WO2016078028A1

WO2016078028A1 - Stator manufacturing method and stator

Info

Publication number: WO2016078028A1
Application number: PCT/CN2014/091593
Authority: WO
Inventors: 李节宝; 陈金涛
Original assignee: 广东威灵电机制造有限公司
Priority date: 2014-11-19
Filing date: 2014-11-19
Publication date: 2016-05-26

Abstract

A stator manufacturing method and a stator. The stator manufacturing method comprises the following steps: a manufacturing step for iron core split bodies (11a): manufacturing at least two split bodies (11a) that can be axially stacked to form a stator iron core (1a) and providing each split body (11a) with one circumferentially closed sub-yoke (111a) and at least one stator tooth (112a) disposed on the sub-yoke (111a); a winding step: winding stator windings around the split bodies (11a) respectively, and forming branch winding coils (2a) on the stator teeth (112a) of the split bodies (11a) respectively; and an assembling step: axially stacking the split bodies (11a) where the branch winding coils (2a) are wound to form a stator in a manner that the stator teeth (112a) are mutually staggered. By means of the stator manufacturing method and the stator, large spaces can be provided for winding performed on the split bodies (11a) independently, so that the winding efficiency of the stator iron core (1a) is improved, the slot fullness rate of the stator is increased, and the material cost of the stator is lowered; openings of winding slots in the stator iron core (1a) can be designed to be small, and the performance of a motor is improved; and meanwhile, the roundness precision of the stator is guaranteed, and the assembling process is simplified.

Description

Stator manufacturing method and stator

Technical field

The invention belongs to the field of electric machines, and in particular relates to a method for manufacturing a stator and a stator produced by the method.

Background technique

A conventional manufacturing method of the motor stator is such that the stator punch is integrally punched out, and then the stator punch is laminated to form an integral stator core, and then the winding is wound on the integral stator core by a winding machine. . The conventional manufacturing method of the stator has the following drawbacks in specific applications: due to the limitation of the winding space requirement, the slot full rate is not high, and the slot opening on the stator core needs to be designed to be large, thereby affecting Improvement in motor performance.

In order to solve the technical problems in the above conventional stator manufacturing method, the prior art proposes two kinds of stator core split winding schemes:

1) One solution is to completely separate the stator yoke and the stator teeth of the stator core, and separately wind the stator teeth and then assemble the stator yoke and the stator teeth around the stator winding coils into an integral stator. Although this scheme solves the technical problem that the winding of the traditional stator manufacturing method is limited by space and the tank full rate is low, there are still some deficiencies in the specific application, which are embodied in the following: assembly of stator teeth and stator yoke on the one hand The process time is long and the assembly is difficult; on the other hand, the accuracy of the inner circularity of the stator is lowered.

2) Another solution is to divide the stator core into a plurality of divided bodies in the circumferential direction, and separately wind the windings around each of the divided bodies, and then divide the divided bodies around the stator winding coils in the circumferential direction. The splicing is assembled into an integral stator. Although this scheme also solves the technical problem that the winding of the traditional stator manufacturing method is limited by space and the tank full rate is low, it still has some deficiencies in the specific application, which is embodied in the following: on the one hand, the inner circle of the stator is reduced. On the other hand, the welding operation is required at the joint of each divided body, the operation process is complicated, and the entire stator needs to be plastically sealed, and the process is complicated, which is disadvantageous to the heat dissipation of the entire stator and the weight reduction of the whole machine.

technical problem

The object of the present invention is to overcome the deficiencies of the prior art described above, and to provide a method for manufacturing a stator and a stator, which solves the problem that the accuracy of the stator roundness is reduced due to the split design of the stator core of the prior art, and the assembly process is complicated after the winding is completed. problem.

Technical solution

In order to achieve the above object, the technical solution adopted by the present invention is: a method for manufacturing a stator, comprising the following steps:

a core split manufacturing step of fabricating at least two split bodies axially laminated to form a stator core, and each of said split bodies having a circumferentially closed sub-yoke and at least one disposed on said sub-yoke Stator teeth;

a winding step of winding a sub-winding on each of the split bodies, and forming respective sub-winding coils on the sub-tooth of each of the split bodies;

In the assembling step, each of the splits around each of the divided winding coils is axially laminated to form the stator in such a manner that each of the stator teeth is offset from each other.

As a specific embodiment of the number of split bodies, in the core split manufacturing step, the number of the split bodies is at least three, and each of the split bodies has a circumferential seal and a thickness smaller than The sub-yoke of the thickness of the stator core and the at least one stator tooth provided on the sub-yoke and having a thickness equal to the thickness of the stator core;

In the assembling step, each of the split bodies is assembled in the axial direction in such a manner that each of the stator teeth is mutually offset, and adjacent sides of one of the stator teeth of any one of the split bodies are provided. They are respectively two of the stator teeth on the other two of the split bodies.

Specifically, the sum of the number of the stator teeth of the stator core is an integral multiple of three, the integer multiple is greater than or equal to one time, and in the core split manufacturing step, the split The number is three.

Alternatively, the sum of the number of the stator teeth of the stator core is an even number greater than two, and in the core split manufacturing step, the number of the splits is made to be an even number greater than two.

