Brushless motor winding welding process method

Abstract

The invention relates to the technical field of brushless motors, and particularly discloses a brushless motor winding welding process method which is based on a welding terminal, one end of the welding terminal is fixedly connected with a rubber-coated stator core, the other end of the welding terminal is connected and conducted with a PCBA, the welding terminal is provided with a wire clamping groove, and a wound phase wire is connected and conducted with the welding terminal through the wire clamping groove. The process method comprises the steps that S1, the welding terminal is fixedly connected with the rubber-coated stator iron core; s2, an inlet wire is automatically clamped into a wire clamping groove of one welding terminal, automatic winding is carried out, and an outlet wire obtained after winding is automatically clamped into a wire clamping groove of the other welding terminal; s3, the phase line is connected and conducted with the welding terminal through electric resistance welding; s4, a bearing is installed at the central axis position of the rubber-coated stator iron core; s5, installing a PCBA (Printed Circuit Board Assembly) on the rubber coated stator core; and S6, the welding terminal penetrating into the soldering tin hole is connected and conducted with the PCBA. The brushless motor has the advantages that the winding welding efficiency of the brushless motor can be improved, and the production cost can be reduced.

Description

Technical Field

[0001] The present application relates to the technical field of brushless motors, and in particular to a brushless motor winding welding process method. Background Art

[0002] In the field of motor manufacturing, with the continuous advancement of technology, motor performance and production processes are also developing continuously. Brushless motors, due to their high efficiency and energy-saving advantages, have been widely used in many fields, such as electric vehicles and industrial automation equipment. Their application not only improves equipment efficiency but also reduces energy consumption, playing a significant role in promoting the development of various industries. In particular, in applications where high motor performance is required, brushless motors can meet the stringent requirements for power output and stability, promoting the upgrading and transformation of related industries.

[0003] Traditional methods for securing brushless motor circuit boards and soldering phase wires to them involve drilling separate holes for securing and soldering the circuit boards. For example, multiple holes are drilled to secure the circuit boards, and multiple holes are drilled to solder the phase wires. However, this approach is time-consuming, requiring double the work hours and substantial labor costs. Soldering the phase wires to the circuit boards is particularly time-consuming, requiring manual labor to hold the terminal blocks in place. This, combined with the significant labor investment and time constraints of mass-producing the circuit boards, reduces market competitiveness.

[0004] To address this issue, patent application CN118137770B discloses a three-phase PIN winding process for brushless motors designed for automated soldering. The process includes the following steps: creating four dual-purpose through-holes on the PCBA (PCBA), which serve both as soldering holes for the three incoming terminals and one common outgoing terminal for three-phase power, and as PCBA anchors; cutting PIN pins and using a PIN jig to press them into the PCBA base for the first time; transferring the PINs from the PIN jig to the PCBA base for the first time; winding the PINs and using a PIN jig to press them into the PCBA base for the second time; installing the PCBA and trimming the wire tails; inserting the bearing into the stator and managing the wire ends; and finally soldering and inspecting the PCBA soldering points. This method, which transfers the PINs from the PIN jig to the base and binds the three-phase wires to the PIN pins, allows for quick wire fixation before soldering, removing barriers and paving the way for automated soldering.

[0005] Regarding the above-mentioned related technologies, the inventor believes that during the wire winding and welding process, not only is it necessary to manually perform the winding operation on the PIN pin, but also two press-fitting operations are required, as well as manual wire end arrangement and tail wire trimming operations. The operation process is relatively complicated, resulting in low wire winding and welding efficiency. At the same time, winding the wire on the PIN pin increases the connection diameter, so that when the phase line is soldered to the circuit board through the PIN pin, more tin material needs to be used and more space on the circuit board is occupied, which is disadvantageous in the micro connection installation of the brushless motor. This problem needs to be solved urgently. Summary of the Invention

[0006] In order to improve the winding welding efficiency of a brushless motor and reduce production costs, the present application provides a brushless motor winding welding process method.

