Brushless motor winding fixing structure

Abstract

This invention discloses a brushless motor winding fixing structure, belonging to the technical field of brushless motor winding fixing. It includes a stator core, an elliptical hollow elastic expansion member, an internal expansion assembly, a central push rod, an end positioning structure, an outer shell elastic heat-conducting sheet, a positioning and locking structure, and a motor housing. The elliptical hollow elastic expansion member is equidistantly distributed along the stator slots and inserted into the slots. The internal expansion assembly is located within the cavity of the elliptical hollow elastic expansion member and connected to the central push rod. The end positioning structure engages with the outer end of the elliptical hollow elastic expansion member. The outer shell elastic heat-conducting sheet is located outside the end positioning structure and is linked to the central push rod. This invention, through the cooperation of the elliptical hollow elastic expansion member and the internal expansion assembly, achieves a large-area elastic fit between the winding and the stator slot, significantly reducing contact thermal resistance, enabling rapid heat conduction from the winding, effectively reducing motor temperature rise, minimizing copper and iron losses, and significantly improving energy efficiency.

Description

Technical Field

[0001] This invention belongs to the field of brushless motor winding fixing technology, and particularly relates to a brushless motor winding fixing structure. Background Technology

[0002] Brushless motors, with their advantages of high efficiency, long lifespan, and low noise, have become a core component of energy-saving drive systems and are widely used in industrial control, home appliances, and new energy equipment. The winding fixing structure, as a key component of the stator assembly, directly determines the motor's temperature rise, energy loss, and overall energy efficiency through its fixing reliability and heat dissipation capabilities.

[0003] Traditional brushless motor winding fixing methods often employ slot wedges, binding straps, or varnish impregnation for curing. These methods commonly suffer from issues such as poor contact between the winding and the iron core slot wall, high contact thermal resistance, and long heat dissipation paths. This leads to increased motor operating temperature, higher copper and iron losses, and difficulty in meeting high-efficiency and energy-saving requirements. Furthermore, traditional fixing structures are mostly rigid, unable to adapt to the thermal expansion and deformation of the winding, resulting in complex assembly. Long-term operation can lead to loosening, vibration, and displacement, increasing mechanical losses and noise. Moreover, heat dissipation and fixing functions are independent, resulting in redundant structures and complex assembly, failing to achieve a harmonious balance between reliable fixing and high-efficiency energy saving. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a brushless motor winding fixing structure. This structure achieves a large-area elastic fit between the winding and the stator slot through the cooperation of an elliptical hollow elastic expansion member and an internal expansion component. This significantly reduces contact thermal resistance, allows for rapid heat conduction from the winding, effectively reduces motor temperature rise, minimizes copper and iron losses, and significantly improves energy efficiency, thus solving the problems of the prior art.

[0005] This invention is implemented as follows: a brushless motor winding fixing structure includes a stator core and winding coils, and further includes an elliptical hollow elastic expansion member, an internal expansion assembly, a central push rod, an end positioning structure, an outer shell elastic heat-conducting sheet, a positioning and locking structure, and a motor housing. The elliptical hollow elastic expansion member is equidistantly distributed in a ring along the stator slots and inserted into the slots. The internal expansion assembly is disposed within the cavity of the elliptical hollow elastic expansion member and connected to the central push rod. The end positioning structure engages with the outer end of the elliptical hollow elastic expansion member. The outer shell elastic heat-conducting sheet is disposed outside the end positioning structure and is linked to the central push rod. Pushing the central push rod simultaneously causes the elliptical hollow elastic expansion member to expand and press against the stator slots, and the outer shell elastic heat-conducting sheet to press against the inner wall of the motor housing, and the overall locking is achieved by the positioning and locking structure.

[0006] As a preferred embodiment of the present invention, the internal expansion component is a slider, and the axial movement of the slider can push the elliptical hollow elastic expansion member outward.

[0007] As a preferred embodiment of the present invention, the internal expansion component is an arc-shaped elastic sheet with an arc-shaped opening in the opposite direction to the central push rod; the inner cavity of the elliptical hollow elastic expansion member is fixedly provided with two blocks, and the arc-shaped elastic sheet is limited and expands outward after moving forward to the position of the block.

