CN-122026647-A - High-power-density block type frameless motor stator and manufacturing method thereof

CN122026647ACN 122026647 ACN122026647 ACN 122026647ACN-122026647-A

Abstract

The invention belongs to the technical field of motors, in particular to a high-power density block type frameless motor stator and a manufacturing method thereof, comprising a plurality of circumferentially spliced block stator units, each unit comprises a stator core block and a single-tooth winding, the core block is laterally provided with a positioning connection structure matched with the stator core block in a concave-convex way, the single-tooth windings are connected with each other through the annular circuit board bus, and the high-heat-conductivity insulating potting layers are filled in the splicing gaps and winding gaps, so that splicing processing, single-tooth winding, accurate positioning splicing, laser welding, circuit board integration and vacuum potting are sequentially completed during manufacturing. By adopting the split type stator structure and the single-tooth winding process, the physical space limitation of the integral stator notch is broken, the slot filling rate of the stator winding is obviously improved, the equivalent resistance and copper loss of the winding are reduced, and the power density and torque density of the motor are fundamentally improved.

Inventors

JIANG BO
FAN JUNLI
GU MIAOMIAO
GUO MINGLU
YANG FANBO
DUAN ZHIJUN
LIN LI
WANG HONGYAN
MIN LIN
ZHANG PENGTAO

Assignees

陕西玖思和创电机科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260212

Claims (10)

1. A high power density split type frameless motor stator and a manufacturing method thereof are characterized in that the stator comprises the following steps: the plurality of split block stator units are circumferentially distributed and mutually spliced to form a circular structure; Wherein each split stator unit comprises a stator core split and a single-tooth winding wound on the stator core split; the lateral surfaces of the stator core segments are provided with mutually matched positioning connection structures, and the positioning connection structures are configured to mechanically restrict adjacent segment stator units in the radial direction and the circumferential direction; The leading-out ends of the single-tooth windings are electrically interconnected through a converging connection assembly.
2. The high-power-density block-type frameless motor stator according to claim 1, wherein the positioning connection structure comprises a groove formed in the longitudinal surface of one side of the stator core block and a protrusion which is formed in the longitudinal surface of the other side of the stator core block and is matched with the groove in shape, and two adjacent stator core blocks are embedded into the groove through the protrusions to achieve positioning.
3. The high power density split type frameless motor stator according to claim 1, wherein the bus connection assembly is an annular circuit board, a plurality of conductive pads and logic wiring are arranged on the annular circuit board, and the leading-out ends of the single-tooth windings are correspondingly welded on the conductive pads and form a preset phase current path through the logic wiring.
4. The high power density modular frameless motor stator of claim 1 wherein the stator core segments are laminated from a high permeability material, the single tooth winding having a slot fill ratio on the stator core segments greater than or equal to seventy percent.
5. The high power density split frameless motor stator of claim 1 further comprising a potting layer formed of a high thermal conductivity insulating material and surrounding the gaps between the single tooth windings and the stator core split and the splice gaps between adjacent split stator units.
6. The high power density modular frameless motor stator of claim 5 wherein the high thermal conductivity insulating material of the potting layer has a thermal conductivity greater than or equal to two-point zero watts per meter kelvin.
7. The high power density modular frameless motor stator of claim 2 wherein said grooves are configured in a dovetail cross-section configuration and said protrusions are configured in a dovetail protrusion configuration corresponding to the shape of said grooves.
8. The high power density modular frameless motor stator of claim 3 wherein said annular circuit board is a multi-layer circuit board.
9. A method of manufacturing a high power density modular frameless motor stator adapted for use in a high power density modular frameless motor stator according to any one of claims 1-8, comprising the steps of: Manufacturing a plurality of independent stator core segments, and machining concave-convex positioning structures matched with each other in the lateral direction of the stator core segments; Step two, a winding process is carried out on a single stator core splicing block by using a winding mechanism to form a single-tooth winding, so as to obtain a splicing block stator unit; step three, radially butting and circumferentially splicing a plurality of spliced stator units through the concave-convex positioning structure, and placing the spliced stator units in a circle splicing tool; welding and fixing the joint parts of the spliced adjacent stator core splicing blocks to form a stator core assembly; Installing a confluence connection assembly at one end of the stator core assembly, and electrically connecting the leading-out ends of the single-tooth windings with corresponding conductive interfaces; and step six, placing the connected components in a mould, and injecting insulating pouring sealant for curing treatment to form the integrally packaged stator.
10. The method of manufacturing a high power density modular frameless motor stator of claim 9 wherein: In the second step, a special winding clamp is adopted to fix the stator core splicing blocks, and the wires are precisely arranged along the axial direction through a winding needle tube; In the fourth step, welding is carried out along the axial seam of the stator core splicing block by adopting a laser welding process; in the sixth step, a vacuum filling and sealing process is adopted, so that the insulating pouring sealant completely fills a gap between the single-tooth winding and the stator core splicing block.

