WO2016015572A1 - 一种永磁同步电机及其制备方法 - Google Patents

一种永磁同步电机及其制备方法 Download PDF

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Publication number
WO2016015572A1
WO2016015572A1 PCT/CN2015/084467 CN2015084467W WO2016015572A1 WO 2016015572 A1 WO2016015572 A1 WO 2016015572A1 CN 2015084467 W CN2015084467 W CN 2015084467W WO 2016015572 A1 WO2016015572 A1 WO 2016015572A1
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WO
WIPO (PCT)
Prior art keywords
coil
iron core
injection molding
rotor
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2015/084467
Other languages
English (en)
French (fr)
Inventor
石华山
郑立楷
王红标
董士刚
李昌建
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JANGMEN IDEAR HANYU ELECTRICAL JOINT-STOCK Co Ltd
Original Assignee
JANGMEN IDEAR HANYU ELECTRICAL JOINT-STOCK Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by JANGMEN IDEAR HANYU ELECTRICAL JOINT-STOCK Co Ltd filed Critical JANGMEN IDEAR HANYU ELECTRICAL JOINT-STOCK Co Ltd
Priority to EP15827338.3A priority Critical patent/EP3176926B1/en
Priority to JP2017503618A priority patent/JP6492299B2/ja
Priority to KR1020177005618A priority patent/KR101979933B1/ko
Priority to RU2017106047A priority patent/RU2643799C1/ru
Priority to BR112017001590A priority patent/BR112017001590B8/pt
Priority to US15/329,068 priority patent/US10601279B2/en
Publication of WO2016015572A1 publication Critical patent/WO2016015572A1/zh
Priority to ZA2017/00703A priority patent/ZA201700703B/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/12—Casings or enclosures characterised by the shape, form or construction thereof specially adapted for operating in liquid or gas
    • H02K5/128—Casings or enclosures characterised by the shape, form or construction thereof specially adapted for operating in liquid or gas using air-gap sleeves or air-gap discs
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/10—Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/02—Units comprising pumps and their driving means
    • F04D13/021—Units comprising pumps and their driving means containing a coupling
    • F04D13/024—Units comprising pumps and their driving means containing a coupling a magnetic coupling
    • F04D13/027—Details of the magnetic circuit
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/02—Units comprising pumps and their driving means
    • F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/02—Units comprising pumps and their driving means
    • F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
    • F04D13/0606—Canned motor pumps
    • F04D13/064—Details of the magnetic circuit
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in the machines
    • H02K15/062—Windings in slots; Salient pole windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/02—Details
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
    • H02K21/18—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures having horse-shoe armature cores
    • H02K21/185—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures having horse-shoe armature cores with the axis of the rotor perpendicular to the plane of the armature
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/30—Windings characterised by the insulating material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/44—Protection against moisture or chemical attack; Windings specially adapted for operation in liquid or gas
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/524—Fastening salient pole windings or connections thereto applicable to stators only for U-shaped, E-shaped or similarly shaped cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/02—Casings or enclosures characterised by the material thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/08—Insulating casings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors

Definitions

  • the invention relates to the field of drainage pumps, in particular to a pump body integrated permanent magnet synchronous motor applied to a washing machine and a dishwasher drainage pump and a preparation method thereof.
  • China utility model patent 201320745113.5 discloses a U-shaped core AC permanent magnet synchronous motor drainage pump.
  • the drain pump is isolated from the iron core and the rotor, so that the water entering the rotor cavity penetrates into the iron core to rust the iron core, or the water penetrates the coil through the iron core to make the coil Burnt out due to a short circuit; and water entering the rotor cavity can also leak outside the drain pump.
  • Such water leakage problems have been plaguing manufacturers.
  • the AC permanent magnet drainage pump in the prior art has the structure that the wound coil and the iron core are integrally formed by injection molding and the pump body, and the integrated pump body structure well solves the working process of the drainage pump.
  • the technical problem of vibration noise, but the problem of water leakage of the drainage pump is not very good.
  • a structure of an AC permanent magnet drain pump in the prior art has an assembled coil and an iron core, and a pump body integrally formed around the contour of the assembled coil and the iron core, and a pump formed by injection molding.
  • the body has a rotor cavity for accommodating the rotor assembly, and the pole arc portion of the iron core and the rotor cylinder form a rotor cavity.
  • the injection of the pump body avoids the relative sway of the iron core and the coil
  • the concave curved surface of the iron core and the rotor cylinder form the inner surface of the rotor cavity, the magnetic gap between the permanent magnet rotor and the iron core is small, and the electromagnetic efficiency of the product is improved.
  • the water entering the rotor cavity may leak through the gap between the laminations of the iron core, or may leak through the gap between the iron core and the plastic, and further Infiltration into the coil causes the coil to burn out.
  • a stainless steel cylinder is disposed in the rotor cylinder to isolate the concave curved surface of the iron core and the permanent magnet rotor.
  • the stainless steel cylinder can prevent the water entering the rotor cavity from coming into contact with the iron core, the manufacturing process is complicated, the cost is high, and the electromagnetic efficiency is greatly reduced.
  • the object of the present invention is to overcome the problems of the prior art mentioned above and to provide a method for preparing a pump body integrated permanent magnet synchronous motor.
  • Another object of the present invention is to provide a pump body integrated permanent magnet synchronous motor.
  • the present invention provides a method for preparing a pump body integrated permanent magnet synchronous motor, comprising the following steps:
  • the rotor cylinder is injection-molded with a core as a skeleton, and forms a separate thin layer at the pole arc portion of the iron core during the second injection molding, and isolates the iron core from the rotor cavity inside the rotor cylinder by isolating the thin layer.
  • the present invention provides a method for preparing a pump body integrated permanent magnet synchronous motor, comprising the following steps:
  • the rotor cylinder is injection-molded with a core as a skeleton, and forms an insulating thin layer at the pole arc portion of the iron core during injection molding, and isolates the iron core from the rotor cavity inside the rotor cylinder by isolating the thin layer.
  • the iron core is positioned by the mold positioning member to align the iron core with the wound coil.
  • the core is U-shaped and includes two parallel longitudinal segments and a transverse segment connecting one ends of the longitudinal segments, the mold positioning member comprising a first positioning member and a second positioning member, the pole arc portion being located at the other end of the longitudinal segment, and A first positioning groove for arranging the first positioning member is disposed, and a corner portion of one end of the longitudinal portion is provided with a second positioning groove for arranging the second positioning member.
  • a groove is formed along the concave curved surface of the pole arc portion of the iron core, and when the injection molding is performed to form the isolation thin layer, the root portion of the insulating layer is formed by inserting the injection molding material into the groove. The root secures the insulating layer to the concave curved surface.