[0008] As a preferred embodiment of the present invention, the central push rod is a screw structure, and the end positioning structure is threadedly engaged with the central push rod. By turning the central push rod, the end positioning structure is driven to move axially, thereby achieving expansion and locking.

[0009] As a preferred embodiment of the present invention, the central push rod is a sliding optical rod, and several strip holes are formed along the axial direction on the elastic heat-conducting sheet of the outer shell; the positioning and locking structure is a wedge-shaped locking block, which is inserted into the strip hole to achieve one-way positioning and locking.

[0010] As a preferred embodiment of the present invention, the strip holes on the outer shell elastic heat-conducting sheet are evenly distributed to increase the heat dissipation area and improve the heat dissipation efficiency.

[0011] As a preferred embodiment of the present invention, a vertical heat sink is fixedly provided on the outer side of the outer shell elastic heat-conducting sheet. The vertical heat sink is arranged perpendicularly to the outer shell elastic heat-conducting sheet to increase the thermal contact area with the motor housing.

[0012] As a preferred embodiment of the present invention, the outer edge of the vertical heat sink or the outer shell elastic heat-conducting sheet is provided with a positioning protrusion; the inner wall of the motor housing is provided with a corresponding housing positioning recess; the positioning protrusion engages with the housing positioning recess for positioning.

[0013] As a preferred embodiment of the present invention, the positioning protrusions and the housing positioning recesses are arranged in several groups along the circumference to improve positioning accuracy, fixing reliability and heat dissipation efficiency.

[0014] As a preferred embodiment of the present invention, the elliptical hollow elastic expansion member is made of a high thermal conductivity insulating elastic material, with pointed guide ends at both ends and a hollow cavity in the middle.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention achieves large-area elastic contact between the winding and the stator slot through the cooperation of the elliptical hollow elastic expansion component and the internal expansion component, which greatly reduces the contact thermal resistance, enables the winding heat to be conducted quickly, effectively reduces the motor temperature rise, reduces copper loss and iron loss, and significantly improves the energy-saving effect.

[0016] 2. The present invention adopts a retractable expansion structure. The arc-shaped elastic sheet and the stop block can be flattened and folded before assembly and expanded and locked after assembly, which greatly reduces the assembly difficulty, while ensuring the support strength and fixation reliability, and is suitable for automated mass production.

[0017] 3. This invention achieves both internal expansion and locking and external heat conduction through a single push rod. The structure is highly integrated, with fewer parts and a simple assembly process, which helps to reduce the overall cost of the motor and improve production efficiency.

[0018] 4. The present invention forms a composite heat dissipation structure by combining an outer shell elastic heat-conducting sheet and a vertical heat sink, which significantly increases the heat dissipation area, strengthens the heat transfer between the stator and the shell, and enables the motor to operate stably at a lower temperature, further improving energy efficiency and output capacity.

[0019] 5. The present invention achieves circumferential positioning and axial locking by engaging the positioning protrusion with the positioning recess of the housing, and further increases the heat-conducting contact area, improves structural stability and heat dissipation efficiency, so that the motor can maintain low vibration, low noise and low loss operation under high speed and variable load conditions.

[0020] 6. This invention provides two sets of positioning and locking implementation methods: screw type and wedge-shaped locking block type. The method can be flexibly selected according to the motor model, power level and assembly requirements. It has strong versatility and wide applicability.

[0021] 7. This invention integrates fixing, locking, heat conduction, heat dissipation, vibration reduction, and positioning functions into one unit, achieving low loss, low temperature rise, and high reliability design from a structural perspective, comprehensively improving the energy efficiency and service life of brushless motors. This invention enhances heat dissipation through multiple structures such as strip-shaped holes, vertical heat sinks, and raised / recessed joints, enabling the motor to maintain high efficiency operation under continuous high load conditions, making it particularly suitable for energy-saving, high-power-density brushless motors. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the brushless motor winding fixing structure provided in an embodiment of the present invention; Figure 2 This is provided by the embodiments of the present invention. Figure 1 A magnified structural diagram of part A in the middle; Figure 3 This is provided by the embodiments of the present invention. Figure 1 A magnified structural diagram of part B in the middle section; Figure 4 This is a schematic diagram of the slider provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the stator core provided in an embodiment of the present invention.