[0007] This application provides a brushless motor winding welding process method, which adopts the following technical solutions: A brushless motor winding welding process method: The process method is based on a welding terminal, one end of which is fixedly connected to the rubber-coated stator core, and the other end of which is connected to the PCBA. The welding terminal has a wire clamping groove, and the wound phase line is connected to the welding terminal through the wire clamping groove. The process comprises the following steps: S1: The welding terminal is fixedly connected to the rubber-coated stator core, and the rubber-coated stator core is provided with a plurality of plug holes, and one end of the plurality of welding terminals is automatically inserted into the plug holes at the same height; S2: The incoming wire is automatically inserted into the wire slot of the welding terminal, and then the automatic winding operation is performed. After the winding is completed, the outgoing wire is automatically inserted into the wire slot of another welding terminal. The U, V, and W phase wires are wound in sequence, and the U, V, and W incoming wires are inserted into the wire slots of different welding terminals. S3: The phase line is connected to the welding terminal by resistance welding; S4: Install the bearing on the center axis of the rubber-coated stator core; S5: Install the PCBA on the rubber-coated stator core. Solder holes are provided on the PCBA at the positions of the solder terminals corresponding to the U, V, and W incoming wires. The PCBA is installed inside the middle position of the rubber-coated stator core, and the other ends of the solder terminals are inserted into the corresponding solder holes. S6: The soldering terminal inserted into the solder hole is connected to the PCBA, and soldering is performed in the solder hole by an automatic soldering machine, so that the soldering terminal is connected to the PCBA.

[0008] By adopting the above technical solution, when it is necessary to perform a winding welding operation on the phase wire of the brushless motor, one end of the welding terminal is inserted into the plug-in hole provided on the rubber-coated stator core to realize a fixed connection between the welding terminal and the rubber-coated stator core. Multiple welding terminals are pressed into place at one time. Compared with the PIN needle winding method, it does not require secondary pressing and cutting operations, and the process is simpler and more reliable. Then the incoming wire is automatically inserted into the wire clamping groove of the welding terminal to achieve fixation. After the automatic winding operation, the outgoing wire is automatically inserted into the wire clamping groove of another welding terminal. Subsequently, a welding joint is formed at the connection part between the phase wire and the welding terminal by resistance welding, so that the phase wire and the welding terminal are connected and conductive. Then the bearing is installed at the center axis position of the rubber-coated stator core and the PCBA is installed on the rubber-coated stator core. On the core, during the installation of the PCBA, the other end of the welding terminal is inserted into the solder hole, and the automatic welding machine solders in the solder hole, so that the welding terminal and the PCBA are connected and conductive, thereby realizing the connection and conductivity between the PCBA and the phase line through the welding terminal. Compared with the existing PIN pin winding method, the diameter of the PIN pin winding increases, which requires a larger groove on the PCBA for the winding PIN pin to penetrate, thereby reducing the accommodation space for components on the PCBA and requiring a long time to heat and tin. The tinning time is longer, and the amount of tin wire used is more, resulting in higher costs. This process realizes the rapid fixation of the welding terminal, facilitates the connection and conductivity between the phase line and the PCBA, is beneficial to improving the winding and welding efficiency of the brushless motor, and is beneficial to reducing production costs.

[0009] Preferably, in step S1, the welding terminals are automatically loaded by an automatic loading device, and the plurality of welding terminals are automatically and uniformly arranged at corresponding positions. The rubber-coated stator core is automatically loaded by a conveyor belt, and the rubber-coated stator core is conveyed to a position below the corresponding plurality of welding terminals. Then, a pressing module is used to press the welding terminals into the positions of the plug-in holes on the rubber-coated stator core.

[0010] By adopting the above technical solution, the welding terminals and the rubber-coated stator core are automatically loaded and pressed, and are fixed in place at one time. The height dimensions of multiple welding terminals fixed on the rubber-coated stator core are consistent, the degree of automation is high, the loading and pressing process is simple and reliable, and it is conducive to improving work efficiency.

