A motor assembly

Abstract

This invention belongs to the field of motor technology and discloses a motor assembly, including a housing, a rotor assembly, a stator assembly, and an output shaft. Both the rotor assembly and the stator assembly are housed within the housing, with the stator assembly fitted over the rotor assembly. The output shaft is connected to the rotor assembly. The stator assembly includes a stator core, a frame, a stator insulation cover, and multiple stator windings. The stator insulation cover includes a base plate with a central opening and a flange at the edge of the base plate. During installation, the base plate covers the frame and the stator windings, the flange surrounds the outer perimeter of the frame, and the housing and frame clamp the stator insulation cover to facilitate installation. This motor assembly, through the stator insulation cover, simplifies assembly, reduces labor intensity, and provides good creepage and insulation, reducing material usage and lowering the overall cost of the motor assembly. Furthermore, the base plate and flange of the stator insulation cover are integrally formed, improving installation efficiency and effectively ensuring strength.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more particularly to a motor assembly. Background Technology

[0002] The stator assembly of an electric motor mainly consists of a stator core, stator windings, and a stator insulation cover. In existing technology, a stator insulation cover is installed at the end of the stator windings to provide overall insulation to the inner, outer, and top rings of the stator windings. However, most existing stator insulation covers are constructed by splicing two semi-circular slots together and covering the stator windings. This method of assembling the stator insulation cover is cumbersome and hinders assembly efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide a motor assembly with a stator insulation cover that is easy to install, has high strength, and improves assembly efficiency.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] An electric motor assembly includes a housing, a rotor assembly, a stator assembly, and an output shaft. The rotor assembly and the stator assembly are both disposed within the housing, and the stator assembly is sleeved around the rotor assembly. The output shaft is fixedly connected to the rotor assembly. The stator assembly includes:

[0006] The stator core includes a first annular body and multiple embedded portions, wherein the multiple embedded portions are circumferentially protruding from the inner sidewall of the first annular body;

[0007] The skeleton includes a second annular body and a plurality of protruding teeth that protrude radially inward from the second annular body. The plurality of protruding teeth are arranged circumferentially around the second annular body. Hollow cavities are provided inside the protruding teeth. The plurality of embedded parts are respectively inserted into the plurality of hollow cavities so that the skeleton is installed on the stator core.

[0008] Multiple stator windings, with one stator winding fitted onto each of the aforementioned protruding teeth;

[0009] The stator insulation cover includes a base plate with a central opening and a flange surrounding the edge of the base plate. The base plate covers the stator winding, and the flange surrounds the outer periphery of the frame. The base plate and the flange are integrally formed, and the housing and the frame clamp and fix the stator insulation cover.

[0010] As an alternative, the flanged side facing away from the frame abuts against the inner side of the housing.

[0011] As an optional solution, anti-slip ribs are provided on the top surface of the housing, and the anti-slip ribs abut against the bottom plate.

[0012] As an alternative, a gap exists between the flange and the stator core along the radial direction of the stator core.

[0013] As an alternative, the conductors of the stator winding form a wire harness, which is tied to the side of the stator winding away from the stator insulation cover using cable ties.

[0014] As an alternative, the frame is provided with a binding groove, which is located on the bottom wall of the hollow cavity on the side opposite to the stator insulation cover, and the binding groove is used to accommodate part of the cable tie.

[0015] As an optional solution, the frame is provided with a positioning post, and the outer periphery of the stator core is provided with a first positioning groove. When the stator core is installed with the frame, the positioning post and the first positioning groove are positioned directly opposite each other.

[0016] As an alternative, the skeleton includes two skeleton bodies that are plugged into each other and fixed. Each of the two skeleton bodies is provided with a plurality of male slots and a plurality of female slots along its circumference. The male slots and female slots on the same skeleton body are alternately arranged. When the two skeleton bodies are fixedly connected to each other, the male slot on one skeleton body can be plugged into the female slot on the other skeleton body to form the protruding teeth and the hollow cavity.

[0017] As an alternative, the skeleton is provided with a barbed post, the barbed post is provided with an outwardly protruding hook, the enameled wire is wound around the skeleton and located on the barbed post, and the hook can limit the enameled wire.

[0018] As an alternative, the hook prevents the enameled wire from moving away from the stator insulation cover.

[0019] As an alternative, the motor assembly further includes a lead coil, and the housing includes a housing and an end cover. The housing is provided with a mounting notch, and the mounting notch and the end cover form a mounting hole for mounting the lead coil.

