A mounting structure of a stator having a flexible PCB circuit board

Abstract

The application relates to the field of motors and discloses a mounting structure of a stator with a flexible PCB circuit board, which comprises a lead frame, a stator tooth arranged on the outer periphery of a stator core, a winding coil mounted on the stator tooth, a flexible circuit board mounted between the stator core and the lead frame, the coil winding being coupled with a printed circuit board on the lead frame, and a guide hole being formed on the circuit board on the lead frame. The flexible printed circuit board comprises a first part and a second part, one end face of the first part is attached to the end face of the lead frame, the other end face is attached to the end face of a stator shell, a plug hole is formed on the lead frame, the second part passes through the second plug hole and is perpendicular to the first part, a guide sleeve is sleeved on the second part and is connected with the lead frame, and a hot sleeve process of the stator core is needed when the stator shell and the stator core are mounted; the mounting structure can protect the flexible PCB from being damaged in the hot sleeve process.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electric machines, and in particular to a mounting structure of a stator with a flexible PCB circuit board. BACKGROUND

[0002] An electric motor system typically comprises an electric motor, a control unit of which is arranged to control the power of the electric motor. As high torque is required for driving a vehicle, the most commonly used electric motor is a three-phase electric motor. A three-phase electric motor typically comprises three coil windings, wherein each coil winding is arranged to generate a magnetic field associated with one of the three phases of an alternating voltage. To increase the number of magnetic poles formed within the electric motor, each coil winding typically has a number of coil sub-groups distributed around the electric motor, which are driven to generate a rotating magnetic field. Chinese patent CN201710715959.7 provides a three-phase permanent magnet brushless DC hub motor.

[0003] As shown in Figure 1 A typical three-phase electric motor has three coil groups 14, 16, 18. Each coil group is composed of four coil sub-groups in series, wherein for a given coil group, the magnetic field generated by each coil sub-group will have a common phase. The three coil groups of a three-phase electric motor are typically configured in a delta or star configuration. The control unit of a three-phase electric motor with a direct current power supply typically comprises an inverter driving the motor generating a three-phase power supply. Each respective voltage phase is applied to a respective coil group of the electric motor. A three-phase bridge inverter, comprising a number of switching devices, such as power electronic switches, for example insulated gate bipolar transistor (IGBT) switches, is used to generate the alternating voltage from the direct current power supply. In the context of an electric vehicle motor, an increasingly popular drive design is an electric motor design integrated within a vehicle wheel, wherein the electric motor and its associated control system are integrated within the vehicle wheel. To provide cooling to the coil groups and associated control system, a heat sink is typically mounted on the electric motor,

[0004] A common technique for connecting the heat sink to the electric motor is by using a thermal drop process. However, as the thermal drop process typically requires heating various electric motor components to a specified temperature, using the thermal drop process can result in imposing additional design constraints on the electric motor. SUMMARY

[0005] The present application provides a mounting structure of a stator with a flexible PCB circuit board according to the problems that the existing hub motor cannot stably measure the temperature of each coil and provide greater power, and installing a heat sink will cause damage to the flexible circuit board.

[0006] To solve the above technical problems, the present application solves the problems by the following technical solutions:

[0007] A stator mounting structure with a flexible PCB circuit board includes a lead frame, stator teeth on the outer circumference of a circumferential support, a winding coil mounted on the stator teeth, a lead frame including a printed circuit board with multiple circuit board layers, a flexible circuit board mounted between the circumferential support and the lead frame, and the coil winding coupled to the printed circuit board on the lead frame. The mounting structure also includes a guide sleeve and a heat sink. The heat sink includes a mounting portion with a circumferential outer wall and a flange portion extending around the outer wall of the mounting portion. A guide hole is provided on the flange portion. The flexible printed circuit board includes a first portion and a second portion. One end face of the first portion is attached to the end face of the lead frame, and the other end face is attached to the end face of the circumferential support. An insertion hole is provided on the lead frame. The second portion passes through the second insertion hole and is perpendicular to the first portion. The guide sleeve is sleeved on the second portion and connected to the lead frame. When the heat sink is installed with the circumferential support, the guide sleeve passes through the guide hole.

[0008] Preferably, the guide sleeve and the lead frame are detachably connected.

[0009] Preferably, the second part can be bent relative to the first part under force, and the second part initially extends radially away from the first part.

[0010] Preferably, the flexible printed circuit board is equipped with a sensor for measuring the temperature of the winding coil, and the sensor is installed on the end face of the first part near the winding coil.

[0011] Preferably, the cross-sectional shape of the first part of the flexible printed circuit board is substantially the same as the cross-sectional shape and size of the lead frame.

[0012] Preferably, the lead frame is a single circumferential shape, or it is composed of two semi-circular lead frames joined together to form a single circumferential lead frame; the flexible printed circuit board is a single circumferential shape, or it is composed of two semi-circular flexible printed circuit boards joined together to form a single circumferential flexible printed circuit board.

[0013] Preferably, each circuit board layer of the printed circuit board on the lead frame includes an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board has at least a first circuit board layer, a second circuit board layer, a third circuit board layer, and a fourth circuit board layer; the first circuit board layer includes a first conductive layer arranged to be electrically coupled to a first coil winding of a first set of coil windings and a first branch of a first inverter; the second circuit board layer includes a second conductive layer arranged to be electrically coupled to a second coil winding of the first set of coil windings and a second branch of the first inverter; the third circuit board layer includes a third conductive layer arranged to be electrically coupled to a third coil winding of the first set of coil windings and a third branch of the first inverter; the fourth circuit board layer includes a fourth conductive layer having multiple conductive layers, the fourth conductive layer being configured to be coupled to the first coil winding, the second coil winding, and the third coil winding of the first set of coil windings to form a neutral point between the first coil winding, the second coil winding, and the third coil winding.

[0014] Preferably, the first, second, and third coil windings each include three coil subgroups, namely a first phase winding, a second phase winding, and a third phase winding; the printed circuit board also includes a fifth circuit board layer having multiple conductive layers arranged to electrically couple the first, second, and third phase windings of the first, second, and third coil windings; each of the first, second, and third phase windings includes multiple coils, and the multiple conductive layers on the fifth circuit board are arranged to allow the multiple coils for each corresponding phase winding to couple relative to each other, so that each coil subgroup generates a magnetic field that is antiparallel to the adjacent coil in a given current direction and has a common phase.

[0015] Preferably, the printed circuit board further includes a set of circuit board layers identical to those in claim 8, for electrically connecting with the second set of coil windings to form a second set of three sub-motors, wherein the set of circuit board layers is electrically isolated from the circuit board layers described in the claim.

[0016] Preferably, the lead frame has multiple grooves formed on the inner and outer edges of the printed circuit board, each groove being arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board.