Description

High-power-density block type frameless motor stator and manufacturing method thereof Technical Field The invention belongs to the technical field of motors, and particularly relates to a high-power-density block-type frameless motor stator and a manufacturing method thereof. Background The frameless motor is used as a core power unit, is widely applied to cooperative robot joints, quadruped robot dogs and humanoid robot systems by virtue of advantages of direct drive, compact structure and the like, has severe requirements on light weight and miniaturization of an actuating mechanism, and is forced to realize high power output and instant torque explosive force in a limited space, so that the improvement of the power density and the torque density of the motor becomes a key technical subject. The existing frameless motor mainly adopts an integral stator core structure, the structure is formed by integrally laminating silicon steel sheets, and winding wiring is carried out by relying on manual wire-down or a needle winding machine, the process is initially aimed at guaranteeing the integrity of a stator magnetic circuit and simplifying assembly, but is constrained by geometrical interference of the spatial closure of a notch of the integral core, so that a spatial window effect exists during winding, and the slot filling rate can only be maintained at a lower level of 45-55%. The low slot filling rate causes the increase of the equivalent resistance of the stator winding, the copper loss and the temperature rise are caused, the frameless motor lacks an effective heat dissipation means, the current density has to be limited for ensuring the operation safety, thus the performance of the robot is improved and locked, and the motion performance of the robot under the extreme working condition is severely restricted, so the technical problem to be solved is urgent by improving the slot filling rate and optimizing the electromagnetic load arrangement by innovating the stator topological structure and the winding mode. To this end, the present invention provides a high power density split type frameless motor stator and a method of manufacturing the same. Disclosure of Invention In order to overcome the deficiencies of the prior art, at least one technical problem presented in the background art is solved. The invention solves the technical problems by adopting the technical scheme that the high-power density split type frameless motor stator and the manufacturing method thereof comprise a plurality of split type stator units, wherein the split type stator units are circumferentially distributed and mutually spliced to form a circular structure; Wherein each split stator unit comprises a stator core split and a single-tooth winding wound on the stator core split; the lateral surfaces of the stator core blocks are provided with mutually matched positioning connection structures for mechanical constraint of adjacent block stator units; The leading-out ends of the single-tooth windings are electrically interconnected through a converging connection assembly. Preferably, the positioning connection structure comprises a groove formed in the longitudinal surface of one side of the stator core block and a protrusion which is arranged on the longitudinal surface of the other side of the stator core block and matched with the groove in shape, and two adjacent stator core blocks are embedded into the groove through the protrusions to realize radial and circumferential positioning. The bus connection assembly is preferably an annular circuit board, a plurality of conductive pads and logic wiring are arranged on the annular circuit board, and the leading-out ends of the single-tooth windings are correspondingly welded on the conductive pads and form a preset phase current path through the logic wiring. Preferably, the stator core segments are laminated from a high permeability material, the cross-sectional shape of the winding region of which is configured such that the slot fill rate of the single tooth winding on the stator core segments reaches a preset threshold. Preferably, the split type frameless motor stator further comprises an encapsulating layer, wherein the encapsulating layer is made of high-heat-conductivity insulating materials and is coated at a gap between the single-tooth winding and the stator core split and at a split gap between the split type stator units. The invention also provides a manufacturing method of the high-power-density block type frameless motor stator, which comprises the following steps: S1, manufacturing a plurality of independent stator core segments, and machining concave-convex positioning structures matched with each other in the lateral direction of the stator core segments; s2, performing a winding process on a single stator core splicing block by using a winding mechanism to form a single-tooth winding, so as to obtain a splicing block stator unit; s3, radially butting and circumfe