A processing technology of brushless direct current motor stator

Abstract

This invention relates to the field of motor stator manufacturing technology, and discloses a brushless DC motor stator processing technology, including assembling an insulating frame onto the stator core, winding the stator core, inserting common terminals, U-phase terminals, V-phase terminals, and W-phase terminals onto the insulating frame, welding the winding copper wires to the corresponding terminals, assembling the stator windings into the housing, and finally installing the U-phase terminals into the U-phase terminals, the V-phase terminals into the V-phase terminals, and the W-phase terminals into the W-phase terminals. This brushless DC motor stator processing technology further optimizes processes involving manual operation, has the advantages of high automation and strong continuous working capability, and can effectively improve production quality and efficiency.

Description

Technical Field

[0001] This invention relates to the field of motor stator manufacturing technology, specifically to a brushless DC motor stator processing technology. Background Technology

[0002] With the mature development of home appliance technology and the rapid advancement of power electronics technology, brushless DC motors are becoming increasingly popular due to their advantages such as high efficiency and low noise. Currently, the assembly process for brushless DC motor stators generally includes assembling the stator insulation frame, winding the stator core, inserting pins into the slots of the insulation frame, winding copper wire around the pins and cutting it close to the pin, immersing the end of the stator coil with the pin in paint remover, brushing off the paint near the pin that was immersed in paint remover, soldering the exposed copper wire to the pin, testing for inter-turn short circuits, pouring insulating varnish from the top of the winding, and finally soldering the Hall plate to the pin. Since the processes of brushing off the paint and installing and soldering the Hall plate are mainly done manually, the labor intensity of workers is high, the work efficiency is low, it is not conducive to automated operations, and it reduces product quality and production efficiency. Therefore, it is necessary to optimize the assembly process of brushless DC motor stators. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the existing technology and provide a brushless DC motor stator processing technology with a high degree of automation, strong continuous working capability, and effective improvement of production quality and efficiency.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0005] A brushless DC motor stator manufacturing process includes the following steps:

[0006] (S1) Assemble the stator insulation frame: Fix the insulation frame onto the stator core;

[0007] (S2) Winding: The stator core is clamped on the winding fixture for winding;

[0008] (S3) Inserting the connecting pieces: Insert the common connecting piece, as well as the U-phase connecting piece, V-phase connecting piece and W-phase connecting piece into the insulating frame;

[0009] (S4) Welding: Weld the winding copper wire to the common terminal block, as well as the U-phase terminal block, V-phase terminal block and W-phase terminal block;

[0010] (S5) Install into the housing: Fix the stator core into the housing;

[0011] (S6) Install the UVW wiring assembly: Insert the U-phase terminal with V-groove into the U-phase terminal piece, wipe off the surface paint on the U-phase terminal piece through the V-groove, and solder the U-phase terminal to the U-phase terminal piece; Insert the V-phase terminal with V-groove into the V-phase terminal piece, wipe off the surface paint on the V-phase terminal piece through the V-groove, and solder the V-phase terminal to the V-phase terminal piece; Insert the W-phase terminal with V-groove into the W-phase terminal piece, wipe off the surface paint on the W-phase terminal piece through the V-groove, and solder the W-phase terminal to the W-phase terminal piece.

[0012] As a further explanation of the above technical solution:

[0013] In step (S2), the stator core is provided with a marking groove, the marking groove of the stator core is aligned with the rib of the winding fixture, the stator core is locked and fixed on the winding fixture, the machine parameters of the winding fixture are adjusted according to the drawing requirements, and the winding is performed.

[0014] In step (S3), the common terminal block is inserted into one end of the diameter of the insulating frame, and the U-phase terminal block, the V-phase terminal block and the W-phase terminal block are inserted into the other end of the diameter of the insulating frame.

[0015] In step (S4), one end of the U-phase winding, V-phase winding and W-phase winding of the stator core is connected to the common terminal block, the other end of the U-phase winding of the stator core is connected to the U-phase terminal block, the other end of the V-phase winding is connected to the V-phase terminal block, and the other end of the W-phase winding is connected to the W-phase terminal block.