[0020] The output coil has a groove on its circumferential sidewall facing the mounting notch, and the inner wall of the mounting notch has a protruding edge that can be inserted into the groove.

[0021] As an alternative, a sealing ring is fitted on the end cap, and the groove extends in an annular shape along the circumference of the output coil, and the sealing ring can be engaged in the groove on the side of the output coil facing the end cap.

[0022] As an alternative, the output coil is made of an elastic material, and the height of the output coil is greater than the depth of the mounting notch along the axial direction of the output shaft.

[0023] The beneficial effects of this invention are:

[0024] This invention provides a motor assembly whose stator insulation cover includes a base plate with a central opening and a flange surrounding the edge of the base plate. During installation, the base plate is placed on the frame and covers the stator windings, the flange surrounds the outer periphery of the frame, and the housing and frame are clamped together to secure the stator insulation cover, facilitating its installation. This stator insulation cover simplifies assembly, reduces labor intensity, and provides good creepage and insulation, reducing material usage and overall cost. Furthermore, the base plate and flange of the stator insulation cover are integrally formed, improving installation efficiency and ensuring strength. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the motor assembly structure described in an embodiment of the present invention. Figure 1 ;

[0026] Figure 2 This is a schematic diagram of the skeleton structure described in an embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the stator core structure according to an embodiment of the present invention;

[0028] Figure 4 This is a schematic diagram of the stator winding structure according to an embodiment of the present invention;

[0029] Figure 5 This is a schematic diagram of the structure of the stator insulating cover according to an embodiment of the present invention;

[0030] Figure 6 This is a schematic diagram of the structure of the shell described in an embodiment of the present invention;

[0031] Figure 7 yes Figure 1 Enlarged view of the structure at point A in the middle;

[0032] Figure 8 This is a schematic diagram of the motor assembly structure described in an embodiment of the present invention. Figure 2 ;

[0033] Figure 9 yes Figure 2 Enlarged view of the structure at point B;

[0034] Figure 10 yes Figure 8 Enlarged view of the structure at point C;

[0035] Figure 11This is a schematic diagram of the skeleton body described in an embodiment of the present invention;

[0036] Figure 12 yes Figure 8 Enlarged view of the structure at point D;

[0037] Figure 13 yes Figure 8 Enlarged view of the structure at point E in the middle.

[0038] In the picture:

[0039] 1. Housing; 11. Shell; 111. Anti-slip ribs; 112. Mounting notch; 1121. Raised edge; 12. End cap; 121. Sealing ring;

[0040] 2. Rotor assembly;

[0041] 3. Stator assembly; 31. Stator core; 311. Embedded part; 312. First positioning groove; 32. Frame; 321. Raised tooth; 3211. Hollow cavity; 322. Binding groove; 323. Positioning post; 324. Frame body; 3241. Male slot; 3242. Female slot; 325. Barbed post; 33. Stator winding; 331. Wire harness; 34. Stator insulation cover; 341. Base plate; 342. Flanged edge; 35. Gap;

[0042] 4. Output shaft;

[0043] 5. Cable ties;

[0044] 6. Enamelled wire;

[0045] 7. Outgoing coil; 71. Groove. Detailed Implementation

[0046] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0047] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium; or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0048] In the description of this invention, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0049] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0050] like Figures 1-13 As shown, this embodiment of the invention provides a motor assembly, including a housing 1, a rotor assembly 2, a stator assembly 3, and an output shaft 4. The stator assembly 3 is fixedly disposed within the housing 1, and the rotor assembly 2 is rotatably disposed within the housing 1 and located inside the stator assembly 3. A drive wheel is mounted on the output shaft 4 and fixedly connected to the rotor assembly 2. When the motor assembly is energized, the stator assembly 3 generates a rotating magnetic field that acts on the rotor assembly 2, causing the rotor assembly 2 to rotate, which in turn drives the output shaft 4 to rotate. The drive wheel on the output shaft 4 is connected to other components for transmission, thereby transmitting the motion of the motor assembly to other components.

