Brushless Motor Assembly for Automotive Cooling Fan

Abstract

The present invention discloses a brushless motor assembly for an automotive cooling fan, which includes a stator assembly, a rotor assembly and a heat dissipation cover. The rotor assembly includes a rotor core, a rotor shaft and magnetic steel. A central hole is provided in the center of the rotor core, and placement grooves for placing the magnetic steel are evenly distributed on the outer circumference of the rotor core. The rotor assembly further includes a front baffle and a rear baffle. The rotor shaft passes through the central hole and the rear baffle and is fixedly connected to the rear baffle. The front baffle is fixed to the front end face of the rotor core, and the rear baffle leans against the rear end face of the rotor core. The magnetic steel is installed in the placement groove and is axially constrained between the front baffle and the rear baffle. A radial limiting structure is provided in each placement groove of the rotor core. The axial position and the radial position of the magnetic steel of the rotor assembly of this brushless motor assembly are both constrained, thereby reducing the crosstalk of the magnetic steel and reducing the magnetic field fluctuation.

Description

Technical Field

[0001] The present invention relates to a brushless motor assembly for an automotive cooling fan, which is used for driving the automotive cooling fan. Background Art

[0002] The brushless motor assembly for an automotive cooling fan includes a stator assembly, a rotor assembly and a heat dissipation cover. The stator assembly, the rotor assembly and the heat dissipation cover are the main components of the brushless motor. The stator assembly includes a stator component, a stator housing and a PCBA component. The stator component is embedded in the stator housing. The rotor assembly includes a rotor core, a rotor shaft and magnetic steel. A central hole is provided in the center of the rotor core, and placement grooves for placing magnetic steel are evenly distributed on the outer circumference of the rotor core. The rotor assembly is located inside the stator component. However, the current motor assembly has the following disadvantages:

[0003] 1. The stator component includes a stator core, a front insulating end cover and a rear insulating end cover arranged at the front and rear ends of the stator core. A stator winding is arranged between the front insulating end cover and the rear insulating end cover. Currently, the stator winding is generally a three-phase winding, and three enameled wires need to be wound around the front insulating end cover and the rear insulating end cover. The ends of the three enameled wires are respectively clamped and fixed together by three copper rings to achieve conductive connection, so as to achieve three-phase connection. Then, there is a connecting piece on the PCBA board, and the connecting piece is in contact with the copper ring and welded and fixed. However, the connection between the three-phase winding joints of this stator assembly and the PCBA board is very troublesome. The copper ring needs to be sleeved on the end, and then welded to the connecting piece on the PCBA board. In order to ensure no false soldering, the contact between the connecting piece and the copper ring and the sleeving of the copper ring both require manual participation, with very low efficiency, and there are also many and messy wire ends in the stator assembly.

[0004] 2. The rotor shaft of the rotor component penetrates the rotor core and the rear baffle. A plurality of placement grooves for placing magnetic steel are provided on the rotor core, and magnetic steel is placed in each placement groove. The magnetic steel adopts a clamping fixing form. The specific fixing method is: a plurality of U-shaped metal clips are clamped on the rotor core. The rotor core is formed by stacking a plurality of silicon steel sheets of different specifications. The placement grooves on the outer circumference of the rotor core are surrounded by a plurality of spaced similar triangular blocks, and the metal clip is clamped on the triangular block. In this way, one side of a metal clip is in each placement groove. When the magnetic steel is clamped in the placement groove, it will contact one side of the metal clip, and finally the placement groove is clamped in the placement groove. However, a relatively large disadvantage of this rotor component is that the magnetic steel is clamped in the placement groove only relying on the tightening force of the metal clip, and the fixing is not firm. The magnetic steel may displace axially and radially, resulting in magnetic field fluctuations. Especially for the driving motor of the cooling fan used in an automobile, due to the bumpy use environment, this disadvantage is amplified and the magnetic field fluctuations are more obvious.

[0005] 3. The current heat dissipation cover is limited by its volume, resulting in a smaller heat dissipation effect. The connection between the wire harness of the heat dissipation cover and the PCB is rather troublesome. The wire harness assembly is press-fitted with the heat dissipation cover for pre-fixation, and then clamp-soldered with the connection pins on the PCB. Thus, the installation of the wire harness requires a high dimensional accuracy. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a brushless motor assembly for an automotive cooling fan. The axial position and radial position of the magnetic steel of the rotor assembly of the brushless motor assembly are both constrained, thereby reducing the displacement of the magnetic steel and reducing the magnetic field fluctuation.

