Stator assembly of brushless motor

Abstract

The stator assembly comprises a motor shell and a plurality of stator iron cores which are extruded in the motor shell in an embracing mode, the outer wall of each stator iron core is sleeved with an insulating frame, a coil is arranged in the middle of the outer wall of the insulating frame in a wrapping mode, coil grooves are symmetrically formed in the middle of the side wall of each stator iron core, and the coil grooves are connected with the stator iron cores in an embracing mode. An adjusting groove is formed in the center of the top of the stator core, inclined planes are symmetrically arranged at the positions, close to the side walls, of the top of the stator core, side grooves are symmetrically formed in the positions, close to the top, of the side walls of the stator core, and the two side grooves are arranged in an arc shape. According to the utility model, coil winding is carried out on the stator iron cores which are arranged in a block shape before installation, rounding and press fitting are carried out after winding is completed, and after rounding and press fitting, the connection part between the stator iron cores is enabled to be smaller than 1mm, so that the cogging torque is reduced to the greatest extent, and the running smoothness and noise level of the motor are improved.

Description

Technical Field

[0001] The utility model relates to the technical field of brushless motor applications, in particular to a stator assembly of a brushless motor. Background Art

[0002] With the rapid development of new energy, brushless motors have also developed rapidly relying on the new energy platform. With the increasing demand for motors with high comfort and long life, brushless motors have also been popularized. Traditional brushless inner rotor motors use a cylindrical disc-riveted stator core, which is easy to wind and press-fit. However, limited by the winding process requirements, in order to facilitate the wire passing of the winding machine, the gap between the adjustment slots needs to be designed large enough, which easily leads to problems such as excessive noise and cogging torque. Therefore, the utility model proposes a stator assembly of a brushless motor. Summary of the Utility Model

[0003] The technical problem to be solved by the utility model is to provide a stator assembly of a brushless motor. By winding the coil on the block-shaped stator core before installation and then performing round pressing after winding, the connection between the stator cores can be made less than 1 mm after round pressing, ensuring that the cogging torque is reduced to the greatest extent, thereby improving the smoothness of the motor operation and the noise level.

[0004] To solve the above technical problem, a technical solution adopted by the utility model is: to provide a stator assembly of a brushless motor, including a motor housing and a plurality of stator cores that are round-pressed inside the motor housing. An insulating frame is sleeved on the outer wall of the stator core, and a coil is wrapped around the middle position of the outer wall of the insulating frame.

[0005] Among them, coil slots are symmetrically opened at the middle position of the side wall of the stator core, an adjustment slot is opened at the center of the top of the stator core, inclined surfaces are symmetrically arranged at the position near the side wall of the top of the stator core, and side slots are symmetrically opened at the position near the top of the side wall of the stator core, and the two side slots are arc-shaped.

[0006] The utility model is further arranged as: the tops of the plurality of stator cores are inclined surfaces and are abutted against the inner wall of the motor housing, and the bottoms of the stator cores are arc-shaped and are embedded in the positioning slots opened at the bottom of the insulating frame.

[0007] Through the above technical solution, it is convenient for the stator core to be pressed against the inner wall of the motor housing through the inclined surface at its top, and the arc-shaped part embedded in the positioning slot at the bottom can enable the rotor inside the motor housing to rotate circumferentially.

[0008] The utility model is further arranged as: the insulating frame is a high-temperature resistant material of PA6-GF30.

[0009] Through the above technical solution, it is convenient for the insulating frame to ensure the high-temperature resistance effect during long-term operation of the motor, thereby improving the performance during use.

[0010] The present utility model is further configured such that: the insulating frame is integrally injection-molded on the outer wall of the stator core or is relatively snap-fitted and sleeved on the outer wall of the stator core.

[0011] Through the above technical solution, the insulating frame can be stably installed on the outer wall of the stator core, improving the connection firmness between the insulating frame and the stator core.

[0012] The present utility model is further configured such that: a convex block is fixedly connected to a position near the top of the side wall of the insulating frame, an extension block is fixedly connected to the top position of the side wall of the insulating frame away from the convex block, and a positioning post is fixedly connected to a position near the corner of the side wall of the insulating frame close to the extension block.

[0013] Through the above technical solution, it is convenient to use the positioning post inside the insulating frame to fix the stator core inside the motor housing, and the connection stability between the insulating frame and the motor housing is further improved under the action of the extension block.

