Stator assembly and brushless motor comprising same

Abstract

The stator assembly comprises a stator iron core, a coil framework, an enameled wire and a circuit board, the enameled wire is wound on the coil framework, and the circuit board is located at one end of the coil framework. The circuit board is provided with a threading hole for an outgoing line of an enameled wire to penetrate, the outer edge of the circuit board is provided with a guide groove communicated with the threading hole, a bonding pad is arranged around the periphery of the threading hole, and the outgoing line of the enameled wire enters the threading hole, is bent along the surface of the circuit board and then is welded with the bonding pad. According to the utility model, the bonding pads are arranged around the periphery of the threading hole of the circuit board, so that the welding direction is more flexible and can be adjusted according to actual requirements, and the enameled wire is integrally bent and welded on the circuit board, so that the effective welding area is increased, the contact resistance between the enameled wire and the circuit board is reduced, and the stability of a product is improved.

Description

Technical Field

[0001] This utility model relates to the field of sports and health technology, and in particular to a stator assembly and a brushless motor containing the stator assembly, specifically a DC brushless motor for a game console steering wheel. Background Technology

[0002] For low-voltage brushless motors with relatively thick enameled wire (diameter > φ1mm), current methods mostly involve tinning or spot welding to the connecting terminals. This results in small contact areas, high contact resistance, and a tendency for the terminals to overheat. Furthermore, the process is complex and prone to issues like cold solder joints. For example, in the structure disclosed in CN103904831A, the enameled wire is perpendicular to the circuit board end face within the bonding groove and is welded to the outer pads via a single ring of electric solder. Therefore, the welding area between the enameled wire and the pads is small, resulting in high contact resistance and a tendency for localized overheating, which can severely burn out the coil.

[0003] Compared to tinning or spot welding, folding soldering can increase the welding area. However, existing folding soldering structures still have certain problems. For example, in the structure disclosed in CN107040056A, the solder pad is located on one side of the welding through hole and is a certain distance away from the welding through hole. After the enameled wire is pulled into the welding through hole, it is necessary to pull the enameled wire toward the welding position where the solder pad is located. This fixing method is inflexible and inconvenient for production.

[0004] In addition, in the existing technology, the circuit board and the coil frame are fixed by screws or hot melt technology. This method is complicated, has high production cost and is not easy to repair. Utility Model Content

[0005] To address the technical problems in existing technologies where the welding structure between enameled wire and circuit board has a small contact area, easily causing localized overheating or inflexible fixing methods, which are detrimental to production, this utility model provides a stator assembly and a brushless motor containing it to solve the above problems.

[0006] This utility model proposes a stator assembly, including a stator core, a coil frame, enameled wire, and a circuit board, wherein the enameled wire is wound around the coil frame, and the circuit board is located at one end of the coil frame.

[0007] The circuit board is provided with a wire-passing hole for the lead wire of the enameled wire to pass through. The outer edge of the circuit board is provided with a guide groove that communicates with the wire-passing hole. The outer periphery of the wire-passing hole is surrounded by solder pads. After the lead wire of the enameled wire enters the wire-passing hole, it is bent along the surface of the circuit board and then soldered to the solder pads.

[0008] In an optional embodiment of this utility model, the solder pads and the wire holes are arranged eccentrically, and the distance between the center of the solder pads and the center of the stator assembly is less than the distance between the center of the wire holes and the center of the stator assembly.

[0009] In an optional embodiment of this utility model, the diameter of the threading hole is smaller than the outer diameter of the enameled wire.

[0010] In an optional embodiment of this utility model, the difference between the outer diameter of the enameled wire and the diameter of the threading hole is 0.05mm to 0.1mm.

[0011] In an optional embodiment of this utility model, the guide groove includes a guide opening and a wire passage groove connecting the guide opening and the wire hole, wherein the guide opening opens in a V shape toward the outer edge of the circuit board.

[0012] In an optional embodiment of this utility model, the diameter of the threading hole is greater than the width of the thread-passing groove.

[0013] In an optional embodiment of this utility model, the outer edge of the circuit board is provided with several bayonet slots, and one end of the coil frame connected to the circuit board is provided with a buckle that engages with the bayonet slots. The buckle axially limits the circuit board to the end of the coil frame.