As another specific embodiment of the number of split bodies, in the core split manufacturing step, the number of the split bodies is two, and one of the split bodies has a first yoke that is circumferentially closed. And a plurality of first teeth spaced apart from each other on the first yoke in a circumferential direction, such that the other of the split bodies has a second yoke that is circumferentially closed and a plurality of circumferentially spaced apart at the second a second tooth on the sub-yoke; at the same time, the sum of the thickness of the first yoke and the thickness of the second yoke, the thickness of the first tooth, and the thickness of the second tooth are equal to The thickness of the stator core;

In the assembling step, the first split body and the second split body are assembled in an axially stacked manner in such a manner that each of the first teeth and each of the second teeth are respectively shifted from each other and alternately arranged.

As another specific embodiment of the number of split bodies, in the core split manufacturing step, the number of the split bodies is equal to the number of stator teeth on the stator core, and each of the split bodies has a sub-yoke circumferentially closed and having a thickness smaller than a thickness of the stator core and a stator tooth provided on the sub-yoke such that a sum of thicknesses of the sub-yokes is equal to the stator core thickness of;

In the assembling step, each of the split bodies is assembled in the axial direction in such a manner that each of the stator teeth is shifted from each other.

Preferably, in the core split manufacturing step, the thicknesses of the sub-yokes of each of the split bodies are equal.

Preferably, in the core split manufacturing step, the first unit and the second unit are separately fabricated, and the first unit has the first yoke and the first portion having a thickness equal to the thickness of the yoke a second unit having a second thickness of the second unit having a thickness equal to a thickness of the first tooth; the first unit and the second unit being axially A laminated connection forms the split body.

Preferably, in the core split manufacturing step, the first unit is formed by laminating a plurality of first punches, and the second unit is formed by stacking a plurality of second punches, and The first punching piece has a yoke piece and a first tooth piece integrally coupled to the yoke piece, such that the second punching piece has a second tooth piece.

Preferably, in the core split manufacturing step, the first punching piece and the second punching piece are punched out on the same punching material, and the first tooth piece and the second piece are made A tooth piece is formed in a circumferential direction around the yoke piece.

Preferably, in the assembling step, when assembling each of the split bodies, fixing the sub-yoke on any of the split bodies to the stator teeth on the remaining split bodies by welding or plastic sealing Or the insulating frame is fixed or the snap connection is connected to each other.

Further, the present invention also provides a stator which is manufactured by the above-described method of manufacturing a stator.

Beneficial effect

The manufacturing method of the stator provided by the present invention and the stator manufactured by the manufacturing method are separately processed and wound by dividing the stator core into at least two separate bodies in the axial direction, and then the respective wound bodies along the winding are completed. The axial direction is formed by laminating the stator teeth in a staggered manner to form an integral stator, which effectively realizes the production of the stator. Since the adjacent sides of one stator tooth of any one of the stators after the assembly is completed are two stator teeth on the other split body, that is, the stator teeth of the same split body on the assembled stator are not adjacently arranged. Therefore, any one of the stator teeth on each of the split bodies before assembly has a large movable space, so that the windings on the stator teeth of each split body can have a larger winding space, so that On the one hand, it is beneficial to improve the winding efficiency of the stator core, on the other hand, it is beneficial to increase the slot full rate of the stator, and on the premise of improving the groove full rate, the copper wire constituting the stator winding can be changed into an aluminum wire, which is beneficial to save the stator. The material cost; on the other hand, the slot opening on the stator core can be designed to be small, improving the performance of the motor. At the same time, since each of the sub-yokes is circumferentially closed and the split bodies are assembled in the axial direction, the roundness precision of the stator is ensured, and welding is not required between the split bodies, which simplifies the assembly process. In turn, it is beneficial to improve the production efficiency of the stator.

DRAWINGS

1 is an exploded perspective view of a stator core of a three-slot inner rotor motor according to a first embodiment of the present invention;

2 is a schematic view showing the assembly of a stator core of a three-slot inner rotor motor according to Embodiment 1 of the present invention;

3 is a schematic view showing the winding coils of the three-slot inner rotor motor respectively wound on the stator teeth according to the first embodiment of the present invention;

4 is an exploded perspective view showing a split body of a three-slot inner rotor motor according to Embodiment 1 of the present invention;

5 is an exploded perspective view of a stator core of a four-slot inner rotor motor according to Embodiment 1 of the present invention;

6 is a schematic view showing the assembly of a stator core of a four-slot inner rotor motor according to Embodiment 1 of the present invention;

7 is an exploded perspective view showing a stator core of a nine-slot inner rotor motor according to Embodiment 1 of the present invention;

8 is a schematic view showing the assembly of a stator core of a nine-slot inner rotor motor according to a first embodiment of the present invention;

9 is an exploded perspective view showing a stator core of a four-slot inner rotor motor according to a second embodiment of the present invention;

10 is a schematic view showing the assembly of a stator core of a four-slot inner rotor motor according to a second embodiment of the present invention;

11 is a schematic view showing the winding of each of the partial winding coils of the four-slot inner rotor motor in each of the separate bodies according to the second embodiment of the present invention;

12 is a schematic view showing the winding of each of the partial winding coils of the four-slot inner rotor motor provided on each of the split bodies according to the second embodiment of the present invention;

13 is an exploded perspective view showing a stator core of a six-slot inner rotor motor according to a second embodiment of the present invention;

14 is a schematic view showing the assembly of a stator core of a six-slot inner rotor motor according to a second embodiment of the present invention;

15 is an exploded perspective view showing a stator core of a twelve-slot inner rotor motor according to a second embodiment of the present invention;

16 is a schematic view showing the assembly of a stator core of a twelve-slot inner rotor motor according to a second embodiment of the present invention;

17 is an exploded perspective view showing a stator core of a twelve-slot outer rotor motor according to a second embodiment of the present invention;

18 is a schematic view showing the assembly of a stator core of a twelve-slot outer rotor motor according to a second embodiment of the present invention;

19 is an exploded perspective view showing a stator core of a three-slot inner rotor motor according to a third embodiment of the present invention;

20 is a schematic view showing the assembly of a stator core of a three-slot inner rotor motor according to a third embodiment of the present invention;

21 is a schematic view showing the winding coils of the three-slot inner rotor motor respectively wound on the respective split bodies according to the third embodiment of the present invention;

22 is an exploded perspective view showing a stator core of a four-slot inner rotor motor according to a third embodiment of the present invention;

23 is a schematic view showing the assembly of a stator core of a four-slot inner rotor motor according to a third embodiment of the present invention.