[0017] This invention, by adopting the above technical solutions, has significant technical effects:

[0018] The lead frame arrangement of this invention allows for the supply of a large current between the inverter and coil windings of a motor or generator, thereby generating large torque and power values. It also allows for a reduction in the space envelope of the motor / generator coil windings and inverter. Furthermore, this invention enables accurate measurement of the temperature of each coil winding group, improving the safety performance of the motor.

[0019] Furthermore, this invention allows the flexible printed circuit board to be used both as a mounting element for the motor sensor and to allow the sensor to be directly electrically connected to the control device to monitor the sensor readings, and there is no risk of damage to the sensor or the flexible printed circuit board during the assembly of the stator. Attached Figure Description

[0020] Figure 1 This illustrates the existing technology of three-phase motors;

[0021] Figure 2 An exploded view of an electric motor incorporating the present invention is provided;

[0022] Figure 3 This is a schematic diagram of the control device;

[0023] Figure 4 This describes the electrical connections provided by the lead frame according to an embodiment of the present invention;

[0024] Figure 5 The lead frame according to Embodiment 2 of the present invention is described;

[0025] Figure 6 The lead frame arrangement according to Embodiment 2 of the present invention is described;

[0026] Figure 7 The lead frame according to Embodiment 1 of the present invention is described;

[0027] Figure 8 The lead frame arrangement according to Embodiment 1 of the present invention is described;

[0028] Figure 9 This describes the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0029] Figure 10 This describes the lead frame according to an embodiment of the present invention;

[0030] Figure 11 A conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention is shown;

[0031] Figure 12 This describes the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0032] Figure 13 The conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention is described.

[0033] Figure 14 This describes the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0034] Figure 15 A lead frame according to an embodiment of the present invention is shown;

[0035] Figure 16 This is a schematic diagram of the coil end and the lead frame cooperating according to an embodiment of the present invention;

[0036] Figure 17 The stator core, coil windings, and lead frame according to embodiments of the present invention are described;

[0037] Figure 18 This is a schematic diagram of the flexible circuit board structure;

[0038] Figure 19 This is a schematic diagram of the structure of the guide sleeve and the stator core;

[0039] Figure 20 This is a schematic diagram of the stator coil windings and the stator core.

[0040] Figure 21 This is an exploded schematic diagram of the stator coil winding unit and the stator core. Detailed Implementation

[0041] Example 1

[0042] like Figure 18 As shown, this embodiment provides a stator mounting structure with a flexible PCB circuit board. The flexible printed circuit board 500 includes a first portion 501 and a second portion 502. A temperature sensor 503 is mounted on the surface of the first portion 501. The conductive strip of the temperature sensor 503 extends to the second portion 502, which is used to connect to the control device of the motor stator. The temperature sensor 503 can be electrically connected to the control device of the stator through the second portion 502. The first portion 501 is used to connect to the coil winding of the stator. The second portion 502 of the flexible printed circuit board 500 extends radially away from the first portion 501 when not bent.

[0043] Typically, the flexible printed circuit board 500 will include a flexible plastic substrate, such as polyimide, PEEK or transparent conductive polyester, and as is well known to those skilled in the art, at least one temperature sensor 503 is mounted on the flexible plastic substrate. In this embodiment, the number of temperature sensors 503 is six.

[0044] The flexible printed circuit board 500 includes a first portion 501 and a second portion 502. The first portion 501 is mounted between the lead frame 255 and the coil 400. The second portion 502 extends radially from the first portion 501 and is arranged to be bent in a direction perpendicular to the first portion 501.

[0045] When the second portion 502 bends in a direction perpendicular to the first portion 501, the second portion 502 is configured to extend through the socket 810 formed in the lead frame 255. Preferably, the first portion 501 of the flexible printed circuit board 500 is substantially flat, wherein the surface of the flexible printed circuit board 500 adjacent to the lead frame 255 has a surface area configuration similar to the corresponding surface of the lead frame 255, thereby facilitating the connection of the lead coil winding to the lead frame 255. When the lead frame 255 is mounted onto the stator core 600, the first portion 501 of the flexible printed circuit board 500 is arranged between the coil 400 and the lead frame 255. When the second portion 502 of the flexible printed circuit board 500 bends to extend perpendicular to the first portion 501 and through the socket 810 formed in the lead frame 255, the end of the second portion 502 of the flexible printed circuit board 500 is arranged to couple with a control device 400 mounted on the stator.

[0046] A conductive strip is formed on the substrate of the flexible printed circuit board 500, which extends from the temperature sensor 503 to the end of the second portion 502 of the substrate of the flexible printed circuit board 500, so as to allow the control device to monitor the coil temperature measured by the temperature sensor 503 on the flexible printed circuit board 500.

[0047] The mounting structure also includes a guide sleeve 700 and a radiator 253. The radiator 253 includes a mounting portion 2531 with a circumferential outer wall and a flange portion 2532 extending around the outer wall of the mounting portion. A guide hole is provided on the flange portion 2532. The guide sleeve 700 is fitted onto the second portion 502 and connected to the lead frame 255. When the radiator 253 is installed with the circumferential support 600, the guide sleeve 700 passes through the guide hole and makes the second portion 502 electrically connected to the control device.

[0048] The specific installation process is as follows: Stator winding units 550 are sequentially inserted into and fixed onto the stator teeth 800 of the stator core 600. There are 54 stator winding units 550. Guide sleeves 700 are first fitted onto the outside of the second part 502 and connected to the lead frame 255. Then, the stator core 600 is heated, increasing its inner diameter. The outer circumference of the mounting portion 2531 of the heat sink 253 is then embedded into the inner diameter of the stator core, while the guide sleeves 700 slide within the hole in the flange portion 2532. The stator core 600 is then cooled to reduce its inner diameter, thus pressing the stator core 600 firmly onto the outer circumference of the mounting portion 2531. Finally, the guide sleeves 700 are removed from the lead frame 255. This process protects the flexible printed circuit board from high-temperature damage during installation.

[0049] The temperature sensor 503 is configured to be mounted on the first portion 501 of the first flexible printed circuit board 500, and the temperature sensor 503 is disposed on the end face of the first portion 501 near the coil.

[0050] In order for the control device to monitor the temperature reading measured by the temperature sensor 503 mounted on the flexible printed circuit board 500 substrate, a conductive strip formed on the flexible printed circuit board 500 substrate extends from the temperature sensor 503 to the end of the second part 502 of the flexible printed circuit board 500 and couples with the control device mounted near the second surface of the lead frame 255.

[0051] The material of the flexible printed circuit board 500 substrate is arranged to electrically isolate the coil windings from the lead frame 255. In this embodiment, the flexible printed circuit board 500 includes two flexible printed circuit boards 500, such as... Figure 2 As shown, each flexible printed circuit board 500 is substantially semi-circular in shape and has three temperature sensors 503 mounted on the substrate of the flexible printed circuit board 500. Each temperature sensor 503 is located on the side of the first portion 501 of the flexible printed circuit board 500 substrate near the coil.

