3) the PA polyamide material used in the first injection molding is low in hardness (material hardness HA85-HA90, under the environment of 150 ℃), and is affected by injection molding pressure and injection molding temperature in the second injection molding, so that the material subjected to the first injection molding can deform to form internal stress, and in order to reduce the deformation and the stress, the volume occupied by the material subjected to the first injection molding is required to be reduced to the greatest extent when the connecting lines between coils are effectively coated with plastic in the first injection molding;

4) the invention has the advantages of high production yield, stable manufacturing process and higher long-term operation reliability of the motor.

Drawings

FIG. 1 is a schematic cross-sectional view of an armature assembly of the present invention;

FIG. 2 is a schematic view of a first shot insert configuration of the armature assembly of the present invention;

FIG. 3 is a schematic view of a second shot insert configuration for the armature assembly of the present invention;

FIG. 4 is a cross-sectional structural schematic view of a first shot insert of the armature assembly of the present invention;

FIG. 5 is a perspective view of a first injection molded insert of the armature assembly of the present invention;

FIG. 6 is a schematic view of another perspective view of a first injection molded insert of the armature assembly of the present invention;

FIG. 7 is a schematic front view of a second shot insert for an armature assembly according to the present invention;

FIG. 8 is a perspective view of a second shot insert for an armature assembly according to the present invention;

FIG. 9 is a perspective view of another embodiment of a second shot insert for an armature assembly according to the present invention;

wherein 1 is iron core, 2 is upper insulation frame, 3 is lower insulation frame, 4 is excitation winding coil, and 5 is power supply lead-out wire

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, shall fall within the scope of protection of the present invention.

As shown in fig. 1-3, an armature assembly includes an iron core 1, an upper insulating frame 2, a lower insulating frame 3, an excitation winding coil 4 and a power supply lead-out wire 5, wherein the iron core 1, the upper insulating frame 2, the lower insulating frame 3, the excitation winding coil 4 and a first injection molding material are molded to form a first injection molding insert, so that the winding coil and the first injection molding material are integrated into a whole to construct an injection molding structure which is profiled with the outside of the winding coil, thereby protecting the winding and improving the mechanical properties of the winding coil; the first injection molding insert is formed by injection molding for the second time through a second injection molding material, the insert manufactured by injection molding for the first time and a cavity part formed by a finally formed motor assembly are filled through injection molding for the second time, and the second injection molding material and the first injection molding material are fused to construct the overall dimension and the installation matching structure of the assembly, so that the motor assembly is finally formed.

The first injection molding material adopts PA thermoplastic particle polyamide, and the basic characteristics of the material are as follows: a. the injection molding fluidity is good, the melt viscosity is less than or equal to 10000mpa.s, the injection molding pressure is low and is 1/10 times of the injection molding pressure of engineering plastics and is between 5 and 40kgf/cm2, the injection molding temperature is lower than the engineering plastics, the actual injection molding temperature of the charging barrel is less than or equal to 250 ℃, based on the characteristics, the injection molding process parameters are within the acceptable pressure and temperature range of the winding coil, and the damage to the winding, the insulating layer on the surface layer of the enameled wire and the like can not be caused in the injection molding process.

Because the PA polyamide material used for the first injection molding is low in hardness (material hardness HA85-HA90, under the environment of 150 ℃), the material for the first injection molding is deformed to form internal stress under the influence of injection molding pressure and injection molding temperature during the second injection molding, and in order to reduce the deformation and the stress, the volume occupied by the material for the first injection molding is required to be reduced as much as possible under the condition that the connecting lines between the coils and the connecting lines are effectively wrapped and molded during the first injection molding.

As shown in FIG. 4, the inner diameter Φ D1 of the first injection molding insert is more than or equal to the inner diameter Φ D2 of the notch of the iron core, and the outer diameter Φ D3 of the first injection molding insert is more than or equal to the outer diameter Φ D4 of the insulating framework. Through the control of inside and outside diameter dimension, the entity of moulding plastics for the first time effectively wraps up the coil appearance to and the connecting wire between each coil. The first injection molding insert is provided with a groove A with the width of 0.5mm-2mm and the length of 0.3-3 mm. As shown in fig. 5, the winding end of the armature coil is provided with a plurality of grooves, the width of each groove is smaller than the interval width of two winding coils, the winding end of one side of the excitation winding coil with the outgoing line is provided with a groove B, and the groove B is connected with the inner cavity of the first injection molding insert in the radial direction; as shown in fig. 6, the groove C provided at the winding end portion on the non-lead wire side of the excitation winding coil penetrates through the inner cavity and the periphery of the primary injection molding insert in the radial direction.

The second injection molding aims at placing the insert manufactured by the first injection molding into a mold, manufacturing the required size and shape of the motor part through injection molding of engineering plastics, and then honing the inner cavity of the motor part to ensure the diameter size and roundness of the inner cavity.

