阅读说明：本技术 用于定子铁芯的绕线装置以及定子制造方法 (Winding device for stator core and stator manufacturing method ) 是由 王奇 孙涛 于 2019-10-28 设计创作，主要内容包括：本发明涉及用于定子铁芯的绕线装置,包括：多个载具；具有圆形中心孔的固定盘,其一侧包括沿中心孔的周向均匀设置的多个凹槽,并且每个凹槽中设有一个滑动孔；能相对固定盘转动的驱动盘,其位于固定盘的另一侧并具有能与多个滑动孔对准的多个驱动孔；和绕线针；其中,滑动孔和驱动孔配置成能接纳载具使得其能够通过转动该驱动盘而在第一径向位置和第二径向位置之间移动,其中第二径向位置比第一径向位置远离圆形中心孔的圆心,在第二径向位置,绕线针适合进入相邻的定子铁芯单体之间对定子铁芯单体进行绕线,在第一径向位置,相邻的定子铁芯单体的轭部彼此抵接并能被不可拆地固定连接在一起。本发明还涉及利用上述绕线装置制造定子的方法。(The invention relates to a winding device for a stator core, comprising: a plurality of carriers; a fixed disk having a circular central hole, one side of which includes a plurality of grooves uniformly arranged along the circumferential direction of the central hole, and each of the grooves is provided with a sliding hole; the driving disk can rotate relative to the fixed disk, is positioned at the other side of the fixed disk and is provided with a plurality of driving holes which can be aligned with the plurality of sliding holes; and a winding needle; wherein the slide hole and the drive hole are configured to receive the carrier such that it can be moved by rotating the drive disc between a first radial position and a second radial position, wherein the second radial position is further away from the center of the circular central hole than the first radial position, and in the second radial position, the winding needle is adapted to enter between adjacent stator core units to wind the stator core units, and in the first radial position, the yoke portions of the adjacent stator core units abut against each other and can be fixedly connected together without being detachable. The invention also relates to a method for manufacturing a stator by using the winding device.)

1. A winding device (1) for a stator core comprising a plurality of stator core cells (100), each having a tooth portion (101) and a yoke portion (102), wherein the winding device comprises:

a plurality of carriers (11), each carrier is used for fixedly holding one stator core single body (100);

a fixed disk (12) having a circular center hole (121), one side of which includes a plurality of grooves (122) uniformly arranged in a circumferential direction of the circular center hole, and each of which is provided with a sliding hole (123);

a drive plate (13) rotatable relative to the fixed plate (12), the drive plate being located on the other side of the fixed plate and having a plurality of drive apertures (133) alignable with the plurality of slide apertures (123); and

a winding needle (14) for winding the stator core single body (100);

wherein the sliding holes (123) and the driving holes (133) are configured to receive the carriers and enable the carriers to move between a first radial position and a second radial position by rotating the driving disc (13), wherein the second radial position is farther from the center of the circular central hole (121) than the first radial position, and in the second radial position, the winding needle (14) is suitable for entering between adjacent stator core single bodies to wind the stator core single bodies, and in the first radial position, the yoke parts of the adjacent stator core single bodies are abutted against each other and can be fixedly connected together in a non-detachable mode.

2. A winding device (1) according to claim 1, wherein the carrier (11) has a sliding shaft (111) adapted to be inserted into the aligned sliding hole (123) and the driving hole (133) and a carrier seat (112) for receiving the stator core unit.

3. A winding device (1) according to claim 2, wherein the carrier part (112) is provided with a first positioning mechanism which is form-fit with a second positioning mechanism provided on the yoke part (102) for positioning the stator core units when winding.

4. A winding device (1) according to claim 3, wherein the first positioning means comprises a positioning protrusion (113) extending in the axial direction of the sliding shaft on the carrier part (112), the first positioning means being a positioning slot (103) located at a side of the yoke part (102) facing away from the tooth part.

5. A winding device (1) according to claim 4, wherein the positioning slot (103) is configured as a dovetail groove and the positioning protrusion (113) is configured as a dovetail protrusion, the second positioning mechanism further comprising a support table (114) at an end of the carriage section near the sliding shaft and perpendicular to the extension direction of the positioning protrusion (113).

