Brushless motor stator assembly

Abstract

A brushless motor stator assembly comprises a stator core and a winding. Two ends of the stator core are respectively provided with a first winding frame and a second winding frame; a plurality of first winding parts are arranged on the inner circumferential wall of the first winding frame at intervals in the circumferential direction; a plurality of second winding parts are arranged on the inner circumferential wall of the second winding frame at intervals in the circumferential direction; the winding is wound on the first winding part and the second winding part; a first gap is formed between every two adjacent first winding parts; a first slot is formed between the stator core and the inner wall of the first gap; a second gap is formed between two adjacent second winding parts, and a second slot is formed between the stator core and the inner wall of the second gap; the stator assembly further comprises a plurality of insulating strips, two sides of each insulating strip are inserted into the first slot and the second slot, and the first gap and the second gap are sealed. Compared with the prior art, the groove fullness rate is better.

Description

Technical Field

[0001] The utility model relates to the field of brushless motors, and particularly to a stator assembly of a brushless motor. Background Art

[0002] The wire frame of a brushless motor mainly plays a role in support and insulation. Currently, for the treatment of slot insulation in the wire frames used in batches on the market, an empty method is generally adopted, and the safety regulations for insulation requirements are mainly achieved by controlling the slot fill factor of the winding. If the slot fill factor of the wire frame is high, the distance between windings is too small, resulting in the brushless motor not meeting the safety regulations; if the slot fill factor is low, the brushless motor meets the safety regulations, but from the perspective of the performance of the motor, a wire frame with a low slot fill factor will lead to a decrease in the output power of the motor and insufficient power output.

[0003] For example, the Chinese invention application with the application number 201811106988.4 (publication number CN109067028A) discloses a stator wire frame of a brushless motor and its winding method; among them, the stator wire frame of the brushless motor includes an annular body, and a plurality of winding parts extend from the inner side of the annular body towards the center position. A winding part is provided at the upper end of the annular body corresponding to the position of the winding part, and a winding slot is provided between adjacent winding parts. This application makes the enameled wire closer to the outside of the stator during winding, improving the fill rate of the winding slot, but the fill rate of the winding slot is still not high enough, and the power density and efficiency of the motor are still low.

[0004] Therefore, it is necessary to improve the existing technology. Summary of the Utility Model

[0005] The technical problem to be solved by the utility model is to provide a stator assembly of a brushless motor with a higher fill rate of the winding slot and meeting the safety regulations for insulation requirements in view of the above technical status.

[0006] The technical solution adopted by the utility model to solve the above technical problem is as follows: it includes a stator core and a winding; first and second wire frames are respectively provided at both ends of the stator core; a plurality of first winding parts are circumferentially spaced on the inner peripheral wall of the first wire frame; a plurality of second winding parts are circumferentially spaced on the inner peripheral wall of the second wire frame; the winding is wound on the first and second winding parts; and it is characterized in that: a first gap is formed between two adjacent first winding parts; a first slot is formed between the stator core and the inner wall of the first gap; a second gap is formed between two adjacent second winding parts, and a second slot is formed between the stator core and the inner wall of the second gap;

[0007] The stator assembly further includes a plurality of insulating strips, and both sides of each insulating strip are inserted into the first slot and the second slot to close the first gap and the second gap.

[0008] To make the first winding part and the second winding part preferably, a first step is provided at the bottom of the first winding part. Correspondingly, a second step for engaging with the first step is provided at the top of the second winding part.

[0009] To facilitate the installation of the stator core and the winding, preferably, the first winding part includes a first base portion provided on the inner peripheral wall of the first winding frame and a first insertion slot located at the bottom of the first base portion; a plurality of insertion posts are circumferentially spaced on the inner peripheral wall of the stator core, and the upper ends of the insertion posts are inserted into the first insertion slot to be connected to the first winding frame.

[0010] To isolate the end of the winding from the external metal end cover, preferably, a first limiting plate extending upward is provided on the inner side of the first base portion, so that there is a gap between the end of the winding and the metal end cover of the motor.

[0011] To prevent the insulating strip from slipping out, preferably, a blocking portion is provided at the bottom of the second winding part, and the blocking portion is located at the bottom of the second slot.

[0012] To facilitate the installation of the insulating strip so that the thickness of the insulating strip is sufficient to achieve the required insulation effect of the stator assembly, preferably, the slot widths of the first slot and the second slot are both 0.3 - 2.0 mm. A slot width of 0.3 - 1.0 mm is suitable for making with strip-shaped strip materials such as paper laminate paper like Quick Bar, DMD, etc., and a slot width of 1.0 - 2.0 mm is suitable for making by phenolic laminate, injection molding, etc.

[0013] Preferably, the height of the second step is 2 - 7 mm. If the height of the second step is too small, the safety distance is insufficient, and if it is too large, the draft angle during manufacturing is difficult and it is easy to lack material.

[0014] To position the core during the installation of the core and the assembly of the motor, preferably, a plurality of core positioning slots are circumferentially spaced on the outer peripheral wall of the stator core.

[0015] Compared with the prior art, the advantages of the present utility model are as follows: The first slot and the second slot are provided, and the insulating strip is installed in the first slot and the second slot, so that the stator assembly can meet the insulation requirements of safety regulations when the slot fill factor is high. In addition, the installation of the insulating strip fills the vacancy on the inner wall of the stator, and the wind resistance during the operation of the stator assembly is lower, and the efficiency and output power of the motor with the stator assembly installed are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic structural diagram of the embodiment;

[0017] Figure 2 It is a schematic structural diagram of the embodiment (except for the insulating strip and the winding);

[0018] Figure 3Schematic diagram of the decomposition of the embodiment

[0019] Figure 4 Schematic diagram of the first winding frame of the embodiment;

[0020] Figure 5 Schematic diagram of the first winding frame of the embodiment in another direction;

[0021] Figure 6 Schematic diagram of the second winding frame of the embodiment. Specific implementation manner

[0022] The present utility model will be further described in detail below in conjunction with the embodiments with reference to the drawings.

