Compact integral brushless motor stator

Abstract

The invention relates to the field of brushless motors, in particular to a compact integral brushless motor stator. A compact integral brushless motor stator comprises a stator lamination, a stator assembly, a PCB connecting plate, output terminals and a plastic sheath, the stator lamination is provided with an upper coil holder and a lower coil holder which play an insulating role, a winding is completed, the PCB connecting plate is welded with three output terminals and then is welded with an end-to-end line of the winding of the stator assembly, and the plastic sheath is connected with the stator assembly. The output terminal is sleeved with an insulated plastic sheath, the PCB connecting plate is annularly provided with six circular bonding pads, the six circular bonding pads are U / V / W / U1 / V1 / W1 phase bonding pads, and every two opposite bonding pads are in short circuit. The three-phase six-slot brushless stator has the beneficial effects that the six independent windings of the three-phase six-slot brushless stator are utilized, and the head and tail wires of the two adjacent windings are welded on the adjacent bonding pads after being subjected to enameled leather removal and tinning, so that the two adjacent windings are mutually conducted, and meanwhile, the short circuit between the windings of the same phase is realized.

Description

Technical Field

[0001] This invention relates to the field of brushless motors, and in particular to compact, integral brushless motor stators. Background Technology

[0002] After the traditional three-phase six-slot brushless stator winding is completed, the enamel is typically removed from the wire ends, tinned, and then copper strips are used to secure it to the lead wires. Finally, heat shrink tubing is used for insulation. However, directly connecting the lead wires to the copper strips after removing the enamel and tinning the wire ends carries a risk of loosening during motor operation. Therefore, the connection needs additional tinning for reinforcement. This process of tinning and reinforcing the connection with heat shrink tubing is not only cumbersome, but also results in large, hard solder joints that are difficult to manage. Furthermore, the burrs on the solder joints can easily puncture the heat shrink tubing, leading to poor stator insulation.

[0003] The industry's improvement to the traditional three-phase six-slot brushless stator winding delta-parallel connection normal tail treatment involves designing a bakelite block on the side of the stator upper winding frame, with three spot-welded terminals connected to the winding. However, this method has two drawbacks: firstly, the wire routing is very complex, and damage to the wires can easily lead to phase-to-phase short circuits; secondly, the side design exceeds the stator's outer diameter, making it difficult to fit this irregularly shaped stator into a compact circular housing, thus limiting its versatility. Summary of the Invention

[0004] To address the technical challenges of complex manufacturing processes, this invention provides a compact, integrated brushless motor stator.

[0005] The technical solution of the present invention is as follows: The compact integrated brushless motor stator includes stator laminations, a stator assembly, a PCB connection board, output terminals, and a plastic sheath. The stator laminations are fitted with an upper and lower winding frame for insulation and complete the winding. Three output terminals are soldered onto the PCB connection board, and then soldered to the beginning and end wires of the stator assembly winding. The output terminals are covered with an insulating plastic sheath. The PCB connection board has six circular pads, which are U / V / W / U1 / V1 / W1 phase pads. The pads are shorted in pairs: U-phase pads are shorted to U1-phase pads; V-phase pads are shorted to V1-phase pads; and W-phase pads are shorted to W1-phase pads.

[0006] The PCB connector has 6 U-shaped hook notches.

[0007] The upper surface of the PCB connector board has a thickened green solder mask layer and a fiberglass board layer covering the current-carrying copper foil.

[0008] The PCB connecting board has two narrow notches and one wide notch distributed at 120° along its edge, and the stator upper frame's locking posts are designed as two narrow locking posts and one wide locking post.

[0009] The copper foil of the PCB connection board connects the U1 phase pad with the U phase pad; the V1 phase pad with the V phase pad; and the W1 phase pad with the W phase pad. The copper foil is distributed in layers, with a fiberglass board in between, so that the copper foil layers are not conductive to each other.

[0010] The PCB connection board is soldered with three output terminals with an overcurrent width of 4.8mm. The two pins of each phase output terminal are shorted to the pads of its corresponding phase.

[0011] The plastic sheath has three terminal through holes that mate with the output terminals, and a circular protective wall on its outer edge.

[0012] The PCB connecting board, plastic sheath, and iron cover are each designed with six equally divided waist-shaped vent holes a, b, and c, which are designed to match the slots of the stator laminations.