[0014] In an optional embodiment of this utility model, the circuit board has a circular ring structure, and the inner circumference of the circuit board is provided with a plurality of positioning grooves, and the coil frame has positioning posts that cooperate with the positioning grooves.

[0015] In an optional embodiment of this utility model, at least one of the bayonet and the positioning groove are staggered in the circumferential direction.

[0016] In an optional embodiment of this utility model, the bayonet and the positioning groove are arranged in an array along the circumferential direction.

[0017] This utility model also proposes a brushless motor, including the stator assembly described above.

[0018] The beneficial effects of this utility model are:

[0019] (1) The present invention has solder pads arranged around the wire holes of the circuit board, which makes the welding direction more flexible and can be adjusted according to actual needs. Furthermore, the enameled wire is bent and welded onto the circuit board as a whole, which increases the effective welding area, reduces the contact resistance between the enameled wire and the circuit board, and improves the stability of the product.

[0020] (2) This utility model increases the contact area between the enameled wire and the solder pad after bending by using an eccentric design of the solder pad and the wire hole, thereby improving the product stability.

[0021] (3) This utility model uses buckles and positioning posts to fix the circuit board axially and radially, making the structure easier to disassemble.

[0022] (4) This utility model achieves the error-proof assembly of the circuit board by staggering the bayonet and positioning groove, thus avoiding the circuit board being installed backwards. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is an exploded view of the stator assembly described in this utility model;

[0025] Figure 2 This is a front view of the circuit board in this utility model;

[0026] Figure 3 yes Figure 2 Enlarged view of point a in the middle;

[0027] Figure 4 This is a schematic diagram of the bending of the lead wire in this utility model;

[0028] Figure 5 This is a perspective view of the upper coil frame in this utility model;

[0029] Figure 6 yes Figure 5 Enlarged view of point b in the middle.

[0030] In the diagram, 1. Stator core, 2. Upper coil frame, 3. Enamelled wire, 301. Lead wire, 4. Circuit board, 5. Lower coil frame, 6. Wire hole, 7. Guide groove, 701. Guide opening, 702. Wire passage groove, 8. Solder pad, 9. First welding position, 10. Second welding position, 11. Third welding position, 12. Bayonet, 13. Buckle, 14. Positioning groove, 15. Positioning post. Detailed Implementation

[0031] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0032] Example 1: A stator assembly includes a stator core 1, a coil frame, an enameled wire 3, and a circuit board 4. The enameled wire 3 is wound around the coil frame, and the circuit board 4 is located at one end of the coil frame.

[0033] like Figure 1As shown, in this embodiment, the coil frame is a two-part frame structure, namely the upper coil frame 2 and the lower coil frame 5. The two coil frames are engaged with the stator core 1 from the upper and lower directions respectively. The enameled wire 3 is wound on the two coil frames together. The lead wire 301 of the enameled wire 3 is led out from the end of the upper coil frame 2. The circuit board 4 is assembled with the upper coil frame 2. The two can be fixed by screws or heat fusion.

[0034] like Figure 2 As shown, the circuit board 4 is provided with a wire hole 6 for the lead wire 301 of the enameled wire 3 to pass through. The outer edge of the circuit board 4 is provided with a guide groove 7 that communicates with the wire hole 6. The outer periphery of the wire hole 6 is surrounded by solder pads 8. After the lead wire 301 of the enameled wire 3 enters the wire hole 6, it is bent along the surface of the circuit board 4 and then soldered to the solder pads 8.

[0035] Compared with the traditional enameled wire 3 welding structure, this utility model adopts a bending welding process. When welding the enameled wire 3 to the pad 8, it is not perpendicular to the end face of the circuit board 4, but is bent along the surface of the circuit board 4 before being welded to the pad 8. Therefore, half of the side of the enameled wire 3 can be used as the welding contact surface. At the same time, since the pad 8 is arranged around the outer periphery of the wire hole 6, the enameled wire 3 can be bent in different angles and directions, and the welding direction has a higher degree of freedom and is more flexible.

[0036] The fixed arrangement of the enameled wire 3 and the circuit board 4 is as follows: the lead wire 301 of the enameled wire 3 is inserted into the wire hole 6 after being inserted through the opening of the guide groove 7. The wire hole 6 initially fixes the enameled wire 3. Then, the lead wire 301 of the enameled wire 3 is bent so that the lead wire 301 is in contact with the surface of the circuit board 4 and is soldered to the pad 8 around the wire hole 6.