[0016] In step (S4), after the common terminal block, the U-phase terminal block, the V-phase terminal block and the W-phase terminal block are connected, they are impregnated with varnish. The insulating varnish is poured into the winding and fills the air gaps in the copper wire of the winding with the insulating varnish.

[0017] In step (S6), the U-phase terminal is automatically inserted into the U-phase connector using a plug-in fixture, the V-phase terminal is automatically inserted into the V-phase connector, and the W-phase terminal is automatically inserted into the W-phase connector.

[0018] In step (S6), the junction box covers the U-phase terminal, the V-phase terminal, and the W-phase terminal, and the junction box is fixedly installed on the enclosure.

[0019] Compared with the prior art, the advantages of the present invention are as follows:

[0020] The stator processing technology of the brushless DC motor of the present invention involves assembling an insulating frame onto the stator core, winding the stator core, inserting a common terminal block, a U-phase terminal block, a V-phase terminal block, and a W-phase terminal block onto the insulating frame, welding the winding copper wires to the corresponding terminal blocks, assembling the stator windings into the housing, and finally inserting the U-phase terminal block into the U-phase terminal block, the V-phase terminal block into the V-phase terminal block, and the W-phase terminal block into the W-phase terminal block. Compared with the prior art, firstly, by inserting a common terminal block, a U-phase terminal block, a V-phase terminal block, and a W-phase terminal block onto the insulating frame, the traditional method of... The step of inserting pins into the slots of the insulating frame eliminates the manual process of welding the Hall plate onto the pins. Secondly, the terminal blocks can be automatically inserted into the connecting pieces using a plug-in fixture. The U-phase, V-phase, and W-phase terminals have V-grooves. During insertion, the inner side of the V-groove scrapes the paint on the surface of the connecting piece, achieving mechanical paint removal, which replaces the manual process of brushing off the paint. This further optimizes processes involving manual operation, and has the advantages of high automation and strong continuous working capability, which can effectively improve production quality and efficiency. Attached Figure Description

[0021] Figure 1 This is a flowchart illustrating the steps of the brushless DC motor stator manufacturing process of the present invention.

[0022] Figure 2 This is the assembly diagram of the insulating frame and stator core for step S1.

[0023] Figure 3 This is an assembly diagram of the terminal block and the insulating frame for step S3.

[0024] Figure 4 This is the assembly diagram of the stator core and housing for step S5.

[0025] Figure 5 This is an assembly diagram of the wiring terminals and connecting pieces for step S6.

[0026] Figure 6 for Figure 5 Enlarged detail of the assembly of the middle terminal block and the connecting piece.

[0027] Figure 7 A schematic diagram of the completed assembly of a brushless DC motor.

[0028] Legend:

[0029] 100. V-groove; 1. Insulating frame; 2. Stator core; 3. Common terminal block; 4. U-phase terminal block; 5. V-phase terminal block; 6. W-phase terminal block; 7. Housing; 8. U-phase terminal block; 9. V-phase terminal block; 10. W-phase terminal block; 11. Junction box. Detailed Implementation

[0030] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] like Figures 1 to 7 As shown, the brushless DC motor stator processing technology of this embodiment includes the following steps:

[0032] (S1) Assemble the stator insulation frame: Fix the insulation frame 1 onto the stator core 2;

[0033] (S2) Winding: The stator core 2 is clamped on the winding fixture for winding;

[0034] (S3) Inserting the connecting pieces: Insert the common connecting piece 3, the U-phase connecting piece 4, the V-phase connecting piece 5 and the W-phase connecting piece 6 into the insulating frame 1;

[0035] (S4) Welding: Weld the winding copper wire to the common terminal block 3, as well as the U-phase terminal block 4, V-phase terminal block 5 and W-phase terminal block 6;

[0036] (S5) Install into the housing: Fix the stator core 2 inside the housing 7;

