BLDC high-voltage motor stator structure and BLDC motor

Abstract

The utility model discloses a BLDC high-voltage motor stator structure and a BLDC motor, a bar-shaped stator is rolled into a ring, the bar-shaped stator comprises a bar-shaped stator iron core, a three-phase coil winding and an end insulation, 12 stator iron core units are provided, each phase winding continuously winds two adjacent stator iron core units and crosses four stator iron core units, and the three-phase coil winding is wound around the bar-shaped stator iron core. A first wire inlet contact pin, a second wire inlet contact pin and a third wire inlet contact pin are inserted into the upper end portions of the fifth tooth, the third tooth and the first tooth in an insulated mode respectively, and a three-phase power supply lead is wired from the top face of the head lug plate fixing support and electrically connected with the first wire inlet contact pin, the second wire inlet contact pin and the third wire inlet contact pin respectively. The wire ends A, B and C of the U-phase winding, the V-phase winding and the W-phase winding are electrically connected with the first wire inlet pin, the second wire inlet pin and the third wire inlet pin respectively. The problem of mutual intersection between the U-phase winding and the V-phase winding is avoided, the requirements of high-voltage resistance test and working in a high-voltage environment of the high-voltage motor are met, and the product reliability is improved.

Description

Technical Field

[0001] This utility model relates to a stator structure for a BLDC high-voltage motor and a BLDC motor. Background Technology

[0002] Currently, brushless DC motors (BLDC motors) are widely used in various environments, including outdoor and indoor units used in conventional environments, as well as special motors used in various high-voltage environments. In addition to the high performance requirements of the motor itself, high-voltage environments also place increasingly higher demands on the reliability of the motor stator windings.

[0003] The applicant's existing conventional brushless DC motor stator structure consists of a strip stator wound into a ring. The strip stator includes a strip stator core, three-phase coil windings, and end insulation. The strip stator core comprises 12 stator core units. Each stator core unit includes a yoke and a tooth protruding from the inside of the yoke. A slot is formed between adjacent teeth. Adjacent stator core units are connected by a connecting part. The end insulation includes upper end insulation and lower end insulation. After the upper and lower end insulation are respectively installed at the upper and lower ends of the strip stator core, the three-phase coil windings are wound around it. The windings include U-phase windings, V-phase windings, and W-phase windings; the bar stator core is numbered from right to left, with each stator core unit being tooth 1#, tooth 2#, tooth 3#, tooth 4#, tooth 5#, tooth 6#, tooth 7#, tooth 8#, tooth 9#, tooth 10#, tooth 11#, and tooth 12#; the winding method of the U-phase windings, V-phase windings, and W-phase windings is as follows: each phase winding continuously winds around two adjacent stator core units, then crosses four stator core units and winds around two more adjacent stator core units, and finally exits; when each phase winding continuously winds around two adjacent stator core units, the winding direction is opposite.

[0004] The above-described stator structure of a brushless DC motor can be quickly wound with enameled wire onto the strip stator core assembly after a specific program is set using a dedicated BLDC winding device. In conventional winding designs, due to limitations in manufacturing processes, the three-phase windings may cross each other during the winding process. While this type of winding can meet the requirements of various BLDC motors under normal operating conditions, it cannot meet the high-voltage withstand voltage test (PDIV test) when applied to motors operating in high-voltage environments. The finished motor faces a significant risk of failure if it operates under high-voltage conditions for a long time, and cannot meet the special requirements of some customers for high-voltage motors. Summary of the Invention

[0005] This utility model provides a stator structure for a BLDC high-voltage motor and a BLDC motor, which solves the technical problem that in the existing BLDC high-voltage motor stator structure, the three-phase windings are intersected. This intersecting winding cannot meet the high-voltage withstand voltage test (PDIV test) when applied to various high-voltage working environments, and the finished motor has a great risk of failure when working in a high-voltage environment for a long time.

[0006] The technical solution of this utility model is implemented as follows:

[0007] A BLDC high-voltage motor stator structure is provided, comprising a strip stator wound into a ring. The strip stator includes a strip stator core, three-phase coil windings, and end insulation. The strip stator core consists of 12 stator core units. Each stator core unit includes a yoke and a tooth protruding from the inside of the yoke. A winding groove is formed between two adjacent teeth. Two adjacent stator core units are connected by a connecting part. The end insulation includes upper end insulation and lower end insulation. After the upper and lower ends of the strip stator core are respectively installed with upper end insulation and lower end insulation, the three-phase coil windings are wound. The three-phase coil windings include U-phase windings, V-phase windings, and W-phase windings. Each stator core unit (11) of the strip stator core is numbered from right to left as tooth 1#, tooth 2#, tooth 3#, tooth 4#, tooth 5#, tooth 6#, tooth 7#, tooth 8#, tooth 9#, tooth 10#, tooth 11#, and tooth 12#.

