A stator substrate structure with slot insulation for a DC motor

Abstract

The present invention relates to the technical field of stator substrates, in particular to a slot insulation stator substrate structure for a DC motor, which comprises a mounting component, including a first slot insulation, a second slot insulation disposed on the first slot insulation, a stator core disposed between the first slot insulation and the second slot insulation, an enameled wire winding disposed in the second slot insulation, a support groove disposed on the first slot insulation, a protruding boss disposed on the first slot insulation, and a control substrate disposed on the lower side of the first slot insulation; a winding component, including a clamping component disposed on the first slot insulation, a wire threading component disposed on the clamping component, and a wire storage component disposed on the first slot insulation. The present invention can directly use the starting and ending ends of the enameled wire of each phase winding to become ready-made enameled wire copper pins through the structure provided on the slot insulation, without setting a winding mutual conduction circuit outside the control substrate, which is convenient for wiring.

Description

Technical Field

[0001] The present invention relates to the technical field of stator substrates, and in particular to a slot insulation stator substrate structure for a DC motor. Background Art

[0002] In a conventional three-phase DC brushless motor, a control substrate is built-in. The circuit of the control substrate is connected to the windings of the stator to control the rotation of the motor. The slot insulation of the motor is generally injection-molded with the stator into an integral component, called a slot insulation stator. After the slot insulation stator is wound, the two ends of each phase winding are connected to the enameled wire by copper terminals or copper pins through fusion or welding to lead out and fix the windings. The lower ends of the copper terminals or copper pins are fixed on the slot insulation, and the upper ends are welded to the control board built into the motor. After welding with the copper terminals, the substrate is fixed. In order to ensure stable and balanced fixation of the substrate in the circumferential direction of the stator, usually 5 to 6 terminals are arranged evenly on the entire circumference, so that the substrate and the stator can be in a substantially parallel state after welding with the terminals.

[0003] After the substrate is connected and fixed to the windings through the terminals, the three-phase windings are connected and conducted through the copper foil on the substrate circuit. Generally, the delta or star connection method is used. However, the control board of a micro motor is usually small in volume and has many components. Especially for a low-voltage motor such as DC24V, the load current itself is large, and the area of the copper foil circuit itself needs to be increased. Adding an additional circuit for winding interconnection will make the substrate wiring extremely difficult and complex. Another conventional connection method is to connect the three ends of the three-phase windings together by welding or fusing, etc., then sleeve with a heat shrinkable tube and heat it in stages to insulate it. After completion, it is hidden between certain wire packages or fixed to a certain part with a tie strap. This solution is time-consuming and laborious, and the process is also relatively complex. Summary of the Invention

[0004] In view of the problems in the above-mentioned prior art that in the delta or star connection method, due to the large load current itself, the area of the copper foil circuit itself needs to be increased, adding an additional circuit for winding interconnection will make the substrate wiring extremely difficult and complex, and the conventional tube sleeve method requires tie strap fixation, which is time-consuming and laborious, the present invention is proposed.

[0005] Therefore, the object of the present invention is to provide a slot insulation stator substrate structure for a DC motor.

[0006] To solve the above technical problems, the present invention provides the following technical solutions: It includes an installation component, which includes a first slot insulation, a second slot insulation disposed on the first slot insulation, a stator core disposed between the first slot insulation and the second slot insulation, an enameled wire winding disposed in the second slot insulation, a support groove disposed on the first slot insulation, a protruding boss disposed on the second slot insulation, and a control substrate disposed on the lower side of the first slot insulation; a winding component, which includes a clamping component disposed on the first slot insulation, a wire threading component disposed on the clamping component, a wire storage component disposed on the first slot insulation, a limiting component disposed on the first slot insulation, a slot opening component disposed on the second slot insulation, and a support component disposed on the slot opening component; an anti-disconnection component, which includes a notch component disposed on the control substrate and a blocking component disposed on the first slot insulation.

[0007] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the clamping component includes a first hook disposed at the bottom of the first slot insulation, an outer end of the first hook is provided with a wire passing groove, an outer end of the wire passing groove is connected with a fixed seat, the fixed seat is provided with a front boss, and the fixed seat is provided with an elastic groove and a round hole.

[0008] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the wire threading component includes three starting end wires disposed in the first slot insulation, and the first slot insulation is provided with a first wire clamping groove cooperating with the starting end wires.

[0009] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the wire storage component includes the tail end wires of the three-phase windings disposed on the first slot insulation, and a second wire clamping groove disposed on the first slot insulation.

[0010] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the limiting component includes a wire hiding groove disposed on the first slot insulation, the first slot insulation is provided with a second hook, and a tapered first boss is fixedly connected in the wire hiding groove.

