Brushless motor

Abstract

A brushless motor includes a stator set, a rotor and a circuit board, the stator set includes a connecting portion, a stator core and a plurality of enameled wires, the stator core has a first end and a second end opposite to each other, the first end is closer to the connecting portion than the second end, the stator core has a plurality of wire slots between the first end and the second end, each enameled wire is wound on each wire slot to form a plurality of stator windings, two ends of each enameled wire extend from the first end to the connecting portion, the rotor corresponds to the stator windings, the circuit board has a board body and a lead wire set, the board body is connected to the connecting portion of the stator set, the lead wire set is arranged on the board body in a layout manner, the lead wire set is electrically connected to the two ends of each enameled wire, and the stator windings are electrically connected through the lead wire set to form a connection configuration.

Description

Technical Field

[0001] This invention relates to motor structure; in particular, it refers to a brushless motor. Background Technology

[0002] With the advancement of technology, people's demands for a better life are increasing, which in turn affects the development of electrical appliances, with motors being a key area of ​​development. In order to improve motors, many high-efficiency and low-loss motors have emerged on the market. Among them, brushless motors, due to their advantages of high efficiency and low noise, are widely used in various electrical appliances. However, today's electrical appliances, whether power tools or household appliances, are developing towards miniaturization, causing existing motors to be too large, which hinders technological development.

[0003] Existing brushless motors include a stator assembly and a rotor assembly. Taking a six-slot brushless motor as an example, the stator assembly includes a stator core with six slots and three enameled wires. The enameled wires are wound from one end of the stator core into three slots, and then from the other end to the opposite three slots, thus forming six stator windings. A rotor of the rotor assembly passes through the stator core and is surrounded by the stator windings. By outputting a commutation signal to the stator windings, different magnetic field changes are generated, causing the rotor to rotate under the influence of the magnetic field, thereby achieving the purpose of brushless motor rotation.

[0004] However, in the aforementioned stator winding method, each enameled wire winds from one slot to the opposite slot, resulting in one segment of each wire protruding from the other end of the stator core. This means three segments of the three wires will be exposed at the other end of the stator core, causing overlap and disorder at the other end, and increasing the axial length of the enameled wire in the stator core. Furthermore, different brushless motors require different winding methods for their stator windings depending on the enameled wire configuration. For example, to connect the stator windings in a Y-type or Δ-type configuration, the way the enameled wire is wound in the slots differs, necessitating different winding methods for different connection configurations. For more complex connection configurations, the winding method becomes even more complex, causing inconvenience in brushless motor manufacturing. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a brushless motor that can shorten the length of the enameled wire in the axial direction of the stator core and simplify the winding method of the stator winding.

[0006] To achieve the above objectives, the present invention provides a brushless motor comprising a stator assembly, a rotor, and a circuit board. The stator assembly includes a connecting portion, a stator core, and multiple enameled wires. The stator core has a first end and a second end opposite to each other, the first end being closer to the connecting portion than the second end. The stator core has multiple slots located in different radial directions between the first end and the second end. Each enameled wire is wound around each slot to form multiple stator windings. Each enameled wire has two ends, and both ends of each enameled wire extend from the first end toward the connecting portion. The rotor corresponds to the multiple stator windings. The circuit board has a plate and a conductor group. The plate is connected to the connecting portion of the stator assembly. The conductor group has multiple conductors arranged in a layout on the plate, and the conductor group electrically connects the two ends of each enameled wire. The multiple stator windings are electrically connected through the conductor group to form a connection configuration.

[0007] The advantage of this invention is that by directly connecting both ends of the enameled wire to the circuit board, the length of the enameled wire along the axial direction of the stator core is effectively shortened. Furthermore, the layout on the circuit board determines the configuration of the stator windings, effectively simplifying the winding method and making the manufacturing of brushless motors easier. Attached Figure Description

[0008] Figure 1 This is a perspective view of a brushless motor according to a preferred embodiment of the present invention.

[0009] Figure 2 This is a partial exploded perspective view of the brushless motor of the preferred embodiment described above.