[0008] The winding method of the U-phase winding, V-phase winding and W-phase winding is as follows: each phase winding continuously winds two adjacent stator core units, then crosses four stator core units and winds two more adjacent stator core units, and finally exits the winding; when each phase winding continuously winds two adjacent stator core units, the winding direction is opposite.

[0009] The feature is that: a first wire inlet pin, a second wire inlet pin, and a third wire inlet pin are respectively inserted into the upper end insulation of teeth #5, #3, and #1; the tops of the first wire inlet pin, the second wire inlet pin, and the third wire inlet pin pass through the head connector fixing bracket; the bottom of the head connector fixing bracket is inserted into the upper end insulation; the three-phase power supply leads run from the top surface of the head connector fixing bracket and are electrically connected to the first wire inlet pin, the second wire inlet pin, and the third wire inlet pin respectively; and the wire ends A, B, and C of the U-phase winding, the V-phase winding, and the W-phase winding are electrically connected to the first wire inlet pin, the second wire inlet pin, and the third wire inlet pin respectively.

[0010] Preferably, the top surface of the head connector fixing bracket has several spaced wire clamps, through which the three-phase power leads are routed.

[0011] Preferably, a plurality of first sockets are provided at the bottom of the head connector fixing bracket, and the first sockets are nested and installed with the first protruding post protruding from the top of the upper end insulation.

[0012] Preferably, a first connecting piece, a second connecting piece, and a third connecting piece are respectively inserted into the upper end insulation 31 of teeth #8, #10, and #12. The tails X, Y, and Z of the U-phase winding, V-phase winding, and W-phase winding are electrically connected to the third connecting piece, the second connecting piece, and the first connecting piece, respectively. The tops of the first connecting piece, the second connecting piece, and the third connecting piece pass through the support frame and the conductive piece. The support frame is supported and installed on the upper end insulation. A groove is provided on the top of the support frame, and the conductive piece is embedded in the groove. The conductive piece is electrically connected to the third connecting piece, the second connecting piece, and the first connecting piece.

[0013] Preferably, a number of second sockets are provided at the bottom of the support frame, and the second sockets are nested and installed with the second protruding post at the top of the upper end that is insulated.

[0014] Preferably, the support frame and the head connector fixing bracket are both made of plastic.

[0015] Preferably, the support frame and the head connector fixing bracket are manufactured as a single unit.

[0016] Preferably, the conductive piece is a copper sheet.

[0017] A BLDC motor includes a stator assembly and a rotor assembly, characterized in that: the stator assembly adopts the BLDC high-voltage motor stator structure described above.

[0018] Compared with the prior art, this utility model has the following advantages:

[0019] 1. This utility model involves inserting a first, second, and third wire-inlet pin into the upper end insulation of teeth #1, #3, and #5, respectively. The tops of the first, second, and third wire-inlet pins pass through the head connector fixing bracket, and the bottom of the head connector fixing bracket is inserted into the upper end insulation. The three-phase power leads run from the top surface of the head connector fixing bracket and are electrically connected to the first, second, and third wire-inlet pins, respectively. The wire ends A, B, and C of the U-phase winding, V-phase winding, and W-phase winding are electrically connected to the first, second, and third wire-inlet pins, respectively. By utilizing the head connector fixing bracket and optimizing the wire-inlet positions of the U-phase winding, V-phase winding, and W-phase winding, the problem of mutual crossing between the U-phase winding and V-phase winding can be avoided, meeting the high-voltage motor's high-voltage resistance test and working requirements in high-voltage environments, thus improving product reliability.

[0020] 2. In this invention, a first, second, and third connecting piece are respectively inserted into the upper end insulation 31 of teeth #8, #10, and #12. The X, Y, and Z ends of the U-phase, V-phase, and W-phase windings are electrically connected to the third, second, and first connecting pieces, respectively. The tops of the first, second, and third connecting pieces pass through a support frame and a conductive piece. The support frame is mounted on the upper end insulation, and a groove is provided on the top of the support frame. The conductive piece is embedded in the groove and electrically connected to the third, second, and first connecting pieces. By designing the common end winding conductive piece + support frame + separate common end connecting piece into three independent connecting pieces, and by fixing the three-phase winding common end connecting piece, the problem of mutual crossing between the three-phase windings at the common end can be effectively improved. This meets the requirements of high-voltage motor withstand voltage testing and operation in high-voltage environments, and improves product reliability.