[0011] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the slot opening component includes a wire blocking ring disposed on the second slot insulation, and the wire blocking ring is provided with a plurality of first slot openings, a plurality of second slot openings and a plurality of third slot openings.

[0012] As a preferred solution of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the depths of the first slot opening, the second slot opening and the third slot opening are all different.

[0013] As a preferred embodiment of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the support assembly includes a second boss disposed on the wire blocking ring, and an arc edge is provided on the side wall of the second boss.

[0014] As a preferred embodiment of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the notch assembly includes a fourth notch disposed on the control substrate, and a pad hole and a welding pad are provided on the control substrate.

[0015] As a preferred embodiment of the slot insulation stator substrate structure for a DC motor of the present invention, wherein: the blocking assembly includes a third hook disposed on the first slot insulation, a first split groove and a second split groove are respectively provided on both sides of the third hook, a limiting groove is provided on the third hook, a positioning post is fixedly connected to the first slot insulation, a small cylinder is fixedly connected to the positioning post, and a wire blocking ring is fixedly connected to the side wall of the first slot insulation.

[0016] The beneficial effects of the slot insulation stator substrate structure for a DC motor of the present invention: the starting and ending ends of the enameled wire of each phase winding are directly turned into ready-made enameled wire copper pins through the structure provided on the slot insulation for welding with the substrate. The ending ends of the three-phase windings are connected and conducted directly through processes such as welding or fusing using the star connection method and are fixed in the special wire storage grooves on the slot insulation, solving the problem of the need to additionally provide a winding mutual conduction circuit on the substrate. Thus, for the delta or star connection methods, since the load current itself is relatively large, the area of the copper foil circuit itself needs to be increased, and additionally adding a circuit for winding mutual connection will make the substrate wiring extremely difficult and complex, and the conventional tube sleeve method requires fixing with a tie, which is time-consuming and laborious. The effect of achieving no need to provide a winding mutual conduction circuit outside the control substrate and facilitating wiring is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0018] Figure 1 It is an exploded view of the slot insulation stator substrate structure for a DC motor.

[0019] Figure 2 It is a schematic diagram of the external structure of the control substrate of the slot insulation stator substrate structure for a DC motor.

[0020] Figure 3 It is a schematic diagram of the external structure of the first slot insulation of the slot insulation stator substrate structure for a DC motor.

[0021] Figure 4 It is a schematic cross-sectional structure diagram of the first slot insulation for the slot insulation stator substrate structure of a DC motor.

[0022] In the figure: 100, mounting component; 101, first slot insulation; 102, second slot insulation; 103, stator core; 104, enameled wire winding; 105, support groove; 106, protruding boss; 107, control substrate; 200, winding component; 201, engaging component; 201a, first hook; 201b, wire passing groove; 201c, fixing seat; 201d, front boss; 201e, round hole; 202, wire threading component; 202a, starting end wire; 202b, first wire clamping groove; 203, wire storage component; 203a, tail end wire; 203b, second wire clamping groove; 204, limiting component; 204a, wire hiding groove; 204b, second hook; 204c, first boss; 205, slot opening component; 205a, wire blocking ring; 205b, first slot opening; 205c, second slot opening; 205d, third slot opening; 206, support component; 206a, second boss; 206b, arc edge; 300, anti-disconnection component; 301, notch component; 301a, fourth slot opening; 301b, pad hole; 301c, welding pad; 302, blocking component; 302a, third hook; 302b, first separation groove; 302c, second separation groove; 302d, limiting groove; 302e, positioning post; 302f, small cylinder. Specific embodiments

[0023] To make the above objects, features, and advantages of the present invention more obvious and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings of the specification.

[0024] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar generalizations without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0025] Secondly, the so-called "one embodiment" or "embodiment" herein refers to a specific feature, structure, or characteristic that can be included in at least one implementation manner of the present invention. The "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor is it an embodiment that is separate or selectively mutually exclusive with other embodiments.

[0026] Embodiment 1, refer to Figures 1 to 4, which is the first embodiment of the present invention. This embodiment provides a slot insulation stator substrate structure for a DC motor, which can achieve the effect of not requiring an additional winding interconnection circuit outside the control substrate 107. It includes an installation component 100, which includes a first slot insulation 101, a second slot insulation 102 disposed on the first slot insulation 101, a stator core 103 disposed between the first slot insulation 101 and the second slot insulation 102, an enameled wire winding 104 disposed in the second slot insulation 102, a support groove 105 disposed on the first slot insulation 101, a protruding boss 106 disposed on the second slot insulation 102, and a control substrate 107 disposed on the lower side of the first slot insulation 101; a winding component 200, which includes a clamping component 201 disposed on the first slot insulation 101, a wire threading component 202 disposed on the clamping component 201, a wire storage component 203 disposed on the first slot insulation 101, a limiting component 204 disposed on the first slot insulation 101, a slot opening component 205 disposed on the second slot insulation 102, and a support component 206 disposed on the slot opening component 205; an anti - detachment component 300, which includes a notch component 301 disposed on the control substrate 107, and a blocking component 302 disposed on the first slot insulation 101.

