Brushless motor stator insulating frame and electric power steering gear integrated brushless motor

Abstract

The utility model discloses a kind of brushless motor stator insulation framework, including sequentially connected inner side installation part, insulation extension arm and outer side installation part, insulation extension arm is located between inner side installation part and outer side installation part, the positioning groove that lets enameled wire embed is set on the opposite two outer surfaces of insulation extension arm, positioning groove is set multiple, and positioning groove is circular-arc groove.The utility model discloses a kind of brushless motor stator insulation framework, set the circular-arc positioning groove of adaptation winding wire diameter, realize winding accurate first positioning to avoid winding layer dislocation, avoid causing winding resistance imbalance, affect the smoothness of motor output torque and other risks, can realize optimization assembly and winding process, reduce production process risk, improve assembly smoothness.The utility model further discloses a kind of brushless motor for electric power assisted steering gear all-in-one machine.

Description

Technical Field

[0001] This utility model belongs to the field of motor technology. Specifically, this utility model relates to a brushless motor stator insulation frame and a brushless motor for an integrated electric power steering system. Background Technology

[0002] In the technical system of electric power steering (EPS) systems for automobiles, the brushless motor of the integrated electric power steering unit is the core actuator, and its operational stability and energy efficiency directly affect steering accuracy and driving safety. The insulating frame, as a key insulating component of the brushless motor stator, not only needs to achieve electrical isolation between the windings and the iron core, but also needs to provide a positioning reference for the winding process.

[0003] In existing technologies, brushless motor stator insulation frames mostly adopt a split structure, mainly composed of an upper frame and a lower frame, which are connected to the stator core by covering the upper and lower ends. The working principle is to use the insulation material of the frame (usually PA66 + 30% glass fiber) to block the conductive path between the winding and the core, while the boss structure on the outer wall of the insulation frame limits the winding range of the enameled wire, preventing inter-turn short circuits or enamel film damage during winding. Existing technologies have the following technical problems:

[0004] 1. Stability issues in the winding assembly process; reduced efficiency in the winding process: Uneven winding can lead to frequent malfunctions such as "winding jams" and "winding breaks" in the winding machine (especially in automated winding equipment), forcing the equipment to stop for adjustments and reducing production cycle time. Subsequent assembly interference: If the winding is too prominent in some areas, it may interfere with the rotor or housing, causing assembly jamming; while sparse areas may experience winding deformation during assembly and pressing due to insufficient structural strength, affecting the overall assembly accuracy of the motor. Inadequate assembly guide design makes assembly difficult, easily causing interference and resulting in a low pass rate.

[0005] 2. Deterioration in heat dissipation: Evenly distributed enameled wires form regular heat dissipation channels, facilitating heat dissipation through the insulation frame and iron core. If the distribution is uneven, heat in dense areas is difficult to dissipate, easily forming local hot spots, accelerating the aging of insulation materials (such as the PA66 material of the frame experiencing performance degradation under long-term high temperatures), and shortening the motor's service life.

[0006] 3. Mechanical and vibration noise issues, electromagnetic force imbalance. Uneven distribution of enameled wires can lead to asymmetrical magnetomotive force distribution in the stator windings, causing additional radial electromagnetic force waves to be generated during motor operation. These force waves excite the stator core to vibrate, which is then transmitted as noise through the housing.

[0007] 4. Structural stress concentration: The enameled wire in dense areas will generate large internal stress under thermal expansion and contraction or vibration conditions. Long-term operation may cause the winding to loosen or even cause the insulation skeleton to deform, further aggravating the unevenness of the winding arrangement and forming a vicious cycle.

[0008] In summary, the uniform arrangement of enameled wire on the insulation frame is a key factor in ensuring motor performance, reliability, and production stability. This is especially true for scenarios with stringent requirements for precision and stability, such as brushless motors in integrated electric power steering systems, where this issue directly relates to product quality and safety.

[0009] Chinese Patent Application No. 201920724856.1 discloses a brushless motor stator insulation frame, comprising: an annular outer ring, the outer wall of which has a recessed structure, the recessed structure being recessed radially inward along the annular outer ring; an annular platform, the outer edge of which is connected to the bottom of the annular outer ring; a column disposed on the top of the platform, the column being opposite to the recessed structure and spaced apart, the inner sidewall of the recessed structure opposite to the column being flat; and an insulation frame body for insulating the teeth and slots of the motor stator core, the top outer edge of the insulation frame body being connected to the inner edge of the annular platform.

