CN118539692A - Motor stator assembly and winding method thereof - Google Patents
Motor stator assembly and winding method thereof Download PDFInfo
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- CN118539692A CN118539692A CN202410649034.7A CN202410649034A CN118539692A CN 118539692 A CN118539692 A CN 118539692A CN 202410649034 A CN202410649034 A CN 202410649034A CN 118539692 A CN118539692 A CN 118539692A
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- 238000004804 winding Methods 0.000 title claims abstract description 35
- 238000000034 method Methods 0.000 title claims abstract description 32
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- 238000003475 lamination Methods 0.000 claims abstract description 10
- 238000005461 lubrication Methods 0.000 claims abstract description 7
- 238000007493 shaping process Methods 0.000 claims abstract description 7
- 238000001514 detection method Methods 0.000 claims abstract description 4
- 239000000314 lubricant Substances 0.000 claims description 16
- 238000012360 testing method Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 12
- 238000013461 design Methods 0.000 claims description 9
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- 230000001050 lubricating effect Effects 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000641 cold extrusion Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 claims description 3
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- 238000003856 thermoforming Methods 0.000 claims description 3
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- 239000012777 electrically insulating material Substances 0.000 claims 1
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- 238000011068 loading method Methods 0.000 abstract description 3
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- 238000009417 prefabrication Methods 0.000 abstract description 3
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- 239000004020 conductor Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
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- Manufacture Of Motors, Generators (AREA)
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
Technical Field
The invention belongs to the field of motors, and particularly relates to a motor stator assembly and a winding method thereof.
Background
The motor stator mainly comprises a stator core, a stator winding and a machine base.
The stator core is formed by laminating silicon steel sheets, and has the characteristics of good magnetic permeability and reduced hysteresis loss. When three-phase alternating current passes through the stator windings, alternating magnetic flux is generated in the core, thereby forming a rotating magnetic field. This rotating magnetic field interacts with the bars or permanent magnets on the rotor, generating electromagnetic forces, depending on the type of motor, driving the rotor in rotation.
The existing motor stator power line is difficult to operate, enameled wires are easy to scratch in the installation process, and poor turn-to-turn short circuit of a stator is caused.
Disclosure of Invention
The technical problems to be solved are as follows: how to optimize the motor electronic wiring design.
The technical scheme is as follows:
In one aspect, the present invention provides a method for 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.
Further, the wire modules are completed by numerical control automatic winding machines which perform precise wire forming by computer control and can produce the same wire modules in a large scale and standardized manner.
Further, the prepared wire module needs to be subjected to insulation test, so that the wires can bear long-time operation without short circuit or damage under the action of electromagnetic force.
Further, the selection of lubricants is 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.
Further, after the coils are inserted into the stator slots, the coils need to be insulated, and a layer of electric insulating material is added between the slot wedge and the coils to prevent electrical short circuits between the coils.
Further, in stator inspection, vibration testing may also be included to check whether the motor structure is firm and abnormal vibration and noise.
In another aspect, the present invention provides a motor stator assembly comprising a stator core and a stator slot, the stator core being formed by stacking a plurality of laminations; the stator slots are formed by stacking lamination slots on the lamination.
The technical effects are as follows: in the invention, the shape and specification of the lead can be accurately controlled, so that human errors can be reduced, the repeatability and reliability of coil manufacturing are ensured, and the quality of the whole product is improved; 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.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
FIG. 1 is a schematic diagram of the method steps of the present invention;
FIG. 2 is a schematic view of a stator core structure according to the present invention;
FIG. 3 is a schematic view of a lamination stack of the present invention;
In the figure: 1. a stator core; 101. lamination; 102. lamination grooves; 2. stator slot.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention; all other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The winding method of the motor stator assembly provided in this embodiment, as shown in fig. 1, includes:
and (3) prefabricating and modularly preparing the lead.
The wire must first be prepared before starting to wind the motor stator assembly. This is an exact cumbersome process. The correctly prefabricated wire module is the basis for ensuring the smooth progress of the whole winding process. First, the specification of the desired wire, including the wire diameter size and the shape of the line, needs to be determined by calculation. 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 accurate Computer Aided Design (CAD) is needed to ensure the optimal fit and space utilization of the winding in the stator slot.
The preparation is usually done by a numerical controlled automatic winding machine. These machines utilize computer control for precise wire shaping and allow mass, standardized production of identical wire modules, which is critical to ensure consistent electrical performance for each coil. The prepared wire module also needs to be subjected to insulation test, so that the wires can bear long-time operation without short circuit or damage under the action of electromagnetic force.
