WO2020029257A1 - 定子铁芯及其加工方法 - Google Patents

定子铁芯及其加工方法 Download PDF

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Publication number
WO2020029257A1
WO2020029257A1 PCT/CN2018/099996 CN2018099996W WO2020029257A1 WO 2020029257 A1 WO2020029257 A1 WO 2020029257A1 CN 2018099996 W CN2018099996 W CN 2018099996W WO 2020029257 A1 WO2020029257 A1 WO 2020029257A1
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WO
WIPO (PCT)
Prior art keywords
teeth
single tooth
stator core
tooth
coil
Prior art date
Application number
PCT/CN2018/099996
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English (en)
French (fr)
Inventor
王雨婷
Original Assignee
西门子股份公司
王雨婷
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 西门子股份公司, 王雨婷 filed Critical 西门子股份公司
Priority to CN201880094879.7A priority Critical patent/CN112313858A/zh
Priority to PCT/CN2018/099996 priority patent/WO2020029257A1/zh
Priority to US17/265,545 priority patent/US20210296953A1/en
Priority to EP18929172.7A priority patent/EP3820023A4/en
Publication of WO2020029257A1 publication Critical patent/WO2020029257A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in machines
    • H02K15/062—Windings in slots; salient pole windings
    • H02K15/065—Windings consisting of complete sections, e.g. coils, waves
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/18—Windings for salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/48—Fastening of windings on the stator or rotor structure in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/15—Sectional machines

Definitions

  • the invention relates to the field of electric machines, in particular to a stator core and a processing method thereof.
  • the current motor manufacturing process has developed a single-tooth rounding process or other structures that can be easily wound on a single tooth.
  • FIG. 1 shows a partial schematic diagram of the prior art when two adjacent single teeth of a stator core are spliced.
  • the numbers 1 to 85 marked on each turn indicate the winding order of the turns.
  • the arrangement of the coils in the single-toothed wire receiving slot on the left side and the arrangement of the coils in the single-toothed wire receiving slot on the right side are completely the same, that is, symmetrical to each other.
  • the present invention proposes a new type of stator core structure and a processing method thereof.
  • a stator core including: a plurality of first single teeth, a plurality of second single teeth, and a coil, wherein the first single teeth and the second single teeth are both I-shaped and Having a long side, a short side, a connecting portion, and a wire receiving groove located on both sides of the connecting portion, and the coil is wound around the connecting portion and formed in the wire receiving groove,
  • stator core is a ring-shaped member composed of a first single tooth and a second single tooth staggered in order
  • the winding manners of the coils on the first single tooth and the coils on the second single tooth are different from each other, so that the outer contour of the coils on the outside of the tolerance groove of the first single tooth and the The contours of the coils on the outside of the cable receiving slot are inconsistent with each other.
  • the above-mentioned staggered arrangement and the structure of the outer coil profile are inconsistent can further improve the slot full rate of the motor.
  • a contour of the coil outside the capacity slot of the first single tooth and a contour of the coil outside the capacity slot of the second single tooth match each other. Matching with each other can make fuller use of the space of the combined part of the adjacent single-tooth wire-groove, and improve the groove full rate.
  • a winding manner of the coil on the first single tooth and the coil on the second single tooth is different only in that: the first single tooth and the first The winding manners of the two single-tooth coils located on the outermost sides of the respective cable receiving slots are different from each other.
  • This winding method can realize the technical effect of the present invention by modifying the program of the existing winding device less.
  • an insulating layer is attached to a slot wall of the first single-tooth and second single-tooth wire receiving slot, so that the first single-tooth and The second single tooth is electrically insulated from the coils thereon.
  • an insulating spacer is provided between the adjacent first single teeth and the second single tooth, and the length of the insulating spacer is greater than the capacity line.
  • the slot has a slot width, and the insulating spacer is made of a flexible material. Flexible insulation spacers can be arranged along the contour of the coil to make certain bends, which has a better insulation effect.
  • the first single tooth and the second single tooth are formed by laminating multiple layers of silicon steel sheets.
  • a method for processing a stator core including:
  • a coil is wound on a plurality of second single teeth in a second winding manner, wherein the first winding manner is different from the second winding manner and an outer coil profile of the first single tooth and the first The contours of the outer coils of the two single teeth are inconsistent with each other;
  • a ring-shaped stator core is formed by staggering the first single teeth and the second single teeth in turn.
  • the first winding mode and the second winding mode are different only in the outer coil contours of the first single tooth and the second single tooth.