[0023] In the diagram: 1. Stator core; 3. Elliptical hollow elastic expansion component; 41. Slider; 42. Arc-shaped elastic spring; 5. Center push rod; 6. End positioning structure; 7. Outer shell elastic heat-conducting sheet; 8. Positioning and locking structure; 9. Motor housing; 10. Vertical heat sink; 11. Positioning protrusion; 12. Housing positioning recess; 13. Stop block; 14. Strip hole. Detailed Implementation

[0024] To further understand the invention's content, features, and effects, the following embodiments are provided, and detailed descriptions are given in conjunction with the accompanying drawings.

[0025] The structure of the present invention will now be described in detail with reference to the accompanying drawings.

[0026] like Figures 1 to 5 As shown in the figure, an embodiment of the present invention provides a brushless motor winding fixing structure, including a stator core 1 and a winding coil, and further including an elliptical hollow elastic expansion member 3, an internal expansion assembly, a central push rod 5, an end positioning structure 6, an outer shell elastic heat-conducting sheet 7, a positioning and locking structure 8, and a motor housing 9; the elliptical hollow elastic expansion member 3 is distributed equidistantly along the stator slot and inserted into the slot; the internal expansion assembly is disposed in the cavity of the elliptical hollow elastic expansion member 3 and connected to the central push rod 5; the end positioning structure 6 cooperates with the outer end of the elliptical hollow elastic expansion member 3; the outer shell elastic heat-conducting sheet 7 is disposed outside the end positioning structure 6 and is linked with the central push rod 5; pushing the central push rod 5 can simultaneously cause the elliptical hollow elastic expansion member 3 to expand and adhere to the stator slot, and the outer shell elastic heat-conducting sheet 7 to adhere to the inner wall of the motor housing 9, and the positioning and locking structure 8 achieves overall locking.

[0027] An elliptical hollow elastic expansion component 3 is inserted into the stator slot. The internal expansion assembly is connected to the central push rod 5. The outer shell elastic heat-conducting sheet 7 is assembled with the end positioning structure 6 to form a single, interconnected structure. Pushing the central push rod 5 simultaneously drives both the internal expansion and the external shell attachment. This achieves integrated fixing, heat conduction, heat dissipation, and locking, resulting in a highly integrated structure and significant energy-saving effects.

[0028] In one embodiment, the internal expansion component is a slider 41, which, when moved axially, can expand the elliptical hollow elastic expansion member 3 outward. The slider 41 is inserted into the internal cavity of the elliptical hollow elastic expansion member 3, and a push rod pushes the slider 41 to move axially. The slider 41 moves forward, pressing against the inner wall, causing the expansion member to expand outward and adhere tightly to the groove wall.

[0029] In another embodiment, the internal expansion component is an arc-shaped elastic sheet 42, with the arc-shaped opening in the opposite direction to the central push rod 5; the inner cavity of the elliptical hollow elastic expansion member 3 is fixedly provided with two blocks 13, and the arc-shaped elastic sheet 42 is limited and expands outward after moving forward to the position of the block 13.

[0030] Before assembly, the arc-shaped elastic spring piece 42 can be flattened to narrow the overall shape and facilitate insertion into the slot; the push rod pushes the spring piece forward to the stop block 13, where it is limited and expanded. After being limited by the stop block 13, the arc-shaped elastic spring piece 42 cannot move forward any further and is forced to arch outward, thereby expanding the elliptical hollow elastic expansion piece 3. It is retractable and easy to assemble, and has strong support after expansion, balancing installation convenience and fixing strength.