[0011] Preferably, in step S2, the rubber-coated stator core with the welding terminal pressed onto it is placed into a pre-adjusted bottom die of an automatic winding machine, the incoming wire is automatically clamped into the wire clamping groove, the wire ends are pressed down to be arranged and automatically cut to fix the incoming wire, and then the automatic winding operation is performed in the winding groove at the edge of the rubber-coated stator core, and the U, V, and W incoming wires are carried out in sequence.

[0012] By adopting the above technical solution, the winding operation is highly automated, which saves time and labor compared to traditional processes and PIN needle winding processes. There is no need for winding wires, manually sorting thread ends, and trimming tail wires, which greatly improves work efficiency.

[0013] Preferably, in step S3, the phase wire is an enameled wire, and the wound rubber-coated stator core is placed in the bottom mold of a resistance welding machine for welding. The paint of the phase wire is vaporized by a resistance heating process, so that the phase wire and the welding terminal are bonded together to form a conductive state.

[0014] By adopting the above technical solution, this process eliminates the paint stripping operation of the traditional process. The mature resistance heating process is used to directly vaporize the paint of the phase wire and bond the phase wire to the welding terminal to form a welding joint to achieve conductivity. Then, the resistance, withstand voltage, leakage and other conditions of the wound stator can be comprehensively tested. Compared with the traditional tin welding process, it is more efficient, reliable and stable, and can effectively prevent false welding, cold welding, desoldering and other phenomena, thereby helping to improve the yield rate.

[0015] Preferably, in step S3, the welding terminal is made of copper.

[0016] By adopting the above technical solution, this arrangement enables the phase line to be bonded to the welding terminal after resistance welding to achieve conduction.

[0017] Preferably, in step S5, the surface of the welding terminal is plated with tin.

[0018] By adopting the above technical solution, the tin material plated on the surface of the welding terminal is integrated with the tin wire during the welding process of the welding terminal, the phase line and the PCBA, making the connection more stable and reliable.

[0019] Preferably, in step S5, the end portion of the welding terminal that penetrates into the solder hole is plated with tin.

[0020] By adopting the above technical solution, the amount of tin plated on the welding terminal is reduced, which is conducive to reducing production costs.

[0021] Preferably, one end of the welding terminal fixedly connected to the rubber-coated stator core and one end of the welding terminal connected and conductively connected to the PCBA are staggered relative to the surface of the PCBA.

[0022] By adopting the above technical solution, the welding terminal is set to this structure. While being fixed on the rubber-coated stator core, it can achieve connection and conduction with the phase line and with the PCBA. The structural design is ingenious.

[0023] Preferably, in step S5, the end of the welding terminal that penetrates the solder hole protrudes from the surface of the PCBA, the protruding portion has a height range of 0.7-0.9 mm, and the protruding portion is lower than the surface height of the rubber-coated stator core.

[0024] By adopting the above technical solution, this arrangement eliminates the need to trim the welding terminal after the wire winding welding operation is completed, which is convenient and quick.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. By providing a welding terminal, the welding terminal serves as the conductive medium between the phase line and the PCBA. The welding terminal achieves rapid connection and conduction with the phase line through a mature resistance welding process. The welding terminal is then connected and conducted to the PCBA by soldering. Compared with the existing PIN pin winding method, the diameter of the PIN pin increases due to the winding, which requires a larger slot on the PCBA for the winding PIN pin to penetrate, thereby reducing the space for components on the PCBA. In addition, it requires long heating and tinning, which takes longer and uses more tin wire, resulting in higher costs. This process achieves rapid fixing of the welding terminal, facilitates the connection and conduction between the phase line and the PCBA, is beneficial to improving the winding and welding efficiency of brushless motors, and is conducive to reducing production costs. It removes obstacles to the use of automated welding and is conducive to promoting faster development of automation in the brushless motor industry.