Details are critical in the prefabrication process. The winding method of each turn must be completely consistent with the design for each angle of the coil. In order to prevent unnecessary physical interference or degradation of electromagnetic properties during subsequent assembly. In addition, quality control in the wire prefabrication process is very important, unqualified products need to be removed in time, and links of occurrence of problems are recorded, so that equipment or process can be adjusted in time, and the quality of the wires is ensured to be always kept at high standard.
And II, lubricating the stator groove.
In this step, the stator slot is lubricated with a special lubricant to reduce friction of the wire during filling of the stator slot, allow the coil to be more smoothly filled into the slot, and prevent the wire from being unnecessarily damaged.
The choice of lubricant needs to meet 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; secondly, 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. The good lubricant also evaporates naturally after the winding is completed, leaving a clean and tidy surface for further processing.
In order to ensure that each groove is uniformly coated with lubricant, precision spraying or brushing equipment is typically used, which can achieve efficient coating operations by means of precise motion control of the machine. Special attention is paid to the control of the amount of lubricant used in the coating process, which is not too much to be lubricated enough to avoid shorting between the conductor grooves or to affect subsequent operations.
The lubrication process also requires strict quality control. First, the lack of lubrication of the grooves can cause the wires to heat, potentially causing the insulation to melt, damaging the motor performance, and even causing a fire. Second, excessive lubrication may cause grease to accumulate, cause short circuits in subsequent operations, or create oil mist in winding, which poses a threat to the health of the operator. Therefore, a strict monitoring of each lubrication step is critical.
And thirdly, loading the lead wire module.
The wire module consists of a pre-prepared coil, the size and shape of which exactly matches the design of the stator slot. During winding, the coils must be placed in the correct sequence and orientation to ensure that the motor produces the correct torque when energized. The winding process requires a high degree of skill and experience because the placement of the wires will directly affect the performance of the motor.
During the loading process, a special wire pusher or winder is used to insert the coil into the stator slot. The device can accurately control the pressure and speed of the coil, and prevent the coil from being excessively bent or deformed to cause damage to the coil.
The wedge feature is then used to secure the coil, ensuring that the coil will not shift during subsequent processing and operation of the motor. The slot wedge is a plastic or paper component designed to fit precisely into the top of the stator slot, pressing the coil into the slot.
After the coil is assembled, the coil is subjected to an insulation treatment, namely a layer of electric insulation material is added between the slot wedge and the coil, so that electric short circuit between the coils is prevented.
And fourthly, connecting wires and shaping.
During the wire connection phase, the coil ends need to be soldered or connected using mechanical connection means. These connection points must be strong enough to withstand long-term movements and vibrations and also ensure reliability of the electrical connection, avoiding disconnection during operation of the motor. Typically, the connection points are also covered with an insulating layer to prevent shorting.
The shaping process is to shape the wire according to a pre-designed shape. This typically involves the use of specialized equipment such as wire forming jigs and heat treatment furnaces. Through cold extrusion or thermoforming, ensure that all coils can closely laminate the shape of stator, not only can optimize the use in space like this, can also improve motor efficiency.
Finally, once the coupling and shaping is completed, a complete visual inspection of each portion of the wire is also required to ensure that there are no excessive mechanical tension or other problems that may cause insulation damage. At this stage, any rejects need to be reworked, since repair of these internal wires becomes extremely difficult once the motor is packaged.
Fifthly, detecting and assembling the stator.
Detection includes, but is not limited to, the following:
High voltage test: the integrity and withstand voltage capability of the insulating layer are checked to ensure that breakdown does not occur at high voltages.
And (3) power test: the performance of the stator under a specified load is tested through actual operation, so that the stator can meet the operation requirement.
Insulation resistance test: and measuring the resistance values between the coils and the ground wire, and eliminating the possibility of short circuit.
Vibration test: whether the motor structure is firm or not is checked, abnormal vibration and noise are avoided, and the service life and performance of the motor can be influenced due to overlarge vibration.
Measurement and control: the dimensions of the coil are compared to the design data to ensure that the dimensions of each component are within the allowable tolerances.
Once the stator passes all necessary tests and checks, the final assembly step can be performed. The final assembly process includes installing the stator into the housing, connecting all external electrical interfaces, and assembling any necessary ancillary equipment, such as cooling systems or sensors.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in 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).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410649034.7A CN118539692A (en) | 2024-05-23 | 2024-05-23 | Motor stator assembly and winding method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410649034.7A CN118539692A (en) | 2024-05-23 | 2024-05-23 | Motor stator assembly and winding method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN118539692A true CN118539692A (en) | 2024-08-23 |
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ID=92393875
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202410649034.7A Pending CN118539692A (en) | 2024-05-23 | 2024-05-23 | Motor stator assembly and winding method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN118539692A (en) |
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- 2024-05-23 CN CN202410649034.7A patent/CN118539692A/en active Pending
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