[0007] To solve the above technical problem, the technical solution of the present invention is: a brushless motor assembly for an automotive cooling fan, including a stator assembly, a rotor assembly and a heat dissipation cover. The rotor assembly includes a rotor core, a rotor shaft and a magnetic steel. A central hole is provided in the center of the rotor core, and placement grooves for placing the magnetic steel are evenly distributed on the outer circumference of the rotor core. The rotor assembly further includes a front baffle and a rear baffle. The rotor shaft penetrates through the central hole and the rear baffle and is fixedly connected to the rear baffle. The front baffle is fixed to the front end face of the rotor core, and the rear baffle leans against the rear end face of the rotor core. The magnetic steel is installed in the placement groove and is axially constrained between the front baffle and the rear baffle. A radial limiting structure is provided in each placement groove of the rotor core.

[0008] After adopting the above technical solution, the effect of the present invention is: the rotor assembly of the brushless motor assembly further includes a front baffle and a rear baffle. The rotor shaft penetrates through the central hole and the rear baffle and is fixedly connected to the rear baffle. The front baffle is fixed to the front end face of the rotor core, and the rear baffle leans against the rear end face of the rotor core. The magnetic steel is installed in the placement groove and is axially constrained between the front baffle and the rear baffle. A radial limiting structure is provided in each placement groove of the rotor core. Therefore, the axial position of the magnetic steel can be effectively restricted by the front baffle and the rear baffle, and at the same time, the radial position of the magnetic steel is restricted by the radial limiting structure, thereby reducing the displacement of the magnetic steel and reducing the magnetic field fluctuation.

[0009] As a preferred solution, the rotor core includes a plurality of stacked silicon steel sheets. The radial limiting structure includes a tongue spring provided at the bottom of the placement groove of each silicon steel sheet of the rotor core. The tongue spring extends towards the groove opening, and limiting protrusions are provided on the inner sides of the two groove openings of each placement groove. In this way, after the magnetic steel is installed in the placement groove, the inner side of the magnetic steel is abutted by the tongue spring, and the outer side of the magnetic steel is restricted by the limiting protrusion, thereby restricting the radial direction and making the fixation of the magnetic steel more stable.

[0010] As a preferred solution, the front baffle includes an annular front baffle body, on which several connecting columns are provided. Corresponding connecting holes are provided on the rotor core. The front baffle body is fixed to the front end of the rotor core through the connecting columns embedded in the connecting holes. Front positioning grooves corresponding to the placement grooves are also provided on the front baffle. In this way, the connecting columns can be better inserted into the connecting holes, making the front baffle more firmly fixed. Further preferably, the connecting holes can adopt the structural form of stepped holes. The corresponding connecting columns include a large-diameter section and a small-diameter section connected to each other. The large-diameter section and the small-diameter section are respectively matched with the large-diameter hole section and the small-diameter hole section of the stepped hole, making the fixation more firm.

[0011] As a preferred solution, the rear baffle includes a circular rear baffle body. A connecting cylinder part is provided on the rear end face of the rear baffle body. A central shaft hole that is interference-fitted with the rotor shaft is provided on the connecting cylinder part. A rear positioning groove for positioning the rear section of the magnet is provided on the front end face of the connecting cylinder part. The front positioning groove and the rear positioning groove can better limit the magnet, with better positioning effect and the magnet being less likely to loosen.

[0012] As a preferred solution, the stator assembly includes a stator housing, a stator component, and a PCBA component. The stator component is embedded in the stator housing. The stator component includes a stator core, a front insulating end cover and a rear insulating end cover provided at the front and rear ends of the stator core. A stator winding is provided between the front insulating end cover and the rear insulating end cover. Three or six metal retaining hooks are fixed on the rear insulating end cover. The stator winding is wound according to the winding rule and straddles the metal retaining hooks and is fixed by clamp welding therewith, so that the stator winding forms a three-phase winding. A conductive support is fixed on the rear insulating end cover. A through hole for the retaining hook to pass through is provided on the conductive support. A PCBA board is detachably fixed to the rear end of the conductive support. Welding through holes are provided on the PCBA board. The metal retaining hooks pass through the welding through holes and are welded and electrically connected to the PCBA board. Therefore, when the stator winding is wound, the stator winding will straddle the metal retaining hooks. The metal retaining hooks can hold the winding, and then the winding will be broken when clamp welding is performed, thus completing the welding and conductive connection of the corresponding ends and realizing the three-phase winding. The winding of the entire stator assembly is more convenient and neater. At the same time, there is no need to use copper rings anymore, saving manpower. It is only necessary to wind the wire directly and then perform automatic clamp welding, with higher efficiency. And the metal retaining hooks are directly inserted into the welding through holes of the PCBA board, which is also convenient for the welding and conductive connection of the PCBA board.

[0013] As a preferred solution, the metal hook includes a hook body. The front end of the hook body is fixedly inserted with a rear insulating end cover. Two strip-shaped openings extending forward and backward are formed at the front end of the hook body. The plate part between the strip-shaped openings is bent outward to form a hook part. The front end of the hook body is provided with an inverted tooth structure on both sides, and the surface of the rear insulating end cover is provided with an embedded groove. The hook body is convenient to form and is firmly fixed to the rear insulating end cover.