[0052] Each temperature sensor 503 is located substantially midway between the front and rear portions of the coil winding, and midway between two of the three coil windings forming a set. A conductive strip extends from each temperature sensor 503 to the end of the second portion 502 of the flexible printed circuit board 500 to allow a control device to monitor the temperature readings measured by each temperature sensor 503 mounted on the substrate of the flexible printed circuit board 500. Any number of flexible printed circuit boards 500 are mounted between the lead frame 255 and the coil to measure the temperature of the coil. The flexible printed circuit boards 500 can take any shape.

[0053] This embodiment provides a lead frame 255 for coupling the inverter of a motor or generator to a DC power supply; the motor in this embodiment is a hub motor for automobile wheels. Figure 2 As shown, the hub motor includes a stator 252 comprising a circumferential bracket serving as a radiator 253, multiple coils 254, and two control devices 300 (not shown) mounted on the circumferential bracket 253 at the rear of the stator for driving the coils. A capacitor and lead frame 255 are mounted between the axial edge of the coils 254 and an axial flange formed on the circumferential bracket 253 for connecting the control devices to the coils 254. The coils 254 are engaged in stator teeth 800 to form coil windings; a stator cover is mounted at the rear of the stator 252, surrounding the control devices and the annular capacitor to form the stator 252, which is then secured to the vehicle and does not rotate relative to the vehicle during use.

[0054] like Figure 3 As shown, each control device 300 includes an inverter 310, and one control device 300 includes a controller regulator 320. In this embodiment, the control device 300 includes a processor for controlling the operation of the two inverters 310. Figure 3 As shown, each control device 300 includes an inverter 310, and one of the control devices includes control logic 320, which in this embodiment includes a processor for controlling the operation of the two inverters 310. As described below, each inverter is coupled to three sets of coil windings, which are electrically connected in parallel to form a three-sub-motor.

[0055] A toroidal capacitor is coupled between the inverter 310 and the DC power supply to the motor to reduce voltage fluctuations on the motor power line, also known as the DC bus, and to reduce voltage overshoot during motor operation. To reduce inductance, the capacitor is mounted near the control unit 300.

[0056] The magnet is close to the coil winding on the stator 252, so the magnetic field generated by the coil interacts with the magnet 242 arranged inside the cylindrical portion 221 of the rotor 240, thereby causing the rotor 240 to rotate. Since the permanent magnet 242 is used to generate the driving torque of the drive motor, the permanent magnet is usually called the drive magnet. In this embodiment, the motor includes six coil windings, each coil winding having three coil subgroups, which are also called coil phase windings in this embodiment; these three coil subgroups are coupled in a Y-shaped structure to form a three-phase sub-motor, thereby the motor has six three-phase sub-motors. The stator includes a circumferential support and stator windings mounted on the circumferential support. The circumferential support is a stator core 600. The stator windings are composed of stator winding units 550, which are teeth with coils wound on them. Each tooth has a slot 801. The outer circumference of the circumferential support is provided with stator teeth 800, and the slots 801 are interference-fitted into the stator teeth 800. In this embodiment, there are 54 stator winding units 550 because there are 2 sets of coil windings. Each set of coil windings includes 3 coil windings, each coil winding includes 3 coil phase windings (subsets), and each coil phase winding includes 3 coils.

[0057] As described below, the operation of each sub-motor is controlled by one of the two control devices 300. Although this embodiment describes a motor with six coil groups (i.e., a six-sub-motor), a motor can also have one or more coil groups with associated control devices. Similarly, each coil group can have any number of coil subgroups, thereby allowing each sub-motor to have two or more phases.

[0058] Figure 3The connections between the various coil groups 60 and the control unit 300 are described, wherein the three coil groups 60 are connected to corresponding three-phase inverters 310 on the control unit 300. As is well known to those skilled in the art, the three-phase inverter comprises six switches, wherein three-phase AC voltage can be generated by the controlled operation of the six switches. However, the number of switches will depend on the number of voltage phases applied to the respective sub-motors, on which any number of phases can be constructed. Each control unit 300 communicates with other control units 300 via a communication bus.

[0059] One of the control units 300 includes a processor 320 for controlling the operation of the inverter switches in both control units 300. The control unit is also electrically connected to a temperature sensor 503 to receive signals from the temperature sensor 503 to determine whether the motor is operating within an acceptable temperature range. Furthermore, each control unit 300 includes an interface arrangement allowing communication between the individual control units 300 via a communication bus 330, with one control unit 300 configured to communicate with a vehicle controller mounted externally to the motor.

[0060] The processor 320 controls the operation of the inverter switches installed within each control device 300 to allow each motor coil group 60 to be equipped with a three-phase voltage power supply, thereby allowing each coil subgroup to generate a rotating magnetic field. As described above, although this embodiment describes each coil group 60 as having three coil subgroups, the invention is not limited thereto, and it should be understood that each coil group 60 may have one or more coil subgroups.

[0061] Under the control of the processor, each three-phase bridge inverter 310 is configured to provide pulse-width modulated voltage control in its respective coil subset, thereby generating current in its respective coil subset to provide the torque required by its respective sub-motor. The PWM control operates by using the motor inductance to average the applied pulse voltage, thereby driving the required current into the motor coils. Using pulse-width modulation control, the applied voltage switches between the motor windings. During the voltage switching through the motor coils, the current in the motor coils rises at a rate determined by its inductance and the applied voltage. The pulse-width modulated voltage control shuts off before the current increases beyond a required value, thus achieving precise current control. For a given coil group, the switches of the three-phase bridge inverter 310 are arranged to apply a single voltage phase to each coil subset. Using PWM switching, multiple switches are arranged to apply AC voltage to the respective coil subsets. The voltage envelope and phase angle of the electrical signal are determined by the modulated voltage pulses.

[0062] An inverter formed on one control device is coupled to three coil groups to form a first group of three-sub-motors, and an inverter formed on another control device is coupled to other coil groups to form a second group of three-sub-motors.

[0063] Two inverters 310 are coupled to their respective coil groups via lead frames 255, with each leg of each inverter 310 coupled to the lead frame 255 via its respective phase winding bus. For this embodiment, the different voltage phases generated by the three branches of the inverters are designated as W, V, and U. The coil windings are coupled to the lead frame 255 to allow current to flow from the DC power supply to the coil windings through the respective inverters 310 in the control unit, thereby allowing the motor to generate drive torque.