  • the present invention provides a pump body integrated permanent magnet synchronous motor prepared by the above preparation method, comprising: a rotor assembly; a stator assembly having a coil wound on a bobbin and an assembly line a core on the ring, wherein the coil is sealed by the coil sealing portion; and a pump body portion formed by injection molding on the basis of the stator assembly, wherein the pump body portion includes: a rotor cylinder formed by injection molding the iron core as a skeleton, and the inside is disposed The rotor cavity of the rotor assembly; and an isolating thin layer formed by injection molding in the pole arc portion of the core to isolate the core from the rotor cavity.
  • the present invention also provides a pump-integrated permanent magnet synchronous motor prepared by the above preparation method, comprising: a rotor assembly; a stator assembly having a coil wound on a bobbin and an iron core assembled on the coil; a coil sealing portion and a pump body portion formed by injection molding based on a stator assembly, wherein the coil sealing portion seals a coil wound on the bobbin, wherein the pump body portion includes: a rotor cylinder formed by injection molding the iron core as a skeleton, and the inside A rotor cavity having a rotor assembly disposed thereon; and an insulating thin layer formed by injection molding in a pole arc portion of the iron core to isolate the iron core from the rotor cavity.
  • the iron core is U-shaped, comprising two parallel longitudinal segments and a transverse segment connecting one end of the longitudinal segment, the pole arc portion is located at the other end of the longitudinal segment, and is provided with a first positioning groove for arranging the first positioning member, A corner of one end of the longitudinal section is provided with a second positioning groove for positioning the second positioning member to center the core with the coil on the wound bobbin.
  • a recess is formed along the concave curved surface of the pole arc portion of the core, the insulating layer having a root embedded in the recess, and the insulating thin layer is fastened to the concave curved surface by the root.
  • the isolating thin layer is integrated with the rotor cylinder, and a continuous rotor cavity is formed by the isolating thin layer and the inner surface of the rotor cylinder.
  • the isolating thin layer maximizes the concave arcuate surface of the pole arc portion to the rotor cavity such that the thickness of the thinnest portion of the insulating thin layer is 0.2-0.75 mm.
  • the iron core and the coil of the present invention are integrally formed by injection molding, thereby improving space utilization efficiency and production The heat dissipation of the product and the reduction of vibration noise.
  • the invention separates the pole arc portion of the iron core from the rotor cavity by using the plastic arc surface isolation layer as the isolation thin layer, and the thickness of the thinnest portion of the isolation thin layer can be as thin as 0.2 mm, thereby preventing water infiltration into the rotor cavity.
  • the iron core prevents the water core from leaking to the coil, avoiding rusting of the core and burning of the coil, and achieving a small air gap between the iron core and the rotor, thereby greatly improving the performance of the motor.
  • FIG. 1 is a schematic structural view of a permanent magnet synchronous motor of the present invention
  • Figure 2 is a front elevational view of the permanent magnet synchronous motor of the present invention
  • Figure 3 is a right side view of Figure 2 (without rotor assembly and sealing cap);
  • Figure 4 is a left side view (the rotorless assembly and the sealing cap) shown in Figure 2;
  • Figure 5a is a schematic view of the coil wound on the bobbin of the embodiment 1 of the present invention after injection molding and sealing;
  • Figure 5b is a schematic view of the iron core of the coil of the embodiment 1 after being injection molded by injection molding;
  • Figure 6 is a cross-sectional view taken along line A-A of Figure 2 of Embodiment 1;
  • Figure 7 is an enlarged view of a portion I in Figure 6;
  • Figure 8 is a cross-sectional view (without a rotor assembly) taken along line B-B of Figure 1 of Embodiment 1 of the present invention
  • Figure 9 is a cross-sectional view taken along line A-A of Figure 2 of Embodiment 2 of the present invention.
  • Figure 10 is a cross-sectional view taken along line B-B of Figure 1 of the second embodiment of the present invention (without a rotor assembly);
  • Figure 11 is a schematic view showing the structure of the iron core of the present invention having a groove
  • FIG 12 and 13 are schematic views showing the assembly of the positioning hole and the sealing cap of the present invention.
  • the permanent magnet synchronous motor of the present invention comprises: a rotor assembly 5 having a permanent magnet rotor for driving rotation of the impeller; and a stator assembly having a coil wound on the bobbin 4 3 and an iron core 2 assembled on the coil 3; formed by injection molding of the contour of the core 2 and the winding coil 3 One-piece pump body.
  • the integrated pump body of the present invention is formed by injection molding using a coil and an iron core mounted on the coil as a skeleton or a foundation.
  • the injection molding material seals the coil 3 wound around the bobbin 4 together with the iron core 2 assembled in the coil, and only the connector end to which the coil is connected to the external circuit is exposed, so that the core 2 and the coil 3 are injection molded.
  • the isolating sheet isolates the core from the rotor cavity inside the rotor barrel.
  • the present invention forms a rotor cavity 50 for positioning the rotor assembly 5 on the inner side of the double-armed arc portion of the core 2, and the inner concave curved surface 231 of the pole portion is separated from the rotor cavity 50.
  • a thin layer of isolation thin layer that is, the arc surface isolation layer 121, in order to achieve a smaller air gap, the thickness of the thinnest portion of the arc spacer layer of the present invention may be selected between 0.2 and 0.75 mm, as shown in FIG.
  • the thinnest portion of the arc spacer layer 121 has a thickness of only 0.5 mm, and the iron core 2 is isolated from the rotor cavity 50 by the arc spacer layer 121, so that water entering the rotor cavity does not penetrate into the iron core. And coils.
  • the integrated pump body of the present invention can be obtained by a one-shot injection molding method or a secondary injection molding method.
  • the one-piece pump body produced by one injection molding or two-shot molding has the same structure, and the injection molding process and the injection molding material used may be different.
  • an integrated pump body for one injection molding and two injection molding is introduced.
  • an integrated pump body is obtained by a method of overmolding.
  • the integrated pump body includes a coil sealing portion 11 for sealing the coil 3 wound on the bobbin 4, and a pump body portion formed by injection molding the core or the base.
  • the pump body portion 1 includes a rotor cylinder 13 having a rotor cavity in which the rotor assembly is disposed, and a core sealing portion 12 for sealing the iron core, and a curved surface isolation layer 121 that fits the concave curved surface 231 of the iron core 2. .
  • the arc surface separation layer 121 and the rotor cylinder 13 are integrated such that the inner surface of the rotor cylinder 13 and the surface of the arc spacer layer 121 together constitute a continuous rotor cavity 50.