[0021] 3. Other advantages of this utility model are described in detail in the embodiments section. Attached Figure Description

[0022] Figure 1 This is a front view of the strip stator according to Embodiment 1 of this utility model;

[0023] Figure 2 This is a top view of the strip stator according to Embodiment 1 of this utility model;

[0024] Figure 3 This is a schematic diagram of the winding of the strip stator according to Embodiment 1 of this utility model;

[0025] Figure 4 This is a perspective view of the strip stator core according to Embodiment 1 of this utility model;

[0026] Figure 5 This is a top view of the strip stator after it has been rolled into a circle according to Embodiment 1 of this utility model;

[0027] Figure 6 This is a schematic diagram of the winding wiring in Embodiment 1 of this utility model;

[0028] Figure 7 This is a perspective view of the BLDC high-voltage motor stator structure according to Embodiment 1 of this utility model;

[0029] Figure 8 This is an exploded view of the stator structure of the BLDC high-voltage motor according to Embodiment 1 of this utility model;

[0030] Figure 9 This is another exploded view of the BLDC high-voltage motor stator structure according to Embodiment 1 of this utility model. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0032] like Figures 1 to 9 As shown, this embodiment provides a BLDC high-voltage motor stator structure, which consists of a strip stator wound into a ring. The strip stator includes a strip stator core 1, three-phase coil windings 2, and end insulation 3. The strip stator core 1 is composed of 12 stator core units 11. Each stator core unit 11 includes a yoke 12 and a tooth 13 protruding from the inside of the yoke 12. A winding groove 14 is formed between two adjacent teeth 13. Two adjacent stator core units 11 are connected by a connecting part. The end insulation... The 3 includes an upper end insulation 31 and a lower end insulation 32. After the upper end insulation 31 and the lower end insulation 32 are installed at the upper and lower ends of the bar stator core 1, a three-phase coil winding 2 is wound. The three-phase coil winding 2 includes a U-phase winding, a V-phase winding, and a W-phase winding. Each stator core unit 11 of the bar stator core 1 is numbered from right to left as tooth 1#, tooth 2#, tooth 3#, tooth 4#, tooth 5#, tooth 6#, tooth 7#, tooth 8#, tooth 9#, tooth 10#, tooth 11#, and tooth 12#.

[0033] The winding method of the U-phase winding, V-phase winding and W-phase winding is as follows: each phase winding continuously winds two adjacent stator core units 11, then crosses four stator core units 11 and winds two more adjacent stator core units 11, and finally exits the winding; when each phase winding continuously winds two adjacent stator core units 11, the winding direction is opposite.

[0034] The invention is characterized in that: a first wire inlet pin 41, a second wire inlet pin 42, and a third wire inlet pin 43 are respectively inserted into the upper end insulation 31 of teeth #5, #3, and #1; the tops of the first wire inlet pin 41, the second wire inlet pin 42, and the third wire inlet pin 43 pass through the head connector fixing bracket 7; the bottom of the head connector fixing bracket 7 is inserted into the upper end insulation 31; the three-phase power supply lead 8 runs from the top surface of the head connector fixing bracket 7 and is electrically connected to the first wire inlet pin 41, the second wire inlet pin 42, and the third wire inlet pin 43 respectively; and the wire ends A, B, and C of the U-phase winding, the V-phase winding, and the W-phase winding are electrically connected to the first wire inlet pin 41, the second wire inlet pin 42, and the third wire inlet pin 43 respectively. By using the head connector to fix the bracket and optimizing the incoming positions of the U-phase winding, V-phase winding and W-phase winding, the problem of mutual crossing between the U-phase winding and V-phase winding can be avoided, which meets the requirements of high voltage motor withstand test and operation in high voltage environment, and improves product reliability.

[0035] Preferably, the top surface of the head connector fixing bracket 7 has several spaced wire clamps 72 protruding from it. The three-phase power supply leads 8 pass through the wire clamps 72 for routing, resulting in a neat wiring arrangement and convenient installation.

[0036] Preferably, the bottom of the head connector fixing bracket 7 is provided with several first sockets 71, and the first sockets 71 are nested with the first protrusion 311 protruding from the top of the upper end insulation 31, making the installation simple and convenient.

[0037] Preferably, a first connecting piece 51, a second connecting piece 52, and a third connecting piece 53 are respectively inserted into the upper end insulation 31 of teeth #8, #10, and #12. The wire tails X, Y, and Z of the U-phase winding, V-phase winding, and W-phase winding are electrically connected to the third connecting piece 53, the second connecting piece 52, and the first connecting piece 51, respectively. The tops of the first connecting piece 51, the second connecting piece 52, and the third connecting piece 53 pass through the support frame 6 and the conductive piece 62. The support frame 6 is supported and installed on the upper end insulation 31. A groove 61 is provided on the top of the support frame 6, and the conductive piece 62 is embedded in the groove 61. The conductive piece 62 is electrically connected to the third connecting piece 53, the second connecting piece 52, and the first connecting piece 51. By redesigning the common-terminal winding conductor piece, support frame, and three independent common-terminal connector pieces, along with the fixing method for the three-phase winding common-terminal connector pieces, the problem of crossover between the three-phase windings at the common terminal can be effectively improved. This meets the requirements of high-voltage motor withstand voltage testing and operation in high-voltage environments, thereby improving product reliability.