6. A winding device (1) according to claim 2 or 3, wherein the carrier part (111) comprises a magnet or is made of a magnetic material for exerting a magnetic attraction force on the stator core unit.

7. A winding device (1) according to any of claims 1-5, wherein the fixed disc is configured as an annular disc, each sliding hole being a racetrack shaped hole with its length extending in radial direction of the annular disc, wherein the driving disc (13) is configured as an annular disc with a driving shank (131), each driving hole being a racetrack shaped hole with its length direction at an angle to the radial direction of the annular disc.

8. A winding device (1) according to any of claims 1 to 5, wherein both sides of the yoke part of the stator core single body are respectively provided with a reserved welding area (104), and in the reserved welding areas, the yoke parts of the adjacent stator core single bodies are respectively fixedly connected together through welding.

9. A method of manufacturing a stator using the winding device according to claim 1, the method comprising the steps of:

s1: providing a plurality of stator core monomers (100);

s2: rotating the drive plate (13) in a first direction such that the plurality of carriers (11) move from a first radial position to a second radial position;

s3: placing the plurality of stator core monomers (100) on each carrier (11) respectively;

s4: enabling a winding needle (14) to enter between adjacent stator core single bodies to wind the stator core single bodies so as to form a winding;

s5: after winding, rotating the drive disc in a second direction opposite to the first direction, so that the plurality of carriers (11) move from the second radial position back to the first radial position;

s6: and fixedly connecting the yoke parts of the adjacent stator core single bodies together in a non-detachable manner.

10. The method of claim 9, wherein in the S6 step, yoke portions of adjacent stator core elements are fixedly connected together by welding.

Technical Field

The invention belongs to the field of motors, and particularly relates to a winding device for a stator core and a stator manufacturing method.

Background

The DC brushless motor has the advantages of small volume, good middle and low speed torque performance, wide speed regulation range, high overload capacity and the like, and is widely applied to the fields of computer peripheral equipment, industrial control, medical equipment, automobiles and household appliances.

The stator core is an important component of the dc brushless motor, and the performance and cost thereof directly affect the overall performance and cost of the dc brushless motor. At first, the stator core of the dc brushless motor is an integral structure, and is plastic-encapsulated after being wound with a coil. However, the winding movement locus of the stator core is a quadrilateral inner loop, and the winding needle needs to pass through the notch (the gap between two teeth) in the winding process, so that the stator core is only suitable for the integral core with a large notch, and has limitations.

Still adopt sharp wire winding among the prior art, stator core includes a plurality of stator core monomers, and these stator core arrange into the straight line fixedly, then wire winding, edge rolling, then the welding makes the stator. The winding process is complex, the production links are multiple, the production time is long, and the product quality is unstable due to multiple clamping and multiple operation, and the production line investment is large.

For this reason, there is currently a need for an apparatus and method for manufacturing a stator core, which can be adapted to a small-slot stator and can overcome the problems of complicated production process of linear winding, difficulty in quality control, and high manufacturing cost.

Disclosure of Invention

The invention aims to provide a winding device for a stator core, which can realize needle winding of a segmented stator core to replace linear winding and has the advantages of simple process and high efficiency.

To this end, the present invention provides a winding apparatus for a stator core including a plurality of stator core units each having a tooth portion and a yoke portion, wherein the winding apparatus includes:

a plurality of carriers, each carrier for fixedly holding a stator core monomer;

the fixing disc is provided with a circular central hole, one side of the fixing disc comprises a plurality of grooves uniformly arranged along the circumferential direction of the circular central hole, and each groove is provided with a sliding hole;

the driving disk can rotate relative to the fixed disk, is positioned at the other side of the fixed disk and is provided with a plurality of driving holes aligned with the plurality of sliding holes;

the winding needle is used for winding the stator core monomer;

wherein the slide holes and the drive holes are configured to receive the carriers and to enable the plurality of carriers to move between a first radial position and a second radial position by rotating the drive disc, wherein the second radial position is farther from the center of the circular central hole than the first radial position, wherein in the second radial position, the winding needle is suitable for entering between adjacent stator core single bodies to wind the stator core single bodies, and in the first radial position, the yoke parts of the adjacent stator core single bodies abut against each other and can be fixedly connected together in an undetachable manner.

