Motor stator assembly, motor, braking system and installation method

Abstract

The invention discloses a motor stator assembly, a motor, a braking system and an installation method, the motor stator assembly comprises a motor stator and a cover plate, the motor stator is formed by uniformly distributing a plurality of iron cores along the circumference, each iron core is wound with a stator winding, and the cover plate is detachably connected with the motor stator. A first sleeve and a second sleeve are arranged on the cover plate, a three-phase lead is led out from the stator winding, the three-phase lead penetrates through the first sleeve and extends to the position above the cover plate, and the stator windings on the iron cores are connected together in the second sleeve. According to the motor stator assembly, the motor, the braking system and the installation method, a busbar which is large in size and high in cost is replaced with the cover plate and the metal sleeve, the size of the motor stator assembly is reduced, the number of welding spots is reduced, and the risk of multi-spot welding is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and in particular relates to a motor stator assembly, a motor, a braking system and an installation method. Background Art

[0002] The automobile braking system refers to a special braking mechanism installed on the car in order to technically ensure the safe driving of the car and increase the average speed of the car. The automobile braking system generally consists of three parts: the motor, the hydraulic module and the controller, which adjusts the rotation speed of the motor.

[0003] In the related art, the motor stator windings are generally connected by a busbar, which is provided with multiple welding points and welded together with each phase winding to form the internal power connection of the motor stator. The motor stator assembly and the controller are usually connected by a plastic-coated copper busbar passing through the hydraulic module. One end of the plastic-coated copper busbar is welded to the motor busbar, and the other end is connected to the internal power terminal of the controller without welding. However, the existing motor power connection component busbar is large in size, complex in structure and high in cost, resulting in poor flexibility of the overall transmission path, which is not conducive to miniaturization and lightweight of the product. In addition, the same series of motors, different hydraulic modules and controllers are matched with each other, the commonality of the power connection structural parts is poor, and the mold and jig cost is high. Summary of the invention

[0004] The purpose of the present invention is to provide a motor stator assembly, a motor, a brake system and an installation method to solve the problem that the busbar structure of the existing motor power connection components is complex and has poor commonality.

[0005] To this end, the present invention provides a motor stator assembly, comprising:

[0006] The motor stator and cover plate, wherein the motor stator is composed of a plurality of iron cores evenly distributed along the circumference, each of the iron cores is wound with a stator winding, the cover plate is detachably connected to the motor stator, a first sleeve and a second sleeve are provided on the cover plate, the stator winding leads out three-phase leads, the three-phase leads pass through the first sleeve and extend to the top of the cover plate, and the stator windings on each of the iron cores are connected together in the second sleeve. The stator winding is an enameled wire, the cover plate is a plastic cover plate, the first sleeve and the second sleeve are metal sleeves, and the cover plate and the motor stator are detachably connected by snaps or spring buckles. By replacing the bulky and costly bus with the cover plate and the metal sleeve, the volume of the motor stator assembly is reduced, the number of welding points is reduced, and the risk of multi-spot welding is reduced.

[0007] Preferably, three first sleeves are provided, and each first sleeve corresponds to a three-phase lead.

[0008] A motor comprises a motor rotor assembly, a motor casing, an anti-rotation sleeve and the above-mentioned motor stator assembly, wherein the motor stator assembly is fixedly installed in the motor casing, the motor rotor assembly is in the motor rotor assembly, the motor rotor assembly is rotatably connected to the motor casing, the anti-rotation sleeve is fixedly installed on the top of the motor casing, and the three-phase lead wire passes through the anti-rotation sleeve to the top of the anti-rotation sleeve.

[0009] Preferably, the ends of the three-phase leads are connected to three-phase terminals.

[0010] Preferably, a motor angle sensor is installed on the motor rotor assembly.

[0011] A braking system comprises a hydraulic module, a controller and the above-mentioned motor, wherein the hydraulic module is fixedly mounted on the top of the motor, and the controller is fixedly mounted on the top of the hydraulic module.

[0012] Preferably, a three-phase bracket is provided in the hydraulic module, and the three-phase bracket is used to support the three-phase lead wires.

[0013] Preferably, a flexible insulating tube is provided in the hydraulic module, and the flexible insulating tube is used to wrap the three-phase lead wires.

[0014] Preferably, the three-phase terminal is fixed on the hydraulic module via a positioning block.