  • the winding manners of several turns of coils are different from each other.
  • the processing method before the step of winding the coil, further includes: placing a wire groove on the first single tooth and / or the second single tooth An insulating layer is attached to the groove wall.
  • the method in the above-mentioned processing method, in the step of forming a ring-shaped stator core in a manner that the first single tooth and the second single tooth are alternately staggered and circled, the method further includes :
  • an insulating spacer is provided between adjacent first and second single teeth, wherein the length of the insulating spacer is greater than the capacity line of the first and second single teeth.
  • the slot has a slot width, and the insulating spacer is made of a flexible material.
  • FIG. 1 shows a partial schematic diagram of two adjacent single teeth of a stator core of the prior art. .
  • FIG. 2 shows a schematic diagram of an embodiment of a stator core according to the present invention.
  • FIG. 3 shows a partial schematic diagram of two adjacent single teeth in the embodiment of FIG. 2.
  • FIG. 4 is a schematic diagram of a winding manner of a first single tooth in the embodiment of FIG. 2.
  • FIG. 5 is a schematic diagram of a winding manner of a second single tooth in the embodiment of FIG. 2.
  • the stator core 10 of the present invention mainly includes a plurality of first single teeth 11, a plurality of second single teeth 12, and a coil 13.
  • the first single tooth 11 and the second single tooth 12 are formed by laminating multiple layers of silicon steel sheets.
  • the stator core 10 has six first single teeth 11 and six second single teeth 12.
  • stator core 10 is a ring-shaped member composed of a first single tooth and a second single tooth that are alternately intertwined.
  • stator core 10 is configured in such a manner that a single first single tooth and a single second single tooth are staggered with each other, as shown in FIG. 2.
  • the shapes of the first single tooth 11 and the second single tooth 12 are basically the same, that is, they are both I-shaped and have long sides 111, 121; short sides 112, 122; the connecting portions 113 and 123 and the wire receiving grooves 114 and 124 on both sides of the connecting portion.
  • the connecting portions 113 and 123 are connected between the long sides 111 and 121 and the short sides 112 and 122 to form an I-shape as shown in FIGS. 4 and 5.
  • the coil 13 is wound around the connecting portions 113 and 123 and is received in the wire receiving grooves 114 and 124.
  • the winding manners of the coils on the first single-tooth 11 and the coils on the second single-tooth 12 are different from each other, so that the outer contour of the coils of the first single-tooth 11 and the second single-tooth 12
  • the outlines of the coils on the outside of the wire receiving groove 124 do not coincide with each other.
  • the top and bottom of the outer coil profile of the first single tooth 11 on the left side are recessed inward, and the middle part projects outward; meanwhile, the second single tooth on the right side is outward.
  • the top and bottom of the outer coil profile of 12 protrude outward, respectively, and the middle part is recessed inward.
  • the outer coil profile of the present invention is not limited to this.
  • the outline of the coil outside the tolerance groove of the first single-tooth 11 and the outline of the coil outside the tolerance groove of the second single-tooth 12 match each other, that is, between adjacent first and second single-tooth 11 and 12 are allowed. It can fit tightly and obtain high space utilization efficiency.
  • the above-mentioned staggered arrangement and the structure of the outer coil profile are inconsistent can further improve the slot full rate of the motor.
  • the number of winding turns (total 88 turns) in the embodiment of the present invention can be greater than that obtained by the single-tooth rounding process of the prior art (FIG. 1 (Shown) for a total of 85 turns. That is, after using the asymmetrical arrangement design of adjacent single-toothed coils on the basis of the coils of FIG. 1, each coil can have three more rows and each slot can have six more rows.
  • the winding manners of the coil 13 on the first single tooth 11 and the coil 13 on the second single tooth 12 may differ only in that the first single tooth 11 and the second single tooth 12 are located at their respective tolerance lines.
  • the winding methods of the outermost turns of the slot are different from each other.
  • the numbers marked on some turns in Fig. 4 and Fig. 5 also indicate the winding order of the turns of the coil.
  • FIG. 4 and FIG. 5 it can be seen that the positions of the same number of turns adjacent to the connecting portions 113 and 123 are the same, but the positions of the same number of turns are only different from each other at the outermost part of the capacity groove, for example, as shown in FIG. 4.
  • the positions of the turns 72, 86, and 87 are different from the positions of the turns 72, 86, and 87 in FIG. 5.
  • Such an arrangement can be achieved by slightly changing the winding program, making the present invention easier to apply to the existing processing technology.