[0010] This invention provides a stator insulation frame for a brushless motor, specifically addressing how to optimize assembly and winding processability, reduce production risks, and improve assembly smoothness. Utility Model Content

[0011] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention provides a brushless motor stator insulation frame, with the purpose of optimizing assembly and winding processability, reducing production process risks, and improving assembly smoothness.

[0012] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a brushless motor stator insulating frame, including an inner mounting part, an insulating extension arm and an outer mounting part connected in sequence, the insulating extension arm being located between the inner mounting part and the outer mounting part, and positioning grooves for embedding enameled wires are provided on the two opposite outer surfaces of the insulating extension arm, multiple positioning grooves are provided, and the positioning grooves are arc-shaped grooves.

[0013] All positioning slots on the same outer surface of the insulated extension arm are equidistantly distributed.

[0014] The positioning grooves on the two opposite outer surfaces of the insulated extension arm are arranged symmetrically.

[0015] The tail end of the brushless motor stator insulation frame is provided with an angled guide groove for assembly guidance.

[0016] The guide surface of the angled guide groove includes a first guide surface, a second guide surface and a third guide surface. The first guide surface is inclined at the end of the inner mounting part, the second guide surface is inclined at the end of the insulating extension arm, and the third guide surface is inclined at the end of the outer mounting part. The second guide surface is located between the first guide surface and the third guide surface.

[0017] This utility model also provides a brushless motor for an integrated electric power steering system, including the brushless motor stator insulation frame.

[0018] The stator insulation frame of this invention for a brushless motor is equipped with an arc positioning groove that adapts to the winding wire diameter. This enables precise pre-positioning of the winding to avoid misalignment between winding layers, thus preventing risks such as uneven winding resistance and affecting the smoothness of the motor's output torque. It can optimize assembly and winding process, reduce production risks, and improve assembly smoothness. Attached Figure Description

[0019] This manual includes the following figures, which illustrate the following:

[0020] Figure 1 This is a schematic diagram of the structure of the stator insulation frame of the brushless motor of this utility model;

[0021] Figure 2 This is a top view of the stator insulation frame of the brushless motor of this utility model;

[0022] Figure 3 This is another structural schematic diagram of the stator insulation frame of the brushless motor of this utility model;

[0023] Figure 4 This is a cross-sectional view of the stator insulation frame of the brushless motor of this utility model;

[0024] The markings in the diagram are: 1. Inner mounting part; 2. Insulated extension arm; 3. Outer mounting part; 4. Positioning groove; 5. First guide surface; 6. Second guide surface; 7. Third guide surface; 8. Angled guide groove; 9. Arc transition. Detailed Implementation

[0025] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solution of this utility model, and to facilitate its implementation.

[0026] It should be noted that in the following embodiments, the terms "first," "second," and "third" do not represent an absolute distinction in structure and / or function, nor do they represent the order of execution; they are merely for the convenience of description.

[0027] Firstly, such as Figures 1 to 4 As shown, this utility model provides a brushless motor stator insulation frame, including an inner mounting part 1, an insulation extension arm 2 and an outer mounting part 3 that are fixedly connected in sequence. The insulation extension arm 2 is located between the inner mounting part 1 and the outer mounting part 3. Positioning grooves 4 for embedding enameled wires are provided on the two opposite outer surfaces of the insulation extension arm 2. Multiple positioning grooves 4 are provided. The positioning grooves 4 are arc-shaped grooves. The enameled wires are installed on the insulation extension arm 2.

[0028] Specifically, such as Figures 1 to 4 As shown, the inner mounting part 1, the insulating extension arm 2, and the outer mounting part 3 are arranged sequentially along the first direction. The length directions of the inner mounting part 1, the insulating extension arm 2, and the outer mounting part 3 are parallel to the second direction, and the first and second directions are perpendicular to each other. The axis of the positioning groove 4 is parallel to the second direction. All positioning grooves 4 provided on the same outer surface of the insulating extension arm 2 are equidistantly distributed, and the positioning grooves 4 provided on two opposite outer surfaces of the insulating extension arm 2 are symmetrically arranged. These two outer surfaces are on the same straight line perpendicular to the first and second directions.