[0064] Figure 4 The diagram illustrates the electrical connection provided by lead frame 255 between the phase winding busbar of one of the control devices and the coil windings mounted on the stator, wherein lead frame 255 is arranged in a Y-configuration for coupling the phase windings of corresponding coil subgroups. However, lead frame 255 can be configured to couple the phase windings of corresponding coil subsets in different configurations. As described above, each coil winding comprises three coil subgroups (i.e., phase windings) to form a three-phase sub-motor. Figure 4 The diagram illustrates the electrical connection provided by lead frame 255 between the phase winding busbar of one of the control devices and the coil windings mounted on the stator, wherein lead frame 255 is arranged in a Y-configuration for coupling the phase windings of corresponding coil subgroups. However, lead frame 255 can be configured to couple the phase windings of corresponding coil subsets in different configurations. As described above, each coil winding comprises three coil subgroups (i.e., phase windings) to form a three-phase sub-motor. In this embodiment, the first, second, and third coil windings of the first group of coil windings correspond one-to-one with the first, second, and third sub-motors described below.

[0065] In this embodiment, each coil group forming the coil subgroup is formed by three separate coils coupled through the circuit board layer of the lead frame 255.

[0066] refer to Figure 4 Coil 401 forms the first phase winding of the first sub-motor 411, coil 402 forms the second phase winding of the first sub-motor 411, and coil 403 forms the third phase winding of the first sub-motor 411. For the second sub-motor 412, coil 404 forms the first phase winding of the second sub-motor 412, coil 405 forms the second phase winding of the second sub-motor 412, and coil 406 forms the third phase winding of the second sub-motor 412. For the third sub-motor 413, coil 407 forms the first phase winding of the third sub-motor 413, coil 408 forms the second phase winding of the third sub-motor 413, and coil 409 forms the third phase winding of the third sub-motor 413. Figure 4 Each coil 400 shown corresponds to a coil on a single stator tooth 800, wherein the end of each coil is arranged to couple with the lead frame 255 to achieve coil alignment. Figure 4The configuration shown is coupled.

[0067] Lead frame 255 is used to connect the W-phase inverter bus to the first coil 400 of the first phase winding 401 of the first sub-motor 411, the first phase winding 404 of the second sub-motor 412, and the first phase winding 407 of the third sub-motor 413. Lead frame 255 also connects the V-phase inverter bus to the first coil 400 of the second phase winding 402 of the first sub-motor 411, the second phase winding 405 of the second sub-motor 412, and the second phase winding 408 of the third sub-motor 413, and connects the U-phase inverter to the first coil 400 of the third phase winding 403 of the first sub-motor 411, the third phase winding 406 of the second sub-motor 412, and the third phase winding 409 of the third sub-motor 413. Figure 4 As shown, the lead frame 255 connects the last coil 400 of the first phase winding 401 of the first sub-motor 411 to the last coil 400 of the second phase winding 402 and the third phase winding 403 of the first sub-motor 411. Similarly, the lead frame 255 also connects the last coil 400 of the first phase winding 404 of the second sub-motor 412 to the last coil 400 of the second phase winding 405 and the third phase winding 406 of the second sub-motor 412, and connects the last coil 400 of the first phase winding 407 of the third sub-motor 413 to the last coil 400 of the second phase winding 408 and the third phase winding 409 of the third sub-motor 413. These connections serve as star points for each sub-motor.

[0068] Furthermore, the lead frame 255 is arranged to electrically connect the individual coils 400 of each phase winding to form a series connection between the individual coils 400 of each phase winding. Accordingly, the lead frame 255 provides electrical connections between the W, V, and U phase inverter buses and their respective coils 400 to form a three-sub-motor driven by a single inverter 310, wherein the coil windings of the respective sub-motors are coupled in a Y-configuration.

[0069] Similarly, the lead frame 255 connects the phase winding busbars of the inverter 310 of the other control device 300 and the coils mounted on the stator in the same manner, forming a three-sub-motor driven by the inverter 310 in the second control device 300. The structure of the lead frame 255 will now be described, wherein in the first embodiment, as... Figure 5 As shown, a substantially circumferential lead frame 255 is used to supply current from two control devices to the corresponding coil groups. Figure 6 As shown, a substantially circumferential lead frame 255 is mounted on an axial mounting surface of the stator core 600, which is close to the coil forming part of the stator 252, the coil being wound on stator teeth 800 formed on the stator core 600.

[0070] The lead frame 255 includes a first set of three holes 660 for receiving corresponding bus lead frame pins for coupling the lead frame 255 to the inverter 310 in the first control device 300, and a second set of three holes 660 for receiving corresponding bus lead frame pins for coupling the lead frame 255 to the inverter 310 in the second set.

[0071] The lead frame 255 has a fixing hole at a predetermined position, and a hot post 630 is inserted into the fixing hole. In this embodiment, the hot post 630 is arranged at the end of the tooth of the stator winding unit 550, close to the lead frame 255, and is arranged to extend through a hole formed in the lead frame 255. Once the lead frame 255 is mounted on the stator core 600, and the respective hot posts 630 pass through the corresponding fixing holes formed in the lead frame 255, the hot posts 630 melt, thereby fixing the lead frame 255 to the stator winding on the stator core 600. However, any suitable method can be used to connect the lead frame 255 to the stator core 600.

[0072] like Figure 6 As shown, the lead frame 255 includes a plurality of grooves 640 formed on the inner and outer radial edges of the lead frame 255 for receiving the ends of the coil wound on the stator teeth 800 and for coupling the coil 400 to the lead frame 255, as described below, wherein for each coil wound on the stator teeth 800, a portion is installed in the groove 640 formed on the inner radial edge of the lead frame 255 and another portion is installed in the groove 640 formed on the outer radial edge of the lead frame 255.

[0073] A single circumferential lead frame 255 serves as a current path from each inverter 310 within the control device 300 to each coil winding, wherein the lead frame 255 is a basic circumferential printed circuit board having multiple circuit board layers. Each layer has a conductive layer printed on it. Each circuit board layer includes an insulating substrate on which the conductive layer is formed. In this embodiment, there are two inverters; in other words, half a circumference of the lead frame printed circuit board is allocated for coupling the first control device 300 to a set of coil windings to form a three-sub-motor formed by the first set of coil windings, and the other half a circumference of the lead frame printed circuit board is allocated for coupling the second control device 300 to a three-sub-motor formed by the second set of coil windings. The multiple circuit board layers are separated by their respective insulating substrates.

[0074] To allow large current to flow from inverter 310 to coil windings, thereby allowing the motor to generate sufficient torque to drive the vehicle, conductive layers on each circuit board layer are arranged to extend to most of each circuit board. Each conductive layer is arranged to correspond to a specific circuit path between each inverter 310 and coil winding, as well as between different subsets of coils constituting each sub-motor. Thus, current flow is optimized for each circuit board layer.

[0075] In order to achieve Figure 4 The circuit configuration shown will now be described in terms of the configuration of the printed circuit board layers and the conductive layers printed on the circuit board layers. Each circuit board layer includes two sets of electrical connections for coupling a first set of three coil windings to one inverter, and for coupling another set of three coil windings to another inverter, but each circuit board layer may include any number of conductive layers based on the number of inverters. For example, if one inverter is used to drive all the coil windings mounted on the stator, the conductive layers printed on each circuit board layer will be arranged to form specific circuit paths between the inverter and the coil windings, and between the different subsets of coils constituting their respective sub-motors, forming their respective sub-motors.