[0014] As a preferred solution, when there are three metal hooks, the stator winding is wound according to the winding rule and straddles the metal hooks and is fixedly clamped and welded thereto. When clamping and welding, the enameled wire of the stator winding is broken and clamped and welded to the three metal hooks to form a three-phase winding;

[0015] When there are six metal hooks, the metal hooks are divided into three groups in pairs. Among them, the stator winding is wound according to the winding rule and straddles the metal hooks and is fixedly clamped and welded thereto. And the two metal hooks in the first group are electrically connected by welding with an enameled wire. Two conductive pins are embedded in the conductive bracket. Two connection pins are provided on each conductive pin. One of the two connection pins of one conductive pin is respectively electrically connected to the two metal hooks in the second group in a one-to-one correspondence, and the two connection pins of the other conductive pin are respectively electrically connected to the two metal hooks in the third group in a one-to-one correspondence. The three groups of metal hooks pass through the welding through holes and are welded and electrically connected to the PCBA board to form a three-phase winding of the stator winding. In this way, it can be selected according to the actual process. When three hooks are selected, the winding process is simplified at this time. Only during the winding process, the area where the enameled wire needs to span on the rear insulating end cover is relatively large; while when six hooks are selected, when winding the three-phase winding, the wire connection between two groups of metal hooks is electrically connected by using the two conductive pins in the conductive bracket. In this way, the enameled wire span distance outside the conductive bracket is relatively short, so the winding is neater.

[0016] As a preferred solution, a centralized wiring area is provided on the back of the PCBA board. A wiring bracket is provided on the centralized wiring area. A plurality of conductive pins on the wiring bracket are fixedly welded to the PCBA board. A plurality of bolt mounting parts are provided on the rear insulating end cover. The PCBA board is fixed to the bolt mounting parts through grounding bolts. A grounding spring is provided on the grounding bolts. The grounding bolts connect the grounding spring to the grounding electrode on the PCBA board. The rear end of the grounding spring abuts against the heat dissipation cover. The installation of the grounding spring is also very convenient. A wire passing area is provided on the heat dissipation cover. A plurality of wire passing holes for facilitating the penetration of the conductive pins on the motor PCB board are provided on the wire passing area. An installation frame is provided on the outer side surface of the heat dissipation cover. The installation frame includes a frame area surrounding the wire passing area and a wire harness connector installation area located outside the frame area. A wire harness fixing block is clamped on the wire harness connector installation area. A wire harness is embedded in the wire harness fixing block. A dust-proof cover is clamped outside the installation frame. The wire harness connector on the wire harness fixing block is fixedly welded corresponding to the conductive pins. Therefore, during installation, the wire harness is embedded in the wire harness fixing block, and the wire harness fixing block is clamped in the wire harness connector installation area, so that pre-positioning can be achieved. At this time, the end of the wire harness can better contact the conductive pins on the wire passing holes, facilitating welding. After welding, the dust-proof cover is then clamped to prepare for potting, and the dust-proof cover can effectively improve the problem of unevenness on the surface of the potting glue.

[0017] As a preferred solution, the dust-proof cover includes a panel and a side surround plate provided on the inner side edge of the panel. The shape of the panel is adapted to the shape of the installation frame. A potting hole is provided on the panel. At least two first card slots or first clamping blocks are provided on the side surround plate. Correspondingly, first clamping blocks and first card slots adapted to the first card slots or first clamping blocks are provided on the installation frame. An insertion plate is provided on the inner side wall of the side surround plate. An insertion gap adapted to the thickness of the installation frame is formed between the insertion plate and the side surround plate. The installation frame is located in the insertion gap after the dust-proof cover is clamped. Therefore, the dust-proof cover can be well clamped on the installation frame, and also provides appropriate space for potting, facilitating potting. The installation frame is located in the insertion gap after the dust-proof cover is clamped. The insertion plate can effectively guide the dust-proof cover and can be used as an auxiliary clamping structure.

[0018] As a preferred solution, second clamping blocks or second card slots are provided on the inner wall of the installation frame in the wire harness connector installation area. Correspondingly, second card slots or second clamping blocks adapted to the second clamping blocks or second card slots are provided on the wire harness fixing block. A plurality of heat dissipation columns are also provided on the outer side surface of the heat dissipation cover. The heat dissipation columns are arranged between the heat dissipation fins. In this way, not only do the heat dissipation fins of the heat dissipation cover have a heat dissipation effect, but also the heat dissipation columns are added, further increasing the heat dissipation area and improving the heat dissipation effect. Description of the Drawings

[0019] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0020] Figure 1 is a perspective view of the brushless motor according to an embodiment of the present invention;

[0021] Figure 2 is an exploded schematic view of the brushless motor according to an embodiment of the present invention Figure 1 ;

