A brushless motor stator assembly
By designing interlaced winding teeth and terminals on the brushless motor stator, using the same enameled wire pinched and soldered winding coil and lead-out ring, and combining the design of the limit column and wiring trough, the complexity and looseness of the stator winding is solved, achieving higher stability and reliability.
Patent Information
- Application Number
- CN202421214095.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-30
- Publication Date
- 2025-04-08
- Estimated Expiration
- 2034-05-30
AI Technical Summary
The winding of the brushless motor stator is complicated and prone to loosening or falling off, resulting in poor indicators such as electromagnetic performance, temperature rise and noise.
A brushless motor stator assembly is adopted, including a stator core, stator end cover and coil winding. By setting interlaced winding teeth and terminals on the stator core, the same enameled wire pinched and soldered winding coil and lead ring are used to increase the number of turns and symmetrical layout of the lead ring, and combined with the design of the limit column and wiring trough, the stability and fixability of the enameled wire are ensured.
It realizes simpler and more reliable stator winding, improves the electrical and mechanical stability of the motor, reduces poor contact problems caused by vibration, simplifies the maintenance process, and adapts to space-constrained application scenarios.
Smart Images
Figure CN222735897U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motors, in particular to a brushless motor stator assembly. Background Art
[0002] Brushless motors are motors that use electronic commutation technology and have better performance and reliability than traditional brushed motors. The winding process of brushless motors is an important part of the motor manufacturing process, and its quality is directly related to the electromagnetic performance, temperature rise, noise and other indicators of the motor.
[0003] At present, the following schemes are adopted for winding the stator of the brushless motor: First, the coil winding is composed of multiple enameled wires, and the multiple enameled wires are respectively wound on different winding teeth. The lead wires of the enameled wires are fixed by terminal blocks, which results in a pause after each enameled wire is wound before the next enameled wire is wound. The winding process is complicated and the winding effect is low.
[0004] In the second type, the coil winding is directly led out after a single enameled wire is sequentially hung on the terminal and wound on the winding teeth. However, there is a lack of effective fixation of the lead wire, and when the enameled wire is subjected to external force, it is easy for the enameled wire to loosen or fall off from the terminal. Utility Model Content
[0005] The utility model aims to provide a brushless motor stator assembly, which solves the problem that the stator winding is complicated or easy to loosen or fall off, makes the stator winding simpler and more reliable.
[0006] In order to achieve the above-mentioned purpose, the utility model adopts the following technical scheme: a brushless motor stator assembly, including a stator core, a stator end cover and a coil winding, the stator core is provided with N winding teeth for winding the coil winding, the stator end cover is arranged at the end of the stator core, the stator end cover is provided with N wiring terminals, the N wiring terminals and the N winding teeth are arranged alternately in sequence along the circumferential direction of the stator core, the coil winding includes a winding coil and a lead-out turn, the winding coil is sequentially pinched and welded on the wiring terminals and wound on adjacent winding teeth along the circumferential direction of the stator core, the lead-out turn includes two wiring terminals pinched and welded along the circumferential direction of the stator core and symmetrically along the axis of the stator core, the winding coil and the lead-out turn are composed of the same enameled wire, the winding coil is provided with at least 1 turn, the lead-out turn is provided with at least N / 2 turns, and the enameled wire between two adjacent lead-out turns is transitioned on two adjacent wiring terminals by pinching and welding.
[0007] After adopting the above technical scheme, the utility model has the following advantages: First, the winding coil is provided with at least 1 circle, and the arrangement of the winding coil and the lead-out circle is completed by using a continuous enameled wire, so that the automatic winding of single-layer, double-layer and multi-layer coils is realized, and the process of connecting the wire ends is reduced, which not only simplifies the production process, but also reduces the failure rate caused by welding or crimping the wire ends, and improves the production efficiency and product quality. Secondly, the lead-out circle is provided with at least N / 2 circles, which increases the fixing strength of the enameled wire on the terminal, and cooperates with the transition design of pinch welding on the adjacent terminal in the circumferential direction, which effectively improves the electrical stability and mechanical stability of the motor during operation, and reduces the problem of poor contact caused by vibration. Finally, the lead-out circle adopts a symmetrical and orderly wiring method. When the motor needs maintenance or a part of the coil is damaged, it can be relatively easy to locate the problem area for local repair or replacement, reducing the maintenance cost and difficulty.
[0008] Furthermore, the winding coil is provided with 2 turns, and the lead-out coil is provided with N turns.