According to an aspect of the present invention, the carrier is configured to have a slide shaft adapted to be inserted into the aligned slide hole and the drive hole, and a carrier seat portion for receiving the stator core unit.

In one aspect of the present invention, the carrier seat portion is provided with a first positioning mechanism that is shape-fitted with a second positioning mechanism provided on the yoke portion for positioning the stator core unit at the time of winding.

In one aspect of the present invention, the first positioning mechanism includes a positioning projection extending in an axial direction of the slide shaft on the mount section, and the second positioning mechanism is a positioning groove located on a side of the yoke section facing away from the tooth section.

In a particular embodiment of the invention, the detent groove is configured, for example, as a dovetail groove, and the corresponding detent projection is, for example, a dovetail projection. The dovetail slots and dovetail projections are exemplary herein, and it should be understood that any positioning structure that can securely retain the stator core segments to the carrier is within the scope of the present application. In addition, the first positioning mechanism further comprises a supporting table which is arranged at one end of the carrying seat part close to the sliding shaft and is vertical to the extending direction of the positioning bulge. The bearing table can be made integrally with the carrier seat portion, for example, and when the stator core single body is placed on the carrier, the lower end of the yoke portion abuts against the bearing table so as to better fixedly hold the stator core single body.

Advantageously, the carrier seat portion includes a magnet or is made of a magnetic material for applying a magnetic attraction force to the stator core unit to better fixedly hold the stator core unit to facilitate a winding operation.

In a preferred aspect, the fixed disk is configured as an annular disk, and each of the sliding holes is a track-shaped hole whose length extends in a radial direction of the annular disk, wherein the driving disk is configured as an annular disk having a driving shank, and each of the driving holes is a track-shaped hole whose length direction makes an angle with the radial direction of the annular disk. Here, the "racetrack shape" has two straight sides in the length direction and two curved sides, for example, semicircular sides, in the width direction. It should be understood that the slide hole and the driving hole may be configured in other suitable shapes in the present invention, which is also covered by the scope of the present application.

In a preferred scheme, two sides of the yoke part of each stator core monomer are respectively provided with a reserved welding area, and the yoke parts of the adjacent stator core monomers can be fixedly connected together through welding respectively in the reserved welding areas.

In addition, the invention also provides a method for manufacturing a stator by using the winding device, which is characterized by comprising the following steps:

s1: providing a plurality of stator core monomers;

s2: rotating the drive plate in a first direction such that the plurality of carriers move from a first radial position to a second radial position;

s3: respectively placing the stator core monomers on each carrier;

s4: enabling a winding needle to enter between adjacent stator core single bodies to wind the stator core single bodies so as to form a winding;

s5: after the winding is finished, rotating the driving disc in a second direction opposite to the first direction, so that the plurality of carriers move from the second radial position to the first radial position;

s6: and fixedly connecting the yoke parts of the adjacent stator core single bodies together in a non-detachable manner.

Further, in step S6, the yoke portions of the adjacent stator core elements are fixedly and non-detachably joined together by welding.

In addition, in the present invention, the above steps S2 and S3 may be interchanged, which is also covered by the scope of the present application.

By using the winding device and the stator manufacturing method, stator products with better stability can be provided, and the manufacturing cost is lower, the process is simple, and the production efficiency is high.