[0037] The threading hole 6 is a round hole, and its size is set according to the specifications of the enameled wire 3. Typically, the diameter of the threading hole 6 is smaller than the outer diameter of the enameled wire 3, so that the lead wire 301 automatically stays in a fixed state after being pulled into the threading hole 6. In a preferred embodiment, the difference between the outer diameter of the enameled wire 3 and the diameter of the threading hole 6 is 0.05mm to 0.1mm.

[0038] The guide groove 7 provides guidance for the lead wire 301 of the enameled wire 3 to enter the wire hole 6, such as... Figure 3 As shown, the guide groove 7 in this embodiment includes a guide opening 701 and a wire-passing groove 702 connecting the guide opening 701 and the wire-passing hole 6. The guide opening 701 opens in a V shape towards the outer edge of the circuit board 4. The width of the wire-passing groove 702 remains basically unchanged, and the V-shaped structure of the guide opening 701 facilitates the quick insertion of the lead wire 301.

[0039] To prevent the lead wire 301 from slipping out of the wire hole 6 and into the wire groove 702 after entering the wire hole 6, it is preferable that the diameter of the wire hole 6 is larger than the width of the wire groove 702.

[0040] The solder pads 8 can be irregularly shaped and arranged around the through hole 6, as long as there is sufficient soldering surface. In this embodiment, the solder pads 8 are annular. To increase the soldering contact surface, the solder pads 8 and the through hole 6 are arranged eccentrically, and the distance between the center of the solder pad 8 and the center of the stator assembly is less than the distance between the center of the through hole 6 and the center of the stator assembly. That is, the solder pads 8 and the through hole 6 are not concentric. The solder pads 8 are offset away from the guide groove 7 relative to the through hole 6. This increases the area of ​​the solder pads 8 in the same direction. When the lead wire 301 is bent, the contact surface between the lead wire 301 and the solder pad 8 is larger.

[0041] like Figure 4 As shown, the first welding position 9 is the location where the lead wire 301 bends along the direction parallel to the guide groove 7. On either side of the first welding position 9 are the second welding position 10 and the third welding position 11. Because the wire hole 6 is located within the area of ​​the pad 8, and because the pad 8 is designed as a ring, the enameled wire 3 can be directly bent after being pulled into the wire hole 6. The bending direction and bending area are flexible, and the bending direction can span from the first welding position 9 to the third welding position 11, with an overall span of 120°, maximizing the achievement of… Bending at different angles improves production operability and flexibility. Simultaneously, this bending and welding method significantly increases the contact area between the lead wire 301 and the circuit board 4 compared to conventional welding. In this embodiment, the effective welding area of ​​the enameled wire 3 is approximately equal to the projected length of the enameled wire 3 on the pad 8 multiplied by the diameter d1 of the enameled wire 3. When the lead wire 301 is at the second welding position 10, the projected length of the enameled wire 3 on the pad 8 is at its maximum, which is the center distance d2 between the through hole 6 and the pad 8 plus the radius r of the pad 8. Therefore, the effective welding area is maximized at this position. The eccentric setting of the pad 8 and the through hole 6 is precisely to increase the projected length of the enameled wire 3 on the pad 8.

[0042] Example 2: Based on the above examples, this example improves the fixing method of the circuit board 4 and the upper coil frame 2. This utility model uses a snap-fit ​​method to fix the two together. The specific structure is as follows: Figure 2 and Figure 5 As shown, the outer edge of the circuit board 4 is provided with several bayonet slots 12, and one end of the coil frame connected to the circuit board 4 is provided with a buckle 13 that engages with the bayonet slots 12. The buckle 13 axially limits the circuit board 4 to the end of the coil frame. Figure 5 and Figure 6 As shown, the latch 13 is located on the outer edge of the upper coil frame 2. Below the latch 13 is a support surface for placing the circuit board 4. After the circuit board 4 is inserted into the upper coil frame 2, it is secured between the support surface and the latch 13. Because the latch 12 is recessed radially inward towards the circuit board 4, when multiple latches 12 are provided, the latches 12 can also have a certain radial and circumferential limiting effect. Compared with the traditional fixing method, this fixing method is easier to disassemble and will not cause wear on the surface of the components.