[0051] Continue to refer to Figures 2-7The stator assembly 3 includes a stator core 31, a frame 32, a stator insulating cover 34, and multiple stator windings 33. The stator core 31 includes a first annular body and multiple inserts 311, which are circumferentially and uniformly protruding from the inner wall of the first annular body. The frame 32 includes a second annular body and multiple radially inwardly protruding teeth 321, which are circumferentially and uniformly arranged around the second annular body. Each tooth 321 contains a hollow cavity 3211 corresponding to an insert 311. When the frame 32 is installed in the stator core 31, the inserts 311 are inserted into and engaged within the hollow cavities 3211. The multiple stator windings 33 are arranged one-to-one with the teeth 321, and each tooth 321 is fitted with a stator winding 33. The function of the stator windings 33 is to generate a rotating magnetic field. Multiple stator windings 33 are evenly arranged on multiple protruding teeth 321 to generate a uniform magnetic field. The stator insulation cover 34 includes a base plate 341 with a central opening and a flange 342 surrounding the edge of the base plate 341. When the base plate 341 covers the stator windings 33, it insulates the stator windings 33 from the housing 1. The central opening does not affect the insulation effect and creepage performance, and it also reduces the amount of material used and lowers the cost. The flange 342 surrounds the outer periphery of the frame 32. The stator insulation cover 34 is sandwiched between the housing 1 and the frame 32. The housing 1 and the frame 32 can clamp and fix the stator insulation cover 34 to further prevent the stator insulation cover 34 from shaking. In addition, the base plate 341 and the flange 342 are integrally formed, which not only ensures the structural strength, but also improves the processing efficiency and installation efficiency.

[0052] Furthermore, the side of the flange 342 facing away from the frame 32 abuts against the inner side of the housing 1. The housing 1 includes a shell 11 and an end cover 12, which are fixedly connected by screws to form the housing 1. During installation, the stator insulation cover 34 is pressed into the shell 11, with the bottom plate 341 of the stator insulation cover 34 abutting against the top surface of the shell 11, and the side of the flange 342 facing away from the frame 32 abutting against the inner side of the shell 11. That is, the flange 342 and the shell 11 adopt a transition fit, and there is a certain assembly strength between them so that the stator insulation cover 34 will not fall out after being pressed into the shell 11. This structure makes assembly simple and convenient.

[0053] To ensure the stator insulation cover 34 is accurately pressed into the housing 11 and to further enhance the fixing firmness between the stator insulation cover 34 and the housing 11, refer to Figure 6 The top surface of the housing 11 is provided with anti-slip ribs 111. When the stator insulation cover 34 is pressed into the housing 11, the bottom plate 341 abuts against the anti-slip ribs 111. The anti-slip ribs 111 can limit the distance of the stator insulation cover 34 pressed into the housing 11, and can also prevent the stator insulation cover 34 from rotating. Furthermore, multiple anti-slip ribs 111 are provided, and the multiple anti-slip ribs 111 are circumferentially distributed on the top surface of the housing 11.

[0054] To ensure that the stator insulation cover 34 is prevented from deforming during installation, refer to... Figure 7 There is a gap 35 between the flange 342 of the stator insulation cover 34 and the stator core 31. This gap 35 can ensure that the flange 342 and the stator core 31 do not interfere with each other.

[0055] like Figure 11 As shown, the skeleton 32 includes two skeleton bodies 324 that are interlocked and fixed together. Each skeleton body 324 has multiple male slots 3241 and multiple female slots 3242 along its circumference. The male slots 3241 and female slots 3242 on the same skeleton body 324 are alternately arranged. When the two skeleton bodies 324 are fixedly connected, the male slot 3241 on one skeleton body 324 can be inserted into the female slot 3242 on the other skeleton body 324 to form the protrusions 321 and hollow cavities 3211 of the skeleton 32. This structure only requires the machining of two identical skeleton bodies 324, which are then interlocked to form the skeleton 32, reducing machining steps and improving manufacturing efficiency.

[0056] Continue to refer to Figure 7 Multiple stator windings 33 are interconnected by wires, and multiple wires form a wire bundle 331 that is led out from the inside to the outside of the motor assembly. In order to fix the wire bundle 331 located inside the motor assembly, the wire bundle 331 is tied to the side of the stator winding 33 away from the stator insulation cover 34 by cable ties 5.

[0057] Reference Figure 2 and combined Figure 11 To prevent the cable tie 5 from moving around the circumference of the second annular body of the frame 32, a binding groove 322 is provided on the frame body 324 near the outlet of the wire harness 331. The binding groove 322 is located on the bottom wall of the hollow cavity 3211 on the side opposite to the stator insulation cover 34. That is, the binding groove 322 is located between the male slot 3241 and the female slot 3242, and extends radially to the baffle between the male slot 3241 and the female slot 3242. The cable tie 5 is confined within the binding groove 322 to bind the wire harness 331. This structure not only restricts the movement of the cable tie 5, but also makes binding the cable tie 5 more convenient. The wire harness 331 can be fixed simply by passing the cable tie 5 through the binding groove 322, and the cable tie 5 does not interfere with the frame 32. In this embodiment, the depth and width of the binding groove 322 are greater than the thickness and width of the cable tie 5, so that the cable tie 5 and the binding groove 322 fit with a gap 35, making it easier to insert the cable tie 5.

