A method for forming a circuit using a multi-layer wiring board in combination with a wire harness

Abstract

The application provides a method for forming a circuit by combining a multi-layer circuit board with a wire harness. The method comprises the following steps: designing circuit lines according to a stator winding electromagnetic scheme between a top plate and a bottom plate of a prefabricated circuit board and welding holes; inserting a plurality of U-shaped wires between each adjacent two wire slots in a top-down order, wherein "top-down" means that the U-shaped wire is inserted from the bottom to the top between the two wire slots and then through the corresponding welding hole on the top plate, and "down-top" means that the U-shaped wire is inserted from the top to the bottom between the two wire slots and then through the corresponding welding hole on the bottom plate; connecting the tail ends of the lines in the A-phase layer, the B-phase layer and the C-phase layer of the top plate and the bottom plate of the prefabricated circuit board with the neutral wire of the middle layer by using strip-shaped wires; and welding the welding ends of the U-shaped wires at the welding holes to form a winding circuit. When designing the same series of motors, the application only needs to modify the design of the multi-layer prefabricated circuit board to adapt to the change of the winding electromagnetic scheme.

Description

Technical Field

[0001] This invention relates to the field of motor design and manufacturing technology, and in particular to a method for forming a circuit using multilayer circuit boards combined with wire harnesses. Background Technology

[0002] Electric motors are widely used in all sectors of society, including industrial equipment, agricultural machinery, automobiles, and home appliances, all requiring motor drive. These motors demand high efficiency, lightweight design, miniaturization, and low cost. Among various types of motors, there are two types of winding wires: round and flat. The current winding process for round wire motors involves three complex and tedious steps: winding the wire into the stator slots, manually arranging the wire in the stator, and manually binding the wire in the stator. This process consumes a significant amount of labor. Flat wire motors, compared to round wire motors, are smaller, more efficient, have better thermal conductivity, lower temperature rise, and lower noise.

[0003] Small size: Compared with traditional round wire motors, flat wire motors are smaller in size, use less material, and have lower cost for the same power. Alternatively, for the same volume, the slot fill factor is increased and the power density is increased.

[0004] Good temperature performance: The interior of the flat wire motor is more compact with fewer gaps, resulting in a larger contact area between the flat wires and better heat dissipation and heat conduction; at the same time, the contact between the winding and the iron core slot is better, resulting in better heat conduction.

[0005] Low noise: Flat wire motors allow for better armature stiffness, which suppresses armature noise. Furthermore, smaller slot sizes can be used, effectively reducing cogging torque and further lowering electromagnetic noise.

[0006] While flat wire motors possess the advantages mentioned above, they are not yet widely used. The main reasons are the complexity of their current manufacturing process, the high precision requirements, the significant investment in manufacturing equipment, and the difficulty in designing product series. They are only suitable for motor production with high performance requirements, large batch sizes of a single specification, and a high degree of automation. Among these, U-shaped flat wire motor technology is the mainstream technology that is widely adopted.

[0007] Currently, the winding processing flow of the stator assembly of the flat wire motor is as follows: slot paper - hairpin manufacturing - hairpin wire insertion - end wire shaping - insulation coating - star phase wire welding - end wire welding.

[0008] After the flat wire is inserted into the iron core, specialized equipment and tooling are needed to twist and shape all the ends of the flat wire as a whole, so that the corresponding wire ends are in contact with each other and aligned flat. This process requires a high degree of precision from the equipment and tooling.

[0009] There are many solder joints at the wire ends, so laser automatic welding equipment is generally used.

[0010] Flat wires are difficult to mass-produce by hand due to their complex processes and high precision requirements. They must rely on specialized high-end equipment, which is a prerequisite for large-scale application and an important reason restricting their localization. However, the processing price abroad is high.

