CN118539692A - Motor stator assembly and winding method thereof - Google Patents

Abstract

The invention relates to the field of motors and discloses a motor stator assembly and a winding method thereof, wherein the winding method comprises wire prefabrication and modular preparation, stator slot lubrication, wire module loading, wire connection and shaping, and stator detection and assembly; the stator assembly includes a stator core formed of laminations. The invention can reduce human error by precisely controlling the shape and specification of the lead, ensure the repeatability and reliability of coil manufacture, thereby improving the quality of the whole product; the winding method reduces the risk of damage to the wires and insulation during assembly. Therefore, the problem of turn-to-turn short circuit caused by scratching of the enameled wires is reduced, and the safety and stability of the motor are enhanced; the regular winding layout is beneficial to reducing the running temperature of the motor, improving the efficiency and power density of the motor, and reducing noise and vibration.

Description

Motor stator assembly and winding method thereof

Technical Field

The invention belongs to the field of motors, and in particular relates to a motor stator assembly and a winding method thereof.

Background Art

The motor stator is mainly composed of stator core, stator winding and frame.

The stator core is made of laminated silicon steel sheets, which has good magnetic conductivity and reduces hysteresis loss. When three-phase alternating current passes through the stator winding, it will generate alternating magnetic flux in the core, thus forming a rotating magnetic field. This rotating magnetic field will interact with the bars or permanent magnets on the rotor, and according to the type of motor, it will generate electromagnetic force to drive the rotor to rotate.

The existing motor stator power line wiring operation is difficult, and the enameled wire is easily scratched during installation, resulting in a short circuit between stator turns.

Summary of the invention

Technical problem to be solved: How to optimize the design of motor electronic wiring.

Technical solution:

In one aspect, the present invention provides a method for winding a stator assembly of a motor, comprising the following steps:

Step 1: Modular preparation of wire prefabrication: Determine the specifications of the required wires through calculation, including the wire diameter and the shape of the wires; the wire diameter must be consistent with the design standards of the motor to ensure the performance and safety of current transmission; the shape of the coil is designed according to the specific structure of the motor stator, and it is precisely computer-aided designed to ensure that the winding has the best fit and space utilization in the stator slot;

Step 2: Lubricate the stator slots: Use precision spray or brush equipment to coat the stator slots so that each stator slot is evenly coated with lubricant. At the same time, during the coating process, attention should be paid to the amount of lubricant control, which should be sufficient for lubrication but not too much to avoid short circuits between the wire slots or affect subsequent operations.

Step 3: Insert the wire module: First, use a wire pusher or winding machine to insert the coil into the stator slot in the correct sequence and direction; then, use a slot wedge to insert into the top of the stator slot and press the coil into the slot to fix the coil;

Step 4: Wire connection and shaping: Use a wire forming fixture and a heat treatment furnace to weld or connect the coil ends by cold extrusion or hot forming so that the coil can fit the shape of the stator tightly;

Step 5, stator inspection and assembly: First, perform a high voltage test on the insulation layer to detect its integrity and voltage resistance; second, test the performance of the stator under the specified load through actual operation; third, measure the resistance between the coils and between the coils and the ground wire to eliminate the possibility of short circuit; then, compare the size of the coil with the design data to ensure that the size of each component is within the allowable tolerance range; finally, install the stator into the casing and connect all external electrical interfaces.

Furthermore, the wire modules are completed by CNC automatic winding machines, which use computer control to perform precise wire shaping and can produce the same wire modules in large quantities and in a standardized manner.

Furthermore, the prepared conductor module needs to be subjected to insulation testing to ensure that the conductor can withstand long-term operation without short circuit or damage under the action of electromagnetic force.

Furthermore, the selection of lubricant is based on the following two basic requirements: first, it should not be corrosive to the material of the wire to prevent damage to the insulation layer of the wire; second, the lubricant should be able to maintain its lubricating properties for a period of time after coating to allow sufficient time for winding operations.

Furthermore, after the coils are inserted into the stator slots, the coils need to be insulated by adding a layer of electrical insulation material between the slot wedges and the coils to prevent electrical short circuits between the coils.

Furthermore, the stator inspection may also include a vibration test to check whether the motor structure is firm and whether there is abnormal vibration and noise.

On the other hand, the present invention provides a motor stator assembly, including a stator core and stator slots, wherein the stator core is formed by stacking a plurality of laminations; and the stator slots are formed by stacking lamination slots on the laminations.

