Integrated injection molding structure of rotary transformer stator

Abstract

The utility model discloses an integrated injection molding structure of a rotary transformer stator, one end of a stator core is electrically connected with an enameled wire, one end Tig of the enameled wire is welded with a long PIN needle, and one end of the long PIN needle is crimped and molded with a crimping terminal head. The number of the long PINs is multiple, and the long PINs are formed by welding the long PINs and the enameled wire. The long PIN is formed by the long strip shape, the long strip shape can greatly reduce the material area required by the long PIN, so that the cost is greatly reduced, meanwhile, the long strip shape can facilitate layout and installation in compact equipment or space, and the stator core, the injection molding shell and the long PIN are integrally formed through injection molding, so that when the product is produced, the production efficiency is improved, and the production cost is reduced. The stator core is not provided with wire harness production and processing, and the automatic production degree is high, so that the integrated injection molding of the stator core and the connector is realized, the procedures of resistance welding, terminal crimping, plastic shell plugging and the like are canceled, the input cost of production equipment is reduced, and the production efficiency is greatly improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of resolver stators, and in particular relates to an integrated injection molding structure of a resolver stator. Background Art

[0002] As a position and speed sensor for permanent magnet synchronous motors, the resolver (hereinafter referred to as resolver) plays a very important role in servo control systems. Due to its advantages of high control accuracy, fast response, high and low temperature resistance, strong anti-interference, good reliability, simple structure, and low manufacturing cost, it is deeply loved by the vast new energy vehicle motor market. Even in a new energy vehicle, 3-4 resolvers are used as control sensor closed loops, such as resolvers for ISG motors, resolvers for cooperative regenerative braking energy systems, resolvers for main drive motors, resolvers for EPS systems, etc. Resolvers can save the overall space of the motor and improve the performance of the motor; resolvers can be used in any insulating medium (oil, dust environment), are not affected by impurities in the medium environment, and transmit signals through electromagnetic principles.

[0003] Traditional resolver stators are made by directly soldering enameled wires and electronic wires together. The electronic wires are soft and difficult to fix, making automated welding difficult. Or copper terminals are used as a transition in the middle. One end of the copper terminal is Tig welded with the enameled wire, and the other end is resistance welded with the enameled wire. The variety of processes greatly reduces production efficiency. In addition, docking user ports also involves connectors, which require additional terminal crimping processes and plastic shell plugging processes, which increases costs and makes operations cumbersome. Utility Model Content

[0004] The utility model aims to provide an integral injection molding structure of a rotary transformer stator to solve the problems of electronic wire softness, production efficiency and production cost in the prior art.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] An integral injection molding structure of a rotary transformer stator comprises a stator core, one end of the stator core is electrically connected to an enameled wire, one end of the enameled wire is Tig-welded with a long PIN needle, and one end of the long PIN needle is crimped to form a crimping terminal head.

[0007] The long PIN needles are provided in plurality, and the plurality of long PIN needles are welded with the enameled wire.

[0008] The long PIN needle is in the shape of a long strip, which can greatly reduce the material area required for the long PIN needle, so the cost can be greatly reduced. At the same time, the long strip shape can adjust the position of the long PIN needle in a compact device or space to avoid blocking parts, which is convenient for layout and installation.

[0009] It also includes a stator core, an injection-molded housing and long PIN needles which are integrally molded by injection molding.

[0010] The outer side of the injection-molded housing is provided with side ears distributed around the stator core.

[0011] The surface of the injection-molded housing is also penetrated by through holes, which are distributed on both sides of the long PIN needle.

[0012] The long PIN needle is set as a block structure. The block-shaped long PIN needle can make the product have better conductivity. The larger the cross-sectional area of ​​the long PIN needle, the better the conductivity.

[0013] The tail end of the injection molded housing is provided with a plug connector opening facing downward, and the tail end of the long PIN needle enters the plug connector. The integrally formed plug connector and the injection molded housing can be directly inserted into the plug connector for conductive connection when in use, and the electrical connector inserted into the plug connector can better contact the tail end of the long PIN needle for power supply.

[0014] A plurality of positioning columns are injection molded on the injection-molded housing. The arrangement of the positioning columns can limit the installation position of the enameled wire and prevent the enameled wire from deviating.

[0015] The technical solution of the utility model has the following beneficial effects:

[0016] 1. The product has high integration and few parts, which effectively reduces the cumbersome production process. The product has fewer welding points and failure points. The product is integrated and has higher reliability. The long PIN needles in long strip shape and block structure can adapt to different usage scenarios.

[0017] 2. The stator core, injection molded shell and long PIN needle are formed into one piece by injection molding, so that when producing this product, the stator core is not produced and processed with a wiring harness, and a high degree of automated production can be achieved. The stator core and connector are integrated into an injection molding, and several processes such as resistance welding, crimping terminals and plugging plastic shells are eliminated, which reduces the investment cost of production equipment and greatly improves production efficiency.