[0023] As Figure 1-6 shown, the brushless motor stator assembly includes a stator core 1, a winding 2, a first winding frame 3, a second winding frame 4, and an insulating strip 5.

[0024] The two ends of the stator core 1 are respectively provided with a first winding frame 3 and a second winding frame 4; a plurality of first winding portions 31 are circumferentially spaced on the inner peripheral wall of the first winding frame 3; a plurality of second winding portions 41 are circumferentially spaced on the inner peripheral wall of the second winding frame 4; the winding 2 is wound around the first winding portions 31 and the second winding portions 41; a first gap 32 is formed between two adjacent first winding portions 31; a first slot 321 is formed between the stator core 1 and the inner wall of the first gap 32; a second gap 42 is formed between two adjacent second winding portions 41, and a second slot 421 is formed between the stator core 1 and the inner wall of the second gap 42; both sides of each insulating strip 5 are inserted into the first slot 321 and the second slot 421, and the first gap 32 and the second gap 42 are closed; a first step 33 is provided at the bottom of the first winding portion 31, correspondingly, a second step 43 that is engaged with the first step 33 is provided at the top of the second winding portion 41. The height of the second step 43 is 2-7 mm; the slot widths of the first slot 321 and the second slot 421 are both 0.3-2.0 mm.

[0025] The first winding portion 31 includes a first base portion 34 provided on the inner peripheral wall of the first winding frame 3 and a first insertion slot 35 located at the bottom of the first base portion 34. The inner side of the first base portion 34 has a first limiting plate 37 extending upward.

[0026] The second winding portion 41 includes a second base portion 44 provided on the inner peripheral wall of the second winding frame 4 and a second insertion slot 45 located at the top of the second base portion 44. The inner side of the second base portion 44 has a second limiting plate 47 extending downward. A blocking portion 48 is provided at the bottom of the second winding portion 41, and the blocking portion 48 is located at the bottom of the second slot 421.

[0027] A plurality of insertion posts 11 are circumferentially spaced on the inner peripheral wall of the stator core 1. The upper ends of the insertion posts 11 are inserted into the first insertion slots 35 to be connected to the first winding frame 3; the lower ends of the insertion posts 11 are inserted into the second insertion slots 45 to be connected to the second winding frame 4. A plurality of core positioning grooves 12 are circumferentially spaced on the outer peripheral wall of the stator core 1.

[0028] Compared with the stator assembly without using the insulating strip 5 in this embodiment, the area utilization rate of the stator assembly in the slot is increased by 20%; in a brushless motor with a speed of 100,000 rpm, when using the stator assembly of this embodiment, the efficiency of the tested motor is increased by 1.5%.

Claims

1. A brushless motor stator assembly, comprising a stator core (1) and a winding (2); a first winding frame (3) and a second winding frame (4) are respectively provided at two ends of the stator core (1); a plurality of first winding portions (31) are circumferentially spaced apart on an inner circumferential wall of the first winding frame (3); a plurality of second winding portions (41) are circumferentially spaced apart on an inner circumferential wall of the second winding frame (4); the winding (2) is wound around the first winding portion (31) and the second winding portion (41); and the characteristics are: A first gap (32) is formed between two adjacent first winding portions (31); a first slot (321) is formed between the stator core (1) and the inner wall of the first gap (32); a second gap (42) is formed between two adjacent second winding portions (41); and a second slot (421) is formed between the stator core (1) and the inner wall of the second gap (42); The stator assembly further comprises a plurality of insulating strips (5), and two sides of each insulating strip (5) are inserted into the first slot (321) and the second slot (421), and close the first gap (32) and the second gap (42).

2. The brushless motor stator assembly according to claim 1, characterized in that: The bottom of the first winding portion (31) is provided with a first step (33), and correspondingly, the top of the second winding portion (41) is provided with a second step (43) which is engaged with the first step (33).

3. The brushless motor stator assembly according to claim 1, characterized in that: The first winding portion (31) comprises a first base (34) arranged on the inner circumferential wall of the first winding frame (3) and a first plug-in slot (35) located at the bottom of the first base (34); a plurality of plug-in posts (11) are arranged at intervals in the circumferential direction on the inner circumferential wall of the stator core (1), and the upper ends of the plug-in posts (11) are inserted into the first plug-in slots (35) to be connected to the first winding frame (3).

4. The brushless motor stator assembly according to claim 3, characterized in that: The inner side of the first base (34) is provided with a first limiting plate (37) extending upward, so that a gap exists between the end of the winding (2) and the metal end cover of the motor.

5. The brushless motor stator assembly according to claim 1, characterized in that: A blocking portion (48) is provided at the bottom of the second winding portion (41), and the blocking portion (48) is located at the bottom of the second slot (421).

6. The brushless motor stator assembly according to claim 1, characterized in that: The width of the first slot (321) and the second slot (421) are both 0.3-2.0 mm.

7. The brushless motor stator assembly according to claim 2, characterized in that: The height of the second step (43) is 2-7 mm.

8. The brushless motor stator assembly according to claim 1, characterized in that: A plurality of core positioning grooves (12) are arranged at intervals in the circumferential direction on the outer peripheral wall of the stator core (1).

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