[0022] Figure 3 is an exploded schematic view of the brushless motor according to an embodiment of the present invention Figure 2 ;

[0023] Figure 4 is a perspective view of the rotor assembly;

[0024] Figure 5 is a perspective view of the rotor assembly from another angle;

[0025] Figure 6 is an exploded schematic view of the rotor assembly;

[0026] Figure 7 is a perspective view of the rear baffle;

[0027] Figure 8 is a front schematic view of the rotor core;

[0028] Figure 9 is a structural schematic view of the heat dissipation cover;

[0029] Figure 10 is a perspective view of the dust cover according to an embodiment of the present invention;

[0030] Figure 11 is a perspective view of the dust cover according to an embodiment of the present invention from another angle;

[0031] Figure 12 is an exploded schematic view of the stator assembly with the PCBA board hidden according to an embodiment of the present invention;

[0032] Figure 13 is an exploded schematic view of the stator assembly according to an embodiment of the present invention;

[0033] Figure 14 is an exploded schematic view of another stator assembly;

[0034] Figure 15 is Figure 14 the winding schematic diagram of the stator assembly in

[0035] In the accompanying drawings:

[0036] 1. Stator assembly; 11. Stator housing; 12. Stator component; 121. Stator core; 122. Front insulating end cover; 123. Rear insulating end cover; 1231. Hook; 1232. Embedded groove; 124. Conductive bracket; 1241. Connection pin one; 1242. Connection pin two; 125. Metal retaining hook; 1251. Strip-shaped opening; 1252. Reverse tooth structure; 1253. Hook part; 126. Stator winding; 13. PCBA component; 131. Wiring bracket; 132. Conductive pin; 133. Grounding spring;

[0037] 2. Rotor assembly; 21. Rotor core; 211. Placing groove; 212. Connection hole; 213. Limiting protrusion; 214. Reed; 215. Central hole; 22. Front baffle; 221. Front baffle body; 222. Connection column; 2221. Small diameter section; 2222. Large diameter section; 223. Front positioning groove; 23. Rear baffle; 231. Rear baffle body plate; 232. Connection cylinder part; 233. Reinforcing rib; 234. Rear positioning groove; 235. Central shaft hole; 236. Radial convex rib 236; 24. Rotor shaft; 25. Magnet; 26. Bearing.

[0038] 3. Heat dissipation cover; 31. Cover body; 311. Heat dissipation fins; 312. Heat dissipation columns; 313. Installation frame; 314. Waterproof and breathable valve; 315. Wiring area; 316. Wiring hole; 317. Wiring harness connector installation area; 318. Male second clamping block; 319. First clamping block; 32. Dust cover; 321. Panel; 322. Side enclosure; 323. First clamping groove; 324. Glue filling hole; 325. Insertion plate; 33. Wiring harness fixing block; 331. Female second clamping block. Specific embodiments

[0039] The present invention will be further described in detail below through specific embodiments.

[0040] As Figures 1 to 15 described, the present invention discloses a brushless motor assembly for an automotive cooling fan, including a stator assembly 1, a rotor assembly 2, and a heat dissipation cover 3. The rotor assembly 2 includes a rotor core 21, a rotor shaft 24, and a magnet 25. A central hole 215 is provided at the center of the rotor core 21, and placing grooves 211 for placing the magnet 25 are evenly distributed on the outer circumference of the rotor core 21. The rotor assembly further includes a front baffle 22 and a rear baffle 23. The rotor shaft 24 passes through the central hole 215 and the rear baffle 23 and is fixedly connected to the rear baffle. The front baffle 22 is fixed to the front end face of the rotor core 21, the rear baffle 23 abuts against the rear end face of the rotor core 21, the magnet 25 is installed in the placing groove 211 and is constrained in the front-rear direction between the front baffle 22 and the rear baffle 23, and a radial limiting structure is provided in each placing groove 211 of the rotor core 21.

[0041] Among them, a central hole 215 is provided at the center of the rotor core 21. Placing grooves 211 for placing permanent magnets 25 are evenly distributed on the outer circumference of the rotor core 21. The rotor core 21 is formed by stacking a number of silicon steel sheets of the same specification.

[0042] The rotor assembly further includes a front baffle 22 and a rear baffle 23. The rotor shaft 24 passes through the central hole 215 and the rear baffle 23 and is fixedly connected to the rear baffle. Bearings 26 are provided at both the front end and the rear end of the rotor shaft 24, facilitating the rotational installation of the entire rotor assembly on the motor housing.

[0043] The front baffle 22 is fixed to the front end face of the rotor core 21. The specific fixing method is as follows: The front baffle 22 includes an annular front baffle body 221. A number of connecting columns 222 are provided on the annular front baffle body 221. Corresponding connecting holes 212 are provided on the rotor core 21 corresponding to the connecting columns 222. The front baffle body 221 is fixed to the front end of the rotor core 21 through the connecting columns 222 embedded in the connecting holes 212.