[0027] Specifically, the first slot insulation 101 and the second slot insulation 102 are inserted and assembled vertically on the stator core 103 to form a slot insulation stator assembly. The support groove 105 on the first slot insulation 101 and the protruding boss 106 on the second slot insulation 102 are inserted into each other, ensuring that there is no gap between the first slot insulation 101, the second slot insulation 102 and the stator core 103 after installation, achieving perfect insulation between the stator core 103 and the subsequent enameled wire winding 104, and ensuring the electrical strength of the DC motor.

[0028] Further, the engaging component 201 includes a first hook 201a disposed at the bottom of the first slot insulator 101. An outer wire groove 201b is provided at the outer end of the first hook 201a. A fixing base 201c is connected to the outer end of the outer wire groove 201b. A front boss 201d is provided on the fixing base 201c. An elastic groove and a round hole 201e are provided on the fixing base 201c; the wire threading component 202 includes three starting end wires 202a disposed in the first slot insulator 101. A first wire clamping groove 202b is provided on the first slot insulator 101 and is adapted to the starting end wires 202a; the wire storage component 203 includes the end wires 203a of the three-phase windings disposed on the first slot insulator 101. A second wire clamping groove 203b is provided on the first slot insulator 101; the limiting component 204 includes a wire storage groove 204a disposed on the first slot insulator 101. A second hook 204b is provided on the first slot insulator 101. A tapered first boss 204c is fixedly connected in the wire storage groove 204a; the slot opening component 205 includes a wire blocking ring 205a disposed on the second slot insulator 102. A plurality of first slot openings 205b, a plurality of second slot openings 205c and a plurality of third slot openings 205d are provided on the wire blocking ring 205a; the depths of the first slot openings 205b, the second slot openings 205c and the third slot openings 205d are all different; the support component 206 includes a second boss 206a disposed on the wire blocking ring 205a. An arc edge 206b is provided on the side wall of the second boss 206a.

[0029] Among them, on each slot of the slot insulator stator assembly (mentioned above), a three-phase enameled wire winding 104 is wound. After the winding is completed, for the U, V, and W three-phase windings (for the convenience of distinction, the three-phase windings are divided into U, V, and W here, the same below), the starting end wires 202a here will be slightly lengthened for later trimming.

[0030] During use, first, the very long starting end wires 202a of the three-phase windings are straightened and respectively clamped and fixed in the wire clamping grooves on the first slot insulator 101. Then, the required length for use is determined, and the excess part is cut off. After removing the paint film of a small section at the end that needs to be used as a copper pin, it is inserted into the elastic groove on the right side of the lower edge of the rear boss on the fixing base 201c and then straightened and fixed in the round hole 201e of the fixing base 201c, thus forming a ready-made copper pin. After removing the paint film, it can be welded and connected to the control substrate 107. Since the copper enameled wire with a diameter of more than φ0.5 has a certain hardness, the provided wire groove 201b can support the twisted enameled wire and prevent it from slipping downward, ensuring that the copper pin is at a certain distance from the upper plane of the fixing base 201c, so that it will not be forced to shrink downward when the substrate is sleeved later;

[0031] After the winding of the tail wires 203a of the three-phase windings is completed, the three wires can be clamped together into the second wire clamping groove 203b on the first slot insulation 101 for fixation. The three wires extend outside the entire stator core 103, facilitating the simultaneous cutting of the redundant parts, so as to retain the required length for fixation. Then, the three ends can be conductively connected by riveting, fusing or welding to form the neutral wire (or neutral point N) of the Y-connection of the windings;

[0032] After the connection of the three ends is completed, they are detached from the second wire clamping groove 203b and hidden in the wire hiding groove 204a. In order to prevent the neutral wire from loosening after being hidden, when the neutral wire is placed in the groove, the conical boss can push the neutral wire towards the outer inner wall of the wire hiding groove 204a, so that the hook can be buckled directly above the neutral wire, preventing it from unhooking and moving and firmly fixing it in the groove. The surrounding wall thickness of the wire hiding groove 204a forms an insulating layer, which can meet the safety requirements such as the specified insulation withstand voltage and creepage distance of the motor;

