Anti-electro-corrosion components and motors

Abstract

This application provides an anti-electro-optical corrosion (EDC) component and a motor. The anti-EDC component includes a stator assembly, comprising a first end cap fixed in place by a plastic encapsulation layer; and a conductive element, with its first end disposed within the plastic encapsulation layer and connected to the first end cap, and its second end exposed within the plastic encapsulation layer for contact with a second end cap. This application utilizes a conductive element inserted within the plastic-encapsulated stator assembly, effectively connecting the end caps at both ends of the stator assembly to form an equipotential, eliminating problems such as induced voltage differences and bearing ball electro-corrosion. Since most of the conductive element is installed within the plastic encapsulation material and does not come into contact with the complex external environment, the small exposed metal portion achieves effective contact. The conductive structure is stable and reliable, and the possibility of ECC failure is extremely low, providing long-term, effective, and stable anti-EDC protection for the motor.

Description

Technical Field

[0001] This application belongs to the field of motor technology, specifically relating to an anti-electro-erosion component and a motor. Background Technology

[0002] In DC brushless motors using plastic encapsulation, the stator core is insulated from the front and rear end covers. During motor operation, high-frequency current and winding imbalance cause excessively high shaft voltage. This current flows through the bearings, resulting in high-frequency electro-corrosion. Electro-corrosion melts and roughens the bearing contact surfaces, leading to bearing wear. This can cause significant noise and vibration in the motor, affecting its reliability and reducing its lifespan.

[0003] Currently, one method used in the industry to prevent electrolytic corrosion is to attach conductive tape to the plastic-encased housing and connect the front and rear end covers of the motor to make the metal covers at both ends of the motor have the same potential. However, this method is prone to aging and falling off. Summary of the Invention

[0004] Therefore, this application provides an anti-electro-erosion component and a motor, which can solve the problem of the conductive tape connecting the front and rear end covers of the motor being prone to aging and falling off in the prior art.

[0005] To address the aforementioned problems, this application provides an anti-electro-erosion component, comprising:

[0006] Stator assembly, including a first end cap that is plastic-sealed and fixed by a plastic encapsulation layer;

[0007] The conductive element has a first end located within the plastic seal layer and connected to the first end cap, and a second end exposed outside the plastic seal layer for contact with the second end cap.

[0008] Optionally, the conductive component includes a conductive strip and an elastic terminal. The conductive strip is embedded in the plastic encapsulation layer and one end is connected to the first end cap. The elastic terminal includes an integrated wire fixing part and an elastic part. The wire fixing part is connected to the other end of the conductive strip, and the elastic part extends out of the plastic encapsulation layer and elastically contacts the second end cap.

[0009] Optionally, the wire fixing part is composed of two oppositely arranged spring pieces, and the other end of the conductive strip is sandwiched between the two spring pieces.

[0010] Optionally, at least one of the opposite sides of the two spring pieces is set as a rough surface.

[0011] Optionally, the stator assembly further includes a first frame, a second frame, and a stator covered by the plastic encapsulation layer. The first frame and the second frame are respectively fitted onto both ends of the stator. The first end is covered on the outside of the first frame, which is the side away from the stator. The first frame, the stator, and the second frame are all provided with limiting structures for the conductive components to pass through in sequence.

[0012] Optionally, the first frame is provided with a slot, and when the conductive component includes a conductive strip, the conductive strip is engaged in the slot.

[0013] Optionally, two slots are provided, which are radially located on the inner and outer sides of the first frame.

[0014] Optionally, the outer wall of the stator is provided with an axial clearance groove.

[0015] Optionally, a mounting groove is provided on the outer side of the second frame, and when the conductive element includes an elastic terminal, the elastic terminal is mounted in the mounting groove.

[0016] Optionally, the slot, the clearance groove, and the mounting groove on the outer side of the first frame are located on the same straight line along the axial direction of the stator.

[0017] According to another aspect of this application, an electric motor is provided, including the anti-electro-erosion component as described above.