[0010] Figure 3 This is a front view of the stator assembly and rotor assembly of the preferred embodiment described above, wherein the enameled wire is omitted.

[0011] Figure 4 for Figure 1 A magnified view of part A.

[0012] Figure 5 for Figure 4 A side view showing the enameled wires hidden.

[0013] Figure 6 This is a front view of the brushless motor of the preferred embodiment described above.

[0014] Figure 7 This is a schematic diagram of a series Y-type connection configuration of the above preferred embodiment.

[0015] Figure 8 This is a schematic diagram of a series Δ-type connection configuration of the above preferred embodiment. Detailed Implementation

[0016] To more clearly illustrate the present invention, preferred embodiments are described in detail below with reference to the accompanying drawings. Please refer to... Figures 1 to 7 The image shows a preferred embodiment of a brushless motor of the present invention, which includes a stator assembly 10, a rotor 20 and a circuit board 22.

[0017] The stator assembly 10 includes a stator core 12, multiple enameled wires 14, and a connecting portion 16a. The stator core 12 has a first end 122 and a second end 124 opposite to each other, and the stator core 12 has multiple slots 126 located in different radial directions between the first end 122 and the second end 124. In this embodiment, the multiple slots 126 are formed by extending radially inward and located on the inner side. Each enameled wire 14 is wound around each slot 126 to form multiple stator windings 12a. In this embodiment, the winding direction of each enameled wire 14 around each slot 126 is the same, for example, all are wound clockwise, thereby simplifying the winding process. In other embodiments, it is not excluded that the enameled wires 14 may have different winding directions. Each of the enameled wires 14 has two ends, and the two ends of each of the enameled wires 14 extend from the first end 122 in a direction away from the second end 124. In other words, each of the enameled wires 14 exits to the same side of the stator core 12.

[0018] In this embodiment, the stator assembly 10 further includes two insulating plates, hereinafter defined as a first insulating plate 16 and a second insulating plate 18. The first insulating plate 16 is coupled to the first end 122 of the stator core 12, and the second insulating plate 18 is coupled to the second end 124 of the stator core 12. The first insulating plate 16 is disposed between the first end 122 of the stator core 12 and the circuit board 22 and has a plurality of screw holes 162, which constitute the connecting portion 16a. The connecting portion 16a is used for the circuit board to be joined. The first end 122 of the stator core 12 is closer to the connecting portion 16a than the second end 124. Both ends of each enameled wire 14 extend from the first end 122 toward the connecting portion 16a and beyond the connecting portion 16a.

[0019] In addition, the first insulating plate 16 has a plurality of fixing seats 164, which are located between the first end 122 of the stator core 12 and the circuit board 22. Please cooperate. Figures 3 to 5Each of the aforementioned fixing seats 164 is located between two adjacent stator windings 12a. In this embodiment, each fixing seat 164 has a body portion 164a and a hook portion 164b. The hook portion 164b extends radially outward from the body portion 164a. One end of the enameled wire 14 of the two adjacent stator windings 12a is wound around the body portion 164a of the fixing seat 164 and then extends to the circuit board 22. The displacement of the enameled wire 14 is restricted by the hook portion 164b, thereby fixing the enameled wire 14, preventing the enameled wire 14 from shaking, and increasing the convenience of assembly. In other embodiments, the fixing seat 164 may not be provided on the first insulating plate 16, and the enameled wire 14 may extend directly from the wire groove 126 to the circuit board 22.

[0020] Please cooperate. Figure 3 The rotor 20 passes through the stator core 12 and corresponds to and is surrounded by the plurality of stator windings 12a. In this embodiment, the rotor 20 includes a magnet 202 and a rotating shaft 204. The magnet 202 is surrounded by the plurality of stator windings 12a. The two ends of the rotating shaft 204 extend outwards from the first end 122 and the second end 124, respectively, and a fan 32 is attached to the rotating shaft 204. In this embodiment, the slot 126 of the stator core 12 is located on the inner side and surrounds the rotor 20. In other embodiments, the slot may be located on the outer side, and the rotor is annular and surrounds the slot.