  • the coil sealing portion 11 and the pump body portion 1 are sequentially injection molded, and the specific injection molding process is as follows:
  • the coil 3 wound on the bobbin 4 is placed in a mold for the first injection molding process, and after the first injection molding process, the coil sealing portion 11 of the sealing coil 3 is formed, as shown in Fig. 5a, the coil is dense.
  • the seal 11 together with the bobbin forms a sealed container that seals the coil 3, as shown in FIG.
  • the iron core 2 is assembled, and the coil 3 sealed by the coil sealing portion and the iron core 2 are placed together in a mold for the second injection molding process.
  • the pump body portion 1 is injection-molded based on the assembled coil 3 and the iron core 2, and the pump body portion 1 includes a rotor cylinder 13 having a rotor cavity therein and a core seal portion 12 of the sealed iron core 2.
  • the coil sealing portion 11 is integrally molded by injection molding with the rotor cylinder 13 and the core sealing portion 12, as shown in Fig. 5b.
  • the coil sealing portion 11 and the pump body portion 1 are made of different plastic materials, respectively.
  • the coil sealing portion is in direct contact with the coil, a high fire rating is required, and the BMC has good thermal conductivity and is cheaper than the fire rated PP, but the plasticity is poor, so the coil sealing portion 11 can be made of a BMC with a high fire rating.
  • the pump body portion 1 is made of a general PP material having high plasticity.
  • the coil sealing portion 11 and the pump body portion 1 can also be made of the same plastic material.
  • the core 2 has a U shape with two longitudinal segments 21, and the two longitudinal segments 21 are parallel to each other and connected by a transverse segment 22; two arc portions 23 at each end of the two longitudinal segments, each pole arc The portion 23 has a concave curved surface 231.
  • the core sealing portion 12 isolates the bobbin 4 from the core 2 and seals the core 2, as shown in FIGS. 2, 6, and 7, the core sealing portion 12 includes: a concave curved surface of the laminated core 2 a curved surface isolation layer 121 of 231; a remaining sealing portion 122 for sealing a surface other than the concave curved surface of the iron core to isolate the coil bobbin 4 from the iron core 2, as shown in FIG.
  • the iron core 2 and the coil there is a gap between the sealed containers of 3, which is filled with the injection molding material when the second injection molding forms the core sealing portion 12, such that the arc insulating layer 121 and the injection molding material filled between the iron core and the coil sealing portion are Preventing water leakage from the rotor cavity to the outside of the drain pump provides two layers of protection.
  • the pump body portion 1 is injection molded, the arc spacer layer 121 and the inner surface of the rotor cylinder 13 connected to the arc spacer layer 121 together form a continuous rotor cavity 50 for arranging the rotor assembly.
  • the arcuate partition layer 121 constituting the core seal portion 12 is connected to the rotor cylinder 13 and there is no seam at the joint thereof. Therefore, a continuous inner surface of the rotor cavity is formed. As shown in FIG. 8, a continuous and seamless plastic is isolated between the rotor cavity 50 and the core 2, and the plastic can prevent water entering the rotor cavity 50 from penetrating into the iron core. 2 and coil 3, can prevent the drain pump from leaking through the core.
  • the magnetic path air gap between the iron core 2 and the permanent magnet rotor is made.
  • the thickness of the arc spacer 121 disposed between the concave curved surface 231 and the rotor cavity 50 is extremely thin, since the concave curved surface 231 of the core has two different sections.
  • the arc surface of the radius, and the rotor cavity required to be formed during injection molding is a standard arc, so the plastic thickness of the arc spacer formed to seal the concave curved surface 231 is different, and the thickness range of the arc spacer formed by the injection molding of the present invention Between 0.5 and 0.65 mm, that is, the thinnest portion of the arc spacer layer 121 has a thickness of only 0.5 mm, and the thickness at the thickest portion is also only 0.65 mm.
  • a groove 2310 is formed along the concave curved surface of the iron core.
  • the injection molding material is caused to flow into the groove 2310 opened along the concave curved surface of the core to form a root portion 1210 extending from the arc spacer layer 121, and the root portion 1210 is opposed to the groove 2310.
  • the fitting is engaged so that the arc spacer 121 can be reliably fixed to the concave curved surface 231.
  • a plurality of grooves 2310 are formed along the concave curved surface 231 of the iron core 2.
  • the molten plastic flows into the groove 2310, and after cooling, forms a curved surface isolation layer 121 to each concave surface.
  • a root 1210 is embedded in the groove 2310 and mates with the groove.
  • the arc spacer layer 121 is pulled by the root portion 1210 embedded in the recess 2310 to be fastened to the indented cam surface 231.
  • the groove 2310 is designed as a narrowing groove, that is, having a small opening and a large inner cavity, and the cross-sectional shape may be a circular shape. It can also be a polygon.
  • a plurality of axially extending grooves 2310 are symmetrically disposed on the concave curved surface 231 of the two pole arc portions of the core 2, so that the tensile force of the arc spacer layer 121 is uniform.
  • the second injection molding is to preheat the concave arc portion of the iron core by forming the pump body portion having the rotor cylinder with the iron core as the skeleton or the foundation, so that the plastic flows from the wider gap to the thicker gap, so that Plastic flow is easier.
  • the coil sealing portion is exposed and directly contacted with the mold, so the iron is required.
  • the core is fully positioned to prevent the coil and the iron core from being centered due to various external forces, so that the gap between the coil and the iron core is uniform, and the plastic poured between the coil and the iron core is evenly thin. In this way, it is avoided that as the use time is extended, the water entering the rotor cavity leaks through the thinner plastic, and penetrates into the iron core or even the coil, thereby damaging the drain pump.
  • the iron core when the iron core is sealed, the iron core is subjected to the three-dimensional direction by using the mold positioning member. Positioning, so that the plastic core and the coil are centered, so that the plastic between the bobbin 4 and the core 2 is thin and uniform.
  • the mold positioning member is used to position the iron core 2 during the injection molding process. Therefore, the iron core sealing portion 12 obtained by injection molding has a positioning hole for positioning the mold positioning member, that is, the shape of the positioning hole is consistent with the shape of the mold positioning member.
  • the embodiment has three sets of positioning holes, each of which has two positioning holes, and two of the positioning holes of each group are symmetrically disposed on the core and the coil. On both sides of the center line after the center.
  • the mold positioning member forming the three sets of positioning holes will be described in detail how to realize the positioning of the iron core in the three directions of x, y and z, and the direction indicated by the arrow in the figure is the positive direction.
  • the mold positioning member comprises a first positioning member, a second positioning member, a third positioning member and a fourth positioning member.