[0018] 3. Long PIN needles are used to replace the original copper terminals + electronic wires, and the resistance welding process between the copper terminals + electronic wires is cancelled, which optimizes the production process and reduces the production cost. At the same time, long PIN needles with fixed shapes are processed to replace traditional wiring harnesses for signal transmission, solving the problem of soft electronic wires. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present utility model, the drawings required for describing the embodiments are briefly introduced below.

[0020] Figure 1 This is a structural schematic diagram of embodiment 1 of the present utility model.

[0021] Figure 2 This is a structural schematic diagram of the second embodiment of the present utility model.

[0022] Figure numerals: 10, stator core; 11, enameled wire; 12, long PIN needle; 13, crimping terminal head; 14, injection molded housing; 15, positioning column; 16, side ear; 17, through hole; 18, plug connector. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solution and advantages of the utility model clearer, the utility model will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the utility model and are not used to limit the utility model. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the utility model.

[0024] Embodiment 1:

[0025] refer to Figure 1 An integrated injection molding structure of a rotary transformer stator includes a stator core 10, characterized in that: one end of the stator core 10 is electrically connected to an enameled wire 11, one end of the enameled wire 11 is Tig-welded with a long PIN needle 12, and one end of the long PIN needle 12 is crimped with a crimping terminal head 13; the long PIN needle 12 is made of any material such as brass, phosphor bronze, beryllium copper, stainless steel, and cemented carbide, and the material selection comprehensively considers the product's use environment, electrical performance requirements, mechanical strength requirements, and cost factors.

[0026] In the above scheme, the long PIN needle 12 and the crimping terminal head 13 are crimped and formed into one piece. When the long PIN needle 12 is electrically connected to the enameled wire 11, it is only necessary to weld the end of the long PIN needle 12 away from the crimping terminal head 13 to the enameled wire 11. The welding method is Tig welding. Tig welding is called non-melting inert gas shielded arc welding. It is a commonly used argon arc welding method. It uses the arc heat generated between the tungsten electrode and the workpiece to melt the parent material and the filler wire (if a filler wire is used) for welding. During the welding process, an inert gas (usually argon) is introduced through a welding torch to form a shield around the arc and on the welding pool to prevent the harmful effects of air on the weld, thereby obtaining a high-quality weld. Thereby, the strength and conductivity of the welded joint are significantly improved, which helps to reduce energy loss and heat generation in the circuit. The weld formed by TIG welding has lower resistance and inductance, which helps to reduce energy loss and heat generation in the circuit. Low resistance and low inductance make the circuit more efficient and can improve the performance and stability of the overall equipment. TIG welding uses inert gas for protection, which can effectively prevent oxidation and corrosion during welding. This helps to extend the service life of the circuit and reduce the risk of performance degradation or failure due to oxidation and corrosion. This embodiment uses a long PIN needle 12 to replace the original copper terminal + electronic wire, eliminates the resistance welding process between the copper terminal + electronic wire, optimizes the manufacturing process, reduces production costs, and processes a long PIN needle of a fixed shape to replace the traditional wiring harness for signal transmission, solving the problem of soft electronic wires.

[0027] Further references Figure 1 , a plurality of long PIN needles 12 are welded with the enameled wire 11, wherein the long PIN needle 12 is in a long strip shape. The plurality of long strip shapes can greatly reduce the material area required for the long PIN needle 12, so the cost can be greatly reduced. At the same time, the long strip shape can adjust the position of the long PIN needle 12 in a compact device or space to avoid the blocking part, which is convenient for layout and installation.

[0028] Embodiment 2:

[0029] refer to Figure 2 The stator core 10, the injection molded housing 14 and the long PIN needle 12 are integrally formed by injection molding. The stator core 10, the injection molded housing 14 and the long PIN needle 12 are integrally formed by injection molding, so that when the product is produced, the stator core 10 is not produced and processed with a wiring harness, and a high degree of automated production can be achieved, thereby integrally injecting the stator core 10 and the connector, eliminating several processes such as resistance welding and crimping terminals and plugging plastic shells, reducing the investment cost of production equipment, and greatly improving production efficiency.

[0030] Furthermore, the outer side of the injection molded housing 14 is provided with side ears 16 distributed around the stator core 10. The surface of the side ears 16 has holes through which the injection molded housing 14 can be fixed with bolts, thereby stabilizing the stator core 10. The surface of the injection molded housing 14 also has through holes 17, which are distributed on both sides of the long PIN needle 12. Bolts are passed through the through holes 17 to further stabilize the injection molded housing 14.