[0015] A method for installing a brake system comprises the following steps:

[0016] S1. Pass the enameled wire of the stator winding through the plastic cover, pass the three-phase lead through the first sleeve, and install the plastic cover on the motor stator;

[0017] S2, fixing the second sleeve on the plastic cover by riveting, fixing the enameled wire of the stator winding, cutting off the enameled wire higher than the second sleeve, welding the enameled wire in the second sleeve together, and obtaining the motor stator assembly;

[0018] S3, assembling the motor stator assembly into the motor housing, assembling the motor rotor assembly into the motor stator assembly, and assembling the anti-rotation sleeve onto the motor housing;

[0019] S4, connecting the three-phase terminals to the three-phase leads, fixing the three-phase terminals, and obtaining the motor assembly;

[0020] S5. Assemble the motor assembly, the hydraulic module and the controller together to obtain a braking system.

[0021] Beneficial effects:

[0022] 1. The present invention provides a motor stator assembly, a motor, a brake system and an installation method, which replaces a busbar that is bulky and costly by a cover plate and a metal sleeve, thereby reducing the volume of the motor stator assembly, reducing the number of welding points, and reducing the risk of multi-point welding.

[0023] 2. In the present invention, by lengthening the length of the enameled wire of the stator winding and providing a bottom plastic-coated copper bar, the flexibility of the connection path is improved, which facilitates the enameled wire to pass through the hole and connect with the controller, thereby helping to reduce the volume of the hydraulic module and the controller.

[0024] 3. In the present invention, since there is no need to use busbars and plastic-coated copper bars, different motors, hydraulic modules and controllers can be matched by only changing the length of the enameled wire. There is no need to open a separate mold for each type of brake system, thereby reducing the production cost of molds and jigs. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0026] Figure 1 It is a schematic diagram of the brake system structure in the related art;

[0027] Figure 2 It is a structural schematic diagram of embodiment 1 of a motor stator assembly in the present invention;

[0028] Figure 3 This is a schematic structural diagram of a second embodiment of a motor in the present invention;

[0029] Figure 4 It is a structural schematic diagram of a third embodiment of a braking system in the present invention;

[0030] Figure 5 This is a schematic diagram of a three-phase bracket structure of a braking system in Example 3 of the present invention;

[0031] Figure 6 This is a schematic diagram of the connection relationship of the three-phase brackets of Example 3 of a braking system in the present invention;

[0032] Figure 7 This is a schematic diagram of the structure of a flexible insulating tube of a braking system in Example 4 of the present invention;

[0033] Figure 8 This is a schematic diagram of the positioning block structure of a braking system in Example 4 of the present invention;

[0034] Fig. 9 This is a schematic diagram of the connection relationship of the positioning blocks of Example 4 of a braking system in the present invention.

[0035] Fig.10 This is a method flow chart of Example 3 of a method for installing a braking system in the present invention.

[0036] In the figure, 1-motor stator, 2-cover plate, 201-first sleeve, 202-second sleeve, 3-stator winding, 301-three-phase lead, 4-motor rotor assembly, 5-motor housing, 6-anti-rotation sleeve, 7-three-phase terminal, 8-motor angle sensor, 9-hydraulic module, 901-positioning groove, 10-controller, 11-three-phase bracket, 12-flexible insulating tube, 13-positioning block, 1301-undercut, 14-bus, 1401-first welding point, 15-plastic-coated copper bus, 1501-second welding point, 16-terminal. DETAILED DESCRIPTION

[0037] The content of the present invention can be more easily understood by selecting the following detailed description of the preferred implementation method of the present invention and the embodiments included. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those of ordinary skill in the art to which the present invention belongs. When there is a conflict, the definition in this specification shall prevail.

[0038] Embodiment 1:

[0039] At present, the popular braking systems on the market are Figure 1 As shown, the motor stator windings are usually connected by a busbar 14, and a plurality of first welding points 1401 are provided on the busbar 14 to be welded together with each phase winding to form an internal power connection of the motor stator. The motor stator assembly and the controller 10 are usually connected by a plastic-coated copper busbar 15 passing through the hydraulic module. One end of the plastic-coated copper busbar 15 is welded to the busbar 14 at a second welding point 1501, and the other end is connected to the controller 10 through a terminal 16. The busbar 14 is large in size, complex in structure, and high in cost. The overall transmission path flexibility is poor, which is not conducive to product miniaturization and lightweight. At the same time, motors of the same series, different hydraulic modules 9 and controllers 10 are matched with each other, the commonality of the power connection structural parts is poor, and the mold and jig cost is high.

