WO2020030195A1 - 一种大功率高速电机外插式拼接定子的装配工装 - Google Patents

一种大功率高速电机外插式拼接定子的装配工装 Download PDF

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Publication number
WO2020030195A1
WO2020030195A1 PCT/CN2019/102274 CN2019102274W WO2020030195A1 WO 2020030195 A1 WO2020030195 A1 WO 2020030195A1 CN 2019102274 W CN2019102274 W CN 2019102274W WO 2020030195 A1 WO2020030195 A1 WO 2020030195A1
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Prior art keywords
coil
center frame
stator
assembly tool
assembly
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PCT/CN2019/102274
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English (en)
French (fr)
Inventor
胡思宁
吴立华
董继勇
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南京磁谷科技有限公司
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Publication of WO2020030195A1 publication Critical patent/WO2020030195A1/zh

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    • 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

Definitions

  • the invention relates to an assembly tool for an external plug-in splicing stator of a high-power high-speed motor.
  • stator of high-power high-speed motor has some special structures and performance characteristics, so there are some difficulties in its manufacturing process.
  • the company's "plug-in splicing stator structure for high-power high-speed motors" solves the manufacturing difficulties of high-power high-speed motor stators, but it also puts forward special requirements for assembly tools and processes.
  • Prefabricated copper bar coil is a stator winding form often used in high-power motors. It has the advantages of good assembly processability, high temperature resistance, large load current, and small coil volume.
  • Spliced stator is also a common method in the motor industry. It is usually used for large-diameter, multi-pole, shallow slot depth motor stators to reduce silicon steel blanking waste and reduce the difficulty of blanking die manufacturing. However, the stitching of the stator is still in accordance with the assembly process of "stator first and then the coil", that is, the stator pieces are spliced into a ring first, and then the coil is inserted into the wire slot from the internal test. Because these stators have large internal holes and shallow slot depths, they do not require special assembly processes.
  • high-speed motors of the same power have fewer rotor poles, smaller rotor diameters, and higher stator currents and higher frequencies. Therefore, the inner diameter of the stator of the high-speed motor is smaller, the wire groove is deeper, and the number of coil turns per bundle is more.
  • stator structure that reverses the assembly order and adopts the "coil first and then stator" method, that is, the prefabricated copper strip coil is inserted from the outside to the center and fixed at The special tool is installed, and then the stator is inserted from the outside of the coil and spliced into a whole ring.
  • the plug-in splicing stator structure can solve the manufacturing problems of high-power high-speed motor stators, it also has a problem that needs to be solved.
  • the coil assembly does not have the support of the stator; and the coil assembly itself cannot guarantee mutual positioning. It can't provide positioning and guidance for the stator insert.
  • the invention provides an assembly tool for a high-power high-speed motor external plug-in splicing stator in order to solve the problems in the prior art.
  • the technical solution adopted by the present invention is: an assembly tool for a high-power high-speed motor with an external plug-in splicing stator, which includes a center frame, an end cover and a coil support, and a plurality of coil supports are inserted on both end surfaces of the center frame,
  • a coil positioning groove is formed between two adjacent coil brackets on the end face of each side of the center frame, and the two end covers are fixedly connected to both sides of the center frame, respectively, and the end covers on each side correspondingly fix the coil brackets on that side to On the center frame.
  • the center frame is a shaft-type structure composed of a three-section cylinder, including a middle cylinder and a side cylinder, and the two side cylinders are fixedly connected to both end surfaces of the middle cylinder, respectively, and the side cylinders Coaxial with the middle cylinder.
  • a circle of pin holes is provided on each end surface of the intermediate cylinder, and the pin holes are located outside the side cylinder.
  • the coil support includes an integrally formed fan-shaped portion and a rectangular portion.
  • the rectangular portion is placed on the bottom of the fan-shaped portion.
  • a positioning pin is provided on the bottom of the rectangular portion.
  • a circular boss is provided on one end surface of the end cover, and a plurality of limiting grooves are provided on the boss.
  • the present invention solves the problem that the coil assembly itself cannot maintain the position during the assembly process of the plug-in splicing stator, thereby ensuring the feasibility of the stator assembly.
  • Tooling can be reused:
  • the structure of the tooling ensures that the coil support can be easily removed from the finished stator product, so the tooling can be reused.
  • the tooling is of an axisymmetric structure and all are fixed on a cylindrical center frame. Therefore, the assembly tool can be rotated along the center frame. This can reduce the work of moving and turning the workpiece, facilitate the assembly operation, and reduce the movement of the worker himself, which greatly reduces the labor intensity.
  • FIG. 1 is a structural diagram of the present invention.
  • FIG. 2 is a structural diagram of a center frame in the present invention.
  • FIG. 3 is a structural diagram of a coil support in the present invention.
  • FIG. 4 is a structural diagram of an end cap in the present invention.
  • FIG. 5 is a diagram showing a preparation state of the coil mounting process.
  • FIG. 6 is a state diagram of the coil incorporated into the assembly tool.
  • FIG. 7 is a preparation state diagram of a stator splicing process.
  • FIG. 8 is a state diagram after the stators are spliced.
  • FIG. 9 is a structural diagram of a stator component after disassembly.
  • the present invention discloses an assembly tool for a high-power high-speed motor with an external plug-in splicing stator, which includes a center frame 1, an end cover 2, and a coil support 3. Both ends of the center frame 1 are plugged in.
  • a plurality of coil brackets 3, and a coil positioning groove 31 is formed between two adjacent coil brackets 3 on the end surface of each side of the center frame, and the two end covers 2 are fixedly connected to both sides of the center frame 1, respectively, and the end covers on each side 2 corresponds to fixing the coil holder 3 on the side to the center frame 1.
  • the center frame 1 is a shaft structure composed of three segments of cylinders, including an intermediate cylinder 11 and a side cylinder 12, and the two side cylinders 12 are fixedly connected to the two end surfaces of the intermediate cylinder 11, respectively, and the side cylinders 12 is arranged coaxially with the middle cylinder 11.
  • the diameter of the intermediate cylinder 11 is equal to the diameter of the stator bore.
  • the length of the intermediate cylinder 11 is slightly shorter than the length of the stator.
  • a circle of pin holes 110 is provided on each end surface of the intermediate cylinder 11 for fixing the coil support 3.
  • the pin hole 110 is located outside the side cylinder 12.
  • the wedge-shaped structure of the coil support 3 includes an integrally formed fan-shaped portion 31 and a rectangular portion 32.
  • the rectangular portion 32 is placed on the bottom of the fan-shaped portion 31, and a positioning pin 33 is provided on the bottom of the rectangular portion 32.
  • the positioning pin 33 is inserted into the pin hole 110.
  • a circular boss 21 is provided on one end surface of the end cover 2, and a plurality of limiting slots 22 are provided on the boss 21.
  • the limiting slots 22 are matched with the rectangular portion 32 of the coil holder 3, and one limiting slot is provided. 22 Clips a coil bracket 3.
  • the number of upper limit slots 22 of the end cover 2 is equal to the number of slots of the stator and cooperates with the rectangular portion 32 of the coil holder.
  • the number of coil supports installed at each end of the center frame is equal to the number of slots of the stator.
  • the positioning pin 33 of the coil support 3 is first inserted into the pin hole 110 of the center frame 1, then the end cover 2 is covered, and then the end cover is pressed on the center frame with a nut or a screw.
  • the steps of the present invention for assembling an external plug-in splicing stator are as follows:
  • stator insert 500 When the stator is spliced, align the slot of the stator insert 500 with the straight line segment of the coil and insert it from the outside to the inside (as shown in Figure 7). After the stator inserts 500 are spliced with each other to form the stator, the coil bracket 3 is outside the end face of the stator.
  • stator inserts can be connected by means of circular clamps or welding to ensure that the stator components will not fall apart (see Figure 8).
  • the steps of removing the tooling of the present invention are:

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

一种大功率高速电机外插式拼接定子的装配工装，包括中心架（1）、端盖（2）和线圈支架（3），在中心架（1）的两侧端面上均插接若干个线圈支架（3），且中心架（1）每侧端面上的相邻两线圈支架（3）之间形成有线圈定位槽（31），两端盖（2）分别固定连接在中心架（1）的的两侧，且每侧的端盖（2）对应将该侧的线圈支架（3）固定于中心架（1）上。该装配工装解决了外插式拼接定子装配过程中，线圈组件自身无法保持位置的问题，保证了定子装配的可行性，装配工装结构简单可靠，方便制造，工装可以重复使用，工人劳动强度低，生产效率高。

Description

一种大功率高速电机外插式拼接定子的装配工装 技术领域：
本发明涉及一种大功率高速电机外插式拼接定子的装配工装。
背景技术：
大功率高速电机的定子有一些特殊的结构、性能特点，因此其制造工艺存在一些难点。本公司的“大功率高速电机的外插式拼接定子结构”解决了大功率高速电机定子的制造难题，但其本身也对装配工装和工艺提出了特殊的要求。
1、(内插式)拼接定子结构：
预制铜条线圈是大功率电机中经常采用的一种定子绕线形式，具有装配工艺性好、耐高温性能好、承载电流大、线圈体积小等优点。
拼接式定子也是电机行业中的常用方法，通常用于大直径、多极数、浅槽深的电机定子，用于减少硅钢冲裁废料、降低冲裁模具制造难度。但拼接定子仍然是按照“先定子后线圈”的装配过程，即先将定子散片拼接成环，然后将线圈从内测放入线槽。因为这类定子的大内孔、浅槽深使得它们不需要特殊的装配工艺。
2、外插式拼接定子结构：
因为高速电机的转速高，所以相同功率的高速电机的转子磁极数少、转子直径小、定子电流大频率高。因此高速电机定子的内径更小、线槽更深、每束线圈匝数更多。
这些特征就导致大功率高速电机的预制铜条线圈更粗更硬，并且在装配时必须先扭转成麻花状再塞入定子内孔，并且需要同时在定子内孔中塞入几个线圈，然后依次插入线槽。(注：因为定子线圈之间会相互叠压，所以最后几个安装时必须把最先的几个移出线槽。即会有多个线圈同时塞在内孔中。)
当电机转速提高到一万转以上时，定子和线圈的结构尺寸已经使这种“先定子后线圈”装配方法基本不可能实现了。
为了解决大功率高度电机的定子制造工艺问题，我们提出了一种定子结构将装配顺序反过来，采用“先线圈后定子”的方式，即先将预制铜条线圈从外侧向中心插入并固定在专用工装上，然后把定子从线圈外侧插入、并拼接成整环。
为了和本专利的拼接定子结构区分，我们根据线圈装配时的插入方向，将这种先组装定子、线圈从内部插入的拼接定子称为“内插式拼接定子”。而本专利的先装从外向内组装线圈、再从外向内插入定子的拼接定子称为“外插式拼接定子”。
外插式拼接定子结构虽然能够解决大功率高速电机定子的制造难题，但其本身也有一个难题需要解决一一即在装配过程中，线圈组件没有定子的支承；而线圈组件自身是不能保证相互定位的，更不能为定子插片提供定位和导向。
因此需要设计一种专用装配工装用于大功率高速电机外插式拼接定子的装配。
发明内容：
本发明是为了解决上述现有技术存在的问题而提供一种大功率高速电机外插式拼接定子的装配工装。
本发明所采用的技术方案有：一种大功率高速电机外插式拼接定子的装配工装，包括中心架、端盖和线圈支架，在中心架的两侧端面上均插接若干个线圈支架，且中心架每侧端面上的相邻两线圈支架之间形成有线圈定位槽，两端盖分别固定连接在中心架的的两侧，且每侧的端盖对应将该侧的线圈支架固定于中心架上。
进一步地，所述中心架是由三段圆柱体组成的轴类结构，包括中间圆柱体和侧圆柱体，两个侧圆柱体分别固定连接在中间圆柱体的两侧端面上，且侧圆柱体与中间圆柱体同轴设置。
进一步地，所述中间圆柱体的两端面上各设有一圈销孔，销孔位于侧圆柱体的外侧。