[0044] Preferably in this embodiment, the connecting hole 212 is a stepped hole. The corresponding connecting column 222 includes a large-diameter section 2222 and a small-diameter section 2221 connected to each other. The large-diameter section 2222 and the small-diameter section 2221 are respectively matched with the large-diameter hole section and the small-diameter hole section of the stepped hole. The connection between the connecting column 222 and the front baffle body 221 can adopt a detachable connection method, such as riveting. Of course, an integrally formed connection can also be adopted, that is, the front baffle 221 is formed by encapsulating and injecting plastic on the rotor core 21, and the connecting column 222 is injection-molded in the connecting hole 212 on the rotor core 21, and the front baffle 22 can be firmly fixed on the rotor core 21, providing an axial limit for the permanent magnet 253.

[0045] The front baffle 22 is also provided with front positioning grooves 223 corresponding to the placing grooves 211 one by one. The front positioning grooves 223 can facilitate the buckling of the front baffle body 221 on the rotor core 21.

[0046] The rear baffle 23 abuts against the rear end face of the rotor core 21. The permanent magnet 25 is installed in the placing groove 211 and is constrained in the front-rear direction between the front baffle 22 and the rear baffle 23. A radial limiting structure is provided in each placing groove 211 of the rotor core 21.

[0047] Among them, the rotor core 21 includes a plurality of stacked silicon steel sheets. The radial limiting structure includes a leaf spring 214 disposed at the bottom of the placement groove 211 of each silicon steel sheet of the rotor core 21. The leaf spring 214 extends towards the notch. Limiting protrusions 213 are disposed on the inner sides of the two notches of each placement groove 211. In this way, the inner end of the magnet 25 abuts against the leaf spring 214 with a certain elasticity, so that the magnet 25 is restricted between the limiting protrusion 213 and the leaf spring 214, ultimately restricting the radial position.

[0048] The rear baffle 23 includes a circular rear baffle body plate 231. A connecting cylinder portion 232 is disposed on the rear end face of the rear baffle body plate 231. Reinforcing ribs 233 are circumferentially and uniformly distributed between the connecting cylinder portion 232 and the rear end face of the rear baffle body plate 231. A central shaft hole 235 that is in interference fit with the rotor shaft 24 is disposed on the connecting cylinder portion 232. A rear positioning groove 234 for positioning the rear section of the magnet 25 is disposed on the front end face of the connecting cylinder portion 232. A plurality of radial ridges 236 are disposed inside the central shaft hole 235.

[0049] As Figures 9 to 11 shown, the above-mentioned drawings disclose the specific structures of the heat dissipation cover 3 and the protective cover. Among them, the heat dissipation cover 3 includes a cover body 31. Heat dissipation fins 311 are disposed on the outer side surface of the cover body 31.

[0050] A centralized wiring area is provided on the back of the PCBA board. A wiring bracket 131 is provided on the centralized wiring area. A plurality of conductive pins 132 on the wiring bracket 131 are welded and fixed to the PCBA board. A plurality of bolt mounting parts are provided on the rear insulating end cover 123. The PCBA board is fixed to the bolt mounting parts through grounding bolts. A grounding spring 133 is provided on the grounding bolts. The grounding bolts connect the grounding spring 133 to the grounding electrode on the PCBA board. The rear end of the grounding spring 133 abuts against the heat dissipation cover 3. The installation of the grounding spring 133 is also very convenient. A wire threading area 315 is provided on the heat dissipation cover 3. A plurality of wire threading holes 316 for facilitating the penetration of the conductive pins 132 on the motor PCB board are provided on the wire threading area 315. An installation frame 313 is provided on the outer side of the heat dissipation cover 3. The installation frame 313 includes a frame area surrounding the wire threading area 315 and a wire harness connector installation area 317 located outside the frame area. A wire harness fixing block 33 is snap-fitted on the wire harness connector installation area 317. A wire harness is embedded in the wire harness fixing block 33. A dust-proof cover 32 is snap-fitted outside the installation frame 313. The wire harness connector on the wire harness fixing block 33 is fixedly welded corresponding to the conductive pin 132. Therefore, during installation, the wire harness is embedded in the wire harness fixing block 33, and the wire harness fixing block 33 is snap-fitted in the wire harness connector installation area 317, so that pre-positioning can be achieved. At this time, the end of the wire harness can better contact the conductive pin 132 on the wire threading hole 316, thus facilitating welding. After welding, the dust-proof cover 32 is then snap-fitted to prepare for potting, and the dust-proof cover can effectively improve the problem of unevenness on the surface of the glue.