[0014] The present utility model is further configured such that: the top of the insulating frame on one side of the convex block is arranged in a plane, and the top of the insulating frame on one side of the extension block is arranged in an arc surface.

[0015] Through the above technical solution, it is convenient to use the convex block to press the internal stator core inside the motor housing, and the arc-shaped extension block on the insulating frame is closely attached to the inner wall of the motor housing near the end face.

[0016] The present utility model is further configured such that: the coil is arranged in two layers, the outer layer of the coil wraps the outer wall of the inner layer of the coil, and the inner layer of the coil wraps the outer wall of the insulating frame.

[0017] Through the above technical solution, using two layers of coils can improve the efficiency and performance of the motor during operation, as well as increase the intensity of the electromagnetic field.

[0018] The beneficial effects of the present utility model are as follows:

[0019] A stator assembly of a brushless motor proposed by the present utility model winds coils around the stator core arranged in a block shape before installation, and after the winding is completed, it is round-pressed. After the round-pressing, the connection between the stator cores is less than 1 mm, ensuring that the cogging torque is reduced to the greatest extent, thereby improving the smoothness and noise level of the motor operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is the installation structure diagram of a stator assembly of a brushless motor of the present utility model;

[0021] Figure 2 This is a block diagram of the stator assembly of a brushless motor of the present utility model;

[0022] Figure 3 This is an exploded view of the stator assembly of a brushless motor of the present utility model;

[0023] Figure 4 This is the first structural diagram of the insulating frame in the stator assembly of a brushless motor of the present utility model;

[0024] Figure 5 This is the second structural diagram of the insulating frame in the stator assembly of a brushless motor of the present utility model;

[0025] Figure 6 This is the structural diagram of the stator core in the stator assembly of a brushless motor of the present utility model.

[0026] In the figure: 100, motor housing; 200, stator core; 201, coil slot; 202, adjustment slot; 203, side slot; 300, insulating frame; 301, positioning slot; 302, convex block; 303, extension block; 304, positioning post; 400, coil. Detailed implementation manners

[0027] The following elaborates on the preferred embodiments of the present utility model in conjunction with the accompanying drawings, so that the advantages and features of the present utility model can be more easily understood by those skilled in the art, thereby making the protection scope of the present utility model more clearly defined.

[0028] As Figures 1-4 shown, a stator assembly of a brushless motor includes a motor housing 100 and a plurality of stator cores 200 that are circularly pressed inside the motor housing 100. Symmetrically arranged coil slots 201 are provided in the middle position of the side wall of the stator core 200. An adjustment slot 202 is provided at the center of the top of the stator core 200. Slopes are symmetrically arranged near the side wall at the top of the stator core 200. Side slots 203 are symmetrically arranged near the top of the side wall of the stator core 200, and the two side slots 203 are arc-shaped. The tops of the plurality of stator cores 200 are arranged in a sloped manner and are abutted against the inner wall of the motor housing 100. The bottom of the stator core 200 is arc-shaped and is embedded inside a positioning slot 301 provided at the bottom of the insulating frame 300, facilitating the stator core 200 to be pressed against the inner wall of the motor housing 100 through the slope at its top, and the arc-shaped portion embedded inside the positioning slot 301 at the bottom can enable the rotor inside the motor housing 100 to rotate circumferentially.

[0029] An insulating frame 300 is sleeved on the outer wall of the stator core 200. The insulating frame 300 is made of a high-temperature resistant material of PA6-GF30, which is convenient for ensuring the high-temperature resistant effect during the long-term operation of the motor, improving the performance during use. The insulating frame 300 is integrally injection-molded on the outer wall of the stator core 200 or is relatively snap-fitted and sleeved on the outer wall of the stator core 200, which can enable the insulating frame 300 to be stably installed on the outer wall of the stator core 200 and improve the connection firmness between the insulating frame 300 and the stator core. A convex block 302 is fixedly connected to the side wall of the insulating frame 300 near the top position. The top of the insulating frame 300 on one side of the convex block 302 is arranged in a plane, which is convenient for using the convex block 302 to press the inner stator core 200 inside the motor housing 100. An extension block 303 is fixedly connected to the top position of the side wall of the insulating frame 300 away from the convex block 302. The top of the insulating frame 300 on one side of the extension block 303 is arranged in an arc surface, so that the arc-shaped extension block 303 on the insulating frame 300 closely adheres to the inner wall of the motor housing 100 near the end face. A positioning column 304 is fixedly connected to the position of the side wall of the insulating frame 300 near the corner of the extension block 303, which is convenient for using the insulating frame 300 to fix the stator core 200 inside the motor housing 100 through the internal positioning column 304, and further improving the connection stability between the insulating frame 300 and the motor housing 100 under the action of the extension block 303. A coil 400 is wrapped around the middle position of the outer wall of the insulating frame 300. The coil 400 is arranged in two layers, with the outer layer coil 400 wrapped around the outer wall of the inner layer coil 400, and the inner layer coil 400 wrapped around the outer wall of the insulating frame 300. Using two layers of coils can improve the efficiency and performance of the motor during operation, as well as increase the intensity of the electromagnetic field.