[0033] Since the three-phase windings U, V, and W are evenly distributed in every three slots on the entire first slot insulation 101, and even more, there will be over-slot wires (wires crossing the first slot opening 205b, the same below, and of course, here it can also be the second slot opening 205c or the third slot opening 205d. The first slot opening 205b, the second slot opening 205c, and the third slot opening 205d can be arbitrarily assigned to the three wires U, V, and W) connecting the U-phase winding wire packages of different slots. The over-slot wires will cross the winding wire packages of phases V and W to connect to the next-slot U-phase winding, and the same is true for phases V and W crossing each other. When the three phases cross together, part of the over-slot wires will overlap. If the enameled wire coating film is damaged during the winding process, it is easy to cause poor phase insulation of the stator. Therefore, a wire blocking ring 205a is provided around the outer circle of the second slot insulation 102. Three first slot openings 205b, second slot openings 205c, and third slot openings 205d with different depths are provided on the wire blocking ring 205a. The three depths respectively correspond to the three-phase windings U, V, and W. When the three-phase windings are wound in the same direction, the over-slot wires will be three-level stratified on the outside of the wire blocking ring 205a according to the different depths of the corresponding slot openings, so that they do not interfere with each other. The upper edge of the wire blocking ring 205a is also provided with a second boss 206a (or barb) for blocking the topmost over-slot wire, preventing the over-slot wire from detaching from the wire blocking ring 205a during the subsequent movement or use of the motor, causing potential safety hazards to the motor.

[0034] In summary, by setting the winding component 200, the starting wires of the enameled wire windings 104 wound for each phase are directly turned into ready-made enameled wire copper pins through the structure setting on the slot insulation for welding with the control board 107. The tail wires 203a of the three-phase windings are directly conductively connected by welding or fusing and other processes in a star connection method and fixed in the special wire hiding groove 204a on the slot insulation, without additionally setting a winding mutual conduction circuit outside the control board 107.

[0035] Example 2. Refer to Figures 1 to 4 , which is the second embodiment of the present invention. Different from the previous embodiment, this embodiment provides a anti - detachment component 300 for the slot insulation stator substrate structure of a DC motor, which solves the problem of preventing the control substrate 107 from loosening. It includes a notch component 301 including a fourth notch 301a provided on the control substrate 107. The control substrate 107 is provided with a pad hole 301b and a welding pad 301c. The blocking component 302 includes a third hook 302a provided on the first slot insulation 101. On both sides of the third hook 302a, a first split groove and a second split groove are respectively provided. A limiting groove 302d is provided on the third hook 302a. A positioning post 302e is fixedly connected to the first slot insulation 101. A small cylinder 302f is fixedly connected to the positioning post 302e. A wire - blocking ring 205a is fixedly connected to the side wall of the first slot insulation 101.

[0036] Specifically, the first split groove and the second split groove provided on both sides of the third hook 302a are separated from the wire - blocking ring 205a on the entire circumference. After separation, the third hook 302a and the wire - blocking ring 205a are separated, so that the four third hooks 302a can be slightly deformed radially outward to make way, facilitating the hard insertion of the control substrate 107 into the four limiting grooves 302d of the third hook 302a along the upper slope.

[0037] During use, when fixing the control substrate 107, only need to hard - insert the third hook 302a into the fourth notch 301a. After the third hook 302a is inserted into the limiting groove 302d, the third hook 302a will return to its original position, and the upper edges of the four limiting grooves 302d will firmly lock the control substrate 107 axially, ensuring that the control substrate 107 does not shift or unhook. The upper - end plane of the fixing seat 201c and the upper - end surface of the positioning post 302e are at the same height. After the control substrate 107 is installed, it is on the same horizontal plane as the positioning post 302e, thereby avoiding the shaking of the first slot insulation 101, ensuring the stability of the induction between the stator core 103 and the inner rotor of the motor, and the performance, speed, etc. of the motor during operation will also remain stable. To facilitate the installation of the control substrate 107, the width of the fourth notch 301a is greater than the width of the third hook 302a. At this time, the small cylinder 302f provided on the positioning post 302e penetrates through the welding pad 301c, causing the control substrate 107 to rotate and shift in the circumferential direction. When the control substrate 107 is installed, the copper insertion pins of the three - phase enameled wires pass through the pad holes 301b at the same time. After installation, the copper insertion pins of the enameled wires can be welded to the welding pad 301c together. Thus, the entire substrate is firmly fixed both axially and radially, and the three - phase windings are also connected and conducted to the control substrate 107. After being installed with the subsequent motor housing, rotor, etc., it can become a qualified motor.