[0011] Due to the aforementioned reasons, the serialization design of flat wire motors is extremely difficult, with flexible design being the most challenging aspect. This severely tests the abilities of motor designers, and producing different specifications involves numerous changes to equipment, tooling, and molds. Consequently, the advantages of flat wire motors—such as improved motor performance, reduced material consumption, and lower product costs—cannot be fully utilized in the production of small batches of multi-specification motors. Summary of the Invention

[0012] The purpose of this invention is to provide a method for forming a circuit using multilayer circuit boards combined with wire harnesses, which allows for flexible design changes.

[0013] The technical solution of this invention is: a method for forming a circuit using a multilayer circuit board combined with a wire harness, comprising: providing an iron core, a prefabricated circuit board top plate and a prefabricated circuit board bottom plate disposed at both ends of the iron core, wherein the iron core has X×3 wire slots; processing welding hole groups corresponding to the X×3 wire slots on the prefabricated circuit board top plate and the prefabricated circuit board bottom plate, wherein each welding hole group has multiple welding holes, and both the prefabricated circuit board top plate and the prefabricated circuit board bottom plate include an A phase layer, a B phase layer, a C phase layer and an intermediate layer, wherein X welding hole groups are provided on the A phase layer, the B phase layer and the C phase layer; and the intermediate layer has X×3 welding hole groups;

[0014] The circuit is designed between the welding holes on the top and bottom plates of the prefabricated circuit board according to the electromagnetic scheme of the stator winding.

[0015] Multiple U-shaped wires are inserted between each pair of adjacent wire slots, and they are inserted in sequence in an up-down order. "Up" means passing the U-shaped wire from bottom to top between the two wire slots and then through the corresponding welding hole on the top plate of the prefabricated circuit board. "Down" means passing the U-shaped wire from top to bottom between the two wire slots and then through the corresponding welding hole on the bottom plate of the prefabricated circuit board.

[0016] In the top and bottom plates of the prefabricated circuit board, the ends of the lines in the A-phase, B-phase, and C-phase layers are connected to the neutral line of the intermediate layer using strip conductors.

[0017] Then, weld the welding ends of each U-shaped conductor to the welding hole and connect them to the circuit to form a winding circuit.

[0018] In the above scheme, both the top and bottom plates of the prefabricated circuit board adopt a multi-layer prefabricated structure, which has a relatively low cost. By setting welding holes on the top and bottom plates of the prefabricated circuit board, and designing the electromagnetic scheme of the stator winding between the welding holes, when designing motors of the same series, only the design of the multi-layer prefabricated circuit board needs to be modified to adapt to the change of the winding electromagnetic scheme, so that the production of motors of different specifications can be realized, and the design change is very flexible.

[0019] Preferably, the X groups of weld holes on the A phase layer are arranged radially, and in each group of weld holes, the weld holes in the odd-numbered positions are staggered with the weld holes in the even-numbered positions; weld holes are set on the B phase layer and the C phase layer in this manner.

[0020] Preferably, among the Z solder holes on the A-phase layer of the prefabricated circuit board top plate, the one closest to the center is designated as 1, and wiring is performed between solder holes No. 1 in two adjacent groups; even-numbered solder holes are wired to adjacent odd-numbered solder holes in pairs, and a U-shaped wire is inserted between the two solder holes; in the X solder hole groups, the Z solder holes in two groups are not connected, and wiring is performed between the Z solder holes in the remaining two adjacent groups; a strip wire is inserted into one of the Z solder holes that is not connected, and the strip wire is connected to the corresponding solder hole in the intermediate layer; a strip wire is inserted into the Z-1 solder hole in the same group as the Z solder hole, and the strip wire is connected to the corresponding solder hole on the A-phase layer of the prefabricated circuit board bottom plate; the same U-shaped wire is inserted into the other Z solder hole that is not connected and the Z-1 solder hole in the same group as the Z solder hole;

[0021] Wiring is performed between the solder holes in the prefabricated circuit board base plate using the method described above, so that the U-shaped conductors of each phase are connected through the wiring on the circuit board.

[0022] Preferably, after the circuit is formed, the assembled structure is fixed to form a "squirrel cage" stator using a frame, and then the top plate and bottom plate of the prefabricated circuit board, as well as the ends of the U-shaped conductors and strip conductors, are insulated.