  • the first set of positioning holes includes two first positioning holes 122a, 122b symmetrically formed at the angular ends of the two pole arc portions of the core, wherein a first positioning hole 122a surrounds the core
  • the three faces of the corner end of one pole portion are formed by a first positioning member forming a first positioning hole 122a during injection molding and three faces of the corner end of one pole portion and respectively applying x positive to the three faces.
  • the opposite direction of the y, forward, and z directions; and the other first locating hole 122b surrounds the three faces of the corner end of the other pole portion of the core, and another another locating hole 122b is formed during injection molding.
  • One first positioning member is in contact with three faces of the corner end of the other pole arc portion and applies a force of x forward, y reverse, and z reverse to the three faces, respectively.
  • the end portion of the pole portion of the core 2 is provided with a positioning groove including two symmetrically disposed near the corner ends of the two pole portions of the core.
  • the first positioning slots 23a, 23b, one first positioning slot 23a is engaged with a first positioning member forming a first positioning hole 122a, and the other first positioning slot 23b is formed with another one forming another first positioning hole 122b.
  • the first positioning member is engaged.
  • the second set of positioning holes includes: two second positioning holes 124a, 124b formed at an outer corner of one end of the two longitudinal sections of the core, correspondingly, the outer corners of the two longitudinal sections of the core 2 have two Two positioning grooves 21a, 21b.
  • the second positioning grooves 21a, 21b have a concave angle with a concave curved surface.
  • a second positioning slot 21a corresponds to a second positioning hole 124a.
  • a second positioning member placed at a second positioning slot 21a during injection molding forms a second positioning hole 124a, and a second positioning member passes through a second.
  • another second positioning member is placed at the other second positioning groove 21b to form another second positioning hole 124b, and the other second positioning member passes through the other second positioning groove.
  • 21b applies a force of x reverse, y reverse, and z reverse to the core.
  • the third set of positioning holes includes: two third positioning holes 123a, 123b on both sides of the core, wherein a third positioning member forming a third positioning hole 123a during injection molding is Applying a y forward and z positive force to the core through one side of the core during injection molding; another third positioning member forming another third positioning hole 123b during injection molding, through the core during injection molding The other side is used to apply a y-reverse, z-positive force to the core.
  • a fourth positioning hole 125 is formed in the middle of the transverse section of the iron core, and the fourth positioning member forming the fourth positioning hole 125 during injection molding can apply an x reverse to the iron core. Force.
  • the first positioning member forming the first positioning hole, the second positioning member forming the second positioning hole, the third positioning member forming the third positioning hole, and the fourth positioning member forming the fourth positioning hole cooperate
  • the precise positioning of the iron core is realized, so that the thickness of the plastic core sealing portion 12 obtained in the embodiment is uniform and the sealing is firm.
  • the core sealing portion 12 is further provided with positioning caps 61a, 61b, 62a, 62b, 63a, 63b, 64 for sealing the respective positioning holes, and the positioning cap is ultrasonically welded to the corresponding positioning holes.
  • the first sealing caps 61a, 61b are respectively disposed in the two first positioning holes 122a, 122b
  • the second sealing caps 62a, 62b are respectively disposed in the two second positioning holes 124a, 124b
  • the two third positioning holes 123a, 123b are respectively disposed.
  • the third sealing caps 63a, 63b are respectively disposed
  • the fourth sealing caps 64 are disposed in the fourth positioning holes 125.
  • This embodiment obtains an integrated pump body by one injection molding.
  • the coil sealing portion 11 and the pump body portion 1 having the core sealing portion 12 and the rotor cylinder 13 are injection molded at one time, and the specific injection molding process is as follows:
  • the coil 3 is wound on the bobbin, and the iron core 2 is assembled to the wound coil 3; then, the assembled iron core and the coil are placed together in a mold, and an injection molding process is performed, and an injection molding process is performed. Thereafter, the coil sealing portion 11 of the sealed coil and the core sealing portion 12 of the sealed iron core are formed, and the rotor cylinder 13 formed by injection molding the core 2 or the base is formed.
  • the coil bobbin cooperates with the ejector pin of the mold to realize the positioning of the coil, such as the Chinese invention patent 200710143209.3.
  • the coil seal portion 11, the core seal portion 12, and the rotor cylinder 13 obtained by one injection molding have an integral structure.
  • the material provides two layers of protection against water leakage from the rotor cavity to the outside of the drain pump.
  • the coil sealing portion 11, the core sealing portion 12, and the rotor cylinder 13 are made of the same plastic material.
  • the coil sealing portion 11, the core sealing portion 12, and the rotor cylinder 13 may each be made of a BMC material having a high fireproof rating, or a PP material having a high plasticity and a high fireproof rating may be used.