[0018] This application provides an anti-electrostatic corrosion component, comprising: a stator assembly, including a first end cap fixed by a plastic seal layer; and a conductive element, the first end of which is disposed within the plastic seal layer and connected to the first end cap, and the second end of which is exposed outside the plastic seal layer for contacting the second end cap.

[0019] This application employs conductive components inserted into the plastic-encapsulated stator assembly, enabling effective conductivity between the end caps at both ends of the stator assembly, forming an equipotential, eliminating problems such as induced voltage difference and bearing ball electro-corrosion, reducing shaft voltage generation, lowering the risk of bearing electro-corrosion, improving motor reliability, and effectively extending motor life.

[0020] Since most of the conductive components are installed inside the molding compound and do not come into contact with the complex external environment, the small exposed metal parts achieve effective contact. The conductive structure is stable and reliable, and the possibility of the anti-electro-erosion structure failing is extremely low. It can provide long-term, effective and stable anti-electro-erosion protection for motors. Attached Figure Description

[0021] Figure 1 This is a cross-sectional view of the motor according to an embodiment of this application;

[0022] Figure 2 This is a schematic diagram of the stator assembly according to an embodiment of this application;

[0023] Figure 3 This is a schematic diagram of the stator assembly structure according to an embodiment of this application;

[0024] Figure 4 This is a schematic diagram of the stator structure according to an embodiment of this application;

[0025] Figure 5 This is a schematic diagram of another assembly structure of the stator assembly according to an embodiment of this application;

[0026] Figure 6 This is a schematic diagram of the wiring terminal structure according to an embodiment of this application;

[0027] Figure 7 Examples of this application Figure 6 Side view;

[0028] Figure 8 This is a schematic diagram of the rotor assembly according to an embodiment of this application.

[0029] The reference numerals in the attached figures are as follows:

[0030] 1. Stator core; 1-1. Clearance slot; 2. First frame; 2-1. Inner wire clamping slot; 2-2. Outer wire clamping slot; 2-2-2. Wire guide slot; 2-2-1. Upper limit post; 2-2-1-1. Limiting protrusion; 3. Second frame; 3-1. Terminal block; 3-1-1. Bottom clearance slot; 3-1-2. Outer ring mounting position; 3-2. Winding connection position; 4. Flexible terminal; 4-1. Flexible part; 4-2. 4-3. Intermediate support section; 4-4. Reinforcing section; 4-5. Bottom support mounting section; 4-6. Wire fixing section; 4-7. Wire hanging section; 4-8. Conductor groove; 5. Winding; 6. First end cover; 6-1. Bearing; 6-2. Mounting reinforcement section; 6-3. Conductive strip mounting position; 7. Conductive strip; 8. Second end cover; 8-1. Contact section; 8-2. Bearing chamber; 9. Rotor assembly; 9-1. Rotor shaft; 9-2. Bearing. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0032] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0033] See also Figures 1 to 8 As shown, according to an embodiment of this application, an anti-electro-erosion component includes:

[0034] Stator assembly, including a first end cap 6 encapsulated and fixed by a plastic encapsulation layer;

[0035] The conductive element has a first end located within the plastic seal layer and connected to the first end cap 6, and a second end exposed outside the plastic seal layer for contact with the second end cap 8.

[0036] This application employs conductive components inserted into the plastic-encapsulated stator assembly, enabling effective conductivity between the end caps at both ends of the stator assembly, forming an equipotential, eliminating problems such as induced voltage difference and ball bearing 9-26-1 electro-corrosion, reducing shaft voltage generation, lowering the risk of ball bearing 9-26-1 electro-corrosion, improving motor reliability, and effectively extending motor life.

[0037] Since most of the conductive components are encapsulated within the molding compound and do not come into contact with the complex external environment, the small exposed metal parts achieve effective contact. The conductive structure is stable and reliable, and the possibility of electro-erosion protection failure is extremely low, providing long-term, effective, and stable electro-erosion protection for the motor. The aforementioned conductive components are made of metal and are conductive.