[0026] 2. By utilizing the resistance heating process to vaporize the paint coating of the phase wire, the phase wire and the welding terminal are bonded together to achieve connection and conduction, eliminating the paint stripping operation of the traditional process. Then, the resistance, withstand voltage, leakage and other conditions of the wound stator can be comprehensively tested. Compared with the traditional tin soldering process, it is more efficient, reliable and stable, and can effectively prevent false welding, cold welding, desoldering and other phenomena, thereby helping to improve the yield rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural diagram of the welding terminal in an embodiment of the present application.

[0028] Figure 2 It is an exploded view of the stator structure in the brushless motor in the embodiment of the present application.

[0029] Figure 3 This is an exploded view from another perspective of the stator structure in the brushless motor in the embodiment of the present application.

[0030] Figure 4 It is a structural schematic diagram of the installation of welding terminals on the rubber-coated stator core in an embodiment of the present application.

[0031] Figure 5 It is a schematic diagram of the structure of the bearing installed on the rubber-coated stator core in the embodiment of the present application.

[0032] Figure 6 This is a structural diagram of installing a PCBA on a rubber-coated stator core in an embodiment of the present application.

[0033] Description of reference numerals: 1. Soldering terminal; 2. Rubber-coated stator core; 3. PCBA; 4. Wire slot; 5. Connector hole; 6. Bearing; 7. Solder hole. DETAILED DESCRIPTION

[0034] The following is combined with Figure 1-6 This application is described in further detail.

[0035] The present application discloses a brushless motor winding welding process method, referring to Figure 1 、 Figure 2 as well as Figure 3 The process method is based on a welding terminal 1, one end of which is fixedly connected to the rubber-coated stator core 2, and the other end of the welding terminal 1 is connected to the PCBA 3 for conduction. At the same time, the welding terminal 1 has a wire clamping groove 4, and the wound phase line is connected to the welding terminal 1 through the wire clamping groove 4 for conduction. The welding terminal 1 serves as a connection bridge between the phase line and the PCBA 3, which simplifies the winding and welding process of the brushless motor, while improving efficiency and stability, and reducing production costs.

[0036] Specifically, the end of the soldering terminal 1 fixedly connected to the rubber-coated stator core 2 and the end of the soldering terminal 1 connected to the PCBA 3 are offset relative to the surface of the PCBA 3. The specific structure is as follows: the end of the soldering terminal 1 fixedly connected to the rubber-coated stator core 2 is rod-shaped and vertically fixedly connected to the rubber-coated stator core 2 through insertion. The end of the soldering terminal 1 connected to the PCBA 3 is L-shaped, so that the end of the soldering terminal 1 fixedly connected to the rubber-coated stator core 2 is offset from the end of the soldering terminal 1 connected to the PCBA 3. The snap-in slot is located at the end of the rod-shaped structure that is away from the insertion position. It should be noted that the soldering terminal 1 is made of a copper material and is tin-plated on the surface of the soldering terminal 1. In this embodiment, only the end of the soldering terminal 1 connected to the PCBA 3 is tin-plated to save tin and reduce production costs.

[0037] A brushless motor winding welding process method comprises the following steps: S1: The welding terminal 1 is fixedly connected to the rubber-coated stator core 2. The rubber-coated stator core 2 is provided with a plurality of insertion holes 5. One end of the plurality of welding terminals 1 is automatically inserted into the insertion holes 5 at the same height. S2: The incoming wire is automatically inserted into the wire slot 4 of the welding terminal 1, and then the winding operation is performed. After the winding is completed, the outgoing wire is automatically inserted into the wire slot 4 of another welding terminal 1. The U, V, and W phase wires are wound in sequence, and the U, V, and W incoming wires are inserted into the wire slots 4 of different welding terminals 1. S3: The phase line is connected to the welding terminal 1 by resistance welding; S4: Install bearing 6 at the center axis of the rubber-coated stator core 2; S5: Install PCBA3 on the rubber-coated stator core 2. Solder holes 7 are provided on the PCBA3 at the positions of the soldering terminals 1 corresponding to the U, V, and W incoming wires. The PCBA3 is installed inside the middle position of the rubber-coated stator core 2. The other ends of the soldering terminals 1 are inserted into the solder holes 7 respectively. S6: The welding terminal 1 that penetrates the solder hole 7 is connected to the PCBA 3 and soldered in the solder hole 7 by an automatic welding machine, so that the welding terminal 1 is connected to the PCBA 3.