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  • Engineering & Computer Science (AREA)
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  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Manufacture Of Motors, Generators (AREA)
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Abstract

一种泵体一体式的永磁同步电机及其制备方法，该方法包括以下顺序进行的步骤：1）将绕制于线圈骨架（4）上的线圈（3）进行第一次注塑，形成密封线圈的线圈密封部；2）将铁芯（2）装配于密封的线圈内，以密封的线圈和铁芯为基础进行第二次注塑以形成具有转子筒体（13）的泵体部，其中转子筒体以铁芯为骨架注塑形成，并且在第二次注塑时在铁芯的极弧部形成隔离薄层，通过隔离薄层使铁芯与转子筒体内部的转子腔隔离。该电机及其制备方法将铁芯和线圈密封在注塑容器中，并且将塑胶弧面隔离层作为隔离薄层使铁芯的极弧部与转子腔隔离，在保证产品电磁性能的前提下，解决了漏水问题。

Description

一种永磁同步电机及其制备方法 技术领域
本发明涉及排水泵领域，尤其涉及一种应用于洗衣机、洗碗机排水泵的泵体一体式的永磁同步电机及其制备方法。
背景技术
中国实用新型专利201320745113.5公开了一种U型铁芯的交流永磁同步电机的排水泵。但是，该排水泵在试验过程中，由于铁芯和转子之间没有防护材料隔离，因而导致进入转子腔的水渗入铁芯使铁芯生锈，或者水会通过铁芯渗到线圈而使线圈因短路而烧坏；并且进入转子腔的水也会渗漏到排水泵外部。这样的漏水问题一直困扰着生产厂家。
现有技术中的交流永磁排水泵，其结构是将绕制好的线圈、铁芯经过注塑与泵体形成一体，这种一体式的泵体结构很好的解决了排水泵工作过程中的震动噪声的技术问题，但是排水泵的漏水问题解决的效果不太好。
例如，现有技术中的一种交流永磁排水泵的结构：具有装配好的线圈和铁芯，以及围绕所述装配好的线圈和铁芯的轮廓一体注塑形成的泵体，注塑形成的泵体具有用于容置转子组件的转子腔，并使铁芯的极弧部与转子筒共同形成转子腔，一方面，注塑该泵体避免了铁芯和线圈不发生相对晃动，另一方面，由于将铁芯的内凹弧面与转子筒共同形成转子腔内表面，从而使永磁转子与铁芯之间的磁路气隙很小，产品的电磁效率得以提高。但具，有以下缺点：当排水泵长时间使用后，用于防止转子腔进水的密封圈会发生磨损，排水泵在工作时，水会经磨损的密封圈进入到转子腔，水进入到转子腔以后，会经裸露在转子腔内的铁芯的内凹圆弧面渗入铁芯内，导致铁芯生锈，随着生锈的加剧，有卡死转子的风险；另外，在铁芯的内凹弧面以外的其余表面的塑胶密封不好的情况下，进入转子腔的水可以通过铁芯的叠片之间的间隙漏水，或者可以通过铁芯与塑胶之间的间隙漏水，进而渗入线圈而导致线圈烧坏。
为了避免因上述漏水导致的线圈烧坏或铁芯生锈的问题，现有技术中采取转子筒体内设置不锈钢筒体，隔离铁芯的内凹弧面与永磁转子。虽然该不锈钢筒体可以阻止进入到转子腔内的水与铁芯接触，但制造工艺复杂，成本高，并且大大降低电磁效率。
发明内容
本发明的目的在于，克服上述现有技术存在的问题，提供一种泵体一体式的永磁同步电机的制备方法，通过将铁芯和线圈密封在注塑容器中，不但保证产品电磁性能，而且解决因转子腔内进水而漏入铁芯的问题，避免了铁芯生锈，为防止转子腔的水渗漏到排水泵外部提供了两层防护。
本发明的另一目的是提供一种泵体一体式的永磁同步电机。
为实现本发明的第一目的，首先，本发明提供一种泵体一体式的永磁同步电机的制备方法，包括以下顺序进行的步骤：
1)将绕制于线圈骨架上的线圈进行第一次注塑，形成密封线圈的线圈密封部；
2)将铁芯装配于密封的线圈内，以密封的线圈和铁芯为基础进行第二次注塑以形成具有转子筒体的泵体部，其中
转子筒体以铁芯为骨架注塑形成，并且在第二次注塑时在铁芯的极弧部形成隔离薄层，通过隔离薄层使铁芯与转子筒体内部的转子腔隔离。
其中，所述铁芯与线圈的密封容器之间有间隙，该间隙在第二次注塑时被注塑材料填充。
其次，本发明提供一种泵体一体式的永磁同步电机的制备方法，包括以下顺序进行的步骤：
1)在线圈骨架上绕制线圈，将铁芯装配于绕制的线圈内；
2)以绕制的线圈和铁芯为基础进行注塑，以形成密封线圈的线圈密封部和具有转子筒体的泵体部，其中
转子筒体以铁芯为骨架注塑形成，并且在注塑时在铁芯的极弧部形成隔离薄层，通过隔离薄层使铁芯与转子筒体内部的转子腔隔离。
其中，所述铁芯与绕制好的线圈之间有间隙，该间隙在注塑时被注塑材料填充。
其中，在进行注塑以形成泵体部时，通过模具定位件对铁芯定位，使铁芯与绕制好的线圈居中对齐。
特别是，铁芯呈U形，包括两平行的纵向段和使纵向段的一端相连的横向段，模具定位件包括第一定位件和第二定位件，极弧部位于纵向段的另一端，并 设置有用于安置第一定位件的第一定位槽，纵向段的一端的角部设置用于安置第二定位件的第二定位槽。
特别是，沿铁芯的极弧部的内凹弧面开设凹槽，在进行注塑以形成隔离薄层时，通过使注塑材料流入凹槽，形成隔离薄层的嵌入凹槽内的根部，通过根部将隔离薄层紧固于内凹弧面。
为实现本发明的另一目的，本发明提供一种由上述制备方法制备的泵体一体式的永磁同步电机，包括：转子组件；定子组件，具有在线圈骨架上绕制的线圈和装配在线圈上的铁芯，其中线圈由线圈密封部密封；以及以定子组件为基础进行注塑而形成的泵体部，其中泵体部包括：以铁芯为骨架注塑形成的转子筒体，内部具有安置转子组件的转子腔；和在铁芯的极弧部注塑形成的隔离薄层，使铁芯与转子腔隔离。
此外，本发明还提供一种由上述制备方法制备的泵体一体式的永磁同步电机，包括：转子组件；定子组件，具有绕制于线圈骨架上的线圈和装配在线圈上的铁芯；以定子组件为基础进行注塑而形成的线圈密封部和泵体部，线圈密封部密封绕制于线圈骨架上的线圈，其中泵体部包括：以铁芯为骨架注塑形成的转子筒体，内部具有安置转子组件的转子腔；和在铁芯的极弧部注塑形成的隔离薄层，使铁芯与转子腔隔离。