[0076] In this embodiment, the lead frame 255 includes a first lead frame 701 and a second lead frame 702, wherein both the first lead frame 701 and the second lead frame 702 are semi-circular. When mounted on the stator 252, the first lead frame 701 and the second lead frame 702 form a substantially circular lead frame 255. Figure 8 As shown, each lead frame 255 is mounted on the axial mounting surface of the stator core 600, which forms part of the stator 252, and the coil is wound on the stator teeth 800 formed on the stator core 600.

[0077] The first lead frame and the second lead frame 702 each include a set of three holes 660 for receiving their respective bus lead frame pins, for coupling the first lead frame 701 and the second lead frame 702 to the inverter 310 in the first control device 300 and the second control device 300, respectively.

[0078] The first lead frame 701 and the second lead frame 702 are mounted to the stator core 600 by connecting to hot posts 630 at predetermined positions. The hot posts 630 are arranged to extend through holes formed in the first lead frame 701 and the second lead frame 702. Once the first lead frame 701 and the second lead frame 702 are mounted on the stator core 600, and the respective hot posts 630 pass through their respective holes formed in the first lead frame 701 and the second lead frame 702, the hot posts 630 melt, thereby holding the first lead frame 701 and the second lead frame 702 fixed to the stator core 600. However, any suitable method can be used to connect the first lead frame 701 and the second lead frame 702 to the stator core 600.

[0079] like Figure 8 As shown, the first lead frame 701 and the second lead frame 702 include a plurality of grooves 640 formed on the inner and outer radial edges of the first lead frame 701 and the second lead frame 702, for receiving end portions of coils 400 wound on stator teeth 800 for coupling, the coils 400 being connected to the first lead frame 701 and the second lead frame 702 respectively. For each coil wound on the stator teeth 800, one end is mounted in the groove 640 formed on the inner radial edge of the first lead frame 701 or the second lead frame 702, and the other end is mounted in the groove 640 formed on the outer radial edge of the corresponding lead frame 255 portion 701.

[0080] The circuit board layer of the first printed circuit board on the first lead frame 701 is a mirror image of the circuit board layer of the second printed circuit board on the second lead frame 702. The first printed circuit board is responsible for the three sub-motors formed by the first group of coil windings (named first sub-motor, second sub-motor, and third sub-motor, or sub-motor 1 / 2 / 3), and the second printed circuit board is responsible for the three sub-motors formed by the second coil windings (named fourth sub-motor, fifth sub-motor, and sixth sub-motor, or sub-motor 4 / 5 / 6).

[0081] The following description uses the circuit board layer and circuit connection of the first lead frame as an example.

[0082] The first printed circuit board includes a first circuit board layer, the first circuit board layer having, as shown in the figure Figure 9The first conductive layer shown extends substantially to a first half-circumferential portion of the circumferential circuit board. This first half-circumferential portion is arranged to be electrically coupled to the first coil of the first phase winding 401 of the first sub-motor 411, the first coil of the first phase winding 404 of the second sub-motor 412, and the first coil of the first phase winding 407 of the third sub-motor 413, and the busbar of the first W-phase inverter 310. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the first circuit board layer, on which the conductive layer is arranged to be electrically coupled to the W-phase inverter busbar of the second inverter and to the corresponding coil windings of the second set of coil windings mounted on the stator.

[0083] like Figure 10 As shown, the W-phase inverter 310 busbar is coupled to the first circuit board layer via busbar lead frame pins 255. These busbar lead frame pins 255 are cylindrical conductive elements coupled to the W-phase inverter 310 busbar, extending through corresponding lead frame pin holes 660 formed in the printed circuit board. The W-phase busbar lead frame pins 1010 are electrically coupled to the first conductive layer 900 at position 910. To couple the first coil of the first phase winding 401 of the first sub-motor 411, the first coil of the first phase winding 404 of the second sub-motor 412, and the first coil of the first phase winding 405 of the third sub-motor 413 to the first conductive layer 900 at positions 920, 930, and 940, the ends of the relevant coils, as described above, are installed in grooves 640 formed within the inner and outer radial edges of the lead frame 255. Specifically, the ends of the coil windings are installed in the grooves 640 formed within the inner radial edge of the lead frame 255, at positions 920, 930, and 940, and are electrically coupled to the first conductive layer 900. The other ends of the first coils of the first phase windings of the first, second, and third sub-motors, and the ends of the remaining coil windings, are installed in their respective grooves formed within the inner and outer radial edges of the lead frame 255, and are electrically isolated from the first conductive layer 900.

[0084] The first printed circuit board includes a second circuit board layer, the second circuit board layer having, as shown in the figure Figure 11The second conductive layer 1100 shown extends substantially into the first half-circumferential portion of the circumferential circuit board, which is arranged to be electrically coupled to the busbar of the U-phase inverter 310 and the first coil of the second phase winding 402 of the first sub-motor 411, the first coil of the second phase winding 405 of the second sub-motor 412, and the first coil of the second phase winding 408 of the third sub-motor 413. The printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the second circuit board layer, on which conductive layers are arranged to be electrically coupled to the U-phase inverter busbar of the second inverter and to the corresponding coil windings of the second set of coil windings mounted on the stator.

[0085] like Figure 10 As shown, the U-phase inverter 310 busbar is coupled to the second circuit board layer via busbar lead frame pins 1010. These busbar lead frame pins 1010 are cylindrical conductive elements coupled to the U-phase inverter 310 busbar, extending through the corresponding lead frame 255 pinholes 660 formed in the printed circuit board. The U-shaped busbar lead frame pins 1010 are electrically coupled to the second conductive layer 1100 at position 1110. To couple the first coil of the second phase winding 402 of the first sub-motor 411, the first coil of the second phase winding 405 of the second sub-motor 412, and the first coil of the second phase winding 408 of the third sub-motor 413 to positions 1120, 1130, and 1140 of the second conductive layer, respectively, and as described above, the relevant coils are installed in grooves 640 formed within the inner and outer radial edges of the lead frame 255. The ends of the coil windings installed in the grooves formed within the inner radial edge of the lead frame 255 are electrically coupled to the second conductive layer at positions 1120, 1130, and 1140. The other ends of the first coils of the second phase windings of the first, second, and third sub-motors, and the ends of the remaining coil windings, are installed in their respective grooves formed within the inner and outer radial edges of the lead frame 255, electrically isolated from the second conductive layer.