[0009] Using the above-mentioned technical solution, the winding coil is set to 2 turns. First, the winding requirement of the double-layer coil is met. At the same time, more lead-out turns provide a more secure electrical connection. Even when the motor runs at high speed or works for a long time, it can maintain a good contact state, reducing the failure rate of the electrical connection parts.
[0010] Furthermore, the connection terminal is located outside the winding teeth in the radial direction of the stator core, and the enameled wire between two connection terminals symmetrically located along the axis of the stator core in the lead-out coil is routed above the winding teeth.
[0011] By adopting the above technical solution, the enameled wire between the two terminal blocks symmetrically located along the axis of the stator core in the lead-out coil is routed along the top of the winding teeth, which effectively utilizes the vertical space inside the stator and avoids occupying more space in the radial direction. This helps to reduce the radial size of the motor and adapt to application scenarios with limited space. It may also reduce the overall weight of the motor.
[0012] Furthermore, a limiting column corresponding to the winding teeth is provided on the stator end cover, and the limiting column is located on the outside of the winding teeth in the radial direction of the stator core. The enameled wire in the lead-out coil between two connecting terminals symmetrical along the axis of the stator core passes through the limiting column at the center position between the two connecting terminals symmetrical along the axis of the stator core.
[0013] By adopting the above technical solution, the enameled wire is accurately guided to transition from one terminal to another through the limit column, ensuring the accurate layout of the enameled wire in three-dimensional space and avoiding unnecessary bending or crossing. The limit column can also provide better support and positioning for the enameled wire, effectively reducing the shaking and vibration of the enameled wire when the motor is running, and at the same time helping to improve production efficiency and assembly accuracy.
[0014] Furthermore, the enameled wire that transitions between two adjacent lead-out coils is routed along the outer side of the limiting column.
[0015] By adopting the above technical solution, the design of routing the enameled wire between two adjacent lead-out coils along the outside of the limit column provides a clear and controlled path for the enameled wire, helps to keep the coils arranged neatly, avoids crossing or entanglement between wires, simplifies the assembly process, and is beneficial to improving production efficiency and finished product qualification rate.
[0016] Furthermore, the pinch welding is arranged between two adjacent connecting terminals and on the outer side of the limiting column to disconnect the enameled wire.
[0017] With the above technical solution, the enameled wire is disconnected at the fixing ring, which means that each winding part can be disassembled and replaced independently without removing the entire winding, which greatly simplifies the maintenance process.
[0018] Furthermore, the connecting terminal is located on the outside of the winding teeth in the radial direction of the stator core, and a wiring groove for the coil winding is provided on the stator end cover below the connecting terminal. The enameled wire between two connecting terminals located symmetrically along the axis of the stator core in the lead-out ring passes through the wiring groove below other connecting terminals located between two connecting terminals located symmetrically along the axis of the stator core.
[0019] By adopting the above-mentioned technical solution, the wiring terminals are placed on the outside of the winding teeth, and the wiring groove design on the stator end cover provides a clear and smooth wiring channel for the enameled wire, especially when the lead-out ring needs to cross multiple wiring terminals. It can effectively guide the enameled wire to transition smoothly, reduce the wiring complexity, and facilitate automated winding and assembly processes, thereby helping to improve production efficiency. The enameled wire is routed along the outside of the winding teeth, which is also beneficial to heat dissipation and reduces heat accumulation of the winding on the winding teeth.
[0020] Furthermore, the stator end cover is provided with a limiting column corresponding to the winding teeth, the limiting column is located outside the winding teeth in the radial direction of the stator core, and the enameled wire transitioning between two adjacent lead-out turns is routed along the outside of the limiting column.
[0021] By adopting the above-mentioned technical solution, the limit column serves as a physical support structure, which can effectively prevent the enameled wire from shifting or loosening due to centrifugal force or vibration when the motor is running, and provides additional stability between the lead-out coils and the entire winding structure. Secondly, the design of routing the enameled wire along the outside of the limit column between two adjacent lead-out coils provides a clear and controlled path for the enameled wire, which helps to keep the coils neatly arranged and avoid crossing or entanglement between wires, simplifies the assembly process, and is conducive to improving production efficiency and the qualified rate of finished products.
[0022] Furthermore, the enameled wire located outside the limiting column is disconnected.
[0023] With the aforementioned technical solution, if a certain part of the coil winding fails, the disconnection setting allows the damaged wire segment to be more easily located and replaced individually without disassembling the entire coil winding, thereby reducing maintenance costs and complexity.