Drawings

Exemplary embodiments of the invention are described with reference to the accompanying drawings, in which:

fig. 1 is a schematic configuration diagram showing the main components of one embodiment of a winding device according to the present invention;

fig. 2 shows a schematic structural view of a stator core element according to the present invention;

FIG. 3 is a schematic view of the structure of one embodiment of a fixing plate of the winding device;

FIG. 4 is a schematic structural view of one embodiment of a drive disk of the winding device;

FIG. 5 is a schematic diagram of a carrier of the winding device according to an embodiment;

fig. 6 is a schematic view of a stator core unit mounted on a carrier;

FIG. 7 is a schematic view of the positioning mechanism on the stator core unit cooperating with the positioning mechanism on the carrier;

figure 8 is a schematic view from above showing the carrier in a first radial position;

figure 9 is a schematic view from above showing the carrier in a second radial position;

and

fig. 10 is a schematic view of the process steps for manufacturing a stator using the winding apparatus according to the present invention.

The figures are purely diagrammatic and not drawn to scale, and moreover they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely mentioned. That is, the present invention may include other components in addition to those shown in the drawings.

Detailed Description

A winding device and a method of manufacturing a stator core using the same according to the present invention will be described below by way of example with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention to those skilled in the art. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. Furthermore, it should be understood that the invention is not limited to the specific embodiments described. Rather, it is contemplated that the invention may be practiced with any combination of the following features and elements, whether or not they relate to different embodiments.

Fig. 1 shows a schematic configuration of main components of one embodiment of a winding device 1 for a stator core including a plurality of individual stator core single bodies 100 according to the present invention. As can be seen from fig. 1, the winding device 1 comprises a plurality of carriers 11, a stationary disc 12 and a driving disc 13 which is rotatable relative to the stationary disc 12. The winding device 1 further includes a winding pin 14 (see fig. 8 and 9), which is not shown in fig. 1, for winding the stator core unit 100.

Fig. 2 is a schematic structural view showing one embodiment of the stator core monomers 100, each stator core monomer 100 having teeth 101 for disposing coils thereon; the yoke parts 102 are connected among the stator core single bodies through the yoke parts 102; and a positioning groove 103 provided on a side of the yoke 102 facing away from the tooth 101, for positioning the stator core during winding. Here, it is contemplated that the positioning slot 103 may be replaced with other suitable positioning structures. In this embodiment, the positioning groove 103 is configured as a dovetail groove (see fig. 7 in particular). Preferably, the two sides of the yoke portion of the stator core single body 100 may be respectively provided with a reserved welding area 104, and in the reserved welding area 104, the yoke portions of the adjacent stator core single bodies may be respectively fixedly connected together by, for example, welding.

Referring to fig. 3, in this embodiment, the fixed disk 12 is an annular disk having a circular central hole, one side of which has a plurality of grooves 122 uniformly arranged along the circumference of the circular central hole, and each of which has a sliding hole 123 provided therein. In this example, the number of the grooves 122 is 12, and accordingly, the number of the slide holes is also 12. It should be understood that the number of slots is exemplary here and that other suitable numbers are possible, such as 9, 15 and 18, and those skilled in the art will appreciate that the number of slots generally depends on the number of stator core elements 100, which is generally an integer multiple of 3. Generally, the number of carriers 11 and the number of grooves 122 are the same as the number of stator core units 100 of the stator core to be manufactured. Further, each slide hole is, for example, a race-track-shaped hole having a length extending substantially in the radial direction of the annular disk 12, and has a first end a near the circular center hole and a second end b opposite to the first end.

Referring to fig. 4, in this embodiment, the driving disk 13 is configured as an annular disk having a driving shank 131 including a plurality of driving holes 133 uniformly arranged in the axial direction of a central circular hole thereof, the number of driving holes being generally equal to the number of sliding holes of the fixed disk, the number of driving holes 133 being 12 here. Also, the driving hole 133 may be configured as a race track hole having a length direction thereof at a certain angle to a radial direction of the ring-shaped disc. As can be seen in fig. 1, the drive disks are located on the other side of the fixed disk and are configured such that each drive hole is aligned with a corresponding slide hole to receive a carrier 11. In this embodiment, the drive shaft 131 may be coupled to a drive device (not shown), for example, a servo device.