[0086] The printed circuit board includes a third circuit board layer 1200, the third circuit board layer having, as shown in... Figure 12 The third conductive layer shown extends substantially to a first half-circumferential portion of the circumferential circuit board, which is arranged to be electrically coupled to the V-phase inverter 310 bus and the first coil of the first phase winding 403 of the first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412, and the first coil of the third phase winding 409 of the third sub-motor 413. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the third circuit board layer, on which the conductive layer is arranged to be electrically coupled to the V-phase inverter bus of the second inverter and to the corresponding coil windings of the second set of coil windings mounted on the stator.Figure 10 As shown, the V-phase inverter 310 bus is coupled to the third circuit board layer via a bus lead frame pin 1010, which is a cylindrical conductive element coupled to the V-phase inverter 310 bus and extends through a pinhole 660 of the associated lead frame 255 formed in the printed circuit board. The V-phase bus lead frame pin 1010 is arranged to be electrically coupled to the third conductive layer 1200 of the printed circuit board at position 1210. In order to couple the first coil of the third phase winding 403 of the first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412, and the first coil of the third phase winding 409 of the third sub-motor 413 to the third conductive layer, the ends of the associated coils are arranged as described above, in the grooves 640 formed in the inner and outer radial edges of the lead frame 255, and the ends of the coil windings installed in the grooves formed in the grooves 1220, 1230, and 1240 of the lead frame 255 are electrically coupled to the third conductive layer. The other ends of the first coils of the third phase windings of the first, second, and third sub-motors, as well as the ends of the remaining coil windings, are installed in their respective grooves formed within the lead frame 255 and the outer radial edge, and are electrically isolated from the third conductive layer.

[0087] The printed circuit board includes a fourth circuit board layer having a fourth conductive layer 1310, a fifth conductive layer 1320, and a sixth conductive layer 1330, such as Figure 13 As shown, the fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 extend together onto the first half-circumferential portion of the annular circuit board. The fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 are electrically isolated from each other.

[0088] The fourth conductive layer 1310 is arranged to electrically couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411, and the last coil of the third phase winding 403 of the first sub-motor 411. A neutral point (i.e., a star point) is formed between the first coil winding 401, the second coil winding 402, and the third coil winding 403 of the first sub-motor 411. To couple the last coil of the first phase winding 401, the last coil of the second phase winding 402, and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the relevant coils are mounted on the inner and outer radial edges formed in the lead frame 255 as described above. The ends of the coil windings mounted in the grooves formed in the outer radial edge of the lead frame 255 are electrically coupled to the fourth conductive layer 1310 at 1311, 1312, and 1313. The other end of the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 and the last coil of the third phase winding 403 of the first sub-motor 411, and the ends of the remaining coil windings are mounted in corresponding grooves formed therein. The inner and outer radial edges of the lead frame 255 are electrically isolated from the fourth conductive layer 1310.

[0089] The fifth conductive layer 1320 is arranged to electrically couple the last coil of the first phase winding 404, the last coil of the second phase winding 405, and the last coil of the third phase winding 406 of the second sub-motor 412. A neutral point (i.e., a star point) is formed between the first coil winding 404, the second coil winding 405, and the third coil winding 406 of the second sub-motor 412. To couple the last coil of the first phase winding 404, the last coil of the second phase winding 405, and the last coil of the third phase winding 406 of the second sub-motor 412, the ends of the relevant coils are arranged to be mounted on the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil windings mounted in the grooves formed in the outer radial edge of the lead frame 255 are electrically coupled to the fifth conductive layer 1320 at 1321, 1322, and 1323. The other end of the last coil of the first phase winding 404 of the second sub-motor 412, the last coil of the second phase winding 405 of the second sub-motor 412, the last coil of the third phase winding 406 of the second sub-motor 412, and the end of the remaining coil windings are mounted in corresponding grooves 640 to thin the inner and outer radial edges of the lead frame 255, electrically isolating it from the fifth conductive layer 1320. A sixth conductive layer 1330 is arranged to electrically couple the last coil of the first phase winding 407 of the third sub-motor 413, the last coil of the second phase winding 408 of the third sub-motor 413, and the last coil of the third phase winding 409 of the third sub-motor 413. A neutral point (i.e., a star point) is formed between the first coil winding 407, the second coil winding 408, and the third coil winding 409 of the third sub-motor 413.

[0090] The printed circuit board of the second lead frame 702 has the same circuit board layer structure as the fifth circuit board layer for connecting the corresponding coils of the second set of coil windings, thereby forming the second set of sub-motors.

[0091] To couple the last coil of the first phase winding 401, the last coil of the second phase winding 402, and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the relevant coils are mounted on the inner and outer radial edges of the lead frame 255 as described above. Specifically, the ends of the coil windings mounted in the grooves formed within the outer radial edge of the lead frame 255 are electrically coupled to the fourth conductive layer 1310 at locations 1311, 1312, and 1313. The other end of the last coil of the first phase winding 407 of the third sub-motor 413, the last coil of the second phase winding 408 and the last coil of the third phase winding 409 of the third sub-motor 413, and the ends of the remaining coil windings are mounted in corresponding grooves 640. The inner and outer radial edges of the lead frame 255 are electrically isolated from the sixth conductive layer 1330.

[0092] The printed circuit board includes a fifth circuit board layer, which has Figure 14 The multiple conductive layers shown are used for electrically coupling to form the coil 400 of the first phase winding 401 of the first sub-motor 411, the coil 400 of the second phase winding 402 of the first sub-motor 411, and the coil 400 of the third phase winding 402 of the first sub-motor 411. Relative to the second sub-motor, the multiple conductive layers are arranged to electrically couple to form the coil 400 of the first phase winding 404 of the second sub-motor 412, the coil 400 of the second phase winding 405 of the second sub-motor 412, and the coil 400 of the third phase winding 406 of the second sub-motor 412. Relative to the third sub-motor, the multiple conductive layers are arranged to electrically couple to form the coil 400 of the first phase winding 407 of the third sub-motor 413, the coil 400 of the second phase winding of the third sub-motor 413, and the coil 400 of the third phase winding 409 of the third sub-motor 413.

[0093] Multiple conductive layers on the fifth circuit board layer are arranged to allow multiple coils in each respective coil subgroup to be coupled, thereby enabling each coil in the coil winding to generate a magnetic field that is antiparallel to its adjacent coil in a given current direction and has a common phase.

[0094] The second printed circuit board includes a circuit board layer corresponding to the fifth circuit board layer. This circuit board layer has multiple conductive layers arranged to electrically couple the first, second, and third phase windings of the second set of coil windings. Each of the first, second, and third phase windings includes multiple coils. The conductive layers are arranged to allow the multiple coils of each corresponding phase winding to couple relative to each other, so that each coil subgroup generates a magnetic field that is antiparallel to the adjacent coils in a given current direction and has a common phase. The connection between the second printed circuit board and the circuit board layer corresponding to the fifth circuit board layer and the second set of coil windings is a mirror image of the connection between the fifth circuit board and the first coil windings.

