US-12627190-B2 - Stator assembly for use in motor and assembly method therefor, and motor

US12627190B2US 12627190 B2US12627190 B2US 12627190B2US-12627190-B2

Abstract

The present invention provides a stator assembly for use in a motor and an assembly method therefor. The stator assembly comprises an iron core ( 1 ), comprising a cylindrical iron core body and a plurality of iron core teeth ( 11 ), conductor slots ( 1 h ) for accommodating conductors ( 3 ) being formed between every two iron core teeth ( 11 ) adjacent in the circumferential direction, side walls of each conductor slot ( 1 h ) formed by the iron core teeth ( 11 ) each comprising a flared portion ( 111 ), and the flared portions ( 111 ) being opposite each other in the circumferential direction and gradually getting further away from each other as the two extend towards radial openings of the conductor slots ( 1 h ), and sheet-like insulators ( 2 ), accommodated in the conductor slots ( 1 h ) in a manner of attaching to the peripheral walls of the conductor slots ( 1 h ), the ends of the sheet-like insulators ( 2 ) being disposed at the flared portions ( 111 ). As such, undesired interference between the conductors and the sheet-like insulators does not occur during the insertion of the conductors into the conductor slots. The present invention also provides a motor comprising the stator assembly for use in a motor, which can produce the same beneficial effect.

Inventors

Zhihao Li
Jie Liang

Assignees

Schaeffler Technologies AG & Co. KG

Dates

Publication Date: 20260512
Application Date: 20210412

Claims (15)

