Patent Application
20240195236
The present disclosure relates to a motor stator, more particularly, a motor stator that can increase power by maximizing the coil fill-in ratio with a small size.
Due to the rapid development of motor technology in these years, the development of the motor tends to be a compact and high-power design. Therefore, it is necessary to redesign the stator structure in order to meet the trend. Generally speaking, the larger the coil fill-in ratio on the stator, the stronger the magnetic field generated, and the higher the power output.
In view of the technological development at present, the winding density of the coil is low, in order to increase the coil winding on the stator structure, the corresponding slot has to be enlarged, which also leads to the overall size and weight of the motor increase. Therefore, how to maintain the motor in a smaller size and output with higher power at the same time is an issue that needs to be improved in the current technology.
Based on the above-mentioned shortcomings, the purpose of the present disclosure is to provide a motor stator, particularly a motor stator with a small size and a maximum coil fill-in ratio that can increase power.
A motor stator is provided according to the purpose of the present disclosure, comprising an annular stator core, a plurality of tooth portions spaced on the inner surface of the annular stator core and protruded toward the center of the annular stator core, each of the tooth portions having a slot formed on each of the two sides of the tooth portions and each of the tooth portions having a coil winding and a portion of the coil being located in the two slots of each of the tooth portions. Wherein, a bobbin is provided between each of the coils and each of the tooth portions, and each of the coils is formed by winding a metal wire around the bobbin several times, the thickness of the metal wire is decreased gradually from one end to the other end.
Wherein, the bobbin has an inner guide frame and an outer guide frame and both have a bottom plate and a side plate set on the bottom plate protruded from the bottom plate toward one side, and the side plate is set vertically with the bottom plate.
Preferably, both the inner and outer guide frames have a T-shaped cross-sectional profile.
Preferably, the coil is attached to the bobbin.
Preferably, each of the adjacent turns in each of the coils is attached to each other and the cross-sectional area of each turn in each of the coils is the same.
Preferably, there is also a three-phase bus-bar provided in the annular stator core having three conducting elements and a neutral element, each conducting element has a plate, a connection end, and four welding ends where the welding end is connected to one of the ends of the metal wire of one of the coils respectively.
Preferably, the cross-sectional profile of each coil is trapezoidal.
Preferably, the width of each metal wire is increased gradually from one end to the other end, so that the cross-sectional profile of each coil is in the shape of a trapezoid.
Preferably, each of the coils occupies 80% of the capacity of two slots of each of the tooth portions.
Preferably, each of the tooth portions is secured to the annular stator core by a wedge buckle structure.
In order to clearly illustrate the specific manner of implementation, the structure, and the effect achieved by the present disclosure, the following embodiments are provided and illustrated with drawings.
The following description is based on the surface of the annular stator core 10 near the center of the circle of the motor stator 100 as the inner side. The descriptions of the orientation, such as up and down, left and right, are used only to indicate the relative relationship of the components in order to conform to the common understanding of those skilled in the art. Referring to
Wherein, a bobbin 40 is provided between each of the coils 30 and each of the tooth portions 20, and each of the coils 30 is formed by winding a metal wire 31 around the bobbin 40 several times from the inner side to the outer side, with the ends of the metal wire 31 extending upward after the coil 30 is formed. In this embodiment, the metal wire 31 is a flat copper wire. In another embodiment, the metal wire 31 may be formed into the coil 30 first and then installed on the bobbin 40.
Referring to
Furthermore, the bobbin 40 includes an inner guide frame 41 and an outer guide frame 42, both of them have a bottom plate 41a,42a and a side plate 41b,42b provided on the bottom plate 41a,42a, and the side plate 41b,42b is protruded towards one side so that the bottom plate 41a,42a and the side plate 41b,42b are set vertically, so that the cross-sectional profiles of the inner guide frame 41 and the outer guide frame 42 are all in a T shape (see
On the other hand, when calculating the power density per unit volume of the motor, the size of the entire motor stator 100 (including the size of the annular stator core 10 and the coil 30) should be taken into account, so when the coil 30 is attached to the bobbin 40, the winding density of the coil 30 of the present disclosure will be higher and the size of the coil 30 will be reduced compared to the prior art, thereby the overall size of the motor stator 100 can be reduced but the power density per unit volume will be increased. In addition, when the size of the coil 30 is reduced, the amount of copper used in the metal wire 31 can be reduced as well which can reduce the production costs.
Further, the motor stator 100 also has a three-phase bus-bar 50 provided on one side of the annular stator core 10, the three-phase bus-bar 50 has three conducting elements 50a and a neutral element 54, and each of the conducting element 50a has a plate 52, a connection end 51, and four welding ends 53. The connection end 51 extends from the plate 52 toward the upper side, the four welding ends 53 being connected to one of the metal wires 31 of the coils 30 at one end, and the other end of the metal wire 31 which is not connected to the welding end 53 being connected to the neutral element 54. The arrangement of the plate 52, the connection end 51, and the welding end 53 of the three-phase bus-bar 50 and the configuration of the connection between the three-phase bus-bar 50 and the coils 30 are well established in the art and need not be elaborated.
The present disclosure is mainly to have the coils 30 attached to the bobbin 40, and to have each turn (T1,T2,T3 . . . Tn) of the coils 30 adjacent to attach each other, so as to increase the occupancy rate of the coil 30 in the slot 15, in order to achieve the effect of minimizing of the volume.