[0040] So it provides Figure 2 A motor stator assembly shown includes:

[0041] The motor stator 1 and the cover plate 2 are composed of a plurality of iron cores evenly distributed along the circumference, each iron core is wound with a stator winding 3, the cover plate 2 is detachably connected to the motor stator 1, the cover plate 2 is provided with a first sleeve 201 and a second sleeve 202, the stator winding 3 leads out a three-phase lead, the three-phase lead passes through the first sleeve 201 and extends to the top of the cover plate 2, and the stator winding 3 on each iron core is connected together in the second sleeve 202. There are three first sleeves 201, and each first sleeve 201 corresponds to a three-phase lead 301. The stator winding 3 is an enameled wire, the cover plate 2 is a plastic cover plate 2, the first sleeve 201 and the second sleeve 202 are metal sleeves, and the cover plate 2 and the motor stator 1 are detachably connected by snaps. The cover plate 2, the first sleeve 201 and the second sleeve 202 replace the busbar which is bulky and expensive, thereby reducing the volume of the motor stator 1 assembly, the number of welding points, and the risk of multi-point welding.

[0042] Embodiment 2:

[0043] like Figure 3 The motor shown includes a motor rotor assembly 4, a motor housing 5, an anti-rotation sleeve 6 and a motor stator assembly described in Example 1, wherein the motor stator assembly is fixedly installed in the motor housing 5, the motor rotor assembly 4 is in the motor rotor assembly 4, the motor rotor assembly 4 is rotatably connected to the motor housing 5, the anti-rotation sleeve 6 is fixedly installed on the top of the motor housing 5, and the three-phase lead 301 passes through the anti-rotation sleeve 6 to the top of the anti-rotation sleeve 6. The end of the three-phase lead 301 is connected to a three-phase terminal 7. A motor angle sensor 8 is installed on the motor rotor assembly 4.

[0044] Embodiment 3:

[0045] like Figure 4-6 A braking system shown includes a hydraulic module 9, a controller 10 and the motor described in Example 2, wherein the hydraulic module 9 is fixedly mounted on the top of the motor, and the controller 10 is fixedly mounted on the top of the hydraulic module 9. A three-phase bracket 11 is provided in the hydraulic module 9, and the three-phase bracket 11 is used to support the three-phase lead 301. Since the enameled wire of the stator winding 3 has a certain flexibility, even if the holes on the cover plate 2, the anti-rotation sleeve 6 and the three-phase bracket 11 are not strictly aligned and have a certain misalignment, the enameled wire can smoothly pass through the cover plate 2, the anti-rotation sleeve 6 and the three-phase bracket 11, which is convenient for hole arrangement.

[0046] like Fig.10 As shown, a method for installing a brake system comprises the following steps:

[0047] S1, pass the enameled wire of the stator winding 3 through the plastic cover 2, pass the three-phase lead 301 through the first sleeve 201, and buckle the plastic cover 2 onto the motor stator 1;

[0048] S2, fix the second sleeve 202 on the plastic cover plate 2 by riveting, fix the enameled wire of the stator winding 3, cut off the enameled wire higher than the second sleeve 202, and weld the enameled wire in the second sleeve 202 together to obtain the motor stator assembly;

[0049] S3, assembling the motor stator assembly into the motor housing 5, assembling the motor rotor assembly 4 into the motor stator assembly, and assembling the anti-rotation sleeve 6 onto the motor housing 5;

[0050] S4, connect the three-phase terminal 7 to the three-phase lead 301, fix the three-phase terminal 7 through the three-phase bracket 11, and fix the three-phase bracket 11 to the motor anti-rotation sleeve 6 to obtain a motor assembly;

[0051] S5. Assemble the motor assembly, the hydraulic module 9 and the controller 10 together to obtain a braking system.

[0052] Embodiment 4:

[0053] The difference between Example 4 and Example 3 is that Figure 7-9 As shown, a flexible insulating tube 12 is provided in the hydraulic module 9 instead of the three-phase bracket 11, and the flexible insulating tube 12 is used to wrap the three-phase lead 301, and the three-phase terminal 7 is fixed on the hydraulic module 9 through a positioning block 13. The positioning block 13 has an undercut 1301, and a positioning groove 901 is provided on the hydraulic module 9. The positioning block 13 is fixed in the positioning groove 901 through the undercut 1301, and the controller 10 is connected to it through a tuning fork PIN welding-free terminal.