Embodiments of the invention

The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It is understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

Embodiment 1:

As shown in FIG. 1 to FIG. 8 , a method for manufacturing a stator according to Embodiment 1 of the present invention includes the following steps:

In the core split manufacturing step, at least two split bodies 11a capable of axially laminating to form the stator core 1a are manufactured, and each of the split bodies 11a has a circumferential seal and a thickness (axial thickness) smaller than that of the stator core 1a. a thickness of the sub-yoke 111a and at least one stator tooth 112a provided on the sub-yoke 111a;

a winding step, respectively, a sub-winding is formed on each of the split bodies 11a, and the sub-winding coils 2a are respectively formed on the sub-tooth of each of the split bodies 11a;

In the assembling step, each of the split bodies 11a around which the respective split windings 2a are wound is axially laminated to form a stator in such a manner that the stator teeth 112a are respectively shifted and alternately arranged, and one stator tooth 112a of any one of the split bodies 11a is formed. The adjacent sides are respectively two stator teeth 112a on the other split body 11a or two stator teeth 112a on the other two split bodies 11a. Specifically, each of the divided bodies 11a is laminated and assembled into a stator core 1a, and each of the divided winding coils 2a is connected in series or in parallel to form a stator winding. On the stator after assembly, any two adjacent stator teeth 112a are enclosed to form a wire groove 100a.

In the embodiment of the present invention, each of the stator teeth 112a of each of the split bodies 11a is separately wound (wrap around the sub-winding), and then the wound partial bodies 11a are respectively axially coupled to each other by the stator teeth 112a. The staggered form is laminated to form an integral stator. Since the adjacent sides of one stator tooth 112a of any one of the split bodies 11a on the assembled stator are the two stator teeth 112a on the other split bodies 11a, that is, the stator teeth 112a of the same split body 11a on the assembled stator. It is not adjacently disposed, so that any one of the stator teeth 112a on each of the split bodies 11a before assembly has a large movable space, so that the stator teeth separately in each of the split bodies 11a The winding wire 112a can have a large winding space, so that on the one hand, the winding efficiency of the stator core 1a is improved, and on the other hand, the slot fullness rate of the stator is improved, and under the premise that the groove full rate is improved, The copper wire constituting the stator winding can be changed to an aluminum wire to save the material cost of the stator; on the other hand, the opening of the wire groove 100a on the stator core 1a can be designed to be small, and even the wire groove 100a can be designed to be approximately closed. The form of the groove, which in turn helps to improve the performance of the motor. At the same time, since each of the sub-yokes 111a is circumferentially closed, the accuracy of the roundness of the stator is ensured, and welding between the split bodies 11a is not required, which simplifies the subsequent assembly process after the winding is completed, thereby facilitating the improvement of the stator. Production efficiency.

Specifically, the wire ends of the respective winding coils 2a can be directly soldered to the PCB board or directly drawn out of the motor, and each of the partial winding coils 2a can be a series winding (that is, a series connection between the respective winding coils 2a) or a parallel winding. (ie, the sub-winding coils 2a are connected in parallel).

Specifically, as shown in FIGS. 1 to 3 and FIGS. 5 to 8, in the core split manufacturing step, the number of the split bodies 11a is at least three, and each of the split bodies 11a has a circumferential seal and a thickness smaller than that. a sub-yoke 111a having a thickness of the stator core 1a and at least one stator tooth provided on the sub-yoke 111a and having a thickness equal to the thickness of the stator core 1a 112a;

In the assembling step, each of the split bodies 11a is assembled in the axial direction in such a manner that the stator teeth 112a are offset from each other, and the adjacent sides of one stator tooth 112a of any one of the split bodies 11a are respectively two points. body Two stator teeth 112a on 11a. In this embodiment, since each of the sub-yokes 111a is circumferentially closed, the accuracy of the roundness of the stator is ensured, and welding is not required between the split bodies 11a, which simplifies the subsequent assembly process after the winding is completed. In turn, it is beneficial to improve the production efficiency of the stator.

Preferably, in the present embodiment, in the core split manufacturing step, the thicknesses of the sub-yokes 111a of the respective split bodies 11a are made equal, and the number of the stator teeth 112a on each of the split bodies 11a is made equal. In this way, it is advantageous to make the structural shapes of the sub-yokes 111a of the respective split bodies 11a the same, thereby facilitating the simplification of the design process of each of the split bodies 11a, and further improving the production efficiency of the stator.

Specifically, the stator provided by the embodiment of the present invention can be applied to an inner rotor motor (the rotor is disposed on the outer side of the stator) or can be applied to the outer rotor motor (the rotor is disposed on the outer side of the stator). Specifically, the sub-yoke 111a has an inner side wall 1111a and an outer side wall 1112a. When the stator is applied to the inner rotor motor, each of the stator teeth 112a is respectively disposed on the inner side wall 1111a of each of the sub-yokes 111a; when the stator is applied to the outer rotor motor When on, each stator tooth 112a are respectively disposed on the outer side wall 1112a of each of the sub-yokes 111a.