[0029] In this embodiment, the insulating frame employs arc-shaped positioning slots 4 adapted to the winding wire diameter. These slots are equidistantly arranged to ensure precise pre-positioning of the windings, preventing misalignment between winding layers and avoiding risks such as uneven winding resistance affecting the smoothness of motor output torque. Secondly, it reduces the increased risk of inter-turn / phase-to-phase short circuits. It avoids excessively dense enameled wire in certain areas, which can easily lead to enamel film damage due to compression and friction during winding, causing inter-turn short circuits. Uniform spacing between adjacent windings prevents phase-to-phase breakdown, which could cause motor burnout, increase copper losses, reduce efficiency, and induce additional harmonic losses, leading to increased motor heating.

[0030] like Figures 1 to 4As shown, the tail end of the stator insulation frame of the brushless motor is provided with an angled guide groove 8 for assembly guidance. The guide surfaces in the angled guide groove 8 include a first guide surface 5, a second guide surface 6, and a third guide surface 7. The first guide surface 5 is inclined at the end of the inner mounting part 1, the second guide surface 6 is inclined at the end of the insulating extension arm 2, and the third guide surface 7 is inclined at the end of the outer mounting part 3. The second guide surface 6 is located between the first guide surface 5 and the third guide surface 7. The width direction of the first guide surface 5, the second guide surface 6, and the third guide surface 7 forms an angle with the second direction, and this angle is acute. The second guide surface 6 extends along the entire width direction of the insulating extension arm 2, and the width direction of the insulating extension arm 2 is parallel to the first direction. The second guide surface 6 and the positioning groove 4 are located at both ends of the length direction of the insulating extension arm 2, respectively. The distance between the first end of the first guide surface 5 and the first end of the third guide surface 7 is less than the distance between the second end of the first guide surface 5 and the second end of the third guide surface 7. The first end and the second end of the first guide surface 5 are the two ends in the width direction of the first guide surface 5, and the first end and the second end of the third guide surface 7 are the two ends in the width direction of the third guide surface 7. The first end of the first guide surface 5 and the first end of the third guide surface 7 are closer to the positioning groove 4 than the second end.

[0031] like Figures 1 to 4 As shown, the insulating extension arm 2 has a U-shaped structure. One end of the insulating extension arm 2 along its length is an open end with an opening, and the other end along its length is a closed end without an opening. The second guide surface 6 is located at the open end, and the positioning groove 4 is located at the closed end. The ends of the two outer surfaces where the positioning groove 4 is located are connected to the two ends of the end face of the closed end, and the end of each outer surface is connected to the end face of the closed end with a rounded transition.

[0032] By providing an angled guide groove 8 at the tail end of the insulating frame for assembly, interference problems caused by stepped guidance are avoided during assembly, thus improving assembly processability. Furthermore, the winding contact area uses an R-shaped arc transition adapted to the wire diameter to avoid right-angle contact, mitigating the risk of enamel film damage caused by friction between the enameled wire and the edge during winding, and avoiding the problem of high damage rate under high-speed winding conditions.

[0033] In this embodiment, the insulating skeleton is made of PA66+GF30 glass fiber.

[0034] The above-described brushless motor stator insulation frame has the following technical advantages:

[0035] 1. Significantly improves motor operation stability and reliability, solving the core problem of winding arrangement:

[0036] By adopting the design of "adaptive winding wire diameter arc + equidistant arrangement", the winding is accurately pre-positioned, avoiding misalignment between winding layers and eliminating the risk of reduced motor output torque smoothness caused by uneven winding resistance. At the same time, it eliminates the problem of enamel film extrusion and damage caused by excessive local density of enameled wire, significantly reducing the risk of inter-turn short circuits, phase-to-phase breakdown and motor burnout. It reduces copper loss, additional harmonic loss and increased heat generation from the root, ensuring motor energy efficiency and output stability.

[0037] 2. Optimize motor performance in multiple dimensions: The uniform arrangement of the windings creates regular heat dissipation channels for the enameled wires, improving the local hot spot problem caused by uneven arrangement in the existing technology and slowing down the aging rate of the insulation material; at the same time, it makes the magnetomotive force distribution of the stator windings symmetrical, reducing additional radial electromagnetic force waves and reducing high-frequency noise; in addition, the uniform arrangement can also avoid stress concentration in dense areas, prevent winding loosening and frame deformation, and eliminate the vicious cycle of uneven arrangement-stress concentration-performance deterioration.