[0024] Furthermore, the wiring terminal includes a body, a pin portion is provided on the top of the body, a wire hanging portion is provided on the bottom of the body, and a positioning portion is provided on the body between the pin portion and the wire hanging portion; or, the wiring terminal includes a body, a positioning portion is provided on the top of the body, and a wire hanging portion is provided on the bottom of the body.
[0025] By adopting the above technical solution, the design with the pin portion is suitable for direct plug-in connection, while the design with only the positioning portion is more suitable for fixed connection methods such as welding, thereby increasing the scope of application. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The utility model is further described below in conjunction with the accompanying drawings:
[0027] Figure 1 This is a structural schematic diagram of a brushless motor stator assembly in Embodiment 1 of the present utility model;
[0028] Figure 2 It is an exploded view of the stator assembly of the brushless motor in the first embodiment of the utility model;
[0029] Figure 3 It is a top view of the stator assembly of the brushless motor in the first embodiment of the utility model;
[0030] Figure 4 It is a side view of the stator assembly of the brushless motor in the first embodiment of the utility model;
[0031] Figure 5 It is a bottom view of the stator assembly of the brushless motor in the first embodiment of the utility model;
[0032] Figure 6 This is a schematic diagram of a circuit for winding a coil in the first embodiment of the present utility model;
[0033] Figure 7 This is a schematic diagram of the winding of the coil in the first embodiment of the present utility model;
[0034] Figure 8 This is a schematic diagram of the structure of one of the wiring terminals in the first embodiment of the utility model;
[0035] Fig. 9 This is a schematic structural diagram of another type of connecting terminal in the first embodiment of the present utility model;
[0036] Fig.10 This is a schematic structural diagram of the front end cover in the first embodiment of the utility model;
[0037] Fig.11 It is an exploded view of the stator assembly of the brushless motor in the second embodiment of the present utility model;
[0038] Fig.12 It is a top view of the stator assembly of the brushless motor in the second embodiment of the utility model;
[0039] Fig.13 It is a side view of the stator assembly of the brushless motor in the second embodiment of the utility model;
[0040] Fig.14 It is a bottom view of the stator assembly of the brushless motor in the second embodiment of the utility model;
[0041] Fig.15 This is a schematic diagram of the circuit of the coil in the second embodiment of the present utility model;
[0042] Fig.16 This is a schematic diagram of the winding of the coil in the second embodiment of the present utility model;
[0043] Fig.17 This is a schematic structural diagram of the front end cover in the second embodiment of the present utility model;
[0044] In the figure, 10, stator core; 11, first winding tooth; 12, second winding tooth; 13, third winding tooth; 14, fourth winding tooth; 15, fifth winding tooth; 16, sixth winding tooth; 20, front end cover; 21, first limiting column; 22, second limiting column; 23, third limiting column; 24, fourth limiting column; 25, fifth limiting column; 26, sixth limiting column; 27, wiring groove; 28, installation groove; 29, limiting groove; 30, rear end cover; 41, first terminal; 42, second terminal; 43, third terminal; 44, fourth terminal; 45, fifth terminal; 46, sixth terminal; 47, pin part; 481, support foot; 482, wire hook; 49, positioning part; 5, enameled wire; 51, winding coil; 52, lead-out ring. DETAILED DESCRIPTION
[0045] In order to make the purpose, technical solutions and advantages of the embodiments of the utility model clearer, the technical solutions in the embodiments of the utility model will be clearly and completely described below in conjunction with the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments.
[0046] The terms "first", "second", "third", "fourth", etc. (if any) in the specification and claims of the present utility model and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the utility model described herein can be implemented in an order other than those illustrated or described herein.
[0047] It should be understood that in various embodiments of the present invention, the size of the serial number of each process does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.
[0048] It should be understood that in the present invention, "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or apparatus comprising a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to these processes, methods, products or apparatuses.
[0049] It should be understood that in the present utility model, "plurality" refers to two or more than two. "And / or" is only a description of the association relationship of associated objects, indicating that three relationships may exist. For example, X and / or Y can represent: X exists alone, X and Y exist at the same time, and Y exists alone. The character " / " generally indicates that the objects associated before and after are in an "or" relationship. "Contains X, Y and Z", "Contains X, Y, Z" means that X, Y, and Z are all included, "Contains X, Y or Z" means that one of X, Y, and Z is included, and "Contains X, Y and / or Z" means that any one, any two, or any three of X, Y, and Z are included.