Specifically, as shown in FIGS. 1 to 3 and FIGS. 7 to 8, when the sum of the number of the stator teeth 112a on the stator core 1a is an integral multiple of three, and the integral multiple is greater than or equal to one time, the split body 11a The number is set to three. Preferably, the thicknesses of the sub-yokes 111a of the three split bodies 11a are equal, and the number of the stator teeth 112a on the three split bodies 11a are equal, that is, the thickness of the sub-yoke 111a of the three split bodies 11a is the stator core 1a. One third of the thickness, the number of stator teeth 112a of the three split bodies 11a is one-third of the total number of stator teeth 112a of the stator core 1a, for example, when the motor is a three-slot motor (the number of the line slots 100a is three) When the number of stator teeth 112a is three, the number of the split bodies 11a is set to three, each of the split bodies 11a includes one sub-yoke 111a and one stator tooth 112a; when the motor is a six-slot motor, the split body The number of 11a is set to three, and each split 11a includes a sub-yoke 111a and two stator teeth 112a; when the motor is a nine-slot motor, the number of the split bodies 11a is set to three, and each of the split bodies 11a includes one sub-yoke 111a and three stator teeth 112a. In the present embodiment, the integral stator core 1a (the stator core 1a assembled by each of the split bodies 11a), the adjacent sides of one stator tooth 112a of any one of the split bodies 11a are respectively the stator teeth 112a on the other two split bodies 11a, thereby making any one One stator tooth 112a of the split body 11a has a large space on both sides (both having at least two slots 100a), which ensures the convenience of winding the individual wires 11a, and ensures the winding of the stator. Efficiency and slot full rate. In the meantime, the present embodiment can minimize the number of the split bodies 11a forming the stator core 1a under the premise of ensuring that the individual windings 11a are individually wound (the winding space is sufficiently large), thereby facilitating the reduction of the respective split bodies 11a. Assembly time, which in turn helps to improve the production efficiency of the stator.

Alternatively, as shown in FIGS. 5 and 6, when the sum of the number of the stator teeth 112a on the stator core 1a is an even number greater than two, the number of the split bodies 11a is an even number greater than two. When the sum of the number of the stator teeth 112a on the stator core 1a is both an even number greater than two and an integral multiple of three, the number of the split bodies 11a may be set to an even number greater than two or may be set to three. Preferably, the thicknesses of the sub-yokes 111a of the respective split bodies 11a are equal, and the number of the stator teeth 112a on each of the split bodies 11a are equal, for example, when the motor is a four-slot motor (the number of the wires 100a is four). The number of the split bodies 11a can be set to four or two; when the motor is a six-slot motor, the number of the split bodies 11a can be set to two or three; when the motor is an eight-slot motor, the number of the split bodies 11a can be Set to eight or four or two. In the present embodiment, on the integral stator core 1a (the stator core 1a assembled by the respective split bodies 11a), the adjacent sides of one stator tooth 112a of any one of the split bodies 11a may be another split body 11a, respectively. The two stator teeth 112a are the two stator teeth 112a of the other two split bodies 11a, so that any one of the splits A stator tooth 112a of 11a has a large space on both sides, which ensures the convenience of winding the individual wires on each of the split bodies 11a, and is advantageous for ensuring the winding efficiency and the slot full rate of the stator.

Preferably, in the core split manufacturing step, the first unit and the second unit are separately fabricated, and the first unit has the sub-yoke 111a and the first split tooth 1121a having a thickness equal to the thickness of the sub-yoke 111a, so that the second The unit has a second dividing tooth 1122a having a thickness equal to the thickness of the first dividing tooth 1121a and equal to the thickness of the stator tooth 112a; the first unit and the second unit are then axially laminated to form a split body. In this embodiment, the stator teeth 112a are divided into two parts: a first partial tooth 1121a and a second partial tooth 1122a, and the first partial teeth 1121a and the sub-yoke are formed. The thicknesses of 111a are uniform and processed together, which facilitates the simplification of the manufacturing process of each of the bodies 11a, thereby facilitating the improvement of the manufacturing efficiency of each of the bodies 11a.

Preferably, each of the second partial teeth 1122a is respectively laminated and fixed on each of the first partial teeth 1121a by riveting or laser welding or glue bonding to form the stator teeth 112a, and the installation process is simple and the fastening is reliable.

Specifically, when the number of the divided bodies 11a forming the stator core 1a is greater than or equal to three, each of the divided bodies 11a forming the stator core 1a includes two end-side splits respectively located at both ends of the stator core 1a in the axial direction. 11a and at least one intermediate split 11a between the end-side split bodies 11a, the second split teeth 1122a of the end-side splits 11a are located on one side of the first split teeth 1121a, and the second split of the intermediate splits 11a The tooth 1122a includes two portions respectively located on opposite sides of the first split tooth 1121a thereof, and the second split tooth of the intermediate split 11a when the intermediate split 11a is manufactured The two portions of 1122a are respectively press-fitted to their first split teeth 1121a from both sides of their first split teeth 1121a.