[0058] like Figures 8-10As shown, the frame 32 is provided with positioning posts 323, and the stator core 31 is provided with a first positioning groove 312 on its outer periphery. When the stator core 31 and the frame 32 are installed, the positioning posts 323 and the first positioning groove 312 are directly opposite each other. With this structure, when the stator core 31 and the frame 32 are installed, the axis of the positioning posts 323 is aligned with the center line of the first positioning groove 312 to ensure that the frame 32 is inserted into the stator core 31 and that the relative positions of the frame 32 and the stator core 31 are accurate.

[0059] Enamelled wire 6 is wound on the frame 32. The enamelled wire 6 is located on the side of the frame 32 where the wire harness 331 is located. The enamelled wire 6 is used to form the winding. To prevent the enamelled wire 6 from detaching from the frame 32, refer to... Figure 7 The skeleton 32 has a barbed post 325 at one end facing the wire harness 331. The barbed post 325 has an outwardly protruding hook. The enameled wire 6 is wound around the skeleton 32 and abuts against the barbed post 325. The hook can limit the enameled wire 6. In this embodiment, the barbed post 325 is located inside the second annular body of the skeleton 32, and the hook is perpendicular to the barbed post 325. The hook does not exceed the outer side of the second annular body of the skeleton 32, so as to save space and material costs.

[0060] Furthermore, the hook body is located at the end of the barbed post 325 away from the frame 32, and the hook body is used to prevent the enameled wire 6 from moving away from the stator insulation cover 34. It can be understood that the barbed post 325 is located inside the second annular body of the frame 32, and when the enameled wire 6 is wound on the frame 32 and abuts against the barbed post 325, the enameled wire 6 is confined between the hook body and the second annular body.

[0061] The rotor assembly 2 includes a magnet and a rotor core, which are bonded together with adhesive.

[0062] A PCB board is located at the center of end cap 12. The PCB board is used for signal conversion and includes a signal output structure. Both the signal output lines and wiring harness 331 need to be routed out of the motor assembly. For easier routing of the signal output lines and wiring harness 331, refer to... Figure 8 , Figures 12-13 The motor assembly also includes a lead coil 7. The housing 11 is provided with a mounting notch 112. When the housing 11 is fixedly connected to the end cover 12, the mounting notch 112 and the end cover 12 form a mounting hole for mounting the lead coil 7. In order to enhance the sealing between the lead coil 7 and the mounting notch 112, the lead coil 7 is provided with a groove 71 on the circumferential sidewall facing the mounting notch 112. The inner wall of the mounting notch 112 is provided with a protrusion 1121. When the lead coil 7 is installed in the mounting notch 112, the protrusion 1121 can be inserted into the groove 71. The protrusion 1121 and the groove 71 are interference fit, which can make the lead coil 7 and the mounting notch 112 have good sealing performance.

[0063] The end of the coil output 7 connected to the mounting notch 112 is a cuboid structure. Grooves 71 are provided on all three circumferential sidewalls of the coil output 7. The mounting notch 112 is a rectangular notch with protruding edges 1121 on all three inner walls. To further improve sealing, a groove 71 is provided on the fourth circumferential sidewall of the coil output 7. The groove 71 extends circumferentially along the coil output 7 in a ring shape. A sealing ring 121 is provided on the end cap 12. After the coil output 7 is installed with the mounting notch 112, the end cap 12 is connected to the housing 11. The sealing ring 121 can be inserted into the groove 71 on the fourth circumferential sidewall of the coil output 7 to form a good sealing effect and improve waterproof performance. In this embodiment, the sealing ring 121 is a rubber sealing ring 121.

[0064] Furthermore, the output coil 7 is made of an elastic material, enabling it to undergo flexible deformation. Rubber is the preferred material for the output coil 7, as it is flexible and corrosion-resistant. Along the axial direction of the output shaft 4, the height of the output coil 7 is greater than the depth of the mounting notch 112. When the housing 11 is installed with the end cap 12, the end cap 12 and the housing 11 can press the output coil 7 together for better sealing.