[0038] In some embodiments, the conductive element includes a conductive strip 7 and an elastic terminal 4. The conductive strip 7 is embedded in the plastic encapsulation layer and one end is connected to the first end cap 6. The elastic terminal 4 includes an integrated wire fixing portion 4-5 and an elastic portion 4-1. The wire fixing portion 4-5 is connected to the other end of the conductive strip 7, and the elastic portion 4-1 extends out of the plastic encapsulation layer and elastically contacts the second end cap 8.

[0039] The conductive strip 7 is encapsulated to prevent aging and prevent it from falling off easily; the elastic part 4-1 in the elastic terminal 4 can make elastic contact with the second end cover 8, ensuring complete contact between the bearing 9-26-1 and the end cover, thus improving the situation where other anti-electro-erosion solutions are used in the existing encapsulated motors in the industry, such as excessive voltage difference between the inner and outer shafts of the bearing 9-26-1, and avoiding the hidden danger of failure of the anti-electro-erosion structure.

[0040] The flexible terminal 4 is easy to manufacture, low in cost, has strong anti-electrolytic corrosion ability, and is easy to install.

[0041] The first end cap 6 is connected to the stator structure via a conductive strip 7. The first end cap 6 is a cap-shaped structure formed by stretching a specific material. The stretched cylindrical structure with an upward-protruding central opening is the bearing chamber 6-1. At the connection between the bearing chamber 6-1 and the outer diameter of the end cap, there is a rounded, recessed structure called 6-2, which serves to make the fit between the end cap, bearing, and stator more secure. The upper part of the end cap is serrated, and the lower part is arc-shaped. Equally sized circular holes are evenly distributed on the outer diameter of the serrated shape. Two circular holes are distributed at both ends of the lower edge, with a conductive strip mounting position 6-3 designed in the middle, equidistant from the circular holes and on the same outer diameter as the other circular holes. The conductive strip mounting position is a U-shaped structure opening towards the bearing chamber. The lower end of the U-shaped structure is located on two rectangular grooves in the middle of the two arc-shaped circular holes, with a protrusion in the middle and a protruding tongue structure at the upper end.

[0042] The conductive strip 7 can be a semi-enclosed U-shaped conductor of equal length. Both ends of the conductive strip are fixed to the mounting positions of the first end cap and are conductive.

[0043] In some embodiments, the wire fixing portion 4-5 is composed of two opposing spring pieces, and the other end of the conductive strip 7 is sandwiched between the two spring pieces. Preferably, at least one of the opposing sides of the two spring pieces is a rough surface.

[0044] The conductive strip 7 is clamped by a spring sheet, especially the opposite surface of the spring sheet is made rough, which makes it easy to clamp the conductive strip 7, prevents it from falling off, and can even puncture the enameled layer of the conductive strip 7 to facilitate conduction.

[0045] The elastic terminal 4 is a crucial conductive structure in this application. The elastic part 4-1 is formed by bending the top of the vertical portion of the L-shaped rib into an S-shaped elastic structure for contact with the second end cap 8. The ribs at the lower end of the elastic part 4-1 are bent inwards to form a concave intermediate support part 4-2, which bears the pressure from the contact portion 8-1 between the elastic part 4-1 and the second end cap. Two arched reinforcing parts 4-3 are rolled up on both sides of the lower end of the intermediate support part 4-2. The connection between the reinforcing parts 4-3 and the intermediate support part 4-2 has a certain slope to support the force borne by the L-shaped rib. The two horizontal portions of the L-shaped rib connected to the reinforcing parts 4-3 are rolled inwards to form a concave structure, the lower end of which is a bottom support mounting part 4-4, which fits tightly with the outer ring mounting position 3-1-2 and the bottom clearance groove 3-1-1 of the second frame. The upper part of the bent "concave" shape is divided into a wire fixing part 4-5. The reinforcing ribs near the reinforcing ribs 4-3 at the upper end of the wire-fixing part 4-5 bend outwards in opposite directions to form an inverted "L"-shaped hanging part 4-6, used to hang one end of the conductive strip that passes through the conductive grooves 4-7 with a spacing of H2. The spacing H2 of the conductive grooves 4-7 needs to be smaller than the diameter of the conductive strip 7. When the conductive strip 7 is installed in the conductive grooves 4-7, its rough inner wall can achieve piercing and conduction with the conductive strip.