  • an insulating layer 15 may be attached to the groove walls of the wire receiving grooves 114 and 124 of the first single tooth 11 and the second single tooth 12 so that the first single tooth 11 and the second single tooth 12 have the same coil thereon. 13 are electrically insulated from each other.
  • one or more insulating spacers 14 may be provided between adjacent first single teeth 11 and second single teeth 12, so that they can be arranged along the contour of the coil to make certain bends. .
  • the length of the insulating spacer 14 is greater than the slot width of the cable receiving slot, and the insulating spacer 14 is made of a flexible material so as to adapt to the above-mentioned inconsistent outer coil profile.
  • the above-mentioned insulating layer 15 and the insulating spacer 14 may also be omitted.
  • the groove full ratio can be further improved.
  • the above-mentioned processing method of the stator core 10 mainly includes: winding a coil on a plurality of first single teeth by a first winding method (step 1); and winding a plurality of second single teeth by a second winding method. Winding the upper coil (step 2), wherein the first winding mode is different from the second winding mode and the outer coil profile of the first single tooth and the outer coil profile of the second single tooth are inconsistent with each other; and the first single tooth and The second single teeth are sequentially staggered to form a circular stator core (step 3).
  • the implementation order of step 1 and step 2 is not limited, that is, step 1 and step 2 may be performed at the same time, or step 2 may be performed first.
  • the difference between the first winding method and the second winding method mentioned in step 1 and step 2 is, for example, only that: a few turns at the outer coil contour of the first single tooth and the second single tooth
  • the coils are wound in different ways.
  • the insulating layer when an insulating layer is required to be attached, the insulating layer may be attached to the groove wall of the first single-tooth and / or second single-tooth wire receiving groove before the coil winding steps of steps 1 and 2 described above. Subsequently, during the rounding process, the above-mentioned insulating spacer is further provided between adjacent first single teeth and second single teeth.