[0021] The circuit board 22 can be a single-layer or multi-layer printed circuit board. Please cooperate. Figure 6 and Figure 7The circuit board 22 has a board body 24 and a conductor group 26. The board body 24 is connected to the connection portion 16a of the stator assembly 10. The board body 24 has a first surface 24a and a second surface 24b facing each other, with the first surface 24a facing the first insulating plate 16. In this embodiment, the board body 24 is fixed to the first insulating plate 16 by multiple bolts 30 locked into multiple screw holes 162. The conductor group 26 has multiple conductors 262, which are arranged in a printed circuit board layout on the board body 24. The conductor group 26 is electrically connected to both ends of each enameled wire 14, for example, by soldering or spot welding, to form a connection configuration. The circuit board 22 also includes three contacts 28, which are arranged in a layout on the board body 24 and located around the three through holes 242 of the board body 24. The three contacts 28 are electrically connected to the conductor group 26. These three contacts 28 are for connecting three-phase wires (U, V, W) to a motor drive circuit board (not shown). The three-phase wires pass through three through holes 242 and are electrically connected to the three contacts 28 by soldering (e.g., soldering or spot welding). (Except as...) Figure 7 In addition to the series Y-type connection configuration shown, other circuit boards with different layouts can also be provided to form a parallel Y-type connection configuration with the stator windings, or as shown in the example. Figure 8 The conductor group 36 of the circuit board 34 shown can be connected in series with the stator winding 12a in a delta configuration or in parallel configuration. The above four connection configurations are just examples, and the layout of the conductor group 26 on the circuit board 22 can be designed according to the actual required connection configuration. When it is necessary to change the connection configuration, simply replace the circuit board 22 and connect it electrically to the stator winding 12a.

[0022] The circuit board 22 has a plate body 24 with multiple slots 244, which are recessed from the periphery of the plate body 24. The enameled wires 14 of two adjacent stator windings 12a extend into each slot 244. The conductor group 26 may have two solder points (not shown) around each slot 244 for soldering two enameled wires 14 respectively. Axially, the orthographic projection of each slot 244 is located between two adjacent stator windings 12a, and at least a portion of each mounting base 164 is located within the projection range of each slot 244. For more details, please refer to... Figure 5Each of the grooves 244 is divided into a first half groove 244a and a second half groove 24b. The hook portion 164b of each of the fixing seats 164 is located within the projection range of the first half groove 244a of each of the grooves 244 and outside the projection range of the second half groove 24b of each of the grooves 244. In other words, the hook portion 164b of each fixing seat 164 is laterally offset relative to each groove 244. As a result, there is more space between each hook portion 164b and each groove 244, making it easier for the enameled wire 14 to extend into the groove 244.

[0023] The brushless motor in this embodiment may further include multiple Hall elements 38, which are disposed on the first surface 24a of the board body 24 of the circuit board 22 and located between the board body 24 of the circuit board 22 and the stator assembly 10. By combining the Hall elements 38 on the circuit board 22 with the wire assembly, the brushless motor does not need to be combined with a circuit board with Hall elements, thereby reducing the axial length of the brushless motor. In other embodiments, multiple commutation switch elements (not shown) may also be disposed on the circuit board 22. Preferably, the commutation switch elements are disposed on the second surface of the board body 24 of the circuit board to facilitate heat dissipation.

[0024] In this way, the commutation signal is output to the wire group 26 of the circuit board 22, which can cause the multiple stator windings 12a to generate different magnetic field changes, so that the rotor 20 is rotated under the action of the magnetic field, thereby achieving the purpose of brushless motor rotation.

[0025] As described above, in the brushless motor of the present invention, the enameled wires 14 of the stator winding 12a all exit from the same side of the stator core 12, and the stator winding 12a is electrically connected to a predetermined connection configuration through the wire group 26 of the circuit board 22. Compared with existing brushless motors, the brushless motor of the present invention can reduce the length of the enameled wires 14 in the axial direction of the stator core 12, and effectively simplify the winding method of the stator winding 12a.