[0031] In one embodiment, the central push rod 5 is a screw structure, and the end positioning structure 6 is threadedly engaged with the central push rod 5. By turning the central push rod 5, the end positioning structure 6 is driven to move axially, achieving expansion and locking. By setting the central push rod 5 as a screw, and the end positioning structure 6 being threadedly connected to the screw, rotating the push rod achieves feeding. The threaded drive achieves axial displacement and self-locking, allowing the expanding component to gradually open. This design provides high adjustment accuracy, stable self-locking, and prevents loosening or backlash.

[0032] In another embodiment, the central push rod 5 is a sliding light rod, and the outer shell elastic heat-conducting sheet 7 has several strip holes 14 opened along the axial direction; the positioning and locking structure 8 is a wedge-shaped block, which is inserted into the strip hole 14 to achieve one-way positioning and locking.

[0033] The push rod is a smooth rod that can be pushed directly; the wedge-shaped locking block engages with the slotted hole 14 to achieve unidirectional limiting. The wedge-shaped locking block only allows the push rod to move forward and prevents it from moving backward, achieving rapid locking. This design results in fast assembly speed, simple operation, and reliable locking.

[0034] The strip-shaped holes 14 on the outer shell elastic heat-conducting sheet 7 are evenly distributed to increase the heat dissipation area and improve heat dissipation efficiency. The uniformly distributed strip-shaped holes 14 on the outer shell elastic heat-conducting sheet 7 increase the contact area with air, enhancing convection heat dissipation. This achieves positioning and locking while improving heat dissipation capacity, reducing temperature rise, and minimizing losses.

[0035] A vertical heat sink 10 is fixedly provided on the outer side of the outer shell elastic heat-conducting sheet 7. The vertical heat sink 10 is arranged perpendicularly to the outer shell elastic heat-conducting sheet 7 to increase the thermal contact area with the motor housing 9. The vertical heat sink 10 fits closely to the housing over a large area, shortening the heat conduction path. This significantly improves the heat dissipation speed, reduces the motor temperature rise, and improves energy efficiency.

[0036] The outer edge of the vertical heat sink 10 or the outer shell elastic heat-conducting sheet 7 is provided with a positioning protrusion 11; the inner wall of the motor housing 9 is correspondingly provided with a housing positioning recess 12; the positioning protrusion 11 and the housing positioning recess 12 are engaged and positioned. When the positioning protrusion 11 is aligned with the housing positioning recess 12, it expands and automatically snaps into place. The engaging structure achieves circumferential positioning and axial limiting. Through this setting, the positioning is accurate, it is not easy to move, the contact is tighter, and the heat dissipation is more stable.

[0037] The positioning protrusions 11 and housing positioning recesses 12 are arranged in several groups along the circumference to improve positioning accuracy, fixing reliability, and heat dissipation efficiency. Multiple groups of protrusions and recesses are evenly arranged along the circumference, enabling multi-point positioning, multi-point heat conduction, and multi-point support. This results in uniform force distribution, uniform heat dissipation, smoother operation, and lower noise.

[0038] The elliptical hollow elastic expansion member 3 is made of a high thermal conductivity insulating elastic material, with pointed guide ends at both ends and a hollow cavity in the middle. The expansion member uses a high thermal conductivity insulating elastomer, with pointed ends and a hollow middle. The pointed shape facilitates insertion, the hollow shape facilitates contraction and expansion, and the high thermal conductivity enables rapid heat transfer. This design ensures insulation safety, rapid heat conduction, good elasticity, wear resistance, and a long service life.

[0039] Working principle: During assembly, the elliptical hollow elastic expansion component 3 is inserted into the stator slot. The central push rod 5 is pushed or turned to move the internal expansion component forward, causing the elliptical hollow elastic expansion component 3 to expand outward and fit tightly against the winding coil and the stator core 1 slot wall over a large area, reducing contact thermal resistance. At the same time, the central push rod 5, in conjunction with the outer shell elastic heat-conducting sheet 7 and the vertical heat sink 10, expands outward and fits tightly against the inner wall of the motor housing 9. It is then positioned by engaging the positioning protrusion 11 with the housing positioning recess 12. Finally, the positioning and locking structure 8 achieves overall locking, so that winding fixation, heat conduction, heat dissipation, vibration reduction, and locking are all completed simultaneously in one structure, thereby reducing motor temperature rise, reducing copper and iron losses, improving operating efficiency, and achieving energy-saving goals.