  • stator core and the processing method of the present invention can effectively improve the slot full rate of the motor, thereby improving the power density of the motor.
  • implementation of the present invention does not need to change the hardware of an existing winding device, and can be implemented only by appropriately adjusting the winding program of the winding device, so the implementation cost is low.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Windings For Motors And Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

本发明提供了一种定子铁芯，包括：多个第一单齿、多个第二单齿和线圈，第一单齿和第二单齿均呈工字型并具有长边、短边、连接部和位于连接部两侧的容线槽，线圈绕连接部绕线形成并容纳于容线槽内，其中，定子铁芯是以第一单齿和第二单齿依次交错拼圆的方式组成的环形件，其中，第一单齿上的线圈和第二单齿上的线圈的绕线方式彼此不同，以使第一单齿的容线槽外侧的线圈轮廓和第二单齿的容线槽外侧的线圈轮廓彼此不一致。此外，本发明还提供了上述定子铁芯的加工方法。

Description

定子铁芯及其加工方法 技术领域
本发明涉及一种电机领域，尤其涉及一种定子铁芯及其加工方法。
背景技术
为了更方便、快捷地制作线圈，当前的电机制造工艺已发展出了单齿拼圆工艺或其他能够在单齿上便捷绕线的结构。
在现有技术中，利用单齿拼圆制成的一个环形定子铁芯由多个单齿拼圆构成。各单齿上的绕组的绕线方式基本一致，使得所有单齿上的每一匝线圈的截面位置基本相同。例如图1示出了现有技术的定子铁芯的相邻两个单齿拼接时的局部示意图。在图1中，每一匝上所标记的数字1～85表示该匝线圈的绕制次序。其中，左侧单齿的容线槽中的线圈排布和右侧单齿的容线槽中的线圈排布位置完全一致，即彼此对称。这样线圈排布完全相同的多个单齿将最终通过拼圆形成上述环形定子铁芯。这种技术相比于嵌线工艺，能够提高电机的槽满率。但，业界仍对槽满率有更高的需求。
发明内容
为了能在现有的单齿拼圆技术的基础上进一步提高槽满率，本发明提出了一种全新的定子铁芯结构及其加工方法。
根据本发明的一个方面，提供了一种定子铁芯，包括：多个第一单齿、多个第二单齿和线圈，所述第一单齿和第二单齿均呈工字型并具有长边、短边、连接部和位于所述连接部两侧的容线槽，所述线圈绕所述连接部绕线形成并容纳于所述容线槽内，
其中，所述定子铁芯是以第一单齿和第二单齿依次交错拼圆的方式组成的环形件，
其中，所述第一单齿上的线圈和第二单齿上的线圈的绕线方式彼此不同，以使所述第一单齿的容线槽外侧的线圈轮廓和所述第二单齿的容线槽外侧的线圈轮 廓彼此不一致。上述交错设置以及外侧线圈轮廓不一致的构造可以进一步提高电机的槽满率。
根据本发明的一个实施例，在上述的定子铁芯中，所述第一单齿的容线槽外侧的线圈轮廓和所述第二单齿的容线槽外侧的线圈轮廓互相匹配。互相匹配可以更充分地利用相邻单齿的容线槽相结合部位的空间，提高槽满率。
根据本发明的一个实施例，在上述的定子铁芯中，所述第一单齿上的线圈和第二单齿上的线圈的绕线方式的区别仅在于：所述第一单齿和第二单齿的位于各自容线槽最外侧的若干匝线圈的绕线方式彼此不同。这种绕线方式可以通过较少地改动既有绕线设备的程序来实现本发明的技术效果。
根据本发明的一个实施例，在上述的定子铁芯中，所述第一单齿和第二单齿的容线槽的槽壁上贴附有绝缘层，以使所述第一单齿和第二单齿同其上的线圈彼此电气绝缘。
根据本发明的一个实施例，在上述的定子铁芯中，所述相邻的第一单齿和第二单齿之间设置有绝缘隔片，所述绝缘隔片的长度大于所述容线槽的槽口宽度，且所述绝缘隔片由柔性材料制成。柔性的绝缘隔片可以沿着线圈轮廓排布做一定的弯曲，起到更好的绝缘效果。
根据本发明的一个实施例，在上述的定子铁芯中，所述第一单齿和第二单齿由多层硅钢片叠压构成。
根据本发明的另一方面，提供了一种定子铁芯的加工方法，包括：
以第一绕线方式在多个第一单齿上绕制线圈；
以第二绕线方式在多个第二单齿上绕制线圈，其中所述第一绕线方式不同于所述第二绕线方式且所述第一单齿的外侧线圈轮廓和所述第二单齿的外侧线圈轮廓彼此不一致；以及