Preferably, in the core split manufacturing step, the first unit is formed by laminating a plurality of first punching sheets (not shown), and the second unit is laminated by a plurality of second punching sheets (not shown). And forming the first punching piece with the yoke piece and the first tooth piece integrally connected to the yoke piece, so that the second punching piece has the second tooth piece. In this embodiment, the first yoke 111a and the first dividing teeth 1121a are formed by laminating a plurality of first punching sheets formed by integral punching, and the second dividing teeth 1122a are formed by a plurality of second punching sheets integrally formed by punching. Pressed, and since the first punching piece and the second punching piece can be integrally stamped by the punching machine, the manufacturing process of the first punching piece and the second punching piece is very simple, high in manufacturing efficiency, and suitable for mass production. The manufacturing process simplifies the manufacturing process of each of the bodies 11a, and improves the manufacturing efficiency of each of the bodies 11a. At the same time, since the circumferentially closed sub-yokes 111a are integrally formed and stamped with the respective first teeth 1121a, the roundness accuracy of the stator core 1a finally formed by the respective split bodies 11a is effectively ensured.

Preferably, in the core split manufacturing step, the first punching piece and the second punching piece are punched out on the same punching material, and the first tooth piece and the second tooth piece are circumferentially punched around the yoke piece. form. In this way, the utilization rate of the raw materials is improved, and the manufacturing efficiency of the first punching sheet and the second punching sheet is improved. Specifically, when the stator is applied to the inner rotor motor, the first tooth piece and the second tooth piece are punched in the circumferential direction to be formed on the inner side of the yoke piece, and after the punching is formed, the first tooth piece and the yoke piece are kept connected, The two tooth pieces are disconnected from the yoke piece; when the stator is applied to the outer rotor motor, the first tooth piece and the second tooth piece are punched in the circumferential direction to be formed on the outer side of the yoke piece, and after the blank forming, the first tooth piece and the first tooth piece are The yoke remains connected and forms a first punch, the second blade being disconnected from the yoke and forming a second punch.

Preferably, in the assembling step, when assembling the respective split bodies 11a, the sub-yoke 111a on any of the split bodies 11a and the second split teeth 1122a on the remaining split bodies 11a are fixed by welding or plastic fixing or insulating frames or The snap connection is connected to each other. In this way, the second split tooth 1122a and the remaining split body on any split body 11a can be effectively realized. The fastening connection of each of the sub-yokes 111a on the 11a ensures the stable reliability of the connection between the respective sub-pieces 11a.

Preferably, the sub-yoke 111a on any of the split bodies 11a and the second split teeth 1122a on the remaining split bodies 11a are connected to each other by a snap connection. Specifically, the first yoke 101a is provided with a first slot 101a, and the second slot 1122a of the stator teeth 112a is provided with a first boss 102a, and each of the splits 11a passes through the first slot 101a and the first protrusion respectively. The card insertion and fastening connection of the table 102a is such that, by the engagement of the first boss 102a with the first card slot 101a, the second partial teeth 1122a and the remaining split bodies 11a on any of the split bodies 11a can be effectively realized. Sub-yoke a snap connection of the 111a; or a second boss (not shown) is disposed on the sub-yoke 111a, and a second slot (not shown) is disposed on the second splitting tooth 1122a of the stator tooth 112a, and each of the splits 11a The connection between the second card slot and the second boss is fastened through the second card slot, so that the second branch of any of the split bodies 11a can be effectively realized by the card insertion and insertion of the second boss and the second card slot. The teeth 1122a are snap-fitted to the respective sub-yokes 111a on the remaining split bodies 11a.

Specifically, as shown in FIG. 4, as a specific arrangement of the first card slot 101a and the first boss 102a, the first card slot 101a includes a notch 1011a of equal width and recessed on the sub-yoke 111a, Along the slot 1011a, the recessed shoulder 1012a is inclined toward the sub-yoke 111a in a gradually increasing width, and the groove bottom 1013a is recessed toward the sub-yoke 111a at a constant width along the shoulder 1012a. The first boss 102a includes The bottom 1021a having a width protruding from the second dividing tooth 1122a and engaging with the notch 1011 is obliquely protruded away from the second dividing tooth 1122a along the bottom of the base 1021a in a gradually increasing width and is matched with the shoulder 1012a. a shoulder 1022a, a body extending along the shoulder 1022a in a direction away from the second dividing tooth 1122a and engaging the groove bottom 1013a 1023a, in this way, the card-fitting connection of the first card slot 101a and the first boss 102a can be realized.

Alternatively, as a further improvement of the first card slot 101a and the first boss 102a, the first card slot In addition to the notch 1011a, the shoulder 1012a and the groove bottom 1013a, the 101a may further include a groove tail (not shown) which is recessed toward the sub-yoke 111a at an equal position along the intermediate position of the groove bottom 1013a; the first boss In addition to the base 1021a, the shoulder 1022a and the platform 1023a, the 102a may further include a top (not shown) which is disposed on the table body 1023a and has a width corresponding to the groove tail along the intermediate position of the table body 1023a. This embodiment facilitates further improving the fastening reliability of the first boss 102a being engaged with the first card slot 101a.

Or alternatively, as another modification of the first card slot 101a and the first boss 102a, the first card slot In addition to the slot 1011a, the shoulder 1012a and the groove bottom 1013a, the 101a may further include a protrusion at the bottom of the groove. a positioning protrusion (not shown) in 1013a; the first boss 102a includes the above-mentioned base 1021a and the shoulder The 1022a and the body 1023a may further include a positioning groove (not shown) recessed on the table body 1023a and engaging with the positioning protrusion. This embodiment also facilitates further improving the fastening reliability of the first boss 102a being engaged with the first card slot 101a. Of course, in a specific application, the first card slot 101a and the first boss 102a may also be configured to be in a mutually inserted manner.