Because the expansion and contraction coefficients of the materials injected twice are different, in order to prevent the fusion boundary of the two materials from peeling off at different temperatures, the outer surface injected for the second time can wrap and cover the outer surface injected for the first time, and the thickness of the covering layer injected for the second time is more than or equal to 0.5 mm. As shown in fig. 7, during the second injection molding, a plurality of clearance grooves D are arranged at the notch position of the iron core, the diameter Φ D5 of the clearance groove D is greater than the diameter Φ D6 of the inner circle of the iron core, the difference between the two diameters is preferably 0.1-1mm, the center of the clearance groove D is aligned with the center of the notch of the iron core, the width of the clearance groove D is the same as that of the notch of the iron core, and the length of the clearance groove D is the same as that of the iron core.

As shown in fig. 8, during the second injection molding, two circular fitting spigots are formed on two sides of the iron core, including a front end cover spigot E and a rear end cover spigot F; and a plurality of grooves are formed in the front end cover seam allowance E and the rear end cover seam allowance F.

During the second injection, the center of a spigot groove E1 on the spigot E of the front end cover is aligned with the center of a notch of the iron core, the width of the spigot groove E1 is the same as that of the notch of the iron core, the height of the spigot groove E1 penetrates through the iron core, and the depth of the spigot groove E1 is the same as that of the notch of the iron core;

as shown in fig. 9, the center of the notch groove F1 on the back end cap notch F is aligned with the center of the core notch, the width of the notch groove F1 is the same as the width of the core notch, the height of the notch groove F1 penetrates through the core, and the depth of the notch groove F1 is the same as the depth of the core notch.

As the actual use working condition of the motor is-40 ℃ to 150 ℃, the material is highly tested, the two different injection molding materials are adopted in the secondary plastic coating process of the technical scheme, and in order to reduce the expansion reaction of the two materials under the actual use working condition, the invention further requires that the difference between the thermal expansion coefficients of the two injection molding materials is not more than 10 times, and the difference between the water absorption rates is not more than 10 times.

While the invention has been described with reference to specific embodiments, the invention is not limited thereto, and various equivalent modifications and substitutions can be easily made by those skilled in the art within the technical scope of the invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims (10)

1. An armature assembly is characterized by comprising an iron core (1), an upper insulation framework (2), a lower insulation framework (3), an excitation winding coil (4) and a power supply outgoing line (5), wherein the iron core (1), the upper insulation framework (2), the lower insulation framework (3), the excitation winding coil (4) and a first injection molding material are subjected to injection molding to form a first injection molding insert; the primary injection molding insert is made of a secondary injection molding material to form a final armature assembly through secondary injection molding, and a plurality of clearance grooves D are formed in the notch position of the iron core (1) during secondary injection molding.

2. An armature assembly according to claim 1 wherein the first shot material comprises PA thermoplastic particle polyamide and the second shot material comprises an engineering plastic.

3. The armature assembly of claim 1, wherein the inner diameter Φ D1 of the first injection molding insert is greater than or equal to the inner diameter Φ D2 of the notch of the iron core, and the outer diameter Φ D3 of the first injection molding insert is less than or equal to the outer diameter Φ D4 of the insulating framework.

4. An armature assembly according to claim 1, wherein the first shot insert is provided with a groove a having a width of 0.5mm to 2mm and a length of 0.3 mm to 3 mm.

5. An armature assembly according to claim 1, characterized in that the winding end part of the field winding coil (4) with the outgoing line is provided with a groove B, and the groove B is connected with the inner cavity of the first injection molding insert in the radial direction;

and the excitation winding coil (4) is provided with a groove C at the winding end part on one side of the non-outgoing line, and the groove C penetrates through the inner cavity and the periphery of the primary injection molding insert in the radial direction.

6. The armature assembly of claim 1, wherein the thickness of the coating layer of the second injection molding material is more than or equal to 0.5mm, and the outer surface of the first injection molding material is coated.

7. An armature assembly according to claim 1, wherein the diameter Φ D5 of the recess D is larger than the diameter Φ D6 of the core, the difference is preferably 0.1-1mm, the center of the recess D is aligned with the center of the core slot, the width of the recess D is the same as the core slot, and the length of the recess D is the same as the core height.

8. An armature assembly according to claim 1, characterized in that during the second injection molding, two circular matching rabbets are formed on two sides of the iron core (1), including a front end cover rabbets E and a rear end cover rabbets F; and a plurality of grooves are formed in the front end cover seam allowance E and the rear end cover seam allowance F.

9. The armature assembly of claim 8, wherein during the second injection molding, the center of the notch E1 on the front end cover notch E is aligned with the center of the core notch, the width of the notch E1 is the same as the width of the core notch, the height of the notch E1 penetrates through the core, and the depth of the notch E1 is the same as the depth of the notch of the core notch;

the center of a spigot groove F1 on the spigot F of the rear end cover is aligned with the center of a notch of the iron core, the width of the spigot groove F1 is the same as that of the notch of the iron core, the height of the spigot groove F1 penetrates through the iron core, and the depth of the spigot groove F1 is the same as that of the notch of the iron core.

10. An electrical machine having an armature assembly, characterised in that the electrical machine comprises an armature assembly according to any one of claims 1 to 9.

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