[0023] Preferably, the soldering holes of the U-shaped conductors of phase A, phase B, and phase C are designed in the same circuit layer, that is, the center points of phase A, phase B, and phase C are soldered separately to the intermediate layer and connected to each other.

[0024] Compared with related technologies, the beneficial effects of the present invention are as follows:

[0025] 1. Both the top and bottom plates of the prefabricated circuit board adopt a multi-layer prefabricated structure, which has a relatively low cost. By setting welding holes on the top and bottom plates of the prefabricated circuit board, and designing the electromagnetic scheme of the stator winding between the welding holes, when designing motors of the same series, only the design of the multi-layer prefabricated circuit board needs to be modified to adapt to the change of the electromagnetic scheme of the winding, so that the production of motors of different specifications can be realized, and the design changes are very flexible.

[0026] Second, this invention can be applied to more industries' motor needs and can take advantage of the performance of flat wire motors.

[0027] Third, in this invention, the wire harness in the stator slot is connected by wiring through a circuit board to generate winding current and realize the motor function.

[0028] Fourth, it simplifies the stator manufacturing process, saves labor costs, and allows for flexible design and production changes, which is conducive to improving motor performance, saving equipment investment, reducing consumption, and promoting the widespread application of energy-saving and high-efficiency motors. Attached Figure Description

[0029] Figure 1 This is a top view of the assembled U-shaped conductor and iron core.

[0030] Figure 2 A schematic diagram of wiring for soldering holes on the top plate of a prefabricated circuit board;

[0031] Figure 3 A schematic diagram of wiring for soldering holes on a prefabricated circuit board substrate;

[0032] Figure 4 This is a schematic diagram showing the arrangement of weld holes on the intermediate layer;

[0033] Figure 5 A schematic diagram showing the U-shaped conductors being inserted one above the other on the top and bottom plates of the prefabricated circuit board.

[0034] Figure 6 This is a schematic diagram of the structure of a U-shaped conductor;

[0035] Figure 7 This is a schematic diagram of the structure of a strip conductor;

[0036] Figure 8 This is a schematic diagram of the structure of a squirrel-cage stator assembled using the method of the present invention. Detailed Implementation

[0037] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other. For ease of description, the terms "upper," "lower," "left," and "right" used below only indicate that they correspond to the upper, lower, left, and right directions in the accompanying drawings and do not limit the structure.

[0038] like Figure 1 As shown, the method for forming a circuit using a multilayer circuit board and wire harness provided in this embodiment includes the following steps:

[0039] S1 provides an iron core 1, a prefabricated circuit board top plate 2 and a prefabricated circuit board bottom plate 3 respectively disposed at both ends of the iron core 1, wherein the iron core 1 has X×3 wire grooves 11 (e.g. Figure 1 (As described above). In this embodiment, X = 12. Welding hole groups corresponding to X × 3 wire grooves 11 are processed on the prefabricated circuit board top plate 2 and prefabricated circuit board bottom plate 3. Each welding hole group has multiple welding holes 6. The prefabricated circuit board top plate 2 and prefabricated circuit board bottom plate 3 both include an A phase layer, a B phase layer, a C phase layer, and an intermediate layer, wherein, as... Figure 2 , Figure 3 As shown, X groups of weld holes are provided on phase A, phase B, and phase C. The intermediate layer has X×3 groups of weld holes (e.g., ...). Figure 4 (As shown). X groups of weld holes on phase A are arranged radially, and in each group of weld holes, weld holes 6 in odd-numbered positions are staggered from weld holes 6 in even-numbered positions; weld holes 6 are arranged in the same manner on phase B and phase C.

[0040] S2, the circuit is designed between the welding holes 6 on the top plate 2 and the bottom plate 3 of the prefabricated circuit board according to the electromagnetic scheme of the stator winding.