[0038] Through the above automation and specific process steps, each step is closely coordinated, and conventional automated equipment is used to reduce manual intervention, achieving efficient and reliable winding and welding of brushless motors. This achieves the beneficial effects of simple process, saving manpower and time, preventing welding defects, reducing space occupation and costs. It should be noted that in the existing PIN pin winding process, the winding operation on the PIN pin was previously performed manually, and the thread ends had to be sorted and the tail wire trimmed. The operation was cumbersome, time-consuming and labor-intensive. In order to realize automated winding on the PIN pin, specially designed high-precision equipment is required for processing, resulting in high production equipment costs for this step.

[0039] Reference Figure 2 and Figure 4In step S1, a conventional automatic loading device, a pressing module and a conveyor belt are required. Specifically, the automatic loading device automatically loads the welding terminal 1, and multiple welding terminals 1 are automatically and uniformly arranged in corresponding positions. The conveyor belt automatically loads the rubber-coated stator core 2, and the rubber-coated stator core 2 is conveyed to the corresponding position below the multiple welding terminals 1. Then, the pressing module is used to press the welding terminal 1 into the position corresponding to the plug-in hole 5 on the rubber-coated stator core 2. In this embodiment, the automatic loading device is selected as a vibration plate, which can automatically and uniformly arrange the welding terminals 1 in the corresponding positions. The vibration plate consists of a hopper, a chassis, a controller and other parts. Its working principle is to use electromagnetic vibration to make the welding terminals 1 in the hopper rise along the spiral track and be arranged neatly, which will not be elaborated here. Of course, the automatic loading device can also be a robot arm, which grabs the welding terminal 1 and places it in the designated position through visual recognition and other technologies. The press-fitting module consists of an upper die and other components. The upper die is made of metal and its shape matches the solder terminals 1, accurately pressing the solder terminals 1 into the sockets 5 of the rubber-coated stator core 2. The upper die can provide pressure via a drive device such as a pneumatic cylinder, or an electric push rod can be used to achieve the press-fitting action. When the automatic loading device and the press-fitting module are combined, the conveyor belt transports the rubber-coated stator core 2 to the corresponding position below the multiple solder terminals 1. The press-fitting module then presses the solder terminals 1 into the corresponding sockets 5 on the rubber-coated stator core 2.

[0040] In existing PIN winding processes, the PINs must be pressed down after winding. This press-fitting process can cause phase line breakage. However, in this solution, press-fitting the soldering terminals 1 is unnecessary after stator winding is complete, reducing production risks. It should be noted that a single rubber-coated stator core 2 typically requires four or six soldering terminals 1. In this embodiment, four soldering terminals 1 are installed per single rubber-coated stator core 2.

[0041] Reference Figure 4In step S2, the rubber-coated stator core 2, with the welded terminals 1 pressed onto it, is placed into a pre-tuned bottom mold of an automatic winding machine. In this embodiment, a robotic arm automatically transfers the rubber-coated stator core 2, with the welded terminals 1 pressed onto it. The three-phase incoming wires are automatically clipped into the wire slots 4, pressed down to tidy up the wire ends, and automatically cut to secure the incoming wires. Automatic winding is then performed in the winding slots along the edge of the rubber-coated stator core 2. After the automatic winding is completed, the outgoing wires are automatically clipped into the wire slots 4 of another welded terminal 1. This process is repeated, allowing the U, V, and W phases to be wound sequentially. It should be noted that the bottom mold of the automatic winding machine is pre-tuned and used to secure the rubber-coated stator core 2 for winding. It consists of a mold body and a positioning structure, which can be either a protrusion or a groove, to accurately fix the position of the rubber-coated stator core 2. The robotic arm has multiple degrees of freedom, allowing it to flexibly grasp and move the rubber-coated stator core 2. Automatic winding machines can be CNC winding machines, which can accurately control the number of turns and tension of the winding; or they can be servo winding machines, which have higher accuracy and stability and do not require the use of expensive customized high-precision equipment.