[0050] The following specific embodiments are used to describe the technical solution of the utility model in detail. The following specific embodiments can be combined or replaced with each other according to actual conditions, and the same or similar concepts or processes may not be described in detail in some embodiments.
[0051] Embodiment 1:
[0052] like Figures 1 to 10As shown, the utility model provides a brushless motor stator assembly, which includes a stator core 10, a stator end cover and a coil winding in order to better adapt to the stator structure. The stator core 10 is provided with N winding teeth for winding the coil winding. The stator end cover is arranged at the end of the stator core 10. The stator end cover is provided with N wiring terminals. The N wiring terminals and the N winding teeth are arranged alternately in sequence along the circumferential direction of the stator core 10. The coil winding includes a winding coil 51 and a lead-out coil 52. The winding coil 5 The lead-out coil 52 is sequentially welded on the connection terminals and wound on adjacent winding teeth along the circumferential direction of the stator core 10, and the lead-out coil 52 is welded on two connection terminals symmetrically along the axis of the stator core 10 along the circumferential direction of the stator core 10. The winding coil 51 and the lead-out coil 52 are composed of the same enameled wire 5, the winding coil 51 is provided with at least 1 turn, and the lead-out coil 52 is provided with at least N / 2 turns. The enameled wire 5 between two adjacent lead-out coils 52 is transitioned by welding on two adjacent connection terminals.
[0053] First, the winding coil 51 is provided with at least one turn. By using a continuous enameled wire 5 to complete the arrangement of the winding coil 51 and the lead-out ring 52, the automatic winding of single-layer, double-layer and multi-layer coils is realized, and the process of connecting the wire ends is reduced, which not only simplifies the production process, but also reduces the failure rate caused by welding or crimping the wire ends, and improves the production efficiency and product quality. Secondly, the lead-out ring 52 is provided with at least N / 2 turns, which increases the fixing strength of the enameled wire 5 on the terminal, and cooperates with the transition design of pinch welding on the adjacent terminal in the circumferential direction, which effectively improves the electrical stability and mechanical stability of the motor during operation, and reduces the poor contact problem caused by vibration. Finally, the lead-out ring 52 adopts a symmetrical and orderly wiring method. When the motor needs maintenance or a part of the coil is damaged, it can be relatively easy to locate the problem area for local repair or replacement, reducing the maintenance cost and difficulty.
[0054] Among them, the terminal is located on the outside of the winding teeth in the radial direction of the stator core 10, and the enameled wire 5 between the two terminal blocks symmetrically located along the axis of the stator core 10 in the lead-out ring 52 is routed along the top of the winding teeth, which effectively utilizes the vertical space inside the stator and avoids occupying more space in the radial direction, which helps to reduce the radial size of the motor and adapt to application scenarios with limited space, and may also reduce the overall weight of the motor.
[0055] Furthermore, a limiting column corresponding to the winding teeth is provided on the stator end cover, and the limiting column is located on the outside of the winding teeth in the radial direction of the stator core 10. The enameled wire 5 located between two connecting terminals symmetrical along the axis of the stator core 10 in the lead-out ring 52 passes through the limiting column at the center position between the two connecting terminals symmetrical along the axis of the stator core 10, ensuring the precise layout of the enameled wire 5 in the three-dimensional space and avoiding unnecessary bending or crossing. The limiting column can also provide better support and positioning for the enameled wire 5, effectively reducing the shaking and vibration of the enameled wire 5 when the motor is running, and at the same time is beneficial to improving production efficiency and assembly accuracy.
[0056] In order to avoid crossing or entanglement between two adjacent lead-out coils, the enameled wire 5 that transitions between two adjacent lead-out coils 52 is routed along the outer side of the limiting column, providing a clear and controlled path for the enameled wire 5 that transitions between two adjacent lead-out coils, which helps to keep the coils arranged neatly and avoid crossing or entanglement between wires, simplifies the assembly process, and is beneficial to improving production efficiency and the qualified rate of finished products.
[0057] In order to achieve better winding, a limiting groove 29 is provided on the outer side of the limiting column. When the enameled wire 5 is routed along the outer side of the limiting column, it is inserted into the limiting groove 29. The inner wall of the limiting groove 29 limits the enameled wire 5, so that the enameled wire 5 is more firmly wound on the stator core 10, effectively reducing the loosening of the enameled wire 5.