[0041] S3, insert 12 U-shaped wires 4 between every two adjacent wire slots 11, and insert them in an up-down order. "Up" means passing the U-shaped wire 4 from bottom to top between the two wire slots 11, and then through the corresponding solder holes 6 on the top plate 2 of the prefabricated circuit board (e.g., Figure 1 As shown in 41), "one step" refers to passing the U-shaped wire 4 from top to bottom between the two wire grooves 11 (e.g., Figure 1 As shown in 42), it then passes through the corresponding solder hole 6 on the prefabricated circuit board base plate 3.

[0042] S4, as Figure 2 , Figure 3 As shown, in the prefabricated circuit board top plate 2, there are Z solder holes on the A phase layer, where Z is an even number, and in this embodiment, Z = 6. The hole closest to the center is designated as 1. Wiring is then done between solder holes 1 (1#) in two adjacent groups. Even-numbered solder holes are wired to adjacent odd-numbered solder holes in pairs, such as between solder holes 2 (2#) and 3 (3#), and between solder holes 4 (4#) and 5 (5#). A U-shaped wire 4 is inserted between the two solder holes 6 that are wired. In the 12 solder hole groups, solder holes 6 (6#) in two groups are not connected, and wiring is done between solder holes 6 in the remaining two adjacent groups. A strip conductor 5 is inserted into one of the unconnected solder holes (No. 6), and this strip conductor 5 is connected to the corresponding solder hole 6 in the intermediate layer. A strip conductor 5 is also inserted into solder hole 5 in the same group as solder hole 6, and this strip conductor 5 is connected to the corresponding solder hole 6 on the A-phase layer of the prefabricated circuit board base plate 3. The same U-shaped conductor 4 is inserted into the other unconnected solder hole (No. 6) and the solder hole 5 in the same group as solder hole 6.

[0043] Wiring is performed between the solder holes 6 in the prefabricated circuit board base plate 3 using the method described above, so that the U-shaped conductors 4 of each phase are connected through the wiring on the circuit board.

[0044] like Figure 4 As shown, in two adjacent groups of solder holes on the intermediate layer, the odd-numbered solder holes 6 in one group correspond to the even-numbered solder holes 6 in the other group, which are the positions of each solder hole 6 in the A phase layer. Each solder hole 6 in the B phase layer and each solder hole 6 in the C phase layer correspond to other solder holes 6 in the top plate 2 of the prefabricated circuit board in the same way.

[0045] S5, the ends of the lines in the A phase layer, B phase layer and C phase layer in the prefabricated circuit board top plate 2 and the prefabricated circuit board bottom plate 3 are respectively connected to the neutral line of the intermediate layer using strip conductors 5.

[0046] S6, then weld the welding ends of each U-shaped conductor 4 at the welding hole 6 to connect with the circuit line to form a winding circuit.

[0047] S7, using a frame to fix the assembled structure to form a "squirrel cage" type stator (e.g. Figure 5 (As shown), the top plate 2 and bottom plate 3 of the prefabricated circuit board, as well as the ends of the U-shaped conductor 4 and the strip conductor 5, are then insulated. For example... Figure 8 As shown, insulating paper 10 covering the U-shaped wire 4 is provided inside the online groove 11.

[0048] This invention employs two four-layer circuit boards, corresponding to the 36 slots of the stator. Each conductor has a soldering hole at its end. The soldering holes for the three phase conductors of the stator are designed in the same circuit layer, one layer each for phase A, phase B, and phase C, with the middle layer being the fourth layer. The neutral points of the three phases are soldered to the middle layer to ensure interconnection. The U-shaped conductors of each phase are connected through wiring on the circuit board, forming a winding current that generates a rotating magnetic field, driving the motor rotor to rotate.

[0049] like Figure 6 As shown, the U-shaped conductor 4 has a U-shaped structure with two pins, which are connected to the corresponding solder holes on the circuit board.

[0050] like Figure 7 As shown, each end of the strip conductor 5 has two pins 51, and the distance between the two pins 51 is greater than the cross-sectional dimension of the middle part of the strip conductor 5. The two pins 51 are inserted into the corresponding solder holes 6 on the circuit board.