[0054] A method for installing a brake system comprises the following steps:

[0055] S1, pass the enameled wire of the stator winding 3 through the plastic cover 2, pass the three-phase lead 301 through the first sleeve 201, and buckle the plastic cover 2 onto the motor stator 1;

[0056] S2, fix the second sleeve 202 on the plastic cover plate 2 by riveting, fix the enameled wire of the stator winding 3, cut off the enameled wire higher than the second sleeve 202, and weld the enameled wire in the second sleeve 202 together to obtain the motor stator assembly;

[0057] S3, assembling the motor stator assembly into the motor housing 5, assembling the motor rotor assembly 4 into the motor stator assembly, and assembling the anti-rotation sleeve 6 onto the motor housing 5;

[0058] S4, connect the three-phase terminal 7 with the three-phase lead 301, the flexible insulating tube 12 is used to wrap the three-phase lead 301, and is connected to the positioning groove 901 of the hydraulic module 9 through the undercut 1301 of the positioning block 13, and the positioning block 13 fixes the three-phase terminal 7 to obtain the motor assembly;

[0059] S5. Assemble the motor assembly, the hydraulic module 9 and the controller 10 together to obtain a braking system.

Claims

1. A motor stator assembly, characterized in that: It includes a motor stator and a cover plate. The motor stator is composed of a plurality of iron cores evenly distributed along the circumference. A stator winding is wound on each of the iron cores. The cover plate is detachably connected to the motor stator. A first sleeve and a second sleeve are provided on the cover plate. The stator winding leads out three-phase leads. The three-phase leads pass through the first sleeve and extend to the top of the cover plate. The stator windings on each of the iron cores are connected together in the second sleeve.

2. The motor stator assembly according to claim 1, characterized in that: The number of the first sleeves is three, and each of the first sleeves corresponds to a three-phase lead wire.

3. A motor, characterized in that: It comprises a motor rotor assembly, a motor casing and an anti-rotation sleeve and a motor stator assembly as claimed in claim 1 or 2, wherein the motor stator assembly is fixedly mounted in the motor casing, the motor rotor assembly is in the motor rotor assembly, the motor rotor assembly is rotatably connected to the motor casing, the anti-rotation sleeve is fixedly mounted on the top of the motor casing, and the three-phase lead wire passes through the anti-rotation sleeve to the top of the anti-rotation sleeve.

4. A motor according to claim 3, characterized in that: The ends of the three-phase lead wires are connected with three-phase terminals.

5. The motor according to claim 3, characterized in that: A motor angle sensor is installed on the motor rotor assembly.

6. A braking system, characterized in that: It comprises a hydraulic module, a controller and the motor according to any one of claims 3 to 5, wherein the hydraulic module is fixedly mounted on the top of the motor, and the controller is fixedly mounted on the top of the hydraulic module.

7. A braking system according to claim 6, characterized in that: A three-phase bracket is arranged in the hydraulic module, and the three-phase bracket is used to support the three-phase lead wires.

8. A braking system according to claim 6, characterized in that: A flexible insulating tube is arranged in the hydraulic module, and the flexible insulating tube is used to wrap the three-phase lead wires.

9. A braking system according to claim 8, characterized in that: The three-phase lead wire is fixed to the hydraulic module through a three-phase terminal.

10. A method for installing a brake system, characterized in that: The steps include: S1. Pass the enameled wire of the stator winding through the plastic cover, pass the three-phase lead through the first sleeve, and install the plastic cover on the motor stator; S2, fixing the second sleeve on the plastic cover by riveting, fixing the enameled wire of the stator winding, cutting off the enameled wire higher than the second sleeve, welding the enameled wire in the second sleeve together, and obtaining the motor stator assembly; S3, assembling the motor stator assembly into the motor housing, assembling the motor rotor assembly into the motor stator assembly, and assembling the anti-rotation sleeve onto the motor housing; S4, connecting the three-phase terminals to the three-phase leads, fixing the three-phase terminals, and obtaining the motor assembly; S5. Assemble the motor assembly, the hydraulic module and the controller together to obtain a braking system.

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