[0058] For the convenience of maintenance, the enameled wire 5 on the outside of the limiting column of the fixing ring is disconnected, which means that each winding part can be disassembled and replaced independently without removing the entire winding, which greatly simplifies the maintenance process.
[0059] Specifically, the terminal is located outside the winding teeth in the radial direction of the stator core 10. The stator core 10 is provided with 6 winding teeth, 6 terminal blocks and 6 limit posts. The 6 winding teeth and the 6 terminal blocks are arranged alternately in the circumferential direction of the stator core 10. The 6 limit posts are located outside the 6 winding teeth. The stator end cover includes a front end cover 20 and a rear end cover 30. The front end cover 20 is provided with a mounting groove 28. The 6 terminal blocks are arranged in the mounting groove 28 of the front end cover 20. The 6 winding teeth include a first winding tooth 11, a second winding tooth 12, a third winding tooth 13 and a fourth winding tooth 14 along the clockwise direction of the stator core 10. The second winding tooth 12, the third winding tooth 13, the fourth winding tooth 14, the fifth winding tooth 15, and the sixth winding tooth 16. The six terminals along the clockwise direction of the stator core 10 include the first terminal 41, the second terminal 42, the third terminal 43, the fourth terminal 44, the fifth terminal 45, and the sixth terminal 46. The six limiting columns along the clockwise direction of the stator core 10 include the first limiting column 21, the second limiting column 22, the third limiting column 23, the fourth limiting column 24, the fifth limiting column 25, and the sixth limiting column 26.
[0060] When the brushless motor stator is wound with a single-layer coil winding, the coil 51 is provided with one turn, and the lead-out coil 52 is provided with three turns, wherein the winding steps of the coil 51 include S1: firstly hanging the first wiring terminal 41, winding the first winding tooth 11, returning to the second wiring terminal 42, hanging the second wiring terminal 42, winding the second winding tooth 12, and returning to the third wiring terminal 43;
[0061] S2: hang the third wiring terminal 43, wind the third winding tooth 13, return to the fourth wiring terminal 44, hang the fourth wiring terminal 44, wind the fourth winding tooth 14, and return to the fifth hook;
[0062] S3: hang the fifth wiring terminal 45, wind the wire tooth around the fifth wiring terminal 45, return to the sixth wiring terminal 46, hang the sixth wiring terminal 46, and wind the sixth winding tooth 16.
[0063] The coil 51 is wound without being cut, and the lead-out coil 52 is wound next.
[0064] The winding step of the lead-out coil 52 includes S4: hanging the first terminal 41, passing the second limiting column 22 along the inner side, hanging the fourth terminal 44 along the inner side, passing the fifth limiting column 25 along the inner side, hanging back the first terminal 41, and returning to the second terminal 42 along the outer side of the first limiting column 21;
[0065] S5: Hang the second wiring terminal 42, along the inner side, pass the third limiting column 23, along the inner side, hang the fifth wiring terminal 45, along the inner side, pass the sixth limiting column 26, hang back the second wiring terminal 42, and return to the third wiring terminal 43 along the outer side of the second limiting column 22;
[0066] S6: Hang the third wiring terminal 43, pass the fourth limiting column 24 along the inner side, hang the sixth wiring terminal 46 along the inner side, pass the first limiting column 21 along the inner side, and hang the third wiring terminal 43 back;
[0067] Then, the ends of the enameled wire 5 are brought out, and then, the enameled wire 5 on the first terminal 41, the second terminal 42, the third terminal 43, the fourth terminal 44, the fifth terminal 45, and the sixth terminal 46 are pinch-welded. After the pinch-welding is completed, the enameled wire 5 pinch-welded between two adjacent terminals and located on the outside of the limiting column is disconnected, specifically referring to the disconnection setting of the enameled wire 5 of the first limiting column 21 and the second limiting column 22, and the ends of the enameled wire 5 entering and exiting the stator core 10 are also removed. The removed enameled wire 5 is represented by a dotted line. If a part of the coil winding fails, the disconnection setting allows the damaged wire segment to be more easily located and replaced individually without disassembling the entire coil winding, thereby reducing maintenance costs and complexity.
[0068] It can be understood that in other embodiments, when the stator of the brushless motor is wound with a double-layer coil winding, the coil is provided with 2 turns and the lead-out coil is provided with 6 turns, wherein the winding steps of the coil include S1: first hanging the first terminal, winding the first winding tooth, returning to the second terminal, hanging the second terminal, winding the second winding tooth, and returning to the third terminal;
[0069] S2: hang the third terminal, wind the third winding tooth, return to the fourth terminal, hang the fourth terminal, wind the fourth winding tooth, return to the fifth hook;
[0070] S3: Hang the fifth terminal, wind the fifth terminal wire tooth, return to the sixth terminal, hang the sixth terminal, and wind the sixth winding tooth.