[0038] In summary, by providing the anti-loosening component 300, when the first slot insulator 101 is attached to the control substrate 107, the limiting groove 302d on the third hook 302a cooperates with the upper end surface of the control substrate 107 to limit the control substrate 107, preventing the control substrate 107 from loosening and ensuring the overall stability.

[0039] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered within the scope of the claims of the present invention.

Claims

1. A slot insulation stator substrate structure for a DC motor, characterized in that: including, an installation component (100), comprising a first slot insulation (101), a second slot insulation (102) disposed on the first slot insulation (101), a stator core (103) disposed between the first slot insulation (101) and the second slot insulation (102), an enameled wire winding (104) disposed in the second slot insulation (102), a support groove (105) disposed on the first slot insulation (101), a protruding boss (106) disposed on the second slot insulation (102), and a control substrate (107) disposed on the lower side of the first slot insulation (101); the control substrate (107) can be directly welded to the enameled wire winding (104) without additionally arranging a conduction loop; a winding component (200), comprising an engaging component (201) disposed on the first slot insulation (101), a wire threading component (202) disposed on the engaging component (201), a wire storage component (203) disposed on the first slot insulation (101), a limiting component (204) disposed on the first slot insulation (101), a slot opening component (205) disposed on the second slot insulation (102), and a support component (206) disposed on the slot opening component (205); a anti - detachment component (300), comprising a notch component (301) disposed on the control substrate (107), and a blocking component (302) disposed on the first slot insulation (101); the engaging component (201) comprises a first hook (201a) disposed at the bottom of the first slot insulation (101), an outer end of the first hook (201a) is provided with a wire passing groove (201b), an outer end of the wire passing groove (201b) is connected with a fixed seat (201c), the fixed seat (201c) is provided with a front boss (201d), and the fixed seat (201c) is provided with an elastic groove and a round hole (201e); the end film of the enameled wire winding (104) is removed, and it is straightened and fixed in the round hole (201e) to form a ready - made copper pin for welding connection with the control substrate (107); the wire passing groove (201b) can support the twisted enameled wire to prevent it from slipping downwards, ensuring that the copper pin is at a certain distance from the upper plane of the fixed seat (201c); the wire threading component (202) comprises three starting - end wires (202a) disposed in the first slot insulation (101), and the first slot insulation (101) is provided with a first wire clamping groove (202b) cooperating with the starting - end wires (202a); the three starting - end wires (202a) are straightened and clamped into the first wire clamping groove (202b) and fixed, and the redundant part is cut off according to the required use length.

2. The slot insulation stator substrate structure for a DC motor according to claim 1, wherein: the wire storage component (203) comprises tail - end wires (203a) of a three - phase winding disposed on the first slot insulation (101), and a second wire clamping groove (203b) disposed on the first slot insulation (101).

3. The slot insulation stator substrate structure for a DC motor according to claim 2, characterized in that: The limit component (204) includes a wire storage groove (204a) provided on the first groove insulator (101). A second hook (204b) is provided on the first groove insulator (101), and a tapered first boss (204c) is fixedly connected in the wire storage groove (204a).

4. The slot insulation stator substrate structure for a DC motor according to claim 2 or 3, characterized in that: The notch component (205) includes a wire blocking ring (205a) provided on the second groove insulator (102). A plurality of first notches (205b), a plurality of second notches (205c) and a plurality of third notches (205d) are provided on the wire blocking ring (205a).

5. The slot insulation stator substrate structure for a DC motor according to claim 4, wherein: The depths of the first notch (205b), the second notch (205c) and the third notch (205d) are all different.

6. The stator substrate structure with slot insulation for a DC motor according to claim 5, characterized in that: The support component (206) includes a second boss (206a) provided on the wire blocking ring (205a). An arc edge (206b) is provided on the side wall of the second boss (206a).

7. The stator substrate structure with slot insulation for a DC motor according to claim 5 or 6, characterized in that: The notch component (301) includes a fourth notch (301a) provided on the control substrate (107). A pad hole (301b) and a welding pad (301c) are provided on the control substrate (107).

8. The stator substrate structure with slot insulation for a DC motor according to claim 7, characterized in that: The blocking component (302) includes a third hook (302a) provided on the first groove insulator (101). A first split groove and a second split groove are respectively provided on both sides of the third hook (302a). A limit groove (302d) is provided on the third hook (302a). A positioning post (302e) is fixedly connected to the first groove insulator (101). A small cylinder (302f) is fixedly connected to the positioning post (302e). A wire blocking ring (205a) is fixedly connected to the side wall of the first groove insulator (101).

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