Further, the present invention also provides a stator which is manufactured by the above-described method of manufacturing a stator. The stator specifically includes the stator core 1a described above and a stator winding wound around the stator core 1a. The stator winding includes a number of winding coils 2a of the same number as the split body 11a, and the respective winding coils 2a are respectively wound around the respective split bodies. 11a is on the stator teeth 112a. Since it is manufactured by the above-described manufacturing method of the stator, on the one hand, the production efficiency of the stator is improved, on the other hand, the performance of the stator is improved, and on the other hand, the material cost of the stator is reduced.

Embodiment 2:

As shown in FIG. 9 to FIG. 18, in the manufacturing method of the stator provided in this embodiment, in the core split manufacturing step, the number of the split bodies 11b is two, and one of the split bodies 11b has a circumferentially closed state. a sub-yoke 111b and a plurality of first teeth 112b spaced apart from each other on the first sub-yoke 111b in the circumferential direction to make another split 11 has a second yoke 121b circumferentially closed and a plurality of second teeth 122b circumferentially spaced apart from each other on the second yoke 121b; at the same time, the thickness of the first yoke 111b and the thickness of the second yoke 121b The sum of the thickness of the first tooth 112b and the thickness of the second tooth 122b are equal to the thickness of the stator core 1b; in the winding step, the first winding coil 201b is wound on the first tooth 112b and the second tooth 122b, respectively. Second winding coil 202b. In the assembling step, the two-part body 11b is assembled in the axial direction by being offset from each other and alternately arranged in the form of the first teeth 112b and the second teeth 122b.

The main difference between the embodiment and the first embodiment is that the number of the splits 11a is set to be at least three, and the number of the splits 11b in the embodiment is only two. However, the present embodiment also solves the technical problem that the stator core core split design of the prior art causes the accuracy of the stator to be reduced, and the assembly process is complicated after the winding is completed. Specifically, in the present embodiment, the first tooth 112b and the second tooth 122b are alternately arranged on the stator core 1b after the assembly is completed, so that any two adjacent first teeth 112b are spaced apart by one. The space of the second teeth 122b is spaced apart from any two adjacent second teeth 122b by a space of the first teeth 112b, so that the first teeth 11b2 and the second teeth of the two-part body 11b can also be made. The windings on the 122b have a large winding space, so that the winding efficiency of the stator core 1 and the slot fullness of the stator can be improved, and the copper constituting the stator winding can be increased on the premise of increasing the tank full rate. The wire is changed to an aluminum wire, which is advantageous for saving the material cost of the stator; and the opening of the wire groove 100b on the stator core 1b can also be designed to be small, improving the performance of the motor. At the same time, since the first yoke 111b and the second yoke 121b are both circumferentially closed, the roundness accuracy of the stator is also ensured, and welding between the two divided bodies 11b is not required, which simplifies the assembly process.

Preferably, as shown in FIG. 11, in the present embodiment, in the winding step, the first winding coil 201 b and the second winding coil 202 are made b is formed on each of the first teeth 112b and the second teeth 122b by continuous winding, and the first winding coil 201b and the second winding coil 202b are in the two-part 11 A total of four wire ends are formed on b, wherein the first winding coil 201 b forms a first wire head and a second wire head on one of the bodies 11 b, and the second winding wire 202 is in another body 11 A third wire head and a fourth wire head are formed on b. In this embodiment, the windings on any of the split bodies 11 b are continuously wound, that is, any of the split bodies 11 The winding process of b does not need to cut the enameled wire, so that the wire breaking and wiring process can be saved on the one hand, thereby reducing the production cost of the stator and improving the production efficiency of the stator; on the other hand, the need for the PCB board can be saved, saving The cost of the PCB board further reduces the production cost of the motor. Of course, as shown in FIG. 12, in a specific application, the first winding coil 201b and the second winding coil 202b may be respectively formed on the two-part body 11b by means of intermittent winding, that is, the first winding coil 201b. The first winding 112b is formed on each of the first teeth 112b of the one body 11b, and the second winding coil 202b is formed in the second tooth of the other partial body 11b by intermittent winding. 122b, and the first winding coil 201b forms a two-wire head on each of the first teeth 112b, and the second winding coil 202b forms two wire ends on each of the second teeth 122, thus, at each of the first teeth 112b The windings on each of the second teeth 122b are intermittently wound. Each time the first tooth 112b is wound, the enameled wire is cut once, and the enameled wire is cut once for each second tooth 122b.

Specifically, the stator provided in this embodiment can also be applied to an inner rotor motor (the rotor is disposed outside the stator) and an outer rotor motor (the rotor is disposed outside the stator). Specifically, the first yoke 111b has a first inner sidewall 1111b and a first outer sidewall 1112b, and the second yoke 121b has a second inner sidewall 1211b and a second outer sidewall 1212b, as shown in FIGS. 9-16, when the stator is applied In the inner rotor motor, the first teeth 112b are circumferentially distributed on the first inner side wall 1111b; the second teeth 122b are circumferentially distributed on the second inner side wall 1211b; as shown in FIGS. 17 and 18. It is shown that when the stator is applied to the outer rotor motor, the first teeth 112b are circumferentially distributed on the first outer sidewall 1112b; the second teeth 122b are circumferentially distributed on the second outer sidewall 1212b.