[0071] The coils of wire are not cut and the above steps are repeated.
[0072] Next, the lead-out coil is wound.
[0073] The winding steps of the lead-out loop include S4: hanging the first terminal, passing the second limiting column along the inner side, hanging the fourth terminal along the inner side, passing the fifth limiting column along the inner side, and hanging the first terminal back, repeating the same steps again, and returning to the second terminal along the outer side of the first limiting column;
[0074] S5: Hang the second terminal, along the inner side, pass the third limiting column, along the inner side, hang the fifth terminal, along the inner side, pass the sixth limiting column, and hang the second terminal back. Repeat the same steps again, and return to the third terminal along the outer side of the second limiting column.
[0075] S6: Hang the third terminal, pass the fourth limit column along the inner side, hang the sixth terminal along the inner side, pass the first limit column along the inner side, and hang the third terminal back. Repeat the same steps once more;
[0076] Then, the ends of the enameled wires are taken out, and the enameled wires on the first terminal, the second terminal, the third terminal, the fourth terminal, the fifth terminal, and the sixth terminal are pinch-welded. After pinch-welding is completed, the enameled wire disconnection setting between two adjacent terminals and located on the outside of the limit column is pinch-welded. Specifically, it refers to the enameled wire disconnection setting of the first limit column and the second limit column, and the ends of the enameled wires entering and exiting the stator core are also removed. The removed enameled wires are indicated by dotted lines. If a part of the coil winding fails, the disconnection setting allows the damaged wire segment to be more easily located and replaced separately without disassembling the entire coil winding, reducing the maintenance cost and complexity. The double-layer coil winding does not require bridge wire shaping, which is easy to make.
[0077] It can be understood that in other embodiments, the winding coil can be provided with 3 turns, 4 turns or multiple turns, so as to meet the winding requirements of multi-layer coil windings.
[0078] It can be understood that in other embodiments, the number of the connecting terminals and the winding teeth can be 9, 12, or other suitable numbers.
[0079] It should be noted that, in this embodiment, there are two types of connection terminals, such as Figure 8 As shown, the first type of terminal block includes a body, a pin portion 47 is provided on the top of the body, a wire hanging portion is provided on the bottom of the body, a positioning portion 49 is provided between the pin portion 47 and the wire hanging portion, the wire hanging portion includes two supporting legs 481 and a wire hanging hook 482 located between the supporting legs 481, and the design with the pin portion 47 is suitable for direct plug-in connection. Fig. 9 As shown, the second type of terminal comprises a body, a positioning portion 49 is provided on the top of the body, a wire hanging portion is provided on the bottom of the body, and the wire hanging portion comprises two supporting legs 481 and a wire hanging hook 482 located between the supporting legs 481. The design containing only the positioning portion 49 is more suitable for fixed connection methods such as welding. When in use, the first type of terminal and the second type of terminal can be selected according to the actual structure of the motor.
[0080] Embodiment 2:
[0081] like Figures 11 to 17 As shown, in this embodiment, since the routing distance of the lead-out ring 52 between the two axially symmetrical terminals of the stator core 10 is relatively large, in order to improve the routing stability of the lead-out ring 52, a routing groove 27 for the coil winding is provided on the stator end cover below the terminal. The enameled wire 5 between the two axially symmetrical terminals of the stator core 10 in the lead-out ring 52 passes through the routing groove 27 below the other terminals between the two axially symmetrical terminals of the stator core 10. The routing groove 27 on the stator end cover is designed to provide a clear and smooth routing channel for the enameled wire 5, especially when the lead-out ring 52 needs to cross multiple terminals, the enameled wire 5 can be effectively guided to transition smoothly, reducing the complexity of wiring, facilitating the automated winding and assembly process, and thus facilitating the improvement of production efficiency. The enameled wire 5 can also be routed along the outer side of the winding tooth, so that the enameled wire 5 of the lead-out ring 52 avoids the top of the winding tooth, which is beneficial to the circulation of heat dissipation air and reduces the heat accumulation of the winding on the winding tooth.
[0082] In this embodiment, no limiting groove 29 is provided on the limiting column.