[0046] In some embodiments, the stator assembly further includes a first frame 2, a second frame 3, and a stator covered by the plastic encapsulation layer. The first frame 2 and the second frame 3 are respectively fitted onto both ends of the stator. The first end cap 6 is located on the outside of the first frame 2, which is the side away from the stator. The first frame 2, the stator, and the second frame 3 are all provided with limiting structures for the conductive components to pass through in sequence.

[0047] A limiting structure is set on the stator assembly to limit the conductive strip 7, which makes the product structure stable and facilitates the overall encapsulation.

[0048] In some embodiments, the first frame 2 is provided with a slot, and when the conductive element includes a conductive strip 7, the conductive strip 7 is engaged in the slot. Preferably, there are two slots, which are radially arranged on the inner and outer sides of the first frame 2.

[0049] like Figure 3As shown, a U-shaped inner wire-locking groove 2-1 is designed on the upper part of the toothed chuck in the inner diameter groove of the first frame 2. Its function is to support and limit the conductive strip, preventing it from moving out of the groove. An outer wire-locking groove 2-2 is vertically designed on the upper part of the outer diameter of the first frame, at the same horizontal plane as the inner wire-locking groove 2-1. This is used to fix and support the conductive strip 7 passing through the inner wire-locking groove 2-1. The outer wire-locking groove 2-2 consists of two cuboid upper limit posts 2-2-1 and two vertical semi-circular arc protrusions pointing outwards from their centers. The distance between the opposing elliptical protrusions of the upper limit posts 2-2-1 is H1, which must be smaller than the outer diameter of the conductive strip 7 to effectively fix the conductive strip 7. The upper limit posts 2-2-1 fix the conductive strip passing through the inner wire-locking groove 2-1 through the limiting protrusions, and then through the wire-locking groove 2-2-2, ensuring that the conductive strip 7 does not move left, right, or up and down. The function of the limiting protrusion 2-2-1-1 is to fix the conductive strip within the wire groove 2-2-2, preventing it from moving left or right or falling off. The conductive strip 7 maintains a sufficient distance from the winding, ensuring it will not come into contact with the winding and eliminating any safety hazards.

[0050] In some embodiments, the outer wall of the stator is provided with an axial clearance groove.

[0051] like Figure 2-5 As shown, a clearance groove 1-1 is designed on the outer wall of the stator core 1. This clearance groove 1-1 is a "U"-shaped groove on the stator core. The clearance groove 1-1 is used to install the conductive strip 7 connected to the second end cover, so that the conductive strip 7 is embedded in the clearance groove 1-1, avoiding the risk of interference and wear between the conductive strip 7 and the outer wall of the core. Moreover, to facilitate installation and reduce the difficulty of operation, the conductive strip is designed to be slightly longer, and the excess conductive strip can be placed in the space provided by the clearance groove. The size of the clearance groove is determined according to the outer diameter of the conductor strip.

[0052] In some embodiments, a mounting groove is provided on the outer side of the second frame 3, and when the conductive element includes an elastic terminal 4, the elastic terminal 4 is mounted in the mounting groove.

[0053] In the second frame 3, a terminal block 3-1 is designed, consisting of two concave grooves of a certain depth. Its position is on the same line as the outer wire-clamping groove in the first frame 2 and the clearance groove 1-1 in the stator core 1. The outer ring mounting position 3-1-2 of the larger concave groove in the terminal block 3-1 is used to install the bottom support mounting part 4-4 of the elastic terminal 4, while the bottom clearance groove 3-1-1 of the smaller concave groove is used to install the intermediate support part 4-2. On the other side of the frame of the 3-1 terminal block, three square bosses with a certain distance between them are designed. Three connecting pins are respectively set on the upper part of the three square bosses. These three connecting pins are the winding connection positions 3-2, used to connect to the three phases of the stator winding.