[0051] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for forming a circuit using a multilayer circuit board combined with a wire harness, characterized in that, Provide an iron core (1), a prefabricated circuit board top plate (2) and a prefabricated circuit board bottom plate (3) respectively disposed at both ends of the iron core (1), the iron core (1) having X×3 wire grooves (11); welding hole groups corresponding to the X×3 wire grooves (11) are processed on the prefabricated circuit board top plate (2) and the prefabricated circuit board bottom plate (3), each welding hole group having multiple welding holes (6), the prefabricated circuit board top plate (2) and the prefabricated circuit board bottom plate (3) both include an A phase layer, a B phase layer, a C phase layer and an intermediate layer, wherein X welding hole groups are provided on the A phase layer, the B phase layer and the C phase layer; the intermediate layer has X×3 welding hole groups; The circuit is designed between the welding holes (6) on the top plate (2) and bottom plate (3) of the prefabricated circuit board according to the electromagnetic scheme of the stator winding; Multiple U-shaped wires (4) are inserted between each pair of adjacent wire slots (11) and inserted in sequence in an up-down order. "Up" means passing the U-shaped wire (4) from bottom to top between the two wire slots (11) and then through the corresponding welding hole (6) on the top plate (2) of the prefabricated circuit board. "Down" means passing the U-shaped wire (4) from top to bottom between the two wire slots (11) and then through the corresponding welding hole (6) on the bottom plate (3) of the prefabricated circuit board. In the top plate (2) and bottom plate (3) of the prefabricated circuit board, the ends of the lines in the A phase layer, B phase layer and C phase layer are connected to the neutral line of the intermediate layer by strip conductors (5). Then, weld the welding ends of each U-shaped conductor (4) at the welding hole (6) to connect with the circuit line to form a winding circuit; X groups of weld holes on phase A are arranged radially, and in each group of weld holes, the weld holes (6) located in odd positions are staggered from the weld holes (6) located in even positions; weld holes (6) are set on phase B and phase C in this manner. In the top plate (2) of the prefabricated circuit board, among the Z solder holes on the A phase layer, the one closest to the center is set to 1. Then, wiring is done between solder holes No. 1 in two adjacent groups. The even-numbered solder holes are wired to the adjacent odd-numbered solder holes in pairs, and a U-shaped wire (4) is inserted between the two solder holes (6). In the X solder hole groups, the Z solder holes in two groups are not connected, and wiring is done between the Z solder holes in the other two adjacent groups. A strip wire (5) is inserted into one of the Z solder holes that is not connected, and the strip wire (5) is connected to the corresponding solder hole in the middle layer. A strip wire (5) is inserted into the Z-1 solder hole in the same group as the Z solder hole, and the strip wire (5) is connected to the corresponding solder hole (6) on the A phase layer in the bottom plate (3) of the prefabricated circuit board. The same U-shaped wire (4) is inserted into the other Z solder hole that is not connected and the Z-1 solder hole in the same group as the Z solder hole. Wiring is performed between the solder holes (6) in the prefabricated circuit board base plate (3) according to the above method, so that the U-shaped conductors (4) of each phase are connected through the wiring on the circuit board.

2. The method for forming a circuit using a multilayer circuit board and wire harness according to claim 1, characterized in that, After the circuit is formed, the assembled structure is fixed to form a "squirrel cage" stator using a frame, and then the top plate (2) of the prefabricated circuit board, the bottom plate (3) of the prefabricated circuit board, the ends of the U-shaped conductor (4) and the strip conductor (5) are insulated.

3. The method for forming a circuit using a multilayer circuit board and wire harness according to claim 1, characterized in that, The welding holes of the U-shaped conductors (4) of the A phase layer, B phase layer and C phase layer are designed in the same circuit layer, that is, the center points of the A phase layer, B phase layer and C phase layer are welded separately to the intermediate layer and connected to each other.

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