[0083] When the brushless motor stator is wound with a single-layer coil winding, the coil 51 is provided with one turn, and the lead-out coil 52 is provided with three turns, wherein the winding steps of the coil 51 include S1: firstly hanging the first wiring terminal 41, winding the first winding tooth 11, returning to the second wiring terminal 42, hanging the second wiring terminal 42, winding the second winding tooth 12, and returning to the third wiring terminal 43;
[0084] S2: hang the third wiring terminal 43, wind the third winding tooth 13, return to the fourth wiring terminal 44, hang the fourth wiring terminal 44, wind the fourth winding tooth 14, and return to the fifth hook;
[0085] S3: hang the fifth wiring terminal 45, wind the wire tooth around the fifth wiring terminal 45, return to the sixth wiring terminal 46, hang the sixth wiring terminal 46, and wind the sixth winding tooth 16.
[0086] The coil 51 is wound without being cut, and the lead-out coil 52 is wound next.
[0087] The winding step of the lead-out coil 52 includes S4: hanging the first wiring terminal 41, passing through the wiring groove 27 below the second wiring terminal 42 and the wiring groove 27 below the third wiring terminal 43, hanging the fourth wiring terminal 44, passing through the wiring groove 27 below the fifth wiring terminal 45 and the wiring groove 27 below the sixth wiring terminal 46, hanging back on the first wiring terminal 41, and returning to the second wiring terminal 42 along the outside of the first limiting column 21;
[0088] S5: Hang the second terminal 42, pass through the wiring groove 27 below the third terminal 43 and the wiring groove 27 below the fourth terminal 44, hang the fifth terminal 45, pass through the wiring groove 27 below the sixth terminal 46 and the wiring groove 27 below the first terminal 41, hang back the second terminal 42, and return to the third terminal 43 along the outside of the second limiting column 22;
[0089] S6: Hang the third terminal 43, pass through the wiring groove 27 below the fourth terminal 44 and the wiring groove 27 below the fifth terminal 45, hang the sixth terminal 46, pass through the wiring groove 27 below the first terminal 41 and the wiring groove 27 of the second terminal 42, and hang back the third terminal 43;
[0090] Then, the ends of the enameled wire 5 are led out, and the enameled wire 5 on the first terminal 41, the second terminal 42, the third terminal 43, the fourth terminal 44, the fifth terminal 45, and the sixth terminal 46 are pinch-welded. After pinch-welding is completed, the enameled wire 5 located outside the limiting column is disconnected, specifically referring to the disconnection setting of the enameled wire 5 outside the first limiting column 21 and the second limiting column 22. The ends of the enameled wire 5 entering and exiting the stator core 10 are also removed, and the removed enameled wire 5 is represented by a dotted line. If a part of the coil winding fails, the disconnection setting allows the damaged wire segment to be more easily located and replaced individually without disassembling the entire coil winding, thereby reducing maintenance costs and complexity.
[0091] It is understandable that in other embodiments, the winding coil may be provided with 2 turns and the lead-out coil may be provided with 6 turns to realize a double-layer coil winding. Specifically, the winding steps of the winding coil include S1: first hang the first terminal, wind the first winding tooth, return to the second terminal, hang the second terminal, wind the second winding tooth, and return to the third terminal;
[0092] S2: hang the third terminal, wind the third winding tooth, return to the fourth terminal, hang the fourth terminal, wind the fourth winding tooth, return to the fifth hook;
[0093] S3: hang the fifth terminal, wind the fifth terminal wire tooth, return to the sixth terminal, hang the sixth terminal, and wind the sixth winding tooth.
[0094] The coil is not cut and the above steps are repeated.
[0095] After that, the lead-out coil is wound.
[0096] The winding steps of the lead-out loop include S4: hanging the first terminal, passing through the wiring groove under the second terminal and the wiring groove under the third terminal, hanging the fourth terminal, passing through the wiring groove under the fifth terminal and the wiring groove under the sixth terminal, hanging back on the first terminal, repeating the same steps again, and returning to the second terminal along the outside of the first limit column;
[0097] S5: Hang the second terminal, pass through the wiring trough under the third terminal and the wiring trough under the fourth terminal, hang the fifth terminal, pass through the wiring trough under the sixth terminal and the wiring trough under the first terminal, hang back the second terminal, repeat the same steps again, and return to the third terminal along the outside of the second limit column;
[0098] S6: Hang the third terminal, pass through the wiring trough under the fourth terminal and the wiring trough under the fifth terminal, hang the sixth terminal, pass through the wiring trough under the first terminal and the wiring trough of the second terminal, hang back the third terminal, and repeat the same steps once more;
[0099] Then, the ends of the enameled wires are led out, and the enameled wires on the first terminal, the second terminal, the third terminal, the fourth terminal, the fifth terminal, and the sixth terminal are pinch-welded. After pinch-welding is completed, the enameled wires located outside the limit column are disconnected. The double-layer coil winding does not require bridge wire shaping, which is easy to manufacture.