[0095] Among the multiple conductive layers formed on the fifth printed circuit board layer, two conductive layers 1501 and 1502 are used to form the coupling coil 400 of the first phase winding 401 of the first sub-motor 411, two conductive layers 1503 and 1504 are used to form the coupling coil 400 of the second phase winding 402 of the first sub-motor 411, and two conductive layers 1505 and 1506 are used to couple and form the coil 400 of the third phase winding 403 of the first sub-motor 411. In the second sub-motor, two conductive layers 1507 and 1508 are used to form the coupling coil 400 of the first phase winding 404 of the second sub-motor 412, and two conductive layers 1509 and 1510 are used to couple the coil 400 of the second sub-motor 412. The phase winding 405 of the second sub-motor 412 and two conductive layers 1511 and 1512 are used to couple the coil 400, which forms the third phase winding 406 of the second sub-motor 412. For the third sub-motor, two conductive layers 1513 and 1514 are used to form the coupling coil 400 of the first phase winding 407 of the third sub-motor 413, and two conductive layers 1515 and 1516 are used to couple the coil 400 of the second phase winding 408 of the third sub-motor 413, which forms the third phase winding 409 of the third sub-motor 413. As described above, one end of the first coil forming the coil group of the first phase winding 401 of the first sub-motor 411 is mounted in a groove 640 at position 920 formed on the inner radial edge of the lead frame 255. It is electrically coupled to a first conductive layer 900 formed on the first circuit board layer, while being electrically isolated from any other conductive layers on other circuit board layers. The other end of the first coil is mounted in a corresponding groove formed on the outer radial edge of the lead frame 255 at position 950, and is electrically coupled to a conductive layer 1502 on the fifth circuit board layer.

[0096] One end of the second coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a groove at position 951 formed on the outer radial edge of the lead frame 255 and electrically coupled to layer 1502 on the conductive fifth circuit board layer, thereby electrically connecting the second coil to the W-phase bus pin via the first coil. The other end of the second coil is mounted in an opposing groove formed at position 952 on the inner radial edge of the lead frame 255 and electrically coupled to the conductive layer 1501 on the fifth circuit board layer, which is electrically isolated from the conductive layer 1502. One end of the third coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a groove at position 953 formed on the inner radial edge of the lead frame 255 and electrically coupled to layer 1501 on the conductive fifth circuit board layer, thereby electrically connecting the third coil to the W-phase bus pin via the first and second coils. The other end of the third coil is mounted in a corresponding groove formed on the outer radial edge of the lead frame 255 at position 954 and is electrically connected to the fourth conductive layer 1310 on the fourth circuit board layer for coupling the third coil to the corresponding coils for forming the second phase winding 402 and the third phase winding 403 of the first sub-motor 411.

[0097] The next set of two conductive layers 1503 and 1504 on the fifth circuit board layer are used to couple the coil 400 of the second phase winding 402 forming the first sub-motor 411 to the V-phase bus pin, and the next set of two conductive layers 1505 and 1506 on the fifth circuit board layer are used to couple the coil 400 of the third phase winding 403 forming the first sub-motor 411 to the U-phase bus pin. The next set of two conductive layers 1507 and 1508 on the fifth circuit board layer are used to couple the coil 400 of the first phase winding 404 forming the second sub-motor 412 to the W-phase bus pin of the next set of two conductive layers 1509. 1510 on the fifth circuit board layer is used to couple the coil 400 of the second phase winding 405 forming the second sub-motor 412 to the V-phase bus pin, and the next set of two conductive layers 1511 and 1512 on the fifth circuit board layer are used to couple the coil 400 of the third phase winding 406 forming the second sub-motor 412 to the U-phase bus pin. The next set of two conductive layers 1513 and 1514 on the fifth circuit board layer are used to couple the coil 400 of the first phase winding 407 forming the third sub-motor 413 to the W phase bus pin of the next set of two conductive layers 1515. 1516 on the fifth circuit board layer is used to couple the coil 400 of the second phase winding 408 forming the third sub-motor 413 to the V phase bus pin. The next set of two conductive layers 1517 and 1518 on the fifth circuit board layer are used to couple the coil 400 of the third phase winding 409 forming the third sub-motor 413 to the U phase bus pin.

[0098] The electrical connections for coupling the W, U, and V phase bus pins and corresponding coils to the lead frame 255 will now be described. For the electrical connections for coupling the phase bus pins 1010 to the corresponding conductive layers printed on the circuit board layer of the lead frame 255, conductive sleeves 1600 are inserted into the corresponding holes formed in the lead frame 255 of the W, U, and V phase bus pins 1010, as follows: Figure 15 As shown. When the W, U, and V phase bus pins are inserted into the corresponding conductive sleeves 1600, the phase bus pins 1010 are configured to make electrical contact with the sleeves 1600. To improve the electrical contact between the pins 1010 and the sleeves 1600, solder or other conductive materials may be used.

[0099] For any conductive layer formed on the corresponding circuit board layer that needs to be electrically connected to the phase bus pin 1010, the corresponding conductive layer is arranged to extend and make electrical contact with the conductive sleeve 1600. For any conductive layer formed on each circuit board layer that is electrically isolated from the phase bus pin 1010, each conductive layer is arranged to be electrically isolated from the conductive sleeve 1600. For example, refer to Figure 15 The lead frame 255 includes ten circuit boards. The first two circuit board layers 1611 and 1612 correspond to the first circuit board layer used to couple the W bus lead frame pins to the lead frame 255. The next two circuit board layers 1613 and 1614 correspond to the second circuit board layer used to connect the U bus lead frame pins to the lead frame 255. The next two circuit board layers 1615 and 1616 correspond to the third circuit board layer used to couple the V bus lead frame pins to the lead frame 255. The next two circuit board layers 1617 and 1618 correspond to the fourth circuit board layer used to couple the first phase winding, the second phase winding, and the third phase winding of each sub-motor. The next two circuit board layers 1619 and 1620 correspond to the fifth circuit board layer used to couple the coils of each phase winding. Figure 15 As shown, the first conductive layers on the first two circuit board layers 1611 and 1612 are in contact with the conductive sleeve for coupling the W busbar lead frame pins to these two conductive layers. Conversely, the conductive layers printed on other circuit board layers are electrically isolated from the conductive sleeve.

[0100] Although this embodiment uses conductive sleeves 1600 to electrically couple the busbar lead frame pins 1010 to the lead frame 255, any mechanism can be used to couple the corresponding inverter pins to the lead frame 255. Regarding the corresponding coils at the end portions, an arrangement similar to that used for electrically coupling the phase busbar pins 1010 can be used to electrically couple the corresponding end portions of the coils 400 to a desired conductive layer printed on one or more circuit board layers, wherein a semi-circular conductive sleeve is placed within a corresponding groove formed in the inner and outer radial edges of the lead frame 255. Alternatively, the ends of each coil 400 can be placed directly within the grooves 640 formed in the inner and outer radial edges of the lead frame 255, with conductive material placed between the coil ends and the associated conductive layer to improve conductivity between the coil ends and the conductive layer, which are electrically connected to the conductive layer. A preferred process for mounting the ends of the coils 400 in the inner and outer radial grooves 640 of the lead frame 255 will now be described.