[0031] Furthermore, the long PIN needle 12 is configured as a block structure. The block-shaped long PIN needle 12 can make the product have better conductivity. The larger the cross-sectional area of ​​the long PIN needle 12, the better the conductivity. A larger cross-sectional area means a larger free space for electrons and weaker interactions between electrons, which helps the free flow of current. Smaller electrical losses: In electrical equipment, a long PIN needle 12 with a large cross-section can improve the electrical conductivity of the equipment, thereby reducing electrical losses and improving the efficiency of the electrical equipment. Higher stability: In situations that carry large amounts of data transmission, such as communication equipment or smart grids, a long PIN needle 12 with a large cross-section can provide higher stability and reliability.

[0032] Furthermore, the tail end of the injection molded housing 14 is provided with a plug connector 18 with an opening facing downward, and the tail end of the long PIN needle 12 enters the plug connector 18. The integrally molded plug connector 18 and the injection molded housing 14 can be directly inserted into the plug connector 18 for conductive connection when in use, and the electrical connector inserted into the plug connector 18 can better contact the tail end of the long PIN needle 12 for power supply. It is worth noting that the other end of the long PIN needle can be designed into any plug-in plastic shell shape according to customer needs, and the structure is more streamlined.

[0033] A plurality of positioning posts 15 are injection molded on the injection molded housing 14. The arrangement of the positioning posts 15 can limit the installation position of the enameled wire 11 and prevent the enameled wire 11 from deflecting.

[0034] In this embodiment, the stator core 10 is used, and the injection-molded housing 14 includes the long PIN needle 12 which is integrally injection-molded. Finally, the enameled wire 11 and the long PIN needle 12 only need to be welded by Tig welding, thereby improving the success rate of product production.

[0035] In summary, in Embodiment 1 and Embodiment 2: the product has high integration and fewer parts, which effectively reduces the complicated production process, reduces the number of welding points and failure points of the product, is integrated, and has higher reliability. The long PIN needles 12 in the shape of long strips and blocks can adapt to different usage scenarios.

[0036] The above embodiments are only exemplary embodiments of the present invention and are not intended to limit the present invention. The protection scope of the present invention is defined by the claims. Various modifications or equivalent substitutions may be made to the present invention within the essence and protection scope of the present invention. Such modifications or equivalent substitutions shall also be deemed to fall within the protection scope of the present invention.

[0037] In the description of the present utility model, it should be noted that the terms "inside", "front", "back", "left", "right" and the like indicate directions or positional relationships based on the directions or positional relationships shown in the attached circles, or the directions or positional relationships in which the utility model product is usually placed when in use, and are only used to facilitate the description of the present utility model and simplify the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, these terms indicating directions or positional relationships cannot be understood as limiting the present utility model.

[0038] In the description of the present invention, it is further explained that, unless otherwise clearly specified and limited, the terms "disposed" and "connected" should be understood in a broad sense. For example, these terms can indicate a fixed connection, a detachable connection, or an integral connection between elements; they can also indicate a mechanical connection, an electrical connection; they can also indicate a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of these terms in the present invention can be understood according to specific circumstances.

Claims

1. An integral injection-molded structure of a resolver stator, comprising a stator core (10), characterized in that: One end of the stator core (10) is electrically connected to an enameled wire (11), one end of the enameled wire (11) is Tig-welded with a long PIN needle (12), and one end of the long PIN needle (12) is crimped to form a crimping terminal head (13).

2. The one-piece injection molding structure of a resolver stator according to claim 1, characterized in that: The long PIN needles (12) are provided in plurality, and the plurality of long PIN needles (12) are welded with the enameled wire (11).

3. The one-piece injection molding structure of a resolver stator according to claim 2, characterized in that: The long PIN needle (12) is in the shape of a long strip.

4. The one-piece injection molding structure of a resolver stator according to claim 1, characterized in that: It also includes a stator core (10), an injection-molded housing (14) and a long PIN needle (12) which are integrally molded by injection molding.

5. The one-piece injection molding structure of a resolver stator according to claim 4, characterized in that: The outer side of the injection-molded housing (14) is provided with side ears (16) distributed around the stator core (10).

6. The one-piece injection molding structure of a resolver stator according to claim 5, characterized in that: The surface of the injection-molded housing (14) is also penetrated by through holes (17), and the through holes (17) are distributed on both sides of the long PIN needle (12).

7. The one-piece injection molding structure of a resolver stator according to claim 6, characterized in that: The long PIN needle (12) is configured as a block structure.

8. The one-piece injection molding structure of a resolver stator according to claim 7, characterized in that: The rear end of the injection-molded housing (14) is provided with a plug connector (18) with its opening facing downward, and the rear end of the long PIN needle (12) enters the plug connector (18).

9. The one-piece injection molding structure of a resolver stator according to claim 8, characterized in that: A plurality of positioning columns (15) are injection-molded on the injection-molded housing (14).

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