进一步地，所述线圈支架包括一体成型的扇形部和矩形部，矩形部置于扇形部的底部，在矩形部的底部设有定位销钉。
进一步地，所述端盖的一侧端面上设有圆形凸台，在凸台上设有若干个限位槽。
本发明具有如下有益效果：
1)本发明解决了外插式拼接定子装配过程中，线圈组件自身无法保持位置的问题，保证了定子装配的可行性。
2)装配工装结构简单可靠，方便制造。
3)工装可以重复使用：工装的结构保证了线圈支架可以从定子成品上方便地拆除，因此工装可以重复使用。
3)工人劳动强度低：工装呈轴对称结构，并且全部固定在圆柱形的中心架上。因此装配工装可以沿着中心架旋转。这可以减少工件的搬运、翻转劳动，方便装配操作，并可以减少工人自身的移动动作，大大降低劳动强度。
4)生产效率高：装配工艺中，大部分操作都是从工装的外侧进行的。因此工人操作方便，工位布置方便，并且允许多人同时进行装配，从而可以提高生产效率。
附图说明：
图1为本发明结构图。
图2为本发明中中心架的结构图。
图3为本发明中线圈支架的结构图。
图4为本发明中端盖的结构图。
图5为线圈装入工序的准备状态图。
图6为线圈装入装配工装的状态图。
图7为定子拼接工序的准备状态图。
图8为定子拼接后的状态图。
图9为拆除工装后的定子部件结构图。
具体实施方式：
下面结合附图对本发明作进一步的说明。
如图1至图4，本发明公开一种大功率高速电机外插式拼接定子的装配工装，包括中心架1、端盖2和线圈支架3，在中心架1的两侧端面上均插接若干个线圈支架3，且中心架每侧端面上的相邻两线圈支架3之间形成有线圈定位槽31，两端盖2分别固定连接在中心架1的两侧，且每侧的端盖2对应将该侧的线圈支架3固定于中心架1上。
中心架1是由三段圆柱体组成的轴类结构，包括中间圆柱体11和侧圆柱体12，两个侧圆柱体12分别固定连接在中间圆柱体11的两侧端面上，且侧圆柱体12与中间圆柱体11同轴设置。
中间圆柱体11的直径等于定子内孔直径，中间圆柱体11的长度略短于定子长度。
在中间圆柱体11的两端面上各设有一圈销孔110，用于固定线圈支架3。销孔110 位于侧圆柱体12的外侧。
线圈支架3楔形结构，包括一体成型的扇形部31和矩形部32，矩形部32置于扇形部31的底部，在矩形部32的底部设有定位销钉33。定位销钉33插接于销孔110内。
端盖2的一侧端面上设有圆形凸台21，在凸台21上设有若干个限位槽22，限位槽22与线圈支架3的矩形部32相适配，一个限位槽22卡接一个线圈支架3。
端盖2上限位槽22的数量等于定子槽数，与线圈支架的矩形部32配合。中心架每一端安装的线圈支架数量等于定子的槽数。
本发明工装装配时，先将线圈支架3的定位销钉33插入中心架1的销孔110内，然后盖上端盖2，再用螺母或螺钉将端盖压紧在中心架上。
结合图5至图8，本发明工装装配外插式拼接定子的步骤如下：
1)装配本发明工装，并将中心架固定好。
2)装入线圈400时，将预制成型线圈400的直线段对准相邻两线圈支架3之间的线圈定位槽31，从外向内插入(如图5和图6)。
3)定子拼接时，将定子插片500的槽口对准线圈直线段，从外向内插入(如图7)，定子插片500相互拼接形成定子后，线圈支架3处于定子端面外侧。
4)定子拼接完成后，可以用圆形卡箍或焊接等方式连接定子插片，保证定子组件不会散开(如图8)。
如图9，拆除本发明工装的步骤为：
1)首先，拆除工装两端的端盖2。
2)然后，将线圈支架3沿着轴向稍微移动，将定位销钉33从中心架的销孔中拔出。
3)接着，从定子端部线圈的缝隙中沿着径向拔出线圈支架。
4)最后，将中心架从定子内孔中拔出。
本工序完成后，外插式拼接定子部件的组装就完成了。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下还可以作出若干改进，这些改进也应视为本发明的保护范围。