Technical effect: In the present invention, precise control of the shape and specification of the wire can reduce human errors, ensure the repeatability and reliability of coil manufacturing, and thus improve the quality of the entire product; during the assembly process, the winding method reduces the risk of damage to the wire and the insulation layer. Thereby reducing the problem of inter-turn short circuit caused by scratches on the enameled wire, and enhancing the safety and stability of the motor; the regular winding layout helps to reduce the operating temperature of the motor, improve the efficiency and power density of the motor, and also reduce noise and vibration.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

FIG1 is a schematic diagram of the method steps of the present invention;

FIG2 is a schematic diagram of the structure of the stator core of the present invention;

FIG3 is a schematic diagram of a lamination structure of the present invention;

In the figure: 1, stator core; 101, lamination; 102, lamination slot; 2, stator slot.

DETAILED DESCRIPTION

The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

The motor stator assembly winding method provided in this specific embodiment, as shown in FIG1 , includes:

1. Modular preparation of conductor prefabrication.

Before you start winding the motor stator assembly, you must first prepare the wire. This is a precise and tedious process. Correctly prefabricated wire modules are the basis for ensuring the entire winding process goes smoothly. First, the specifications of the required wire, including the wire diameter and the shape of the wire, need to be determined by calculation. The wire diameter must be consistent with the design standards of the motor to ensure performance and safety when the current is transmitted. The shape of the coil is designed according to the specific structure of the motor stator and must be accurately designed by computer-aided design (CAD) to ensure that the winding has the best fit and space utilization in the stator slot.

The preparation work is usually done by CNC automatic winding machines. These machines use computer control to perform precise wire shaping and can produce identical wire modules in large quantities and in a standardized manner, which is essential to ensure that each coil has consistent electrical properties. The prepared wire modules also need to undergo insulation testing to ensure that the wires can withstand long-term operation under the action of electromagnetic forces without short circuiting or damage.

In the prefabrication process, details are crucial. Every angle of the coil and every winding method must be exactly the same as the design. This prevents unnecessary physical interference or degradation of electromagnetic performance during the subsequent assembly process. In addition, quality control during the wire prefabrication process is very important. Unqualified products need to be removed in a timely manner, and the links where the problems occur need to be recorded so that equipment or processes can be adjusted in a timely manner to ensure that the quality of the wire is always maintained at a high standard.

Second, stator slot lubrication.

In this step, the stator slots are lubricated with a special lubricant to reduce the friction of the wires during the process of filling the stator slots, allowing the coils to fill the slots more smoothly and preventing unnecessary damage to the wires.

The selection of lubricants needs to meet two basic requirements: first, it should not be corrosive to the wire material to prevent damage to the wire insulation layer; second, the lubricant needs to be able to maintain its lubricating properties for a period of time after application to allow sufficient time for winding operations. A good lubricant will also evaporate naturally after winding, leaving a clean and tidy surface for the next step of processing.

In order to ensure that each slot is evenly coated with lubricant, precision spray or brush equipment is usually used, which can achieve efficient coating work with the help of precise motion control of the machine. During the coating process, special attention should be paid to the amount of lubricant control, which should be sufficient for lubrication but not too much to avoid short circuits between wire slots or affect subsequent operations.

The lubrication process also requires strict quality control. First, a groove that lacks lubrication will cause the wire to heat up, which may cause the insulation layer to melt, damage the motor performance, or even cause a fire. Second, excessive lubrication may cause grease accumulation, causing a short circuit during subsequent operations, or generate oil mist during winding, posing a threat to the health of the operator. Therefore, strict monitoring of each lubrication step is crucial.

3. Install the wire module.

The wire module consists of pre-prepared coils whose size and shape precisely match the design of the stator slots. During the winding process, the coils must be placed in the correct sequence and direction to ensure that the motor produces the correct torque when energized. The winding process requires a high degree of skill and experience, as the arrangement of the wires will directly affect the performance of the motor.

During the loading process, a special wire pusher or winding machine is used to insert the coil into the stator slot. This equipment can accurately control the pressure and speed of the coil to prevent the coil from being excessively bent or deformed, causing damage to the coil.

Then, slot wedges are used to secure the coils, ensuring that they do not shift during subsequent manufacturing processes and motor operation. Slot wedges are plastic or paper components designed to fit precisely into the top of the stator slots, pressing the coils into the slots.

After the coil is installed, it must be insulated, that is, a layer of electrical insulation material is added between the slot wedge and the coil to prevent electrical short circuit between the coils.

Fourth, wire connection and shaping.

During the wire connection stage, the coil ends need to be welded or connected using mechanical connection devices. These connection points must be strong enough to withstand long-term movement and vibration, and also ensure the reliability of the electrical connection to avoid short circuits during motor operation. Usually, the connection points are also covered with a layer of insulation to prevent short circuits.