[0030] When the utility model is in use, first, the insulating frame 300 is directly injection-molded on the outer wall of the stator core 200 through a mold or the insulating frame 300 with a split snap-fit connection is installed on the stator core 200. Then, double-layer coils 400 are wound at the coil slots 201 corresponding to the stator core 200 on the insulating frame 300. After winding multiple stator cores 200, the multiple stator cores are pressed inside the motor housing 100 in a way of holding the circle, so that the top of the stator core 200 closely adheres to the inner wall of the motor housing 100, and the stator cores 200 can be closely pressed and fixed to each other. At the same time, the insulating frame 300 is limited and fixed inside the motor housing 100 through the positioning column 304, and the arc-shaped extension block 303 is made to adhere to the inner wall of the motor housing 100 near the end face position. After the assembly is completed, the connection between the stator cores 200 is less than 1 mm, improving the smoothness of the motor during operation and the effect of reducing noise.

[0031] The above are only embodiments of the present utility model, and thus do not limit the patent scope of the present utility model. Any equivalent structure or equivalent process transformation made by using the content of the specification and drawings of the present utility model, or directly or indirectly applied in other related technical fields, shall be similarly included within the patent protection scope of the present utility model.

Claims

1. A stator assembly of a brushless motor, comprising a motor housing (100) and a plurality of stator cores (200) that are circularly held and pressed inside the motor housing (100), characterized in that: An insulating frame (300) is sleeved on the outer wall of the stator core (200), and a coil (400) is wrapped and arranged at the middle position of the outer wall of the insulating frame (300); Among them, coil slots (201) are symmetrically opened at the middle position of the side wall of the stator core (200), an adjustment slot (202) is opened at the center of the top of the stator core (200), inclined surfaces are symmetrically arranged near the side wall at the top of the stator core (200), and side slots (203) are symmetrically opened at the position near the top of the side wall of the stator core (200), and the two side slots (203) are arc-shaped; 2. The stator assembly of a brushless motor according to claim 1, wherein: The tops of multiple stator cores (200) are inclined and abut against the inner wall of the motor housing (100), the bottoms of the stator cores (200) are arc-shaped and are embedded in the positioning slots (301) opened at the bottom of the insulating frame (300); 3. The stator assembly of a brushless motor according to claim 1, characterized in that: The insulating frame (300) is made of a high temperature resistant material of PA6-GF30; 4. The stator assembly of a brushless motor according to claim 1, characterized in that: The insulating frame (300) is integrally injection-molded on the outer wall of the stator core (200) or is relatively snap-fitted and sleeved on the outer wall of the stator core (200); 5. The stator assembly of a brushless motor according to claim 1, characterized in that: A convex block (302) is fixedly connected to the position near the top of the side wall of the insulating frame (300), an extension block (303) is fixedly connected to the top position of the side wall of the insulating frame (300) far from the convex block (302), and a positioning column (304) is fixedly connected to the position of the side wall of the insulating frame (300) near the corner of the extension block (303); 6. The stator assembly of a brushless motor according to claim 5, characterized in that: The top of the insulating frame (300) on one side of the convex block (302) is flat, and the top of the insulating frame (300) on one side of the extension block (303) is arc-shaped; 7. The stator assembly of a brushless motor according to claim 1, characterized in that: The coil (400) is arranged in two inner and outer layers, the outer layer of the coil (400) is wrapped on the outer wall of the inner layer of the coil (400), and the inner layer of the coil (400) is wrapped on the outer wall of the insulating frame (300);

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