[0040] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0041] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A brushless motor winding fixing structure, comprising a stator core (1) and winding coils, characterized in that, It also includes an elliptical hollow elastic expansion member (3), an internal expansion assembly, a central push rod (5), an end positioning structure (6), an outer shell elastic heat-conducting sheet (7), a positioning and locking structure (8), and a motor housing (9); the elliptical hollow elastic expansion member (3) is distributed equidistantly along the stator slot and inserted into the slot; the internal expansion assembly is located in the cavity of the elliptical hollow elastic expansion member (3) and connected to the central push rod (5); the end positioning structure (6) cooperates with the outer end of the elliptical hollow elastic expansion member (3); the outer shell elastic heat-conducting sheet (7) is located outside the end positioning structure (6) and is linked with the central push rod (5); pushing the central push rod (5) can simultaneously cause the elliptical hollow elastic expansion member (3) to expand and adhere to the stator slot, and the outer shell elastic heat-conducting sheet (7) to adhere to the inner wall of the motor housing (9), and the positioning and locking structure (8) achieves overall locking.

2. The brushless motor winding fixing structure according to claim 1, characterized in that, The internal expansion component is a slider (41), which can push the elliptical hollow elastic expansion member (3) outward by axial movement of the slider (41).

3. The brushless motor winding fixing structure according to claim 1, characterized in that, The internal expansion component is an arc-shaped elastic sheet (42), with the arc-shaped opening in the opposite direction to the central push rod (5); the inner cavity of the elliptical hollow elastic expansion member (3) is fixed with two blocks (13), and the arc-shaped elastic sheet (42) is limited and expands outward after moving forward to the position of the block (13).

4. The brushless motor winding fixing structure according to claim 1, characterized in that, The central push rod (5) is a screw structure, and the end positioning structure (6) is threadedly engaged with the central push rod (5). By turning the central push rod (5), the end positioning structure (6) is driven to move axially, thereby achieving expansion and locking.

5. The brushless motor winding fixing structure according to claim 1, characterized in that, The central push rod (5) is a sliding light rod, and several strip holes (14) are opened along the axial direction on the outer shell elastic heat-conducting sheet (7); the positioning and locking structure (8) is a wedge-shaped block, which is inserted into the strip hole (14) to achieve one-way positioning and locking.

6. The brushless motor winding fixing structure according to claim 5, characterized in that, The strip holes on the outer shell elastic heat-conducting sheet (7) are evenly distributed to increase the heat dissipation area and improve the heat dissipation efficiency.

7. The brushless motor winding fixing structure according to claim 1, characterized in that, A vertical heat sink (10) is fixedly provided on the outer side of the outer shell elastic heat-conducting sheet (7). The vertical heat sink (10) is arranged perpendicular to the outer shell elastic heat-conducting sheet (7) to increase the heat-conducting contact area with the motor housing (9).

8. The brushless motor winding fixing structure according to claim 7, characterized in that, The outer edge of the vertical heat sink (10) or the outer shell elastic heat-conducting sheet (7) is provided with a positioning protrusion (11); the inner wall of the motor housing (9) is provided with a corresponding housing positioning recess (12); the positioning protrusion (11) and the housing positioning recess (12) are engaged and positioned.

9. The brushless motor winding fixing structure according to claim 8, characterized in that, The positioning protrusions (11) and the housing positioning recesses (12) are arranged in several groups along the circumference to improve positioning accuracy, fixing reliability and heat dissipation efficiency.

10. The brushless motor winding fixing structure according to claim 1, characterized in that, The elliptical hollow elastic expansion member (3) is made of a high thermal conductivity insulating elastic material, with pointed guide ends at both ends and a hollow cavity in the middle.

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