[0013] The technical solution of this invention features a novel structure and ingenious, simple design. Utilizing the six individual windings of a three-phase, six-slot brushless stator, the start and end wires of adjacent windings are de-coated and tinned before being soldered to adjacent pads. This achieves mutual conduction between adjacent windings while simultaneously short-circuiting windings of the same phase, ultimately realizing an equivalent delta parallel connection of the three-phase, six-slot brushless stator windings. The improved overcurrent terminal structure of this invention uses a 4.8mm wide tail terminal output as the motor output, eliminating the need for lead wire structures. This avoids excessively large and hard solder joints at the connection between the winding tail and the lead wire, which are difficult to manage. The burrs at the solder joints can easily puncture the heat shrink tubing, causing poor stator insulation. Furthermore, the improved 4.8mm wide tail of the overcurrent terminal can be directly plugged into the customer's female terminal, saving the step of soldering lead wires. (2) The present invention has 6 U-shaped hook notches on the PCB connection board to achieve the horizontal posture of the double wires after bending at the beginning and end of the two adjacent windings, which increases the contact area between the wire tail and the PCB connection board pad, making the solder joint fuller and ensuring that the vibration of the motor during operation will not loosen the wire tail. (3) The copper foil of the PCB connection board connects the U1 phase pad with the U phase pad; the V1 phase pad with the V phase pad; and the W1 phase pad with the W phase pad. The copper foil is distributed in layers with a fiberglass board in between, so that each layer of copper foil is not conductive and is mutually insulated. This layered structure of copper foil increases the area of ​​motor overcurrent. (4) In addition, the upper surface of the PCB connection board has a thickened green solder mask layer and a fiberglass board layer covering the copper foil that is subjected to overcurrent, which plays a role in double insulation protection; even if the solder temperature is too high or the green solder mask layer is mechanically damaged, the fiberglass board layer still provides insulation protection; this prevents the exposed copper foil that is subjected to overcurrent from being soldered after the solder pad is damaged and the green solder mask layer is damaged, thus ensuring the quality of the solder. (5) The present invention utilizes the circular pads that are shorted in pairs on the PCB connection board to solder the first and last wires of two adjacent windings after removing the enamel and applying tin, and then soldering them onto the adjacent pads. This achieves mutual conduction between two adjacent windings and short-circuiting between windings of the same phase, ultimately achieving the equivalent connection of the three-phase six-slot brushless stator windings in delta parallel. (6) The present invention utilizes two narrow notches and one wide notch distributed at 120° on the edge of the PCB connecting board, which cooperate with the narrow and wide clamping posts of the stator upper frame respectively, to prevent the problem of incorrect PCB assembly angle; (7) The present invention increases the creepage distance between the live parts of the stator assembly and the metal casing and iron cover by using a plastic sheath, thereby improving the safety of the motor; (8) In addition, the PCB connecting board, plastic sheath and iron cover of the present invention are designed with six equally divided waist-shaped vent holes a, b and c, which cooperate with the slots of the stator laminations to ensure the smooth flow of air inside the motor. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the present invention in its explosive state; Figure 2 , 3 These are top and cross-sectional structural schematic diagrams of the PCB connection board of the present invention; Figure 4 This is a schematic diagram of the output terminal and PCB connection board of the present invention; Figure 5 This is a schematic diagram of the stator assembly of the present invention; Figure 6 , 7 This is the winding diagram and equivalent circuit diagram of the three-phase six-slot stator winding in delta parallel connection of the present invention; Figure 8 This is a schematic diagram of the structure of the plastic sheath of the present invention; Figure 9 This is a schematic diagram of the structure of the plastic protective sleeve of the present invention mounted on the stator assembly.