1 . A stator assembly for a motor, comprising: an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots; and sheet-like insulators, wherein the sheet-like insulators are accommodated in the conductor slots in a manner of attaching to peripheral walls of the conductor slots, and ends of the sheet-like insulators are disposed at the flared portions, wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly, wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction, and wherein the sheet-like insulators curve at an interface of the flared portion and the equidistant portion of the side wall of the conductor slots.
2 . The stator assembly according to claim 1 , wherein in the cross section orthogonal to the central axis of the iron core body taken along the radial direction, an angle of an obtuse angle formed by the contour line of the flared portion and a contour line of the equidistant portion is not less than 150 degrees.
3 . The stator assembly according to claim 1 , wherein there is a non-smooth transition or a smooth transition between the flared portion and the equidistant portion.
4 . The stator assembly according to claim 1 , wherein an end of the iron core tooth at the radial opening of the conductor slot has a slot wedge portion protruding towards the inside of the conductor slot, and the slot wedge portion is adjacent to the flared portion.
5 . The stator assembly according to claim 4 , wherein the ends of the sheet-like insulators extend to a face of the slot wedge portion adjacent to the flared portion.
6 . The stator assembly according claim 1 , wherein the stator assembly includes conductors, and a plurality of conductors are respectively accommodated and installed in each conductor slot formed by the iron core.
7 . The stator assembly according to claim 6 , wherein the conductor is a wave winding.
8 . An assembly method for a stator assembly for use in a motor, the assembly method comprising the following steps: providing a stator comprising an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots, wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly, wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction; and putting a sheet-like insulator into the conductor slot, wherein the sheet-like insulator curves at an interface of the flared portion and the equidistant portion of the side wall of the conductor slot, the sheet-like insulator is attached to the peripheral wall of the conductor slot, and an end of the sheet-like insulator is disposed at the flared portion; and inserting the conductor into the conductor slot along the radial direction.
9 . A motor, comprising a stator assembly having an iron core, wherein the iron core includes a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth having flared portions, and the flared portions being opposite each other in the circumferential direction and diverging from each other as the flared portions extend towards radial openings of the conductor slots; and sheet-like insulators, wherein the sheet-like insulators are accommodated in the conductor slots in a manner of attaching to peripheral walls of the conductor slots, and ends of the sheet-like insulators are disposed at the flared portions, wherein in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly, wherein the side walls further comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction, and wherein the sheet-like insulators curve at an interface of the flared portion and the equidistant portion of the side wall of the conductor slots.
10 . The motor according to claim 9 , wherein in the cross section orthogonal to the central axis of the iron core body taken along the radial direction, an angle of an obtuse angle formed by the contour line of the flared portion and a contour line of the equidistant portion is not less than 150 degrees.
11 . The motor according to claim 9 , wherein there is a non-smooth transition or a smooth transition between the flared portion and the equidistant portion.
12 . The motor according to claim 9 , wherein an end of the iron core tooth at the radial opening of the conductor slot has a slot wedge portion protruding towards the inside of the conductor slot, and the slot wedge portion is adjacent to the flared portion.
13 . The motor according to claim 12 , wherein the ends of the sheet-like insulators extend to a face of the slot wedge portion adjacent to the flared portion.
14 . The motor according to claim 9 , wherein the stator assembly includes conductors, and a plurality of conductors are respectively accommodated and installed in each conductor slot formed by the iron core.
15 . The motor according to claim 14 , wherein the conductor is a wave winding.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is the U.S. National Phase of PCT Appln. No. PCT/CN2021/086586, filed Apr. 12, 2021, the entire disclosure of which is incorporated by reference herein. TECHNICAL FIELD The present disclosure relates to the field of motors, and in particular to a stator assembly for use in a motor and an assembly method therefor, and a motor comprising the stator assembly. BACKGROUND Motors are one of the conventional power sources and have a wide range of uses, not only for large industrial equipment, but also for vehicles, etc. In a stator assembly for use in a motor, generally, insulating paper attaching to a peripheral wall of a conductor slot is pre-disposed in the conductor slot of an iron core, and then the conductor (such as a wave winding) is inserted into the conductor slot via a radial opening of the conductor slot. The insulating paper is used to protect the conductor from being damaged during insertion of the conductor, and can also provide insulation protection between the conductor and the iron core after the conductor is inserted into the conductor slot. Referring to FIGS. 1A and 1B, in an existing stator assembly for use in a motor, the iron core 10 of the stator assembly is formed with a plurality of conductor slots 10h that open towards a radially inner side, and the insulating paper 20 is installed in each conductor slot 10h in a manner of attaching to the peripheral wall of each conductor slot 10h such that the conductor 30 is inserted into the conductor slot 10h through the radial opening of the conductor slot 10h from the radially inner side (as shown by arrows in FIGS. 1A and 1B). In the stator assembly, the conductor slot 10h is a straight slot, and it can be clearly seen from the cross section of the iron core 10 that the conductor slot 10h is presented as a rectangle. This design, brings about the following problems: the insulating paper 20 may not fit particularly well with the conductor slot 10h if the insulating paper is not bonded to the peripheral wall of the conductor slot 10h, and the conductor 30 may interfere with an end of the insulating paper 20 and cause the end of the insulating paper 20 to curl during insertion of the conductor 30 into the conductor slot 10h. As shown in FIG. 1B, when such curling is serious, the end of the insulating paper 20 may be greatly bent, so that the insulating paper 20 blocks insertion of the conductor into the conductor slot 10h, thereby exerting adverse effects on the assembly process and on insulation performance between the iron core 10 and the conductor 30 after assembly. SUMMARY The present disclosure has been made in order to overcome deficiencies of the prior art as described above. An object of the present disclosure is to provide a novel stator assembly for use in a motor and an assembly method therefor, which can avoid the problem of mutual interference between insulating paper and the conductor in the process of inserting the conductor into the conductor slot to a greater extent than the stator assembly for use in a motor described in the background art above, thereby eliminating adverse effects on assembly and insulation performance of the stator assembly caused by interference. Another object of the present disclosure is to provide a motor comprising the above stator assembly for use in a motor. To achieve the above objects, the following technical solutions are adopted. The present disclosure provides a stator assembly for a motor, comprising an iron core, wherein the iron core comprises a cylindrical iron core body and a plurality of iron core teeth, the plurality of iron core teeth protruding from the iron core body along a radial direction of the iron core body and being arranged along a circumferential direction of the iron core body, conductor slots for accommodating conductors being formed between every two iron core teeth adjacent in the circumferential direction, side walls of the conductor slots formed by the iron core teeth comprising flared portions, and the flared portions being opposite each other in the circumferential direction and gradually getting further away from each other as the two extend towards radial openings of the conductor slots; and sheet-like insulators, wherein the sheet-like insulators are accommodated in the conductor slots in a manner of attaching to peripheral walls of the conductor slots, and ends of the sheet-like insulators are disposed at the flared portions. Preferably, in a cross section orthogonal to a central axis of the iron core body taken along the radial direction, a contour line of the flared portion extends linearly or curvilinearly. More preferably, the side walls also comprise equidistant portions adjacent to the flared portions, the equidistant portions being opposite to each other in the circumferential direction, and a spacing in the circumferential direction between the equidistant portions being always equal in the radial direction