[0100] It can be understood that in other embodiments, the winding coil can be provided with 3 turns, 4 turns or multiple turns, so as to meet the winding requirements of multi-layer coil windings.
[0101] In addition to the above-mentioned preferred embodiments, the present invention also has other implementation modes. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work are within the scope of protection requested by the present invention.
Claims
1. A brushless motor stator assembly, comprising a stator core (10), a stator end cover and a coil winding, wherein the stator core (10) is provided with N winding teeth for winding the coil winding, the stator end cover is arranged at the end of the stator core (10), the stator end cover is provided with N wiring terminals, the N wiring terminals and the N winding teeth are arranged alternately in sequence along the circumferential direction of the stator core (10), and characterized in that: The coil winding comprises a winding coil (51) and a lead-out coil (52), wherein the winding coil (51) is sequentially welded on a connection terminal and wound on adjacent winding teeth along the circumferential direction of the stator core (10), and the lead-out coil (52) comprises two connection terminals welded along the circumferential direction of the stator core (10) and symmetrically along the axis of the stator core (10), the winding coil (51) and the lead-out coil (52) are composed of the same enameled wire, the winding coil (51) is provided with at least one coil, and the lead-out coil (52) is provided with at least N / 2 coils, and the enameled wire (5) between two adjacent lead-out coils (52) is transitioned on two adjacent connection terminals by welding.
2. The brushless motor stator assembly according to claim 1, characterized in that: The winding coil (51) is provided with 2 turns, and the lead-out coil (52) is provided with N turns.
3. The brushless motor stator assembly according to claim 1, characterized in that: The connection terminal is located outside the winding teeth in the radial direction of the stator core (10), and the enameled wire (5) between two connection terminals symmetrically located along the axis of the stator core (10) in the lead-out coil (52) is routed above the winding teeth.
4. The brushless motor stator assembly according to claim 3, characterized in that: The stator end cover is provided with a limiting column corresponding to the winding teeth, the limiting column being located outside the winding teeth in the radial direction of the stator core (10), and the enameled wire (5) located between two connecting terminals symmetrical along the axis of the stator core (10) in the lead-out coil (52) passes through the limiting column at the center position between the two connecting terminals symmetrical along the axis of the stator core (10) for routing.
5. The brushless motor stator assembly according to claim 4, characterized in that: The enameled wire (5) transitioning between two adjacent lead-out coils (52) is routed along the outer side of the limiting column.
6. The brushless motor stator assembly according to claim 5, characterized in that: The pinch welding is arranged between two adjacent connection terminals and the enameled wire (5) is disconnected and located outside the limit column.
7. The brushless motor stator assembly according to claim 1, characterized in that: The connecting terminal is located outside the winding teeth in the radial direction of the stator core (10); a wiring groove (27) for routing the coil winding is provided on the stator end cover below the connecting terminal; the enameled wire (5) between two connecting terminals symmetrically located along the axis of the stator core (10) in the lead-out ring (52) passes through the wiring groove (27) below the other connecting terminal between two connecting terminals symmetrically located along the axis of the stator core (10).
8. The brushless motor stator assembly according to claim 7, characterized in that: The stator end cover is provided with a limiting column corresponding to the winding teeth, the limiting column is located outside the winding teeth in the radial direction of the stator core (10), and the enameled wire (5) transitioning between two adjacent lead-out turns (52) is routed along the outside of the limiting column.
9. The brushless motor stator assembly according to claim 8, characterized in that: The enameled wire (5) located outside the limiting column is disconnected.
10. The brushless motor stator assembly according to claim 1, characterized in that: The wiring terminal comprises a body, a pin insertion portion (47) is provided at the top of the body, a wire hanging portion is provided at the bottom of the body, and a positioning portion (49) is provided between the pin insertion portion (47) and the wire hanging portion; or, the wiring terminal comprises a body, a positioning portion (49) is provided at the top of the body, and a wire hanging portion is provided at the bottom of the body.