[0038] 3. Optimize assembly and winding processes to reduce production risks and improve winding safety:

[0039] The winding contact area adopts an R-arc transition adapted to the wire diameter, replacing the traditional right-angle structure. This completely solves the problem of paint film damage caused by friction between the enameled wire and the skeleton edge under high-speed winding conditions, reduces the paint film damage rate, and reduces subsequent failures caused by paint film damage.

[0040] 4. Improve assembly smoothness: The tail end of the insulating frame is designed with an angled guide groove 8, which replaces the traditional stepped guide structure and completely avoids interference problems during assembly.

[0041] The above-described brushless motor stator insulation frame has the following economic advantages:

[0042] 1. Improve production efficiency and reduce production losses to enhance the efficiency of the winding process: Solve the problems of "wire jamming" and "wire breakage" caused by uneven winding in the existing technology. By accurately positioning the winding and reducing the risk of varnish damage, reduce the frequency of equipment downtime for adjustment, shorten the production cycle, and directly improve the efficiency of the winding process.

[0043] 2. Reduce assembly scrap rate: The angled guide groove 8 avoids assembly interference problems and reduces the scrap of parts caused by assembly jamming and winding deformation; at the same time, it reduces the risk of faults such as inter-turn / phase short circuit and motor burnout, reduces the defect rate of finished motors, and reduces the waste of raw materials.

[0044] 3. Reduce total life cycle costs and reduce after-sales maintenance costs: Improved motor heat dissipation, slower aging of insulation materials, reduced risk of winding loosening and frame deformation, extended motor life, reduced after-sales maintenance and component replacement frequency and costs for end users, and reduced after-sales service investment for manufacturers.

[0045] 6. Reduced energy consumption and material costs: The uniform winding arrangement reduces copper loss and harmonic loss, improves motor efficiency, and reduces energy consumption during long-term use; at the same time, it avoids the extra consumption of enameled wire caused by excessive local winding density, thus optimizing material utilization efficiency.

[0046] 7. Enhance product market competitiveness and create commercial value. The improved motor is superior to existing products in terms of precision, stability, lifespan and comfort, and can better meet the high reliability and high safety requirements of automotive EPS systems. This will help improve the market acceptance of brushless motors and EPS devices equipped with this insulated frame, help companies gain an advantage in industry competition, and indirectly promote product sales and market share.

[0047] Secondly, this utility model also provides a brushless motor for an integrated electric power steering system, including the brushless motor stator insulation frame with the above-described structure. This brushless motor stator insulation frame can be referred to... Figures 1 to 4 The details will not be elaborated further here. Since the brushless motor for the integrated electric power steering system of this utility model includes the brushless motor stator insulation frame in the above embodiments, it has all the advantages of the above-mentioned brushless motor stator insulation frame.

[0048] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A brushless motor stator insulation frame, characterized in that: It includes an inner mounting part, an insulating extension arm, and an outer mounting part connected in sequence. The insulating extension arm is located between the inner mounting part and the outer mounting part. Positioning grooves for embedding enameled wire are provided on the two opposite outer surfaces of the insulating extension arm. Multiple positioning grooves are provided, and the positioning grooves are arc-shaped grooves.

2. The brushless motor stator insulation frame according to claim 1, characterized in that: All positioning slots on the same outer surface of the insulated extension arm are equidistantly distributed.

3. The brushless motor stator insulation frame according to claim 1, characterized in that: The positioning grooves on the two opposite outer surfaces of the insulated extension arm are arranged symmetrically.

4. The brushless motor stator insulation frame according to any one of claims 1 to 3, characterized in that: The tail end of the brushless motor stator insulation frame is provided with an angled guide groove for assembly guidance.

5. The brushless motor stator insulation frame according to claim 4, characterized in that: The guide surface of the angled guide groove includes a first guide surface, a second guide surface and a third guide surface. The first guide surface is inclined at the end of the inner mounting part, the second guide surface is inclined at the end of the insulating extension arm, and the third guide surface is inclined at the end of the outer mounting part. The second guide surface is located between the first guide surface and the third guide surface.

6. A brushless motor for an integrated electric power steering system, characterized in that: Includes the brushless motor stator insulation frame as described in any one of claims 1 to 5.

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