以第一单齿和第二单齿依次交错拼圆的方式组成环形的定子铁芯。
根据本发明的一个实施例，在上述的加工方法中，所述第一绕线方式和第二绕线方式的区别仅在于：所述第一单齿和第二单齿的所述外侧线圈轮廓处的若干匝线圈的绕线方式彼此不同。
根据本发明的一个实施例，在上述的加工方法中，在所述绕制线圈的步骤之 前，所述加工方法还包括：在所述第一单齿和/或第二单齿的容线槽的槽壁上贴附绝缘层。
根据本发明的一个实施例，在上述的加工方法中，在所述以第一单齿和第二单齿依次交错拼圆的方式组成环形的定子铁芯的步骤中，所述加工方法还包括：
在拼圆的过程中，在相邻的第一单齿和第二单齿之间设置绝缘隔片，其中所述绝缘隔片的长度大于所述第一单齿和第二单齿的容线槽的槽口宽度，且所述绝缘隔片由柔性材料制成。
应当理解，本发明以上的一般性描述和以下的详细描述都是示例性和说明性的，并且旨在为如权利要求所述的本发明提供进一步的解释。
附图说明
包括附图是为提供对本发明进一步的理解，它们被收录并构成本申请的一部分，附图示出了本发明的实施例，并与本说明书一起起到解释本发明原理的作用。附图中：
图1示出了现有技术的定子铁芯的相邻两个单齿的局部示意图。。
图2示出了根据本发明的定子铁芯的一个实施例的示意图。
图3示出了图2实施例中的相邻两个单齿的局部示意图。
图4示出了图2实施例中的第一单齿的绕线方式的示意图。
图5示出了图2实施例中的第二单齿的绕线方式的示意图。
附图标记说明：
10                定子铁芯
11                第一单齿
12                第二单齿
13                线圈
14                绝缘隔片
15                 绝缘层
111、121           长边
112、122           短边
113、123           连接部
114、124           容线槽
具体实施方式
现在将详细参考附图描述本发明的实施例。现在将详细参考本发明的优选实施例，其示例在附图中示出。在任何可能的情况下，在所有附图中将使用相同的标记来表示相同或相似的部分。此外，尽管本发明中所使用的术语是从公知公用的术语中选择的，但是本发明说明书中所提及的一些术语可能是申请人按他或她的判断来选择的，其详细含义在本文的描述的相关部分中说明。此外，要求不仅仅通过所使用的实际术语，而是还要通过每个术语所蕴含的意义来理解本发明。
参考附图来更详细地讨论本发明的基本原理和优选实施例。为了提高槽满率，本发明的构思是对相邻单齿的线圈排布做不同的设计，在保证匝数相同的前提下尽量提高可绕匝数。如图2所示，本发明的定子铁芯10主要包括多个第一单齿11、多个第二单齿12和线圈13。第一单齿11和第二单齿12由多层硅钢片叠压构成。例如，在该实施例中，该定子铁芯10具有六个第一单齿11和六个第二单齿12。此外，该定子铁芯10是以第一单齿和第二单齿依次交错拼圆的方式组成的环形件。换言之，该定子铁芯10是以单个第一单齿和单个第二单齿彼此交错设置的方式构成的，如图2所示。
此外，如图4和图5中进一步示出的，第一单齿11和第二单齿12的形状基本相同，即两者均呈工字型并具有长边111、121；短边112、122；连接部113、123和位于连接部两侧的容线槽114、124。连接部113、123连接在长边111、121和短边112、122之间，以构成图4和图5所示的工字型。线圈13绕连接部113、123绕线形成并容纳于容线槽114、124内。特别是，第一单齿11上的线圈和第二单齿12上的线圈的绕线方式彼此不同，以使第一单齿11的容线槽114外 侧的线圈轮廓和第二单齿12的容线槽124外侧的线圈轮廓彼此不一致。在图3所示的实施例中，左侧的第一单齿11的外侧线圈轮廓的顶部和底部分别向内凹入，且中间部位则是向外突出；同时，右侧的第二单齿12的外侧线圈轮廓的顶部和底部分别向外突出，且中间部位则向内凹入。当然，本发明的外侧线圈轮廓不限于此。如此，第一单齿11的容线槽外侧的线圈轮廓和第二单齿12的容线槽外侧的线圈轮廓互相匹配，即允许相邻的第一单齿11和第二单齿12之间能紧密贴合，获得较高的空间利用效率。
上述交错设置以及外侧线圈轮廓不一致的构造可以进一步提高电机的槽满率。例如，在容线槽尺寸相同的前提下，本发明的实施例(图3所示)中的绕线匝数(共88匝)可以大于现有技术的单齿拼圆工艺所获得(图1所示)的绕线匝数(共85匝)。即，在图1线圈基础上对相邻单齿线圈采用不对称排布设计后，每个线圈可以多排3根线，每个槽可以多排6根线。
根据一个实施例，第一单齿11上的线圈13和第二单齿12上的线圈13的绕线方式的区别可以仅在于：第一单齿11和第二单齿12的位于各自容线槽最外侧的若干匝线圈的绕线方式彼此不同。例如，图4和图5中的一些匝上所标记的数字同样表示该匝线圈的绕制次序。通过比较图4和图5可以看到，在邻近连接部113和123的相同匝数的位置是相同的，而仅在容线槽最外侧处的相同匝数的位置彼此不同，例如图4中的匝数72、86、87的位置和图5中的匝数72、86、87的位置彼此不同。这样的排布方式可以通过少许更改绕线程序来实现，使得本发明更容易应用于现有技术的加工技术中。