Claims (5)

  1. 一种大功率高速电机外插式拼接定子的装配工装，其特征在于：包括中心架(1)、端盖(2)和线圈支架(3)，在中心架(1)的两侧端面上均插接若干个线圈支架(3)，且中心架每侧端面上的相邻两线圈支架(3)之间形成有线圈定位槽(31)，两端盖(2)分别固定连接在中心架(1)的两侧，且每侧的端盖(2)对应将该侧的线圈支架(3)固定于中心架(1)上。
  2. 如权利要求1所述的大功率高速电机外插式拼接定子的装配工装，其特征在于：所述中心架(1)是由三段圆柱体组成的轴类结构，包括中间圆柱体(11)和侧圆柱体(12)，两个侧圆柱体(12)分别固定连接在中间圆柱体(11)的两侧端面上，且侧圆柱体(12)与中间圆柱体(11)同轴设置。
  3. 如权利要求2所述的大功率高速电机外插式拼接定子的装配工装，其特征在于：所述中间圆柱体(11)的两端面上各设有一圈销孔(110)，销孔(110)位于侧圆柱体(12)的外侧。
  4. 如权利要求1所述的大功率高速电机外插式拼接定子的装配工装，其特征在于：所述线圈支架(3)包括一体成型的扇形部(31)和矩形部(32)，矩形部(32)置于扇形部(31)的底部，在矩形部(32)的底部设有定位销钉(33)。
  5. 如权利要求1所述的大功率高速电机外插式拼接定子的装配工装，其特征在于：所述端盖(2)的一侧端面上设有圆形凸台(21)，在凸台(21)上设有若干个限位槽(22)。
PCT/CN2019/102274 2018-08-06 2019-08-23 一种大功率高速电机外插式拼接定子的装配工装 WO2020030195A1 (zh)

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WO2022234354A1 (en) * 2021-05-06 2022-11-10 Marsilli S.P.A. Method for the making of a stator for electric motors, and respective stator for electric motors

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* Cited by examiner, † Cited by third party
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CN108847756A (zh) * 2018-08-06 2018-11-20 南京磁谷科技有限公司 一种大功率高速电机外插式拼接定子的装配工装
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