[0051] The dust cover 32 includes a panel 321 and a side enclosure 322 provided at the edge of the inner side of the panel 321. The shape of the panel 321 is adapted to the shape of the mounting frame 313. A glue injection hole 324 is provided on the panel 321, and at least two first card slots 323 or first card blocks 319 are provided on the side enclosure 322. Correspondingly, a first card block 319 and a first card slot 323 adapted to the first card slot 323 or the first card block 319 are provided on the mounting frame 313. An insertion plate 325 is provided on the inner side wall of the side enclosure 322. An insertion gap adapted to the thickness of the mounting frame 313 is formed between the insertion plate 325 and the side enclosure 322, which facilitates the accurate insertion between the protective cover and the mounting frame 313. After the dust cover 32 is clamped, the mounting frame 313 is located in the insertion gap. A second card block or a second card slot is provided on the inner wall of the wiring harness connector installation area 317 of the mounting frame 313. Correspondingly, a second card slot or a second card block adapted to the second card block or the second card slot is provided on the wiring harness fixing block 33. Preferably, a male second card block 318 is provided on the inner wall of the wiring harness connector installation area 317, and a female second card block 331 is provided on the outside of the wiring harness fixing block 33 to achieve clamping cooperation.

[0052] A plurality of heat dissipation columns 312 are further provided on the outer side surface of the heat dissipation cover 3, and the heat dissipation columns 312 are arranged between the heat dissipation fins 311. In this way, not only the heat dissipation fins 311 of the heat dissipation cover 3 have a heat dissipation effect, but also the heat dissipation columns 312 are added to further increase the heat dissipation area and improve the heat dissipation effect. A waterproof breathable valve 314 is also provided on the heat dissipation cover 3.

[0053] Such as Figures 12 to 15As shown in the figure, the stator assembly 1 includes a stator housing 11, a stator component 12, and a PCBA component 13. The stator component 12 is embedded in the stator housing 11. The stator component 12 includes a stator core 121, a front insulating end cover 122 and a rear insulating end cover 123 arranged at the front and rear ends of the stator core 121. A stator winding 126 is arranged between the front insulating end cover 122 and the rear insulating end cover 123. Three or six metal hooks 125 are fixed on the rear insulating end cover 123. The stator winding 126 is wound according to a winding rule and straddles the metal hooks 125 and is clamped and welded to them, so that the stator winding 126 forms a three-phase winding. A conductive bracket 124 is fixed on the rear insulating end cover 123. A through hole for the hook to pass through is arranged on the conductive bracket 124. A PCBA board is detachably fixed at the rear end of the conductive bracket 124. Welding through holes are arranged on the PCBA board. The metal hooks 125 pass through the welding through holes and are welded and electrically connected to the PCBA board. Therefore, when the stator winding 126 is wound, the stator winding will straddle the metal hooks 125. The metal hooks 125 can clamp the winding. Then, when clamping and welding, the winding will be broken through, so that the welding and conductive connection of the corresponding end is completed, thus realizing the three-phase winding. The winding of the entire stator assembly 1 is more convenient and neater. At the same time, there is no need to use copper rings anymore, which saves manpower. It is only necessary to wind the wire directly and then perform automatic clamping and welding, with higher efficiency. And the metal hooks 125 are directly inserted into the welding through holes of the PCBA board, which is convenient for the welding and conductive connection of the PCBA board.

[0054] The metal hook 125 includes a hook body. The front end of the hook body is inserted and fixed to the rear insulating end cover 123. Two strip-shaped openings 1251 extending forward and backward are opened at the front end of the hook body. The plate part between the strip-shaped openings 1251 is bent outward to form a hook part 1253. Inverted tooth structures 1252 are arranged on both sides of the front end of the hook body. An embedded groove 1232 is arranged on the surface of the rear insulating end cover 123. The hook body is convenient to form and is firmly fixed to the rear insulating end cover 123.

[0055] As a preferred solution, when there are three metal hooks 125, the stator winding 126 is wound according to a winding rule and straddles the metal hooks 125 and is clamped and welded to them. When clamping and welding, the enameled wire of the stator winding 126 is broken through and clamped and welded to the three metal hooks 125 to form a three-phase winding.

[0056] When there are six metal hooks 125, the six metal hooks 125 are divided into three groups in pairs. The stator winding 126 is wound according to the winding rule and straddles the metal hooks 125 and is clamped and fixed thereto. Moreover, the two metal hooks 125 in the first group are conductively connected by soldering an enameled wire therebetween. Two conductive pins 132 are embedded in the conductive bracket 124. Two connection pins are provided on each of the conductive pins 132. One of the two connection pins of one conductive pin 132 is conductively connected to the two metal hooks 125 in the second group respectively in one-to-one correspondence, and the two connection pins of the other conductive pin 132 are conductively connected to the two metal hooks 125 in the third group respectively in one-to-one correspondence. The three groups of metal hooks 125 pass through the welding through holes and are welded and electrically connected to the PCBA board to form a three-phase winding for the stator winding 126. In this way, selection can be made according to the actual process. When three hooks are selected, the winding process is simplified at this time. However, during the winding process, the area where the enameled wire needs to span on the rear insulating end cover 123 is relatively large. When six hooks are selected and the three-phase winding is wound, the wire connection between two of the groups of metal hooks 125 is conductively connected by the two conductive pins 132 in the conductive bracket 124. In this way, the spanning distance of the enameled wire outside the conductive bracket 124 is relatively short, and thus the winding is neater.