[0042] Reference Figure 4 In step S3, the phase wire is an enameled wire. The wound, rubber-coated stator core 2 is placed in the bottom mold of a resistance welding machine for welding. The paint coating of the phase wire is vaporized using a resistance heating process, so that the phase wire and the welding terminal 1 are bonded together to form a conductive connection. Specifically, the bottom mold of the resistance welding machine is used to place the wound, rubber-coated stator core 2 for welding. The bottom mold of the resistance welding machine is made of high-temperature resistant materials, such as ceramics, to withstand the high temperatures during welding. The welding process eliminates the paint stripping process of the traditional process and uses a mature resistance heating process to directly vaporize the paint coating of the phase wire (enameled wire). The copper terminal and the enameled wire are then bonded together to form a conductive connection.

[0043] Reference Figure 2 and Figure 5 In step S4, the bearing 6 is mounted on the rubber-coated stator core 2 using a bearing 6 mounting device. The bearing 6 mounting device can be hydraulic, using a hydraulic system to provide stable pressure to mount the bearing 6 to the center axis of the rubber-coated stator core 2; or it can be mechanical, using a screw or other mechanism to apply pressure for installation. This is a conventional bearing 6 mounting device and will not be described in detail here.

[0044] Reference Figure 2 and Figure 6 In step S5, the end of the solder terminal 1 that penetrates the solder hole 7 protrudes from the outer surface of the PCBA 3. The protruding portion has a height range of 0.7-0.9 mm and is lower than the surface height of the rubber-coated stator core 2. In this embodiment, the protruding portion height is set to 0.8 mm.

[0045] Reference Figure 2 and Figure 3 In step S6, the solder holes 7 are only for the ends of the soldering terminals 1 to pass through, so that the solder holes 7 on the PCBA 3 occupy a small space. Most of the components on the PCBA 3 can be installed on the inner surface of the PCBA 3. When the automatic soldering machine performs the soldering operation, the small number of components on the PCBA 3 is unlikely to hinder the soldering operation, and the soldering process is unlikely to cause secondary damage to the components on the PCBA 3. At the same time, the small space occupied by the solder holes 7 reduces the amount of tin used in the soldering process and the soldering time is also correspondingly reduced, thereby improving production efficiency and reducing production costs. In addition, because the solder holes 7 occupy a small space, it is convenient for the arrangement of components on the PCBA 3, thereby helping to reduce the impact of overcurrent on the components.

[0046] The implementation principle of a brushless motor winding welding process method in an embodiment of the present application is as follows: the entire process method adopts a dual combination of automated equipment and resistance welding and soldering processes, which greatly simplifies the winding welding process of the brushless motor. In the step of connecting the welding terminal 1 and the rubber-coated stator core 2, the tedious operations such as secondary pressing and cutting of the pins in the PIN needle winding process are avoided; the phase wire winding step is fully automated, saving a lot of manpower and time; the butt welding process improves the welding quality and effectively prevents false welding, cold welding and desoldering; the welding terminal 1 serves as a carrier between the phase wire and the PCBA3, reducing space occupancy and cost; finally, the installation and welding of the PCBA3 and the bearing 6 are also more convenient and efficient. Compared with the existing process, the present process method has significant improvements and improvements in efficiency, quality and cost, which removes obstacles and paves the way for the use of automated welding, and promotes faster development of automation in the brushless motor industry.