Preferably, in this embodiment, the sum of the number of the first teeth 112b and the number of the second teeth 122b is an even number greater than or equal to four, and the number of the first teeth 112b and the number of the second teeth 122b are equal, such that On the entire stator core 1, the first teeth 112b and the second teeth 122b are alternately arranged in the circumferential direction, which ensures that the winding head has a sufficiently large movable space when winding the two separate bodies 11b separately, thereby facilitating the improvement. Winding efficiency of the stator windings. Specifically, as shown in FIG. 9 to FIG. 12, when the motor is a four-slot motor (the number of the wires 100b is four), the first tooth 112b and the second tooth 122b are respectively provided with two, and the first tooth 112b. And the second teeth 122b are alternately distributed in the circumferential direction; as shown in FIG. 113 and FIG. 14, when the motor is a six-slot motor (the number of the wires 100b is six), the first teeth 112b and the second teeth 122b are respectively provided. There are three, and the first tooth 112b and the second tooth 122b are alternately distributed in the circumferential direction; as shown in FIGS. 15 to 18, when the motor is a twelve-slot motor (the number of the wire slots 100b is twelve), the first The teeth 112b and the second teeth 122b are respectively provided with six, and the first teeth 112b and the second teeth 122b are alternately distributed in the circumferential direction.

Preferably, in order to realize the connection of the two sub-pieces 11b, a first card slot 101b may be disposed on the first sub-yoke 111b and between any two adjacent first teeth 112b, and each of the first teeth 112b is provided with a first a second latching groove 103b is disposed on the second sub-yoke 121b and between any two adjacent second teeth 122b, and each of the second teeth 122b is provided with a second boss 104b, and each of the first latching slots 101b The second bosses 104b are respectively inserted into the card, and the first bosses 102b are respectively inserted and connected to the second card slots 103b.

Other specific steps of the manufacturing method of the stator of the present embodiment can be optimized according to the first embodiment, and will not be described in detail herein.

Embodiment 3:

As shown in FIGS. 19 to 23, in the method of manufacturing the stator according to the present embodiment, in the core split manufacturing step, the number of the split bodies 11c is equal to the number of the stator teeth 112c on the stator core 1c, and the split bodies are made. Each of the 11c has a sub-yoke 111c which is circumferentially closed and has a thickness smaller than the thickness of the stator core 1c and a stator tooth 112c which is provided on the sub-yoke 111c so that the sum of the thicknesses of the respective sub-yokes 111c is equal to the thickness of the stator core 1c. Specifically, the stator core 1c includes a stator yoke 10c and a plurality of stator teeth 112c provided on the stator yoke 10c. The number of the split bodies 11c is equal to the number of the stator teeth 112c, and the stator teeth 112c of the respective split bodies 11c are in the stator iron. The cores 1c are respectively arranged offset from each other in the circumferential direction; in the winding step, the sub-windings are separately wound on the respective sub-pieces 11c, and the respective sub-winding coils 2c are wound on the stator teeth 112c of the respective sub-pieces 11c; In the step, each of the split bodies 11c is stacked and assembled in the axial direction with the stator teeth 112c being shifted from each other and alternately arranged. On the stator after assembly, any two adjacent stator teeth 112c are enclosed to form a wire groove 100c.

The main difference between the embodiment and the first embodiment and the second embodiment is the manner of setting the number of the splits. The number of the splits 11a in the first embodiment is set to be at least three, and the number of the splits 11b in the second embodiment is set to be In the present embodiment, the number of the split bodies 11c is the same as the number of the stator teeth 112c on the stator core 1c, and the embodiment also solves the problem that the stator roundness accuracy of the prior art stator core split design is reduced. The technical problem of complicated assembly process after winding. Specifically, in this embodiment, since only one stator tooth 112c is provided on each of the split bodies 11c, the stator teeth 112c on each of the split bodies 11c before assembly have a large movable space, thereby making The winding head can have a large winding space when wound on the stator teeth 112c of each of the split bodies 11c, so that on the one hand, it is advantageous to improve the winding efficiency of the stator core 1c, and on the other hand, it is advantageous to increase the slot of the stator. Rate, and under the premise of increasing the tank full rate, the copper wire constituting the stator winding can be changed to aluminum wire, which is beneficial to save the material cost of the stator; on the other hand, the opening of the wire slot 100c on the stator core 1 can be designed according to the design requirements. The flexible design allows the opening of the wire groove 100c to be designed to be small, and even the wire groove 100c can be designed in the form of an approximately closed groove, improving the performance of the motor. At the same time, since each of the sub-yokes 111c is circumferentially closed, it ensures the roundness precision of the stator, and welding between the split bodies 11c is not required, which simplifies the subsequent assembly process after the winding is completed, thereby facilitating the improvement of the stator. Production efficiency.

Specifically, the stator core 1c provided in this embodiment may also be respectively applied to an inner rotor motor (the rotor is disposed on the outer side of the stator) and an outer rotor motor (the rotor is disposed on the outer side of the stator), that is, each of the stator teeth 112c may be separately provided. The inner side walls 1111c of the respective sub-yokes 111c may be provided on the outer side walls 1112c of the respective sub-yokes 111c, respectively.

Specifically, in the embodiment, when the motor is a three-slot motor (the number of the wire grooves 100c is three and the number of the stator teeth 112c is three), as shown in FIGS. 19 to 21, the number of the stator teeth 112c is three. The number of the split bodies 11c is correspondingly set to three, and each of the split bodies 11c includes a sub-yoke 111c and a stator tooth 112c which are circumferentially closed and have a thickness of one third of the thickness of the stator yoke 10c; when the motor is four In the case of the slot motor, as shown in FIGS. 22 and 23, the number of the stator teeth 112c is four, and the number of the split bodies 11c is set to four, and each of the split bodies 11c includes a circumferentially closed one and a thickness of the stator yoke 10c. a quarter of the thickness of the sub-yoke 111c and a stator tooth 112c; when the motor is a nine-slot motor, the number of the stator teeth 112c is nine, and the number of the split bodies 11c is correspondingly set to nine, and each of the split bodies 11c includes a circumferentially closed and a thickness nine of the thickness of the stator yoke 10c. One sub-yoke 111c and one stator tooth 112c.