The shaping process is to shape the wire according to the pre-designed shape. This usually involves the use of specialized equipment, such as wire forming jigs and heat treatment furnaces. Through cold extrusion or hot forming, all coils can be closely fitted to the shape of the stator, which can not only optimize the use of space but also improve the efficiency of the motor.

Finally, once the connections and shaping are complete, a thorough visual inspection of each section of wire is performed to ensure there is no excessive mechanical tension or other issues that could cause insulation damage. Any defects will require rework at this stage, as it is extremely difficult to make repairs to the internal wires once the motor is encapsulated.

5. Stator inspection and assembly.

Testing includes but is not limited to the following:

High voltage test: Check the integrity and voltage resistance of the insulation layer to ensure that no breakdown occurs under high voltage.

Power test: Test the performance of the stator under specified load through actual operation to ensure it can meet the operating requirements.

Insulation resistance test: Measure the resistance between coils and between coils and ground to eliminate the possibility of short circuit.

Vibration test: Check whether the motor structure is firm and there is no abnormal vibration and noise. Excessive vibration may affect the motor life and performance.

Measure and compare: Compare the dimensions of the coil with the design data to ensure that the dimensions of each component are within the allowed tolerance range.

Once the stator has passed all necessary tests and inspections, it can proceed to the final assembly steps. This includes installing the stator in the housing, connecting all external electrical connections, and fitting any necessary ancillary equipment such as cooling systems or sensors.

It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims (8)

1. A method of winding a stator assembly of an electric machine, comprising the steps of:

Step one, prefabricating and modularizing a wire: determining the specification of the required wire by calculation, including the wire diameter and the shape of the line; the wire diameter is in accordance with the design standard of the motor, so that the performance and the safety of current transmission are ensured; the shape of the coil is designed according to the specific structure of the motor stator, and the coil is designed by accurate computer assistance so as to ensure that the winding has optimal adaptation degree and space utilization rate in a stator slot;

Step two, lubrication of stator grooves: coating the stator slots using a precision spray or brush apparatus such that each stator slot is uniformly coated with a lubricant; meanwhile, in the coating process, the dosage control of the lubricant is required to be focused, so that the lubricant is not lubricated enough, but cannot be excessively used for preventing short circuit phenomenon from occurring between the wire grooves or influencing subsequent operation;

Step three, lead wire module is installed: firstly, inserting coils into stator slots according to the correct sequence and direction by using a wire propeller or a winding machine; then, using slot wedges to be embedded into the top of the stator slot, pressing the coil into the slot to fix the coil;

Step four, wire connection and shaping: welding or connecting the coil ends by cold extrusion or thermoforming by using a wire forming clamp and a heat treatment furnace, so that the coil can be tightly attached to the shape of the stator;

step five, stator detection and assembly: firstly, performing high-voltage test on an insulating layer to detect the integrity and voltage resistance of the insulating layer; secondly, testing the performance of the stator under a specified load through actual operation; thirdly, measuring the resistance values between the coils and the ground wire, and eliminating the possibility of short circuit; next, comparing the dimensions of the coil with the design data to ensure that the dimensions of each component are within the allowable tolerance; finally, the stator is installed into the housing, connecting all external electrical interfaces.

2. The method of claim 1, wherein the wire-winding modules are implemented by numerically controlled automatic wire-winding machines that are computer controlled to perform precise wire-winding and mass-produce identical wire-winding modules.

3. The method of claim 2, wherein the prepared wire module is subjected to insulation testing to ensure that the wire is able to withstand prolonged operation without shorting or damage under electromagnetic forces.

4. The method of claim 1, wherein the lubricant is selected based on two basic requirements: firstly, the material of the wire is not corrosive so as to prevent the insulating layer of the wire from being damaged; second, the lubricant needs to be able to maintain its lubricating properties for a period of time after application to allow for a sufficient time for the winding operation.

5. The method of winding a stator assembly of an electric machine according to claim 1, wherein after the coils are inserted into the stator slots, the coils are subjected to an insulation process, and a layer of an electrically insulating material is added between the slot wedge and the coils to prevent electrical shorting between the coils.

6. The method of claim 1, wherein after the coils are connected, an insulating layer is applied to the connection points to prevent short circuits.

7. The method of claim 1, further comprising a vibration test to check whether the motor structure is strong and abnormal vibration and noise are present during the stator inspection.

8. The motor stator assembly according to any one of claims 1-7, comprising a stator core (1) and stator slots (2), the stator core (1) being formed by stacking a plurality of laminations (101); the stator slots (2) are formed by stacking lamination slots (102) on the laminations (101).