[0057] A plurality of bolt mounting parts are provided on the rear insulating end cover 123. The PCBA board is fixed to the bolt mounting parts by grounding bolts. A grounding spring 133 is provided on the grounding bolts. The grounding bolts connect the grounding spring 133 to the grounding electrode on the PCBA board. The fixing manner between the rear insulating end cover 123 and the conductive bracket 124 is snap-fitting. A plurality of hooks 1231 are provided on the rear insulating end cover 123. A hook part 1253 extending outward is provided at the rear end of the hook 1231. A hook step for hooking and cooperating with the hook part 1253 is provided on the conductive bracket 124.

[0058] As Figure 14 and Figure 15 shown, there are six metal hooks 125, and the six metal hooks 125 are divided into three groups in pairs. Figure 15It can be found that the three groups of the metal hooks 125 are: V1-V2; W1-W2; U1-U2, a total of three groups. Among them, the stator winding 126 is wound according to the winding rule and straddles the metal hook 125 and is fixedly clamped and welded therewith. Moreover, the two metal hooks 125 in the first group are electrically connected by soldering with an enameled wire. Two conductive connecting pieces are embedded in the conductive bracket 124. Two connecting pins are arranged on each conductive connecting piece, namely two connecting pins one 1241 and two connecting pins two 124264. The two connecting pins one 1241 of one conductive connecting piece are respectively and correspondingly electrically connected to the two metal hooks 125 in the second group, and the two connecting pins two 1242 of the other conductive connecting piece are respectively and correspondingly electrically connected to the two metal hooks 125 in the third group. The three groups of metal hooks 125 pass through the welding through holes and are welded and electrically connected to the PCBA board to form a three-phase winding of the stator winding 126.

[0059] As Figure 15 shown, the total number of winding grooves of the stator core 121 is 12, and they are respectively defined as slots 1-12. Among them, the winding route of the enameled wire is: V1-slot 1-slot 4-W1-slot 2-slot 5-U1-slot 3-slot 6-V2-slot 7-slot 10-W2-slot 8-slot 11-U2-slot 9-slot 12-V1-V2. Among them, V1 and V2 are connected by another wire, while W1 and W2, U1 and U2 are respectively connected by the conductive connecting pieces in the conductive bracket 124.

[0060] The above-described embodiments are only descriptions of the preferred embodiments of the present invention and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various deformations and modifications made to the technical solutions of the present invention shall fall within the protection scope determined by the claims of the present invention.

Claims

1. The brushless motor assembly for an automotive cooling fan includes a stator assembly, a rotor assembly, and a heat dissipation cover. The rotor assembly includes a rotor core, a rotor shaft, and magnetic steel. A central hole is provided in the center of the rotor core, and placement grooves for placing magnetic steel are evenly distributed on the outer circumference of the rotor core. It is characterized in that: The rotor assembly further includes a front baffle and a rear baffle. The rotor shaft passes through the central hole and the rear baffle and is fixedly connected to the rear baffle. The front baffle is fixed to the front end face of the rotor core, and the rear baffle leans against the rear end face of the rotor core. The magnetic steel is installed in the placement groove and is constrained between the front baffle and the rear baffle in the front-rear direction. A radial limiting structure is provided in each placement groove of the rotor core. The stator assembly includes a stator housing, a stator component, and a PCBA component. The stator component is embedded in the stator housing. The stator component includes a stator core, a front insulating end cover and a rear insulating end cover provided at the front and rear ends of the stator core. A stator winding is provided between the front insulating end cover and the rear insulating end cover. Three or six metal retaining hooks are fixed on the rear insulating end cover. The stator winding is wound according to a winding rule and straddles the metal retaining hooks and is clamp-welded and fixed thereto, so that the stator winding forms a three-phase winding. A conductive bracket is fixed on the rear insulating end cover. A through hole for facilitating the passing of the retaining hook is provided on the conductive bracket. A PCBA board is detachably fixed to the rear end of the conductive bracket. Welding through holes are provided on the PCBA board. The metal retaining hooks pass through the welding through holes and are welded and electrically connected to the PCBA board. A centralized wiring area is provided on the back surface of the PCBA board. A wiring bracket is provided on the centralized wiring area. A plurality of conductive pins on the wiring bracket are welded and fixed to the PCBA board. A plurality of bolt mounting parts are provided on the rear insulating end cover. The PCBA board is fixed to the bolt mounting parts by grounding bolts. A grounding spring is provided on the grounding bolt. The grounding bolt connects the grounding spring to the grounding electrode on the PCBA board. The rear end of the grounding spring abuts against the heat dissipation cover. A wire passing area is provided on the heat dissipation cover. A plurality of wire passing holes for facilitating the passing of the conductive pins on the motor PCB board are provided on the wire passing area. An installation frame is provided on the outer side surface of the heat dissipation cover. The installation frame includes a frame area surrounding the wire passing area and a wire harness connector installation area located outside the frame area. A wire harness fixing block is clamped on the wire harness connector installation area. A wire harness is embedded in the wire harness fixing block. A dust-proof cover is clamped outside the installation frame. The wire harness connector on the wire harness fixing block is correspondingly welded and fixed to the conductive pin.