[0065] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A motor assembly, comprising a housing (1), a rotor assembly (2), a stator assembly (3), and an output shaft (4), wherein the rotor assembly (2) and the stator assembly (3) are both disposed within the housing (1), the stator assembly (3) is sleeved outside the rotor assembly (2), and the output shaft (4) is fixedly connected to the rotor assembly (2), characterized in that, The stator assembly (3) includes: The stator core (31) includes a first annular body and a plurality of embedded parts (311), wherein the plurality of embedded parts (311) are circumferentially protruding on the inner sidewall of the first annular body; The skeleton (32) includes a second annular body and a plurality of protruding teeth (321) that protrude radially inward from the second annular body. The plurality of protruding teeth (321) are arranged circumferentially around the second annular body. A hollow cavity (3211) is provided in the protruding teeth (321). The plurality of embedded parts (311) are respectively inserted into the plurality of hollow cavities (3211) so that the skeleton (32) is installed on the stator core (31). Multiple stator windings (33), each of the convex teeth (321) is fitted with one of the stator windings (33); The stator insulation cover (34) includes a base plate (341) with a central opening and a flange (342) surrounding the edge of the base plate (341). The base plate (341) covers the stator winding (33), and the flange (342) surrounds the outer periphery of the frame (32). The base plate (341) and the flange (342) are integrally formed. The housing (1) and the frame (32) clamp and fix the stator insulation cover (34).

2. The motor assembly according to claim 1, characterized in that, The flange (342) is opposite to the side of the frame (32) and abuts against the inner side of the housing (1).

3. The motor assembly according to claim 1, characterized in that, The top surface of the housing (1) is provided with anti-slip ribs (111), which abut against the bottom plate (341).

4. The motor assembly according to claim 1, characterized in that, Along the radial direction of the stator core (31), there is a gap (35) between the flange (342) and the stator core (31).

5. The motor assembly according to any one of claims 1-4, characterized in that, The conductors of the stator winding (33) form a wire harness (331), and the wire harness (331) is tied to the side of the stator winding (33) away from the stator insulation cover (34) by cable ties (5). Preferably, the frame (32) is provided with a binding groove (322), the binding groove (322) is located on the bottom wall of the hollow cavity (3211) away from the stator insulation cover (34), and the binding groove (322) is used to accommodate part of the cable tie (5).

6. The motor assembly according to any one of claims 1-4, characterized in that, The frame (32) is provided with a positioning post (323), and the stator core (31) is provided with a first positioning groove (312) on its outer periphery. When the stator core (31) is installed with the frame (32), the positioning post (323) and the first positioning groove (312) are positioned opposite each other.

7. The motor assembly according to any one of claims 1-4, characterized in that, The skeleton (32) includes two skeleton bodies (324) that are plugged into each other and fixed. Each of the two skeleton bodies (324) is provided with a plurality of male slots (3241) and a plurality of female slots (3242) along its circumference. The male slots (3241) and female slots (3242) on the same skeleton body (324) are alternately arranged. When the two skeleton bodies (324) are fixedly connected to each other, the male slot (3241) on one skeleton body (324) can be plugged into the female slot (3242) on the other skeleton body (324) to form the protruding tooth (321) and the hollow cavity (3211).

8. The motor assembly according to any one of claims 1-4, characterized in that, The skeleton (32) is provided with a barbed post (325), the barbed post (325) is provided with an outwardly protruding hook body, the enameled wire (6) is wound around the skeleton (32) and located on the barbed post (325), and the hook body can limit the enameled wire (6); Preferably, the hook prevents the enameled wire (6) from moving away from the stator insulation cover (34).

9. The motor assembly according to any one of claims 1-4, characterized in that, The motor assembly also includes a lead coil (7), and the housing (1) includes a housing (11) and an end cover (12). The housing (11) is provided with a mounting notch (112), and the mounting notch (112) and the end cover (12) form a mounting hole for mounting the lead coil (7). The output coil (7) has a groove (71) on its circumferential sidewall facing the mounting notch (112), and the inner wall of the mounting notch (112) has a protruding edge (1121) that can be inserted into the groove (71). Preferably, a sealing ring (121) is fitted on the end cap (12), and the groove (71) extends in a ring shape along the circumference of the output coil (7). The sealing ring (121) can be inserted into the groove (71) on the side of the output coil (7) facing the end cap (12).

10. The motor assembly according to claim 9, characterized in that, The output coil (7) is made of an elastic material, and the height of the output coil (7) is greater than the depth of the mounting notch (112) along the axial direction of the output shaft (4).

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