[0015] In the diagram: 1. Plastic sheath; 2. Output terminal; 3. PCB connection board; 4. Stator upper frame; 5. Winding; 6. Stator laminations; 7. Lower frame; 8. Narrow notch; 9. Wide notch; 10. U-shaped hook notch; 11. Narrow retaining post; 12. Wide retaining post; 13. Winding start and end wires; 14. Circular solder pad; 15. Terminal foot soldering hole; 16. Solder point; 17. Copper foil; 18. Fiberglass board layer; 19. Green solder resist layer; 20. Waist-shaped vent a; 21. Terminal foot; 22. Terminal output end; 23. Terminal through hole; 24. Waist-shaped vent b; 25. Circular protective wall; 26. Stator assembly; Top surface of the sheath; 27. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments. Example

[0017] like Figure 1 , 2 The compact integrated brushless motor stator shown in 3, 4, 5, 6, 7, 8, and 9 includes stator laminations 6, stator assembly 26, PCB connecting board 3, output terminals 2, and plastic sheath 1. The stator laminations 6 are equipped with an upper wire frame 4 and a lower wire frame 7 for insulation, and the windings 5 ​​are completed. Three output terminals 2 are soldered onto the PCB connecting board 3, and then soldered together with the start and end wires 13 of the windings 5 ​​of the stator assembly 26. The output terminals 2 are covered with insulating plastic sheaths 1. The PCB connecting board 3 has 6 circular pads 14 arranged around it. The 6 circular pads are U / V / W / U1 / V1 / W1 phase pads. The pads opposite each other are short-circuited: U phase pads are short-circuited with U1 phase pads; V phase pads are short-circuited with V1 phase pads; and W phase pads are short-circuited with W1 phase pads.

[0018] The PCB connector 3 has six U-shaped hook notches 10. These notches serve to prevent reverse assembly of the PCB connector 3. The six U-shaped hook notches 10 are used to hook the bent start and end wires 13 of two adjacent windings. After the enamel of the start and end wires 13 is stripped and tinned, they are bent horizontally at the U-shaped hook notches 10 and soldered onto the corresponding circular pads 14 on the PCB connector 3. This horizontal orientation of the wire ends increases the contact area between the wire ends and the PCB connector pads, resulting in fuller solder joints 16. The U1 phase pad is shorted to the opposite U phase pad via copper foil 17. Correspondingly, the V1 phase pad is shorted to the opposite V phase pad, and the W1 phase pad is shorted to the opposite W phase pad via copper foil 17.

[0019] The upper surface of the PCB connector board 3 has a thickened green solder mask layer 16 and a fiberglass board layer 15 covering the overcurrent copper foil 17.

[0020] The PCB connecting board 3 has two narrow notches 8 and one wide notch 9 distributed at 120° along its edge, and the stator upper frame 4 has two narrow notches 11 and one wide notch 12 as its locking posts.

[0021] The copper foils of the PCB connector board 3 connecting the U1 phase pads with the U phase pads, the V1 phase pads with the V phase pads, and the W1 phase pads with the W phase pads are distributed in layers, separated by a fiberglass board 16, so that the layers of copper foil 17 are non-conductive and mutually insulated. This layered structure of the copper foil 17 increases the area for motor overcurrent. The upper surface of the PCB connector board 3 has a thickened green solder mask layer 19 and a fiberglass board layer 18 covering the overcurrent copper foil 17, providing double protection. If the soldering temperature is too high or the green solder mask layer 19 is mechanically damaged, the fiberglass board layer 18 still provides insulation protection, preventing the exposed overcurrent copper foil 17 from soldering after the pads are damaged and the green solder mask layer 19 is damaged.

[0022] The PCB connection board 3 is soldered with three output terminals 2 with an overcurrent width of 4.8mm. The two pins of each phase output terminal 2 are shorted to the pads of its corresponding phase.

[0023] The plastic sheath 1 has three terminal through holes 23 that mate with the output terminals 2, and a circular protective wall on its outer edge.

[0024] The PCB connecting board, plastic sheath, and iron cover are each designed with six equally divided waist-shaped vent holes a20, b24, and c, which cooperate with the slot shape of the stator lamination 6.

[0025] In use, the PCB connector 3 has six terminal pin soldering holes 15. The three output terminals 2 are vertically placed on the PCB connector 3 through their corresponding terminal pin soldering holes 15 and soldered together. Since the two terminal pin soldering holes 15 of each phase, such as the U1 phase pad, are connected to the U1 phase pad, the U phase pad opposite to the U1 phase pad is also connected, and the same applies to the other two phases. The overcurrent output terminal 2 structure uses a 4.8mm wide tail terminal output end 22 as the motor output, eliminating the need for lead wires. The terminal output end 22 can be directly plugged into the customer's female terminal, and the terminal through hole 23 on the terminal output end 22 can engage with the snap-fit ​​point on the customer's female terminal to prevent the output terminal 2 from slipping.