[0054] In some embodiments, the slot, the clearance groove, and the mounting groove on the outer side of the first frame 2 are located on the same straight line along the axial direction of the stator.

[0055] The first frame 2 is inserted into the lower end of the stator core 1, and the external clamping groove 2-2 in the first frame 2 is aligned with the clearance groove 1-1 of the stator core 1. The second frame 3 is inserted into the upper end of the stator core, and its terminal block 3-1 is aligned with the clearance groove of the stator core and is on the same line. After the stator structure is assembled, the external clamping groove 2-2 of the first frame, the clearance groove 1-1 of the stator core, and the terminal block 3-1 of the second frame are aligned, so that the three are on the same straight line. The bottom support mounting part 4-4 of the elastic terminal 4 cooperates with the terminal block 3-1 in the second frame 3, so that the two are in a tight fit. The windings 5 ​​are evenly distributed on the armature of the stator structure, completing the stator structure assembly.

[0056] The middle part of the conductive strip mounting position 6-3 of the first end cover 6 is aligned with the inner wire clamping groove 2-1, ensuring that the length of the conductive strip on both sides is consistent. The bearing chamber 6-1 of the first end cover is aligned with the stator. The other parts of the end cover are aligned with the first skeleton support column in the stator structure, ensuring that there is a certain distance between the end cover and the winding. The conductive strip mounting positions 6-3 respectively embed the two ends of the conductive strip 7. The two ends of the conductive strip are firmly fixed by the upper tongue and the lower protrusion of the conductive strip mounting position. After being fixed, the conductive strip passes through the inner wire clamping groove 2-1 and then enters the outer wire clamping groove 2-2. It is limited by the upper limit post 2-1-1 and the limiting protrusion 2-2-1-1, so that the conductive strip is not exposed. After being fixedly embedded in the wire clamping groove 2-2-2 and the clearance groove 1-1 in the stator core, it enters the conductive groove 4-7 in the elastic terminal. After being fixed and supported by the wire fixing part 4-5, it is hung on the hanging part 4-6 nested in the stator structure. After installation, the conductive strip mounting position of the first end cover is on the same side as the inner wire clamping groove 2-1, outer wire clamping groove 2-2, clearance groove 1-1 and terminal block 3-1 in the stator structure, and is in an aligned state to complete the stator assembly.

[0057] In the anti-electro-erosion structure of the encapsulated motor, the stator assembly is injection molded with encapsulating material. After injection molding, the first end cover and the stator in the stator assembly are encapsulated by the encapsulating material. Four trapezoidal mounting feet are injection molded at the top, each with a screw hole evenly distributed around the stator. Two parts of the upper end of the injection-molded stator are exposed above the encapsulating material: one part is the winding connection point 3-2, facilitating the lead-out of the motor's three-phase windings; the other part is the elastic part 4-1, used for contact with the contact part 8-1 of the second end cover 8.

[0058] According to another aspect of this application, an electric motor is provided, including the anti-electro-erosion component as described above.

[0059] The second end cap 8 of the anti-electro-erosion structure for the encapsulated motor is connected to the other end of the stator assembly. The end cap material is composed of inner and outer circles after special processing. The internal structure of the central cylindrical part is a bearing chamber 8-2. On the lower side of the bearing chamber 8-2, there is a U-shaped protrusion, which is a contact part 8-1, used to contact the elastic part 4-1 in the elastic terminal, ensuring that the second end cap and the spring part are in complete contact and achieve a conductive state. Long strip-shaped reinforcing ribs are designed on both sides of the end cap, and screw holes are designed at both ends of the reinforcing ribs for installation with related external structures. Four trapezoidal mounting feet are evenly distributed outward around the end cap, and screw holes are provided on the mounting feet for assembly with screw holes on the injection-molded stator.