[0037] (S6) Install the UVW wiring assembly: Insert the U-phase terminal 8 with V-groove 100 into the U-phase terminal piece 4, wipe off the surface paint on the U-phase terminal piece 4 through the V-groove 100, and solder the U-phase terminal 8 into the U-phase terminal piece 4; Insert the V-phase terminal 9 with V-groove 100 into the V-phase terminal piece 5, wipe off the surface paint on the V-phase terminal piece 5 through the V-groove 100, and solder the V-phase terminal 9 into the V-phase terminal piece 5; Insert the W-phase terminal 10 with V-groove 100 into the W-phase terminal piece 6, wipe off the surface paint on the W-phase terminal piece 6 through the V-groove 100, and solder the W-phase terminal 10 into the W-phase terminal piece 6.

[0038] The stator processing technology for this brushless DC motor involves assembling an insulating frame 1 onto the stator core 2, winding the stator core 2, inserting a common terminal block 3, a U-phase terminal block 4, a V-phase terminal block 5, and a W-phase terminal block 6 onto the insulating frame 1, welding the winding copper wires to the corresponding terminals, assembling the stator windings into the housing 7, and finally inserting the U-phase terminal block 8 into the U-phase terminal block 4, the V-phase terminal block 9 into the V-phase terminal block 5, and the W-phase terminal block 10 into the W-phase terminal block 6. Compared with existing technologies, firstly, by inserting the common terminal block 3, U-phase terminal block 4, V-phase terminal block 5, and W-phase terminal block 6 onto the insulating frame 1... It replaces the step of inserting pins into the slots of the insulating frame, thus eliminating the manual process of welding the Hall plate onto the pins; secondly, it can automatically insert the terminals into the connecting pieces through the insertion tool. The U-phase terminal 8, V-phase terminal 9 and W-phase terminal 10 are provided with V-grooves 100. During insertion, the inner side of the V-grooves 100 scrapes the paint on the surface of the connecting piece, realizing mechanical paint removal, replacing the manual process of brushing off the paint, thereby further optimizing the process involving manual operation. It has the advantages of high degree of automation and strong continuous working ability, which can effectively improve production quality and production efficiency.

[0039] Specifically, in step (S2), the stator core 2 is provided with a marking groove. The marking groove of the stator core 2 is aligned with the rib of the winding fixture. The stator core 2 is locked and fixed on the winding fixture. The machine parameters of the winding fixture are adjusted according to the drawing requirements, and the winding is performed. Note that the stator core 2 must be fixed tightly, otherwise the copper wire is easily broken.

[0040] Specifically, in step (S3), the common terminal block 3 is inserted into one end of the diameter of the insulating frame 1, and the U-phase terminal block 4, V-phase terminal block 5 and W-phase terminal block 6 are inserted into the other end of the diameter of the insulating frame 1.

[0041] Specifically, in step (S4), one end of the U-phase winding, V-phase winding and W-phase winding of the stator core 2 is connected to the common terminal block 3, the other end of the U-phase winding of the stator core 2 is connected to the U-phase terminal block 4, the other end of the V-phase winding is connected to the V-phase terminal block 5, and the other end of the W-phase winding is connected to the W-phase terminal block 6.

[0042] Specifically, in step (S4), after the common terminal block 3, as well as the U-phase terminal block 4, V-phase terminal block 5, and W-phase terminal block 6 are connected, they are impregnated with insulating varnish. The insulating varnish is poured into the winding, filling the air gaps in the copper wires. The impregnated stator winding is then placed in an oven and dried at 130℃ for approximately two hours. The purpose of impregnation is to remove moisture from the insulating material and fill the air gaps in the copper wires with insulating varnish. This improves the insulation strength and moisture resistance of the winding, as well as its heat resistance and heat dissipation. It also enhances the mechanical properties, chemical stability, thermal conductivity, heat dissipation effect, and delays aging of the winding insulation.

[0043] Specifically, in step (S6), the U-phase terminal 8 is automatically inserted into the U-phase connector 4, the V-phase terminal 9 is automatically inserted into the V-phase connector 5, and the W-phase terminal 10 is automatically inserted into the W-phase connector 6 using a plug-in fixture. This high degree of automation further improves production efficiency.