其中，铁芯呈U形，包括两平行的纵向段和使纵向段的一端相连的横向段，极弧部位于纵向段的另一端，并设置有用于安置第一定位件的第一定位槽，纵向段的一端的角部设置用于安置第二定位件的第二定位槽，以便使铁芯与绕制线圈骨架上的线圈居中对齐。
特别是，沿所述铁芯的极弧部的内凹弧面开设凹槽，隔离薄层具有嵌入凹槽内的根部，通过根部将隔离薄层紧固于内凹弧面。
其中，隔离薄层与转子筒体成一体，通过隔离薄层与转子筒体的内表面形成连续的转子腔。
特别是，隔离薄层最大程度地使极弧部的内凹弧面接近转子腔，使隔离薄层最薄处的厚度为0.2-0.75mm。
本发明的有益效果体现在以下方面：
1)本发明的铁芯和线圈通过注塑形成一体，不但提高空间利用效率以及产 品的散热性能，而且减少了震动噪音。
2)本发明通过由塑胶弧面隔离层作为隔离薄层，使铁芯的极弧部与转子腔隔离，隔离薄层最薄处的厚度可以薄到0.2mm，既阻止转子腔内的水渗入铁芯和阻止通过铁芯叠片漏水至线圈，避免铁芯生锈和线圈烧坏，又能在铁芯和转子之间实现较小的气隙，大大提高电机性能。
附图说明
图1是本发明永磁同步电机的结构示意图；
图2是本发明永磁同步电机的主视图；
图3是图2所示的右视图(无转子组件和密封帽)；
图4是图2所示的左视图(无转子组件和密封帽)；
图5a是本发明实施例1绕制在线圈骨架上的线圈经注塑密封后的示意图；
图5b是实施例1安装在注塑后的线圈内铁芯经注塑密封后的示意图；
图6是实施例1的沿图2中A-A线的剖视图；
图7是图6中的I部放大图；
图8是本发明实施例1的沿图1中B-B线的剖视图(无转子组件)；
图9是本发明实施例2的沿图2中A-A线的剖视图；
图10是本发明实施例2的沿图1中B-B线的剖视图(无转子组件)；
图11是本发明铁芯具有凹槽的结构示意图；
图12和图13是本发明定位孔和密封帽的装配示意图。
附图标记说明：11-线圈密封部；12-铁芯密封部；121-弧面隔离层；1210-根部；122-其余密封部；122a、122b-第一定位孔；124a、124b-第二定位孔；123a、123b-第三定位孔；125-第四定位孔；1-泵体部；13-转子筒体；2-铁芯；21-纵向段；21a、21b-第二定位槽；22-横向段；23-极弧部；231-内凹弧面；2310-凹槽；23a、23b-第一定位槽；3-线圈；4-线圈骨架；5-转子组件；50-转子腔；61a、61b-第一密封帽；62a、62b-第二密封帽；63a、63b-第三密封帽；64-第四密封帽。
具体实施方式
如图1、2、6和9所示，本发明的永磁同步电机，包括：转子组件5，具有用于驱动叶轮转动的永磁体转子；定子组件，具有绕制于线圈骨架4上的线圈3和装配在线圈3上的铁芯2；围绕铁芯2和绕组好的线圈3的轮廓注塑而形成的 一体式泵体。
其中，本发明的一体式泵体通过以线圈和装配于线圈上的铁芯为骨架或基础进行注塑形成。在注塑时，注塑材料将绕在线圈骨架4上的线圈3和装配于线圈内的铁芯2一起密封，只将线圈与外电路连接的接插端裸露，使铁芯2和线圈3通过注塑形成一体结构，减少震动噪音；特别是，在利用模具注塑密封铁芯2和线圈3的同时以铁芯为骨架注塑形成转子筒体13，并且在铁芯的极弧部形成隔离薄层，通过该隔离薄层使铁芯与转子筒体内部的转子腔隔离。
本发明在铁芯2的双臂极弧部内侧形成与内凹弧面231接近的用于安置转子组件5的转子腔50，极弧部的内凹弧面231与转子腔50之间仅隔一层厚度极薄的隔离薄层，即弧面隔离层121，为实现较小的气隙，本发明弧面隔离层最薄处的厚度范围可选择在0.2～0.75mm之间，如图6、7所示，弧面隔离层121最薄处的厚度仅为0.5mm，铁芯2通过弧面隔离层121与转子腔50形成隔离，这样，进入转子腔的水就不会渗入到铁芯和线圈。
本发明的一体式泵体可以通过一次注塑成型的方法或二次注塑成型的方法得到。通过一次注塑成型或二次注塑成型制得的一体式泵体的结构相同，注塑工艺过程和所使用的注塑材料可以不同。下面通过两个实施例分别对一次注塑成型和二次注塑成型的一体式泵体进行介绍。
实施例1
本实施例通过二次注塑的方法得到一体式泵体。
如图2、5a、5b和6所示，一体式泵体包括：线圈密封部11，用于密封绕制于线圈骨架4上的线圈3；以铁芯为骨架或基础注塑形成的泵体部1。其中，泵体部1包括：转子筒体13，内部具有安置转子组件的转子腔；密封铁芯的铁芯密封部12，具有贴合铁芯2的内凹弧面231的弧面隔离层121。形成泵体部1时，弧面隔离层121和转子筒体13成一体，使得转子筒体13内表面与弧面隔离层121的表面共同构成连续的转子腔50。
该实施例在制作一体式泵体时，线圈密封部11与泵体部1依次注塑而成，具体注塑过程如下：
首先，将绕制在线圈骨架4上的线圈3放入模具进行第一次注塑处理，经过第一次注塑处理后，形成密封线圈3的线圈密封部11，如图5a所示，该线圈密 封部11与线圈骨架一起形成了密封线圈3的密封容器，如图6所示。
然后，在如图5a所示的塑封于线圈密封部11内的线圈3内，装配上铁芯2，将由线圈密封部密封的线圈3和铁芯2一起放入模具进行第二次注塑处理。第二次注塑处理，以装配好的线圈3和铁芯2为基础注塑形成泵体部1，泵体部1包括内部具有转子腔的转子筒体13以及密封铁芯2的铁芯密封部12，线圈密封部11经过注塑与转子筒体13和铁芯密封部12为一体结构，如图5b所示。
通过二次注塑形成一体式泵体时，优选的，线圈密封部11与泵体部1分别采用不同的塑胶材料制成。例如，由于线圈密封部与线圈直接接触，要求较高的防火等级，并且BMC导热性能好，且价格比防火等级的PP便宜，但可塑性较差，因此线圈密封部11可以采用防火等级高的BMC材料，泵体部1采用可塑性高的一般PP材料。当然，线圈密封部11和泵体部1也可采用相同的塑胶材料制成。
下面结合附图详细描述本实施例的具体结构。
如图11所示，铁芯2呈U形，具有两个纵向段21，两个纵向段21相互平行且通过横向段22相连；分别位于两纵向段一端的两极弧部23，每个极弧部23具有内凹弧面231。