此外，第一单齿11和第二单齿12的容线槽114、124的槽壁上可以贴附有绝缘层15，以使第一单齿11和第二单齿12同其上的线圈13彼此电气绝缘。此外，如图3所示，相邻的第一单齿11和第二单齿12之间还可以设置有一层或多层绝缘隔片14，使其可以沿着线圈轮廓排布做一定的弯曲。该绝缘隔片14的长度大于容线槽的槽口宽度，且绝缘隔片14由柔性材料制成，以适应于上述不一致的外侧线圈轮廓。此外，如果线圈13采用符合电气绝缘要求的漆包线，也可以省略上述绝缘层15和绝缘隔片14。特别是，若取消上述的绝缘隔片14，还能使槽满率进一步提高。
另一方面，上述定子铁芯10的加工方法主要包括：以第一绕线方式在多个第一单齿上绕制线圈(步骤1)；以第二绕线方式在多个第二单齿上绕制线圈(步骤2)，其中第一绕线方式不同于第二绕线方式且第一单齿的外侧线圈轮廓和第二单齿的外侧线圈轮廓彼此不一致；以及以第一单齿和第二单齿依次交错拼圆的方式组成环形的定子铁芯(步骤3)。在上述方法中，步骤1和步骤2的实施顺序不受限制，即可以同时实施步骤1和步骤2，也可以先实施步骤2。
如以上已讨论过的，步骤1和步骤2中提及的第一绕线方式和第二绕线方式的区别例如仅在于：第一单齿和第二单齿的外侧线圈轮廓处的若干匝线圈的绕线方式彼此不同。
此外，在需要贴附绝缘层时，可以在上述步骤1和步骤2的绕制线圈步骤之前，在第一单齿和/或第二单齿的容线槽的槽壁上贴附绝缘层。随后，在拼圆的过程中，在相邻的第一单齿和第二单齿之间进一步设置上述的绝缘隔片。
综上，本发明的定子铁芯及其加工方法可以有效提高电机的槽满率，进而提高电机的功率密度。此外，本发明的实现无需对既有的绕线设备的硬件做出更改，只需对绕线设备的绕线程序进行适当调整即可实现，因此实施成本较低。
本领域技术人员可显见，可对本发明的上述示例性实施例进行各种修改和变型而不偏离本发明的精神和范围。因此，旨在使本发明覆盖落在所附权利要求书及其等效技术方案范围内的对本发明的修改和变型。

Claims (10)

  1. 一种定子铁芯(10)，其特征在于，包括：多个第一单齿(11)、多个第二单齿(12)和线圈(13)，所述第一单齿和第二单齿均呈工字型并具有长边(111、121)、短边(112、122)、连接部(113、123)和位于所述连接部两侧的容线槽(114、124)，所述线圈绕所述连接部绕线形成并容纳于所述容线槽内，
    其中，所述定子铁芯是以第一单齿和第二单齿依次交错拼圆的方式组成的环形件，
    其中，所述第一单齿上的线圈和第二单齿上的线圈的绕线方式彼此不同，以使所述第一单齿的容线槽外侧的线圈轮廓和所述第二单齿的容线槽外侧的线圈轮廓彼此不一致。
  2. 如权利要求1所述的定子铁芯(10)，其特征在于，所述第一单齿(11)的容线槽(114)外侧的线圈轮廓和所述第二单齿(12)的容线槽(124)外侧的线圈轮廓互相匹配。
  3. 如权利要求1所述的定子铁芯(10)，其特征在于，所述第一单齿(11)上的线圈和第二单齿(12)上的线圈的绕线方式的区别仅在于：所述第一单齿和第二单齿的位于各自容线槽最外侧的若干匝线圈的绕线方式彼此不同。
  4. 如权利要求1所述的定子铁芯(10)，其特征在于，所述第一单齿(11)和第二单齿(12)的容线槽(114、124)的槽壁上贴附有绝缘层(15)，以使所述第一单齿和第二单齿同其上的线圈彼此电气绝缘。
  5. 如权利要求4所述的定子铁芯(10)，其特征在于，所述相邻的第一单齿(11)和第二单齿(12)之间设置有绝缘隔片(14)，所述绝缘隔片的长度大于所述容线槽(114、124)的槽口宽度，且所述绝缘隔片由柔性材料制成。
  6. 如权利要求1所述的定子铁芯(10)，其特征在于，所述第一单齿和第二单齿由多层硅钢片叠压构成。
  7. 一种定子铁芯的加工方法，其特征在于，包括：
    以第一绕线方式在多个第一单齿上绕制线圈；
    以第二绕线方式在多个第二单齿上绕制线圈，其中所述第一绕线方式不同于所述第二绕线方式且所述第一单齿的外侧线圈轮廓和所述第二单齿的外侧线圈轮廓彼此不一致；以及
    以第一单齿和第二单齿依次交错拼圆的方式组成环形的定子铁芯。
  8. 如权利要求7所述的加工方法，其特征在于，所述第一绕线方式和第二绕线方式的区别仅在于：所述第一单齿和第二单齿的所述外侧线圈轮廓处的若干匝线圈的绕线方式彼此不同。
  9. 如权利要求7所述的加工方法，其特征在于，在所述绕制线圈的步骤之前，所述加工方法还包括：在所述第一单齿和/或第二单齿的容线槽的槽壁上贴附绝缘层。
  10. 如权利要求7所述的加工方法，其特征在于，在所述以第一单齿和第二单齿依次交错拼圆的方式组成环形的定子铁芯的步骤中，所述加工方法还包括：
    在拼圆的过程中，在相邻的第一单齿和第二单齿之间设置绝缘隔片，其中所述绝缘隔片的长度大于所述第一单齿和第二单齿的容线槽的槽口宽度，且所述绝缘隔片由柔性材料制成。
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