[0101] Before the lead frame 255 is mounted to the stator core 600, the ends of the coil are arranged to extend radially away from the stator core 600 and are coplanar with the axial mounting surface of the stator core 600. In this configuration, the ends of the coil on the outer radial edge of the stator core 600 are arranged to extend radially away from the center of the stator core 600. The inner radial edge of the stator core 600 is arranged to extend radially toward the center of the stator core 600. Preferably, by using a heating post, wherein the grooves formed in the inner and outer radial edges of the lead frame 255 are arranged to align with the ends of the coil, such that the corresponding grooves 640 formed in the inner and outer radial directions are positioned on the corresponding end segments of the coil in the lead frame 255. Figure 16 A coil end 1610 is shown, extending radially. The ends of each coil are then rotated 90 degrees to extend into printed circuit board recesses and lead frame 255 recesses 640 located above the respective ends of each coil, resulting in coil ends 1620 extending axially. Any device can be used to rotate the ends into corresponding recesses formed on the inner and outer radial edges of the lead frame 255.

[0102] Figure 17A portion of the stator core is shown, illustrating six coils 400, each with its coil end extending into inner and outer radial grooves 640 formed in the lead frame 255 for coupling the respective coil to the lead frame 255. To improve electrical contact between the ends of the individual coils and the lead frame 255, solder or some other conductive material can be used between the ends of the coils and the lead frame 255. In this embodiment, since each portion of the lead frame 255 is only formed as a semi-circular section, this has the advantage of reducing the manufacturing cost of the entire lead frame 255 arrangement compared to the manufacturing cost of a single circumferential lead frame 255.

[0103] Example 2

[0104] The difference between this embodiment and Embodiment 1 is that the lead frame in this embodiment is a complete circumferential frame. Each conductive layer of each circuit board layer on the circumferential printed circuit board includes two semi-circular conductive layers. One part of the two conductive layers is used to connect with the first controller, the first inverter, and the first set of coil windings to form sub-motors 1 / 2 / 3; the other part is used to connect with the second controller, the second inverter, and the second set of coil windings to form sub-motors 4 / 5 / 6. The two conductive layers are located in different areas of the circuit board layer and are electrically isolated from each other. The stator includes a single flexible printed circuit board 500, wherein the flexible printed circuit board 500 is ring-shaped. The flexible printed circuit board 500 includes six temperature sensors 503 mounted on the substrate of the flexible printed circuit board 500.

[0105] Example 3

[0106] This embodiment provides a motor that adopts the stator mounting structure of Embodiment 1.

[0107] In summary, the above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the present invention.

Claims

1. A mounting structure for a stator with a flexible PCB circuit board, characterized in that: The system includes a lead frame and a circumferential support with stator teeth on their outer circumference. The stator winding is mounted on the stator teeth. The lead frame includes a printed circuit board with multiple circuit board layers. A flexible circuit board is mounted between the circumferential support and the lead frame. The coil winding of the stator winding is coupled to the printed circuit board on the lead frame. The mounting structure also includes a guide sleeve and a heat sink. The heat sink includes a mounting portion with a circumferential outer wall and a flange portion extending around the outer wall of the mounting portion. A guide hole is provided on the flange portion. The flexible printed circuit board includes a first part and a second part. One end face of the first part is attached to the end face of the lead frame, and the other end face is attached to the end face of the circumferential support. An insertion hole is provided on the lead frame. The second part passes through the insertion hole and is perpendicular to the first part. The guide sleeve is fitted onto the second part and connected to the lead frame. When the heat sink is installed with the circumferential support, the guide sleeve passes through the guide hole. The flexible printed circuit board is equipped with a sensor for measuring the temperature of the winding coil. The sensor is mounted on the end face of the first part near the winding coil. The guide sleeve and the lead frame are detachably connected.

2. The mounting structure of a stator with a flexible PCB circuit board according to claim 1, characterized in that: The second part is bent relative to the first part under stress, and the second part initially extends radially away from the first part.

3. The mounting structure of a stator with a flexible PCB circuit board according to claim 1, characterized in that: The cross-sectional shape of the first part of the flexible printed circuit board is the same as the cross-sectional shape and size of the lead frame.

4. The mounting structure of a stator with a flexible PCB circuit board according to claim 1, characterized in that: The lead frame is a single circular shape, or it can be composed of two semi-circular lead frames joined together to form a single circular lead frame; the flexible printed circuit board is a single circular shape, or it can be composed of two semi-circular flexible printed circuit boards joined together to form a single circular flexible printed circuit board.

5. The mounting structure of a stator with a flexible PCB circuit board according to claim 1, characterized in that: Each circuit board layer of the printed circuit board on the lead frame includes an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board has at least a first circuit board layer, a second circuit board layer, a third circuit board layer, and a fourth circuit board layer; the first circuit board layer includes a first conductive layer arranged to be electrically coupled to a first coil winding of a first set of coil windings and a first branch of a first inverter; the second circuit board layer includes a second conductive layer arranged to be electrically coupled to a second coil winding of the first set of coil windings and a second branch of the first inverter; the third circuit board layer includes a third conductive layer arranged to be electrically coupled to a third coil winding of the first set of coil windings and a third branch of the first inverter; the fourth circuit board layer includes a fourth conductive layer having multiple conductive layers, the fourth conductive layer being configured to be coupled to the first coil winding, the second coil winding, and the third coil winding of the first set of coil windings to form a neutral point between the first coil winding, the second coil winding, and the third coil winding.

6. The mounting structure of a stator with a flexible PCB circuit board according to claim 5, characterized in that: The first, second, and third coil windings each include three coil subgroups, namely a first phase winding, a second phase winding, and a third phase winding; the printed circuit board also includes a fifth circuit board layer having multiple conductive layers arranged to electrically couple the first, second, and third phase windings of the first, second, and third coil windings; each of the first, second, and third phase windings includes multiple coils, and the multiple conductive layers on the fifth circuit board are arranged to allow the multiple coils for each corresponding phase winding to couple relative to each other so that each coil subgroup generates a magnetic field that is antiparallel to the adjacent coil in a given current direction and has a common phase.

7. The mounting structure of a stator with a flexible PCB circuit board according to claim 6, characterized in that: The printed circuit board also includes a set of circuit board layers identical to those in claim 6, for electrically connecting with the second set of coil windings to form a second set of three-phase sub-motors, wherein the set of circuit board layers is electrically isolated from the circuit board layer described in claim 6.

8. The mounting structure of a stator with a flexible PCB circuit board according to claim 1, characterized in that: Multiple grooves are formed on the inner and outer edges of the printed circuit board of the lead frame, wherein each groove is arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board.

Images