Preferably, in order to achieve the fastening connection between the stator teeth 112c of any of the split bodies 11c and the respective sub-yokes 111c of the remaining split bodies 11c, in this embodiment, the number of the stator yokes 111c is less than one of the number of stator teeth 112c. The first card slot 101c is provided with a first boss 102c on the stator teeth 112c of each of the stator teeth 112c, and each of the split bodies 11 is inserted into and engaged with each of the first bosses 102c through the first card slots 101c. The fastening is fastened, so that the stator teeth of any of the split bodies 11c can be effectively realized by the snap fit of each of the first bosses 102c and the first card slots 101c. a fastening connection of 112c to each of the sub-yokes 111c of the remaining split body 11c;

The above is only the preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included in the protection of the present invention. Within the scope.

Claims

A method of manufacturing a stator, comprising: the following steps:

a core split manufacturing step of fabricating at least two split bodies axially laminated to form a stator core, and each of said split bodies having a circumferentially closed sub-yoke and at least one disposed on said sub-yoke Stator teeth;

a winding step of winding a sub-winding on each of the split bodies, and forming respective sub-winding coils on the sub-tooth of each of the split bodies;

In the assembling step, each of the splits around each of the divided winding coils is axially laminated to form the stator in such a manner that each of the stator teeth is offset from each other.
A method of manufacturing a stator according to claim 1, wherein in said core split manufacturing step, said number of said split bodies is at least three, and each of said split bodies has a circumferential direction The sub-yoke closed and having a thickness smaller than a thickness of the stator core and at least one of the stator teeth disposed on the sub-yoke and having a thickness equal to a thickness of the stator core;

In the assembling step, each of the split bodies is assembled in the axial direction in such a manner that each of the stator teeth is mutually offset, and adjacent sides of one of the stator teeth of any one of the split bodies are provided. They are respectively two of the stator teeth on the other two of the split bodies.
A method of manufacturing a stator according to claim 2, wherein a sum of the number of said stator teeth of said stator core is an integral multiple of three, said integer multiple being greater than or equal to one time, and said iron In the core split manufacturing step, the number of the splits is three.
A method of manufacturing a stator according to claim 2, wherein a sum of the number of said stator teeth of said stator core is an even number greater than two, and in said core split manufacturing step, The number of said fragments is an even number greater than two.
A method of manufacturing a stator according to claim 1, wherein in said core split manufacturing step, said number of said split bodies is two, and one of said split bodies is circumferentially closed. a first yoke and a plurality of first teeth spaced apart from each other on the first yoke in a circumferential direction, such that the other of the split bodies has a circumferentially closed second yoke and a plurality of circumferentially spaced apart a second tooth on the second yoke; at the same time, a sum of a thickness of the first yoke and a thickness of the second yoke, a thickness of the first tooth, and a thickness of the second tooth Both equal to the thickness of the stator core;

In the assembling step, the first split body and the second split body are assembled in an axially stacked manner in such a manner that each of the first teeth and each of the second teeth are respectively shifted from each other and alternately arranged.
A method of manufacturing a stator according to claim 1, wherein in said core split manufacturing step, said number of said split bodies is equal to the number of stator teeth on said stator core, and said each The split body has a sub-yoke circumferentially closed and having a thickness smaller than a thickness of the stator core and a stator tooth provided on the sub-yoke, such that the sum of the thicknesses of the sub-yokes is equal to The thickness of the stator core;

In the assembling step, each of the split bodies is assembled in the axial direction in such a manner that each of the stator teeth is shifted from each other.
The method of manufacturing a stator according to any one of claims 1 to 6, wherein in the core split manufacturing step, the thicknesses of the sub-yokes of the respective divided bodies are equal.
The method of manufacturing a stator according to any one of claims 1 to 6, wherein in the core split manufacturing step, the first unit and the second unit are separately manufactured, and the first unit is provided The sub-yoke and a first partial tooth having a thickness equal to a thickness of the sub-yoke, the second unit having a second portion having a thickness equal to a thickness of the first partial tooth equal to a thickness of the stator tooth And locating the first unit and the second unit in an axial direction to form the split body.
The method of manufacturing a stator according to claim 8, wherein in the step of manufacturing the core, the first unit is formed by laminating a plurality of first punches, and the second unit is The plurality of second punching sheets are laminated, and the first punching piece has a yoke piece and a first tooth piece integrally connected to the yoke piece, so that the second punching piece has a second tooth piece.
The method of manufacturing a stator according to claim 9, wherein in the step of manufacturing the core, the first punch and the second punch are formed by punching on the same punch material. And forming the first tooth piece and the second tooth piece in a circumferential direction around the yoke piece.
The method of manufacturing a stator according to any one of claims 1 to 6, wherein in said assembling step, said sub-yoke on any of said split bodies is assembled when said each of said split bodies is assembled The stator teeth on the remaining split bodies are connected to each other by soldering or plastic sealing or insulating frame fixing or snap connection.
A stator characterized in that the stator is produced by the method of manufacturing the stator according to any one of claims 1 to 11.