2. The brushless motor assembly for an automotive cooling fan as described in claim 1, It is characterized in that: The rotor core includes a plurality of stacked silicon steel sheets. The radial limiting structure includes a tongue spring provided at the bottom of the placement groove of each silicon steel sheet of the rotor core. The tongue spring extends towards the groove opening. Limiting protrusions are provided on the inner sides of the two groove openings of each placement groove.

3. The brushless motor assembly for an automotive cooling fan as described in claim 2, It is characterized in that: The front baffle includes an annular front baffle body, on which a number of connecting posts are provided. Correspondingly, the rotor core is provided with connecting holes corresponding to the connecting posts. The front baffle body is fixed to the front end of the rotor core by the connecting posts inserted into the connecting holes. The front baffle is also provided with front positioning grooves corresponding to the placement grooves one by one.

4. The brushless motor assembly for an automotive radiator fan according to claim 3, characterized in that: The rear baffle includes a circular rear baffle body, on the rear end face of which a connecting cylinder part is provided. The connecting cylinder part is provided with a central shaft hole for interference fit with the rotor shaft. The front end face of the connecting cylinder part is provided with a rear positioning groove for positioning the rear section of the magnet.

5. The brushless motor assembly for an automotive radiator fan according to claim 4, characterized in that: The metal retaining hook includes a retaining hook body. The front end of the retaining hook body is inserted and fixed to the rear insulating end cover. Two strip-shaped openings extending forward and backward are opened at the front end of the retaining hook body. The plate part between the strip-shaped openings is bent outward to form a hook part. The front end sides of the retaining hook body are provided with reverse tooth structures. The surface of the rear insulating end cover is provided with an embedding groove.

6. The brushless motor assembly for an automotive radiator fan according to claim 5, characterized in that: When there are three metal retaining hooks, the stator winding is wound according to the winding rule and straddles the metal retaining hooks and is clamped and welded to them. When clamping and welding, the enameled wire of the stator winding is broken and clamped and welded to the three metal retaining hooks to form a three-phase winding; When there are six metal retaining hooks, the metal retaining hooks are divided into three groups in pairs. Among them, the stator winding is wound according to the winding rule and straddles the metal retaining hooks and is clamped and welded to them. And the two metal retaining hooks in the first group are electrically connected by welding with enameled wire. Two conductive pins are embedded in the conductive bracket. Each conductive pin is provided with two connecting pins. One of the two connecting pins of one conductive pin is respectively electrically connected to the two metal retaining hooks in the second group in one-to-one correspondence, and the two connecting pins of the other conductive pin are respectively electrically connected to the two metal retaining hooks in the third group in one-to-one correspondence. The three groups of metal retaining hooks pass through the welding through holes and are welded and electrically connected to the PCBA board to form a three-phase winding of the stator winding.

7. The brushless motor assembly for an automotive radiator fan according to claim 6, characterized in that: The dust cover includes a panel and a side surround plate arranged on the edge of the inner side of the panel. The shape of the panel is adapted to the shape of the installation frame. The panel is provided with potting holes. The side surround plate is provided with at least two first card slots or first blocks. Correspondingly, the installation frame is provided with first blocks and first card slots adapted to the first card slots or first blocks. An insertion plate is arranged on the inner side wall of the side surround plate. The insertion plate and the side surround plate form an insertion gap adapted to the thickness of the installation frame. After the dust cover is clamped, the installation frame is in the insertion gap.

8. The brushless motor assembly for an automotive radiator fan according to claim 7, characterized in that: The installation enclosure is provided with second clamping blocks or second clamping grooves on the inner wall of the wiring harness connector installation area, and the corresponding wiring harness fixing blocks are provided with second clamping grooves or second clamping blocks that cooperate with the second clamping blocks or second clamping grooves. A plurality of heat dissipation columns are further provided on the outer side surface of the heat dissipation cover, and the heat dissipation columns are arranged between the heat dissipation fins.

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