[0044] Specifically, in step (S6), the junction box 11 covers the U-phase terminal 8, V-phase terminal 9 and W-phase terminal 10. The junction box 11 is fixedly installed on the enclosure 7, which can prevent external force from damaging the terminals and help extend their service life.

[0045] The above description is merely a preferred embodiment of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. For those skilled in the art, improvements and modifications obtained without departing from the inventive concept should also be considered within the scope of protection of the present invention.

Claims

1. A brushless DC motor stator processing technology, characterized in that, Includes the following steps: (S1) Assemble the stator insulation frame: Fix the insulation frame (1) onto the stator core (2); (S2) Winding: The stator core (2) is clamped on the winding fixture for winding; (S3) Insert the connecting pieces: Insert the common connecting piece (3), the U-phase connecting piece (4), the V-phase connecting piece (5) and the W-phase connecting piece (6) into the insulating frame (1); (S4) Welding: Weld the winding copper wire to the common terminal block (3), as well as the U-phase terminal block (4), V-phase terminal block (5) and W-phase terminal block (6); After the common terminal block (3), the U-phase terminal block (4), the V-phase terminal block (5) and the W-phase terminal block (6) are connected, they are impregnated with varnish. The insulating varnish is poured into the winding and the space gap in the copper wire of the winding is filled with the insulating varnish. (S5) Install into the housing: Fix the stator core (2) inside the housing (7); (S6) Install the UVW wiring assembly: Insert the U-phase terminal (8) with the V-groove (100) into the U-phase terminal piece (4), wipe off the surface paint on the U-phase terminal piece (4) through the V-groove (100), and solder the U-phase terminal (8) into the U-phase terminal piece (4); Insert the V-phase terminal (9) with the V-groove (100) into the V-phase terminal piece (5), wipe off the surface paint on the V-phase terminal piece (5) through the V-groove (100), and solder the V-phase terminal (9) into the V-phase terminal piece (5); Insert the W-phase terminal (10) with the V-groove (100) into the W-phase terminal piece (6), wipe off the surface paint on the W-phase terminal piece (6) through the V-groove (100), and solder the W-phase terminal (10) into the W-phase terminal piece (6).

2. The brushless DC motor stator processing technology according to claim 1, characterized in that, In step (S2), the stator core (2) is provided with a marking groove. The marking groove of the stator core (2) is aligned with the rib of the winding fixture. The stator core (2) is locked and fixed on the winding fixture. The machine parameters of the winding fixture are adjusted according to the drawing requirements to perform winding.

3. The brushless DC motor stator processing technology according to claim 2, characterized in that, In step (S3), the common terminal block (3) is inserted into one end of the diameter of the insulating frame (1), and the U-phase terminal block (4), the V-phase terminal block (5) and the W-phase terminal block (6) are inserted into the other end of the diameter of the insulating frame (1).

4. The brushless DC motor stator processing technology according to claim 3, characterized in that, In step (S4), one end of the U-phase winding, V-phase winding and W-phase winding of the stator core (2) is connected to the common terminal block (3), the other end of the U-phase winding of the stator core (2) is connected to the U-phase terminal block (4), the other end of the V-phase winding is connected to the V-phase terminal block (5), and the other end of the W-phase winding is connected to the W-phase terminal block (6).

5. The brushless DC motor stator processing technology according to claim 4, characterized in that, In step (S6), the U-phase terminal (8) is automatically inserted into the U-phase connector (4) by a plug-in fixture, the V-phase terminal (9) is automatically inserted into the V-phase connector (5), and the W-phase terminal (10) is automatically inserted into the W-phase connector (6).

6. The brushless DC motor stator processing technology according to claim 5, characterized in that, In step (S6), the U-phase terminal (8), the V-phase terminal (9) and the W-phase terminal (10) are covered by a junction box (11), and the junction box (11) is fixedly installed on the enclosure (7).

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