铁芯密封部12使线圈骨架4与铁芯2之间隔离并将铁芯2密封，如图2、6和7所示，铁芯密封部12包括：贴合铁芯2的内凹弧面231的弧面隔离层121；用于密封铁芯的内凹弧面以外的表面的其余密封部122，使线圈骨架4与铁芯2之间隔离，如图6所示，铁芯2与线圈3的密封容器之间有间隙，该间隙在第二次注塑形成铁芯密封部12时被注塑材料填充，这样，弧面隔离层121以及填充在铁芯和线圈密封部之间的注塑材料为防止转子腔的水渗漏到排水泵外部提供了两层防护。其中，注塑形成泵体部1时，弧面隔离层121以及与弧面隔离层121相连的转子筒体13的内表面共同形成用于安置转子组件的连续的转子腔50。
由于形成泵体部的铁芯密封部12和转子筒体13为一次注塑形成，则构成铁芯密封部12的弧面隔离层121与转子筒体13相连且在其连接处不存在接缝，因此形成连续的转子腔内表面，如图8所示，转子腔50与铁芯2之间隔离了一层连续完整无接缝的塑胶，该塑胶可以阻止进入转子腔50的水渗入到铁芯2和线圈3，可以阻止排水泵通过铁芯漏水。
如图6、7所示，为了使铁芯的极弧部的内凹弧面231最大程度接近转子筒体13内部的转子腔50，使铁芯2与永磁体转子之间的磁路气隙达到更小，以获得更高的电磁效率，本发明设置在内凹弧面231与转子腔50之间的弧面隔离层121厚度极薄，由于铁芯的内凹弧面231具有两段不同半径的圆弧面，而注塑时要求形成的转子腔为一个标准圆弧，因此形成密封内凹弧面231的弧面隔离层的塑胶厚度不同，本发明注塑形成的弧面隔离层的厚度范围在0.5～0.65mm之间，即弧面隔离层121最薄处的厚度仅为0.5mm，最厚处的厚度也仅为0.65mm。
如图6至8所示，由于弧面隔离层121的厚度很薄，为了保证该薄层具有足够的强度而贴合于内凹弧面，沿铁芯的内凹弧面开设凹槽2310，在进行注塑以形成弧面隔离层121时，使注塑材料流入沿铁芯的内凹弧面开设的凹槽2310内，形成由弧面隔离层121延伸的根部1210，根部1210与凹槽2310相嵌配合，以便使弧面隔离层121能可靠地固定在内凹弧面231上。
本实施例沿铁芯2的内凹弧面231上开设有多个凹槽2310，在注塑时，熔化的塑料就会流入凹槽2310内，冷却后形成自弧面隔离层121向每个凹槽2310内嵌入并与凹槽紧密配合的根部1210。通过嵌入凹槽2310内的根部1210将弧面隔离层121拉住而使其紧固在内凹弧面231上。
优选地，为了通过与凹槽2310嵌合的根部1210更好地拉住弧面隔离层121，凹槽2310设计为缩口槽，即具有口小内腔大的特点，截面形状可以为圆形、也可以为多边形。本实施例中，在铁芯2的两个极弧部的内凹弧面231上对称设置多个轴向贯通的凹槽2310，使弧面隔离层121受的拉力均匀。
第二次注塑在以铁芯为骨架或基础形成具有转子筒体的泵体部时，先对铁芯的内凹弧部预热，使塑胶从较宽的间隙向较厚的间隙流动，以便塑胶流动更容易。
由于铁芯2装配到线圈绕组上时与线圈骨架4之间存在装配间隙，因此，在实际使用泵体塑封模具制造一体式泵体时，线圈密封部外露与模具直接接触定位，所以需要对铁芯进行充分定位，避免由于各种外力使线圈和铁芯不能居中对齐，使得线圈和铁芯之间的间隙大小均匀，进而使浇注在线圈和铁芯之间的塑胶薄厚均匀。这样，避免了随着使用时间的延长，进入到转子腔的水会通过较薄处的塑胶漏水，渗到铁芯甚至线圈内，导致损坏排水泵。
因此，本实施例在密封铁芯时，通过使用模具定位件在三维方向对铁芯进行 定位，从而使塑封好的铁芯和线圈居中对齐，使线圈骨架4与铁芯2之间的塑胶薄厚均匀。
注塑过程中使用模具定位件来定位铁芯2，因此注塑得到的铁芯密封部12上具有用于安置模具定位件的定位孔，即定位孔的形状与模具定位件的形状一致。
具体的，如图3、4和6所示，本实施例形成有三组定位孔，每组定位孔均具有两个定位孔，每组定位孔中的两个定位孔对称设置在铁芯和线圈对中后的中心线的两侧。下面将参照如图1所示的坐标方向，详细描述形成三组定位孔的模具定位件如何实现对铁芯在x、y、z三个方向定位，设图中箭头所指的方向为正方向。其中，模具定位件包括第一定位件、第二定位件、第三定位件和第四定位件。
如图4和6所示，第一组定位孔包括：对称形成在铁芯的两个极弧部的角端的两个第一定位孔122a、122b，其中，一个第一定位孔122a包围铁芯的一个极弧部的角端的三个面，则注塑时形成一个第一定位孔122a的一个第一定位件与一个极弧部的角端的三个面接触并分别给这三个面施加x正向、y正向、z反向的作用力；而另一个第一定位孔122b包围铁芯的另一个极弧部的角端的三个面，则注塑时形成另一个第一定位孔122b的另一个第一定位件与另一个极弧部的角端的三个面接触并分别给这三个面施加x正向、y反向、z反向的作用力。
为了定位牢固，如图4和6所示，铁芯2的极弧部的端部设置了定位槽，该定位槽包括：对称设置在铁芯的两个极弧部的角端附近的两个第一定位槽23a、23b，一个第一定位槽23a与形成一个第一定位孔122a的一个第一定位件卡合，另一个第一定位槽23b与形成另一个第一定位孔122b的另一个第一定位件卡合。
第二组定位孔包括：形成在铁芯的两个纵向段的一端外角部的两个第二定位孔124a、124b，对应的，铁芯2的两个纵向段的一端外角部具有两个第二定位槽21a、21b。
如图4和6所示，第二定位槽21a、21b呈具有内凹弧面的凹角。其中，一个第二定位槽21a对应一个第二定位孔124a，注塑时放置于一个第二定位槽21a处的一个第二定位件形成一个第二定位孔124a，一个第二定位件通过一个第二定位槽21a来给铁芯施加x反向、y正向、z反向的作用力；另一个第二定位槽 21b对应另一个第二定位孔124b，注塑时另一个第二定位件放置于另一个第二定位槽21b处形成另一个第二定位孔124b，另一个第二定位件通过另一个第二定位槽21b来给铁芯施加x反向、y反向、z反向的作用力。
如图3和6所示，第三组定位孔包括：位于铁芯两侧的两个第三定位孔123a、123b，其中，注塑时形成一个第三定位孔123a的一个第三定位件，在注塑时通过铁芯的一个侧部来给铁芯施加y正向、z正向的作用力；注塑时形成另一个第三定位孔123b的另一个第三定位件，在注塑时通过铁芯的另一个侧部来给铁芯施加y反向、z正向的作用力。
另外，如图4所示，本实施例还在铁芯的横向段中间形成一个第四定位孔125，则注塑时形成第四定位孔125的第四定位件可对铁芯施加x反向的作用力。