[0060] One end of the rotor shaft in rotor assembly 9 is placed into the first end cover at the bottom of the injection-molded stator, allowing the shaft to pass through the bearing chamber 6-1 of the first end cover 6, with the shaft end extending out of the bearing chamber. The bearing mates with the bearing chamber 6-1. The other bearing of the rotor assembly is installed into the bearing chamber of the second end cover 8-2. The elastic part 4-1 of the elastic terminal exposed outside the molding compound in the injection-molded stator contacts the contact part 8-1 of the second end cover 8, aligning the four screw holes with the four screw holes of the injection-molded stator. The rear end cover is then pressed tight, completing the assembly of the encapsulated motor. Through the contact between the elastic part and the end cover contact part, the motor achieves effective conductivity at the second end cover, reducing electrolytic corrosion and improving motor life and reliability.

[0061] It will be readily understood by those skilled in the art that the above embodiments can be freely combined and superimposed without conflict.

[0062] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application. The above description is merely a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the protection scope of this application.

Claims

1. An anti-electrolytic corrosion component, characterized in that, include: The stator assembly includes a first end cap (6) that is fixed in place by a plastic sealant layer; The conductive component has a first end located inside the plastic seal layer and connected to the first end cap (6), and a second end exposed outside the plastic seal layer for contact with the second end cap (8). The conductive component includes a conductive strip (7) and an elastic terminal (4). The conductive strip (7) is embedded in the plastic encapsulation layer and one end is connected to the first end cap (6). The elastic terminal (4) includes an integrated wire fixing part (4-5) and an elastic part (4-1). The wire fixing part (4-5) is connected to the other end of the conductive strip (7), and the elastic part (4-1) extends out of the plastic encapsulation layer and elastically contacts the second end cap (8). The ribs at the lower end of the elastic part (4-1) are bent inward to form an intermediate support part (4-2). The intermediate support part (4-2) is used to bear the pressure from the elastic part (4-1) when it comes into contact with the second end cap (8). The two sides of the lower end of the intermediate support part (4-2) are rolled up to form a reinforcing part (4-3). The two sides of the reinforcing part (4-3) are provided with transverse ribs. The two transverse ribs are rolled inward to form a bottom support mounting part (4-4). The upper end of the bottom support mounting part (4-4) is divided into the fixing part (4-5). The stator assembly also includes a stator, the outer wall of which is provided with an axial clearance groove (1-1), and the conductive strip (7) is embedded in the clearance groove (1-1).

2. The anti-electro-erosion component according to claim 1, characterized in that, The wire fixing part (4-5) is composed of two spring pieces arranged opposite each other, and the other end of the conductive strip (7) is sandwiched between the two spring pieces.

3. The anti-electrolytic corrosion component according to claim 2, characterized in that, At least one of the opposite sides of the two spring pieces is designated as a rough surface.

4. The anti-electrolytic corrosion component according to any one of claims 1-3, characterized in that, The stator assembly also includes a first frame (2) and a second frame (3) covered by the plastic encapsulation layer. The first frame (2) and the second frame (3) are respectively fitted onto both ends of the stator. The first end cap (6) is located on the outside of the first frame (2), which is the side away from the stator. The first frame (2), the stator and the second frame (3) are all provided with limiting structures for the conductive components to pass through in sequence.

5. The anti-electrolytic corrosion component according to claim 4, characterized in that, The first frame (2) is provided with a slot, and when the conductive component includes a conductive strip (7), the conductive strip (7) is engaged in the slot.

6. The anti-electrolytic corrosion component according to claim 5, characterized in that, Two slots are provided, which are radially located on the inner and outer sides of the first frame (2).

7. The anti-electrolytic corrosion component according to claim 6, characterized in that, The second frame (3) has a mounting groove on its outer side. When the conductive component includes an elastic terminal (4), the elastic terminal (4) is installed in the mounting groove.

8. The anti-electrolytic corrosion component according to claim 7, characterized in that, The slot, the clearance groove (1-1), and the mounting groove on the outer side of the first frame (2) are located on the same straight line along the axial direction of the stator.

9. An electric motor, characterized in that, Includes the anti-electro-erosion component as described in any one of claims 1-8.

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