[0047] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A brushless motor winding welding process, characterized by: The process method is based on a welding terminal (1), one end of the welding terminal (1) is fixedly connected to a rubber-coated stator core (2), the other end of the welding terminal (1) is connected and conducted with a PCBA (3), the welding terminal (1) has a wire clamping groove (4), and the wound phase line is connected and conducted with the welding terminal (1) through the wire clamping groove (4); The process comprises the following steps: S1: The welding terminal (1) is fixedly connected to the rubber-coated stator core (2), the rubber-coated stator core (2) is provided with a plurality of plug holes (5), and one end of the plurality of welding terminals (1) is automatically inserted into the plug holes (5) at the same height; S2: The incoming wire is first automatically inserted into the wire slot (4) of the welding terminal (1), and then the automatic winding operation is performed. After the winding is completed, the outgoing wire is automatically inserted into the wire slot (4) of another welding terminal (1). The U, V, and W phase wires are wound in sequence, and the U, V, and W incoming wires are inserted into the wire slots (4) of different welding terminals (1); S3: The phase line is connected to the welding terminal (1) by resistance welding; S4: Install the bearing (6) at the center axis of the rubber-coated stator core (2); S5: The rubber-coated stator core (2) is installed with a PCBA (3), and solder holes (7) are provided on the PCBA (3) at positions corresponding to the soldering terminals (1) for the U, V, and W incoming wires. The PCBA (3) is installed inside the middle position of the rubber-coated stator core (2), and the other ends of the soldering terminals (1) are respectively inserted into the solder holes (7); S6: The welding terminal (1) inserted into the solder hole (7) is connected to the PCBA (3) and soldered in the solder hole (7) by an automatic welding machine, so that the welding terminal (1) is connected to the PCBA (3).

2. The brushless motor winding welding process according to claim 1, characterized in that: In the step S1, the welding terminals (1) are automatically loaded by an automatic loading device, and the plurality of welding terminals (1) are automatically and uniformly arranged at corresponding positions. The rubber-coated stator core (2) is automatically loaded by a conveyor belt, and the rubber-coated stator core (2) is conveyed to a position below the corresponding plurality of welding terminals (1). Then, a pressing module is used to press the welding terminals (1) into positions corresponding to the plug holes (5) on the rubber-coated stator core (2).

3. The brushless motor winding welding process according to claim 1, characterized in that: In the step S2, the rubber-coated stator core (2) with the welding terminal (1) pressed thereon is placed in a pre-adjusted bottom die of an automatic winding machine, the incoming wire is automatically clamped into the clamping groove (4), the wire ends are pressed down to be arranged and automatically cut to fix the incoming wire, and then the automatic winding operation is performed in the winding groove at the edge of the rubber-coated stator core (2), and the U, V, and W incoming wires are performed in sequence.

4. The brushless motor winding welding process according to claim 1, characterized in that: In step S3, the phase wire is an enameled wire, and the wound rubber-coated stator core (2) is placed in the bottom mold of a resistance welding machine for welding. The paint coating of the phase wire is vaporized by a resistance heating process, so that the phase wire and the welding terminal (1) are bonded together to form a conductive connection.

5. The brushless motor winding welding process according to claim 4, characterized in that: In the step S3, the welding terminal (1) is made of copper.

6. The brushless motor winding welding process according to claim 1, characterized in that: In the step S5, the surface of the welding terminal (1) is plated with tin.

7. The brushless motor winding welding process according to claim 1, characterized in that: In the step S5, the end portion of the welding terminal (1) that penetrates into the solder hole (7) is plated with tin.

8. The brushless motor winding welding process according to claim 1, characterized in that: One end of the welding terminal (1) fixedly connected to the rubber-coated stator core (2) and one end of the welding terminal (1) connected and conducted to the PCBA (3) are arranged in a staggered manner relative to the surface of the PCBA (3).

9. The brushless motor winding welding process according to claim 1, characterized in that: In step S5, the end of the welding terminal (1) that penetrates the solder hole (7) protrudes from the surface of the PCBA (3), the height of the protruding portion ranges from 0.7 to 0.9 mm, and the protruding portion is lower than the surface height of the rubber-coated stator core (2).

Images