综上，通过形成第一定位孔的第一定位件、形成第二定位孔的第二定位件、形成第三定位孔的第三定位件以及形成第四定位孔的第四定位件的共同作用，实现铁芯的精确定位，从而使得本实施例制得的铁芯密封部12的塑胶厚度薄厚均匀，密封牢固。
如图12和13所示，铁芯密封部12上还设置有用于密封各个定位孔的定位帽61a、61b、62a、62b、63a、63b、64，定位帽通过超声波焊接到与其对应的定位孔上，实现对铁芯密封部12的密封。两个第一定位孔122a、122b内分别安置第一密封帽61a、61b，两个第二定位孔124a、124b内分别安置第二密封帽62a、62b，两个第三定位孔123a、123b内分别安置第三密封帽63a、63b，第四定位孔125内安置第四密封帽64。
实施例2
该实施例通过一次注塑的方法得到一体式泵体。
该实施例在制作一体式泵体时，一次注塑而成线圈密封部11以及具有铁芯密封部12和转子筒体13的泵体部1，具体注塑过程如下：
首先，将线圈3绕制在线圈骨架上，将铁芯2装配到绕制好的线圈3上；然后，将装配好的铁芯和线圈一起放入模具，进行一次注塑处理，经过一次注塑处理后，形成密封线圈的线圈密封部11和密封铁芯的铁芯密封部12，并形成以铁芯2为骨架或基础注塑形成的转子筒体13。其中线圈骨架与模具的顶针配合实现线圈的定位，如中国发明专利200710143209.3。
如图2、9和10所示，通过一次注塑得到的线圈密封部11、铁芯密封部12以及转子筒体13为一体结构。
如图9所示，铁芯2与绕制好的线圈4之间有间隙，该间隙在一次注塑时被注塑材料填充，这样，弧面隔离层121以及填充在铁芯和线圈之间的注塑材料为防止转子腔的水渗漏到排水泵外部提供了两层防护。
由于本实施例通过一次注塑形成，如图9和10所示，线圈密封部11、铁芯密封部12和转子筒体13采用相同的塑胶材料制成。例如，线圈密封部11、铁芯密封部12、转子筒体13可以均采用防火等级高的BMC材料，也可以均采用可塑性高且防火等级高的PP材料。
本实施例的其余结构与实施例1相同，不再详细描述。
尽管上述对本发明做了详细说明，但本发明不限于此，本技术领域的技术人员可以根据本发明的原理进行修改，因此，凡按照本发明的原理进行的各种修改都应当理解为落入本发明的保护范围。

Claims (12)

  1. 一种泵体一体式的永磁同步电机的制备方法，其特征在于包括以下顺序进行的步骤：
    1)将绕制于线圈骨架上的线圈进行第一次注塑，形成密封线圈的线圈密封部；
    2)将铁芯装配于密封的线圈内，以密封的线圈和铁芯为基础进行第二次注塑以形成具有转子筒体的泵体部，其中
    转子筒体以铁芯为骨架注塑形成，并且在第二次注塑时在铁芯的极弧部形成隔离薄层，通过隔离薄层使铁芯与转子筒体内部的转子腔隔离。
  2. 一种泵体一体式的永磁同步电机的制备方法，其特征在于包括以下顺序进行的步骤：
    1)在线圈骨架上绕制线圈，将铁芯装配于绕制的线圈内；
    2)以绕制的线圈和铁芯为基础进行注塑，以形成密封线圈的线圈密封部和具有转子筒体的泵体部，其中
    转子筒体以铁芯为骨架注塑形成，并且在注塑时在铁芯的极弧部形成隔离薄层，通过隔离薄层使铁芯与转子筒体内部的转子腔隔离。
  3. 如权利要求1或2所述的制备方法，其特征在于：
    在进行注塑以形成泵体部时，通过模具定位件对铁芯定位，使所述铁芯与绕制好的线圈居中对齐。
  4. 如权利要求3所述的制备方法，其特征在于：
    所述铁芯呈U形，包括两平行的纵向段和使纵向段的一端相连的横向段，极弧部位于纵向段的另一端，并设置有用于安置第一定位件的第一定位槽，纵向段的所述一端的角部设置用于安置第二定位件的第二定位槽。
  5. 如权利要求1或2所述的制备方法，其特征在于：
    沿所述铁芯的极弧部的内凹弧面开设凹槽，在进行注塑以形成所述隔离薄层 时，通过使注塑材料流入所述凹槽，形成所述隔离薄层的嵌入凹槽内的根部，通过根部将隔离薄层紧固于内凹弧面。
  6. 如权利要求1所述的制备方法，其特征在于，所述铁芯与线圈的密封容器之间有间隙，该间隙在第二次注塑时被注塑材料填充。
  7. 如权利要求2所述的制备方法，其特征在于，所述铁芯与绕制好的线圈之间有间隙，该间隙在注塑时被注塑材料填充。
  8. 一种泵体一体式的永磁同步电机，其特征在于包括：
    转子组件；
    定子组件，具有在线圈骨架上绕制的线圈和装配在线圈上的铁芯，其中线圈由线圈密封部密封；以及
    以定子组件为基础进行注塑而形成的泵体部，其中泵体部包括：
    以铁芯为骨架注塑形成的转子筒体，内部具有安置转子组件的转子腔；和
    在铁芯的极弧部注塑形成的隔离薄层，使铁芯与转子腔隔离。
  9. 一种泵体一体式的永磁同步电机，其特征在于包括：
    转子组件；
    定子组件，具有绕制于线圈骨架上的线圈和装配在线圈上的铁芯；
    以定子组件为基础进行注塑而形成的线圈密封部和泵体部，线圈密封部密封绕制于线圈骨架上的线圈，其中泵体部包括：
    以铁芯为骨架注塑形成的转子筒体，内部具有安置转子组件的转子腔；和
    在铁芯的极弧部注塑形成的隔离薄层，使铁芯与转子腔隔离。
  10. 如权利要求8或9所述的永磁同步电机，其特征在于：
    所述铁芯呈U形，包括两平行的纵向段和使纵向段的一端相连的横向段； 极弧部位于纵向段的另一端，并设置有用于安置第一定位件的第一定位槽，纵向段的所述一端的角部设置用于安置第二定位件的第二定位槽，以便使所述铁芯与绕制线圈骨架上的线圈居中对齐。
  11. 如权利要求8或9所述的永磁同步电机，其特征在于：
    沿所述铁芯的极弧部的内凹弧面开设凹槽，所述隔离薄层具有嵌入凹槽内的根部，通过根部将隔离薄层紧固于内凹弧面；
    所述隔离薄层与转子筒体成一体，通过隔离薄层与转子筒体的内表面形成连续的转子腔。
  12. 如权利要求11所述的永磁同步电机，其特征在于，所述隔离薄层的最薄处的厚度为0.2-0.75mm。
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