JP2024088221A - Motor stator - Google Patents

Abstract

A motor stator having a small size and a maximum coil packing ratio that can increase power is provided. The motor stator has an annular stator core and a plurality of teeth 20 spaced apart on an inner surface of the annular stator core, the teeth having slots 15 formed on each of two sides of each of the teeth. Each of the teeth has a coil winding, and a portion of a coil 30 is positioned within the two slots of each of the teeth. Each of the coils is formed by a metal wire wound multiple times from the inside to the outside around a bobbin. The bobbin has an inner guide frame and an outer guide frame, both of which have a structure with a vertically arranged bottom plate and a side plate, whereby the coil can be attached to the bobbin to make the motor stator compact. [Selected Figure] Figure 2

Description

The present disclosure relates to a motor stator, and more particularly to a motor stator that is small in size and can increase power by maximizing the coil filling factor.

Due to the rapid development of motor technology in recent years, motor development is trending towards small size and high power design. Therefore, to accommodate this trend, the stator structure needs to be redesigned. In general, the higher the coil filling factor in the stator, the stronger the magnetic field generated and the higher the power output.

Considering the current technological development, the coil winding density is low, and in order to increase the coil winding in the stator structure, the corresponding slots must be enlarged, which leads to an increase in the overall size and weight of the motor. Therefore, how to output higher power while keeping the motor in a smaller size is a challenge that needs to be improved in the current technology.

Based on the above-mentioned shortcomings, the objective of the present disclosure is to provide a motor stator, in particular a motor stator having a small size and a maximum coil filling factor that can increase power.

In accordance with the objectives of the present disclosure, there is provided a motor stator comprising an annular stator core and a plurality of teeth spaced apart on an inner surface of the annular stator core and projecting toward a center of the annular stator core, each of the teeth having a slot formed on each of two sides of the tooth portion, each of the teeth having a coil winding, a portion of the coil being positioned within the two slots of each of the tooth portions, wherein a bobbin is provided between each of the coils and each of the tooth portions, each of the coils being formed by winding a metal wire around the bobbin multiple times, the thickness of the metal wire gradually decreasing from one end to the other.

Here, the bobbin has an inner guide frame and an outer guide frame, both of which have a bottom plate and a side plate disposed on the bottom plate and protruding from the bottom plate towards one side, the side plate being disposed perpendicular to the bottom plate.

Preferably, both the inner and outer guide frames have a T-shaped cross-sectional shape.

Preferably, the coil is attached to a bobbin.

Preferably, each of the adjacent turns in each of the coils are attached to one another and the cross-sectional area of each turn in each of the coils is the same.

A three-phase busbar is also provided within the annular stator core, preferably having three conductive elements and one neutral element, each conductive element having a plate, a connection end and four welded ends, each connected to one of the metal wire ends of one of the coils.

Preferably, the cross-sectional shape of each coil is trapezoidal.

Preferably, the width of each metal wire gradually increases from one end to the other, so that the cross-sectional profile of each coil is trapezoidal in shape.

Preferably, each coil occupies 80% of the volume of the two slots in each tooth portion.

Preferably, each tooth portion is secured to the annular stator core by a wedge buckle structure.

FIG. 1 is a schematic diagram of one embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an embodiment of the present disclosure. FIG. 3 is a partially enlarged view of FIG. 2 . FIG. 2 is an exploded view of the tines, bobbin and coil components of an embodiment of the present disclosure. FIG. 2 is an exploded view of components of an embodiment of the present disclosure. FIG. 2 is a top schematic view of a coil of the present disclosure.

In order to clearly explain the specific aspects of the implementation, structure, and effects achieved by the present disclosure, the following embodiments are provided and described with the aid of drawings.

The following description is based on the surface of the annular stator core 10 near the center of the circle of the motor stator 100 as the inside.
Orientational descriptions such as up and down, left and right, etc. are used solely to indicate the relative relationships of components, as per common knowledge of those skilled in the art.
1-6, a motor stator 100 is shown comprising an annular stator core 10, a plurality of tooth portions 20 spaced apart on an inner surface of the annular stator core 10 and projecting toward the center of the annular stator core 10, and a slot 15 formed in each of two sides of each of the tooth portions 20. Each of the tooth portions 20 has a coil 30 wound therearound, with a portion of the coil 30 positioned within the two slots 15 of each of the tooth portions 20, and each of the tooth portions 20 is secured to the annular stator core 10 by a wedge buckle structure 21.

Here, a bobbin 40 is provided between each of the coils 30 and each of the tooth portions 20, and each of the coils 30 is formed by winding a metal wire 31 around the bobbin 40 from the inside to the outside multiple times, and after the coils 30 are formed, the ends of the metal wire 31 extend upward. In this embodiment, the metal wire 31 is a flat copper wire. In another embodiment, the metal wire 31 can be first formed into a coil 30 and then placed on the bobbin 40.