Fig. 5 shows a schematic structural diagram of a carrier 11 according to an embodiment of the present invention. As shown, the carrier 11 has a slide shaft 111 adapted to be inserted into the aligned slide hole 123 and the driving hole 133 and a carrier seat 112 adapted to receive the stator core unit 100. In order to receive and hold the stator core unit 100, the carrier part 112 is provided with a positioning lug 113 which is form-fit with the positioning slot 103 on the stator core unit 100, in this example, the positioning lug 113 is configured as a dovetail lug which extends in the axial direction of the slide shaft 111 and does not extend along the entire carrier part 112. As can be seen from fig. 5, a support table 114 perpendicular to the extending direction of the positioning boss 113 is formed at one end of the carriage part 112 close to the slide shaft 111. When the stator core unit 100 is placed on the carrier 11, the support stand 114 abuts against the lower end of the carrier seat portion 112, while the stator core unit 100 is fixedly held on the carrier by the mating of the dovetail projection and the dovetail groove (see fig. 6). Advantageously, in order to better fixedly hold the stator core unit, the carrier seat portion 112 may be made of a magnetic material, or a magnet may be provided on a side of the carrier seat portion facing the stator core unit, for applying a magnetic attraction force to the stator core unit. Alternatively, the carriage part may be provided with an electromagnet.

In the winding device 1 according to the present invention, the sliding hole 123 and the driving hole 133 are configured to receive the sliding shaft 111 of the carrier 11, and by rotating the driving disc 13, the sliding shaft 111 can slide in the sliding hole 123, so as to drive the carrier 11 to slide between a first radial position and a second radial position, wherein the second radial position is farther from the center of the circular center hole 121 than the first radial position.

Referring to fig. 8, each carrier 11 is located at a first radial position where the yoke portions of the adjacent stator core units abut against each other, and the gap width between the teeth 101 of the adjacent stator core units 100 is smaller than the width (e.g., diameter) of the winding needle 14, where the winding needle 14 interferes with the teeth of the stator core units, so that the stator core cannot be wound. And, at the first radial position, the slide shaft 111 of the carrier 11 abuts against the first end a of the slide hole 123 of the fixed disk 12.

In this embodiment, the driving disc 13 is rotated clockwise, for example, to apply radial separation to the sliding shaft 111 of the carrier 11, so that the carrier drives the stator core single bodies 100 to slide radially outward in the sliding holes 123 to a second radial position (see fig. 9), in which the gap width between the teeth 101 of the adjacent stator core single bodies 100 is larger than the width (e.g., diameter) of the winding needle 14, so that the winding needle 14 fits into between the adjacent stator core single bodies to wind the stator core single bodies. And, in the second radial position, the slide shaft 111 of the carrier 11 abuts against the second end b of the slide hole 123 of the fixed disk 12.

A method of manufacturing a stator core using the winding apparatus 1 according to the present invention will be described below in a general order of process steps with reference to fig. 10.

S1: providing a plurality of stator core monomers 100; in this step, specifically, the steel plates are punched, laminated and riveted, and then plastic-coated, so as to obtain the single stator core unit 100 shown in fig. 2. In this step, for example, 12 stator core monomers may be provided. Of course, other numbers of individual stator cores may be selected, such as 9, 18, or other integer multiples of 3, depending on the requirements of the stator core to be manufactured.

S2: rotating the drive disc 13 in a first direction (e.g., clockwise) such that the plurality of carriers 11 move from a first radial position to a second radial position;

s3: placing a plurality of stator core units 100 on each carrier 11;

s4: the winding needle 14 enters between the adjacent stator core single bodies 100 to wind the stator core single bodies so as to form a winding;

s5: after winding, rotating the driving disc in a second direction (e.g. counterclockwise) opposite to the first direction, so that the plurality of carriers 11 move from the second radial position to the first radial position;

s6: and fixedly connecting the yoke parts of the adjacent stator core single bodies together in a non-detachable manner. In this step, the yoke portions of the adjacent stator core elements are preferably fixedly joined together by welding.

Also, in the above method, the step of S2 and the step of S3 may be interchanged.

It will be appreciated by those skilled in the art that changes may be made in the described examples without departing from the principles and spirit thereof, and that such changes are contemplated by the inventors and are within the scope of the invention as defined in the appended claims.