[0026] The above description is only a preferred and feasible embodiment of the present invention. Any equivalent changes made by applying the present invention specification and the claims should be included within the patent scope of the present invention.

[0027] Explanation of reference numerals in the attached figures

[0028] [This invention]

[0029] 10: Stator assembly

[0030] 12: Stator core

[0031] 12a: Stator winding

[0032] 122: First End

[0033] 124: Second End

[0034] 126: Cable tray

[0035] 14: Enamelled wire

[0036] 16: First Insulation Board

[0037] 16a: Connecting part

[0038] 162: Screw hole

[0039] 164: Fixture

[0040] 164a: Ontology

[0041] 164b: Hook

[0042] 18: Second Insulation Board

[0043] 20: Rotor

[0044] 202: Magnet

[0045] 204: Shaft

[0046] 22: Circuit board

[0047] 24: Board body

[0048] 24a: First surface

[0049] 24b: Second surface

[0050] 242: Through hole

[0051] 244: Groove

[0052] 244a: First half of the groove

[0053] 244b: Second half groove

[0054] 26: Conductor group

[0055] 262: Wire

[0056] 28: Contact

[0057] 30: Bolt

[0058] 32: Fan

[0059] 34: Circuit board

[0060] 36: Conductor group

[0061] 38: Hall element

Claims

1. A brushless motor, comprising: A stator assembly includes a connecting portion, a stator core, and multiple enameled wires. The stator core has a first end and a second end opposite to each other, the first end being closer to the connecting portion than the second end. The stator core has multiple slots located in different radial directions between the first end and the second end. Each enameled wire is wound around each slot to form multiple stator windings. Each enameled wire has two ends, and both ends of each enameled wire extend from the first end toward the connecting portion. One rotor corresponds to the plurality of stator windings; A circuit board has a board body and a wire group. The board body is connected to the connection part of the stator group. The wire group has multiple wires. The multiple wires are arranged in a layout on the board body. The wire group is electrically connected to the two ends of each enameled wire. The multiple stator windings are electrically connected through the wire group to form a connection configuration. in, The stator assembly includes multiple fixing seats, which are disposed between the first end of the stator core and the circuit board. Each fixing seat is located between two adjacent stator windings, and one end of the enameled wire of the two adjacent stator windings is wound around the fixing seat and extends to the circuit board to electrically connect the wire assembly. The stator assembly includes an insulating plate disposed between the first end of the stator core and the circuit board. The insulating plate has the connecting portion and the plurality of fixing seats, which are insulating fixing seats. Each of the fixed seats has a body portion and a hook portion, the hook portion extending radially outward from the body portion; one end of the enameled wire of two adjacent stator windings is wound around the body portion of the fixed seat and its displacement is restricted by the hook portion; The circuit board has multiple slots, which are recessed from the periphery of the board. The enameled wires of two adjacent stator windings extend into each slot. At least a portion of each mounting base is located within the projection range of each slot. Each of the grooves is divided into a first half groove and a second half groove. The hook of each of the fixing seats is located within the projection range of the first half groove of each groove and outside the projection range of the second half groove of each groove. The hook portion of each of the fixed seats is offset laterally relative to each of the grooves.

2. The brushless motor as described in claim 1, wherein, The enameled wire of two adjacent stator windings extends into each of the slots.

3. The brushless motor as described in claim 2, wherein, The orthographic projection range of each of the cuts is located between two adjacent stator windings.

4. The brushless motor as described in claim 1, wherein, The circuit board includes three contacts arranged in a layout on the board body, and the three contacts are electrically connected to the wire group.

5. The brushless motor as described in claim 1, wherein, It includes multiple Hall elements, which are disposed on the board body of the circuit board and located between the board body of the circuit board and the stator assembly.

6. The brushless motor as described in claim 1, wherein, The winding direction of each of the enameled wires on each of the wire grooves is the same.

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