Referring to Fig. 3, a metal wire 31 is wound multiple times from the inside to the outside to form a coil 30. The thickness T of the metal wire 31 gradually decreases from one end 30a to the other end 30b, while the width W gradually increases from one end 30a to the other end 30b, so that the cross-sectional area of each coil is the same (i.e., the value of the thickness T multiplied by the width W of each turn (T1, T2, T3...Tn) is the same). This avoids uneven current distribution when current flows through the coil 30.
However, in another embodiment, the coil may have the same thickness for each turn (T1, T2, T3...Tn) of the coil, and different thicknesses for different turns (T1, T2, T3...Tn) of the coil, with the thickness of the different turns (T1, T2, T3...Tn) of the coil gradually decreasing.

Further, the bobbin 40 includes an inner guide frame 41 and an outer guide frame 42, both of which have bottom plates 41a, 42a and side plates 41b, 42b provided on the bottom plates 41a, 42a, and the side plates 41b, 42b protrude toward one side, such that the bottom plates 41a, 42a and the side plates 41b, 42b are vertically arranged, so that the cross-sectional profiles of the inner guide frame 41 and the outer guide frame 42 are all T-shaped (see Figures 2 and 4).
In this embodiment, due to the structure of the side plates 41b, 42b, the bottom plates 41a, 42a are vertically positioned so that the coil 30 can be attached to the bobbin 40. In addition, the placement of the bobbin 40 facilitates the placement of the coil 30, whereby adjacent turns (T1, T2, T3...Tn) of the coil 30 can be attached to each other, increasing the winding density of the coil 30.
In this embodiment, each coil 30 occupies 80% of the volume of the two slots 15 of each of the tooth portions 20. This increases the volume utilization of the slots 15 and allows the motor stator 100 to be minimized without having to wind more coils around the tooth portions as in the prior art in the art.

On the other hand, when calculating the power density per unit volume of the motor, the size of the entire motor stator 100 (including the size of the annular stator core 10 and the coil 30) should be taken into consideration, so that when the coil 30 is attached to the bobbin 40, the winding density of the coil 30 of the present disclosure is higher and the size of the coil 30 is reduced compared to the prior art. This allows the overall size of the motor stator 100 to be reduced and the power density per unit volume to be increased. In addition, when the size of the coil 30 is reduced, the amount of copper used in the metal wire 31 can also be reduced, thereby reducing manufacturing costs.

The motor stator 100 further includes a three-phase busbar 50 provided on one side of the annular stator core 10. The three-phase busbar 50 includes three conductive elements 50a and one neutral element 54, and each of the conductive elements 50a includes a plate 52, a connection end 51, and four welding ends 53.
The connection ends 51 extend upward from the plates 52, and the four welding ends 53 are connected at one end to one of the metal wires 31 of the coils 30, and the other end of the metal wire 31 not connected to the welding ends 53 is connected to the neutral element 54. The arrangement of the plates 52, the connection ends 51 and the welding ends 53 of the three-phase busbar 50, as well as the structure of the connection between the three-phase busbar 50 and the coils 30 are well established in the art and need not be described in detail.

The present disclosure is primarily concerned with having a coil 30 mounted on a bobbin 40 and having adjacent turns (T1, T2, T3...Tn) of the coil 30 attached to each other so as to increase the occupancy of the coil 30 within the slot 15 to achieve a volume minimization effect.

Claims (10)

A motor stator,
An annular stator core;
a plurality of teeth spaced apart on an inner surface of the annular stator core and projecting toward a center of the annular stator core;
Each of the tooth portions has a slot formed on each of two sides of the tooth portion;
Each of the tooth portions has a coil wound therearound;
a portion of the coil is positioned within the two slots of each of the tooth portions;
a bobbin is provided between each of the coils and each of the tooth portions;
Each of the coils is formed by winding a metal wire multiple times around the bobbin;
The thickness of the metal wire gradually decreases from one end to the other end.
Motor stator. The motor stator of claim 1, characterized in that the bobbin has an inner guide frame and an outer guide frame. The motor stator of claim 2, characterized in that the inner guide frame and the outer guide frame each have a bottom plate and a side plate disposed on the bottom plate and protruding from the bottom plate toward one side, the side plate being disposed perpendicular to the bottom plate. The motor stator of claim 2, characterized in that the inner guide frame and the outer guide frame both have a T-shaped cross section. The motor stator of claim 1, characterized in that the coil is attached to the bobbin. The motor stator of claim 1, characterized in that adjacent turns in each of the coils are attached to each other and the cross-sectional area of each of the turns in each of the coils is the same. The motor stator of claim 1, characterized in that a three-phase busbar having three conductive elements and one neutral element is provided in the annular stator core, each conductive element having a plate, a connection end, and four welded ends, each of which is connected to one of the ends of the metal wire of one of the coils. The motor stator of claim 1, characterized in that the width of each metal wire gradually increases from one end to the other, thereby causing each coil to have a trapezoidal cross-sectional shape. The motor stator of claim 1, characterized in that each of the coils occupies 80% of the volume of two slots of each of the tooth portions. The motor stator of claim 1, characterized in that each of the tooth portions is fixed to the annular stator core by a wedge buckle structure.

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