[0026] This invention implements a delta-parallel connection method for six-slot three-phase brushless stator windings. First, the start and end wires 13 of two adjacent windings 5 ​​are soldered to the pads on the PCB connecting board 3, thus connecting the six windings 5 ​​end to end. Then, the copper foil 17 inside the PCB connecting board 3 enables the U1 phase pad to conduct with the U phase pad, the V1 phase pad to conduct with the V phase pad, and the W1 phase pad to conduct with the W phase pad. Finally, the three-phase output of the U1 phase pad, V1 phase pad, and W1 phase pad is achieved through the three output terminals 2. The six windings 5 ​​are first connected in parallel in pairs, and then connected in a delta configuration (Note: Because the U1 phase pad to the U phase pad, the V1 phase pad to the V phase pad, and the W1 phase pad to the W phase pad are all interconnected, they actually form the common vertices of the delta: U1 phase pad-U phase pad, V1 phase pad-V phase pad, and W1 phase pad-W phase pad).

[0027] The plastic sleeve 1 provided by this invention serves as insulation, with the output terminal 22 of the output terminal 2 passing through the terminal through-hole 23 of the plastic sleeve 1. The outer edge of the plastic sleeve 1 has a circular protective wall 25, ensuring insulation between the side of the stator assembly 26 and the inner wall of the integral housing. Furthermore, the top surface 27 of the plastic sleeve 13 increases the creepage distance between the PCB connection board 3 and the motor cover in the stator assembly 26. The six oblong vents b24 on the plastic sleeve 1 communicate with the corresponding oblong vents a20 on the PCB connection board 3, ensuring unobstructed airflow inside the motor.

[0028] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A compact, integrated brushless motor stator, comprising stator laminations (6), a stator assembly (26), a PCB connection board (3), output terminals (2), and a plastic sheath (1), characterized in that: The stator laminations (6) are fitted with an upper wire frame (4) and a lower wire frame (7) for insulation, and the windings (5) are completed. Three output terminals (2) are soldered onto the PCB connecting board (3), and then soldered together with the start and end wires (13) of the windings (5) of the stator assembly (26). The output terminals (2) are covered with insulating plastic sleeves (1). The PCB connecting board (3) is surrounded by 6 circular pads (14). The 6 circular pads (14) are U / V / W / U1 / V1 / W1 phase pads. The pads that are opposite each other are short-circuited: the U phase pad is short-circuited with the U1 phase pad; the V phase pad is short-circuited with the V1 phase pad; and the W phase pad is short-circuited with the W1 phase pad.

2. The compact integral brushless motor stator according to claim 1, characterized in that: The PCB connecting board (3) has 6 U-shaped hook notches (10).

3. The compact integral brushless motor stator according to claim 1, characterized in that: The upper surface of the PCB connector board (3) has a thickened green solder resist layer (19) and a glass fiber board layer (18) covering the overcurrent copper foil (17).

4. The compact integrated brushless motor stator according to claim 1, characterized in that: The PCB connecting board (3) has two narrow notches (8) and one wide notch (9) distributed at 120° on its edge. The stator upper frame (4) has two narrow notches (11) and one wide notch (12).

5. The compact integrated brushless motor PCB connection board structure according to claim 1, characterized in that: The copper foil of the PCB connecting board (3) connects the U1 phase pad with the U phase pad, the V1 phase pad with the V phase pad, and the W1 phase pad with the W phase pad. The copper foil is distributed in layers with a glass fiber board (18) in between, so that the copper foil layers (17) are not connected to each other.

6. The compact integral brushless motor stator according to claim 1, characterized in that: The PCB connection board (3) is soldered with three output terminals (2) with an overcurrent width of 4.8mm. The two pins of each phase output terminal (2) are shorted to the pads of its corresponding phase.

7. The compact integral brushless motor stator according to claim 1, characterized in that: The plastic sheath (1) has three terminal through holes (23) that mate with the output terminal (2), and a circular protective wall on the outer edge.

8. The compact integral brushless motor stator according to claim 1, characterized in that: The PCB connecting board, plastic sheath and iron cover are each designed with six equally divided waist-shaped vent holes a (20), b (24) and c, which are in coordination with the slots of the stator lamination (6).

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