[0043] In a further design, the circuit board 4 has a circular structure, and its inner circumference is provided with several positioning grooves 14. The upper coil bobbin 2 has positioning posts 15 that cooperate with the positioning grooves 14. The cooperation between the positioning grooves 14 and the positioning posts 15 allows for more precise radial positioning.

[0044] Example 3: In Example 2, if the latches 12 and positioning slots 14 are arranged in a one-to-one correspondence along the same radial direction, then when installing the circuit board 4, it can be successfully assembled with the upper coil frame 2 regardless of whether the front or back of the circuit board 4 is facing upwards. However, this may result in reverse installation. Therefore, this example makes the following improvement: at least one of the latches 12 and positioning slots 14 is staggered in the circumferential direction. In this case, if the circuit board 4 is oriented incorrectly, it cannot be paired with each latch 13 and positioning post 15, thus ensuring assemblability and preventing mistake-proofing.

[0045] Both the bayonet 12 and the positioning slot 14 are preferably arranged in an array along the circumferential direction. In this embodiment, there are three bayonet 12s evenly distributed and two positioning slots 14 evenly distributed. The misalignment angle between the bayonet 12 and the positioning slot 14 that is closer to it is approximately 75°.

[0046] Example 4: A brushless motor, including the stator assembly described above.

[0047] In the description of this utility model, it should be understood that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this utility model, unless otherwise stated, "a number" means two or more.

[0048] In this specification, the illustrative expressions of the terms do not necessarily refer to the same embodiments. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments.

[0049] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A stator assembly, characterized in that: It includes a stator core (1), a coil frame, an enameled wire (3) and a circuit board (4), wherein the enameled wire (3) is wound around the coil frame and the circuit board (4) is located at one end of the coil frame; The circuit board (4) is provided with a wire hole (6) for the lead wire (301) of the enameled wire (3) to pass through. The outer edge of the circuit board (4) is provided with a guide groove (7) that communicates with the wire hole (6). The outer periphery of the wire hole (6) is surrounded by a solder pad (8). After the lead wire (301) of the enameled wire (3) enters the wire hole (6), it is bent along the surface of the circuit board (4) and then soldered to the solder pad (8).

2. The stator assembly according to claim 1, characterized in that: The pads (8) and the through holes (6) are arranged eccentrically, and the distance between the center of the pads (8) and the center of the stator assembly is less than the distance between the center of the through holes (6) and the center of the stator assembly.

3. The stator assembly according to claim 1, characterized in that: The diameter of the threading hole (6) is smaller than the outer diameter of the enameled wire (3).

4. The stator assembly according to claim 3, characterized in that: The difference between the outer diameter of the enameled wire (3) and the diameter of the thread hole (6) is 0.05mm~0.1mm.

5. The stator assembly according to claim 1, characterized in that: The guide groove (7) includes a guide opening (701) and a wire passage groove (702) connecting the guide opening (701) and the wire hole (6). The guide opening (701) opens in a V shape towards the outer edge of the circuit board (4).

6. The stator assembly according to claim 5, characterized in that: The diameter of the thread hole (6) is greater than the width of the thread groove (702).

7. The stator assembly according to claim 1, characterized in that: The outer edge of the circuit board (4) is provided with several slots (12), and one end of the coil frame connected to the circuit board (4) is provided with a buckle (13) that engages with the slots (12). The buckle (13) axially limits the circuit board (4) to the end of the coil frame.

8. The stator assembly according to claim 7, characterized in that: The circuit board (4) has a circular ring structure, and the inner circumference of the circuit board (4) is provided with several positioning grooves (14). The coil bobbin has positioning posts (15) that cooperate with the positioning grooves (14).

9. The stator assembly according to claim 8, characterized in that: At least one of the bayonet (12) and the positioning groove (14) are staggered in the circumferential direction.

10. The stator assembly according to claim 8, characterized in that: The bayonet (12) and the positioning groove (14) are arranged in an array along the circumferential direction.

11. A brushless motor, characterized in that: Includes the stator assembly as described in any one of claims 1-10.

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