[0038] Preferably, the support frame 6 is provided with a number of second sockets 63 at the bottom. The second sockets 63 are nested with the second protruding post 312 protruding from the top of the upper end insulation 31, which makes the installation simple and convenient.

[0039] Preferably, the support frame 6 and the head connector fixing bracket 7 are both made of plastic.

[0040] Preferably, the support frame 6 and the head connector fixing bracket 7 are manufactured as one piece to simplify the structure.

[0041] Preferably, the conductive piece 62 is a copper sheet.

[0042] Example 2:

[0043] A BLDC motor includes a stator assembly and a rotor assembly, characterized in that: the stator assembly adopts the BLDC high-voltage motor stator structure described in Embodiment 1. This meets the requirements of high-voltage motor withstand voltage testing and operation in high-voltage environments, improving product reliability.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A BLDC high-voltage motor stator structure, comprising a strip stator wound into a ring, the strip stator including a strip stator core (1), three-phase coil windings (2), and end insulation (3), wherein the strip stator core (1) is composed of 12 stator core units (11), each stator core unit (11) including a yoke (12) and a tooth (13) protruding from the inside of the yoke (12), a winding groove (14) is formed between two adjacent teeth (13), and two adjacent stator core units (11) are connected by a connecting part, wherein the end insulation (3) The bar stator core (1) includes upper end insulation (31) and lower end insulation (32). After the upper and lower ends of the bar stator core (1) are respectively installed with upper end insulation (31) and lower end insulation (32), a three-phase coil winding (2) is wound. The three-phase coil winding (2) includes a U-phase winding, a V-phase winding and a W-phase winding. The bar stator core (1) numbers each stator core unit (11) from right to left as 1# tooth, 2# tooth, 3# tooth, 4# tooth, 5# tooth, 6# tooth, 7# tooth, 8# tooth, 9# tooth, 10# tooth, 11# tooth and 12# tooth. The winding method of the U-phase winding, V-phase winding and W-phase winding is as follows: each phase winding continuously winds two adjacent stator core units (11), then crosses four stator core units (11) and winds two more adjacent stator core units (11), and finally exits the winding; when each phase winding continuously winds two adjacent stator core units (11), the winding direction is opposite. characterized in that The first input pin (41), the second input pin (42), and the third input pin (43) are respectively inserted into the upper end insulation (31) of the 5#, 3#, and 1# teeth. The tops of the first input pin (41), the second input pin (42), and the third input pin (43) pass through the head connector fixing bracket (7). The bottom of the head connector fixing bracket (7) is inserted into the upper end insulation (31). The three-phase power supply lead (8) runs from the top surface of the head connector fixing bracket (7) and is electrically connected to the first input pin (41), the second input pin (42), and the third input pin (43) respectively. The wire ends A, B, and C of the U-phase winding, the V-phase winding, and the W-phase winding are electrically connected to the first input pin (41), the second input pin (42), and the third input pin (43) respectively.

2. A BLDC high voltage motor stator structure as claimed in claim 1, wherein: The top surface of the head connector fixing bracket (7) has several spaced wire clamps (72), through which the three-phase power supply leads (8) pass for routing.

3. A BLDC high voltage motor stator structure as claimed in claim 2, wherein: The bottom of the head connector fixing bracket (7) is provided with several first sockets (71), and the first sockets (71) are nested and installed with the first protruding post (311) protruding from the top of the upper end insulation (31).

4. A BLDC high voltage motor stator structure as claimed in claim 1 or 2 or 3, wherein: The first connecting piece (51), the second connecting piece (52), and the third connecting piece (53) are respectively inserted into the upper end insulation (31) of teeth #8, #10, and #12. The tails X, Y, and Z of the U-phase winding, V-phase winding, and W-phase winding are electrically connected to the third connecting piece (53), the second connecting piece (52), and the first connecting piece (51), respectively. The tops of the first connecting piece (51), the second connecting piece (52), and the third connecting piece (53) pass through the support frame (6) and the conductive piece (62). The support frame (6) is supported and installed on the upper end insulation (31). The top of the support frame (6) is provided with a groove (61). The conductive piece (62) is embedded in the groove (61). The conductive piece (62) is electrically connected to the third connecting piece (53), the second connecting piece (52), and the first connecting piece (51).

5. A BLDC high voltage motor stator structure as claimed in claim 4, wherein: The support frame (6) is provided with several second sockets (63) at the bottom. The second sockets (63) are nested and installed with the second protruding post (312) protruding from the top of the upper end insulation (31).

6. A BLDC high voltage motor stator structure as claimed in claim 5, wherein: The support frame (6) and the head connector fixing bracket (7) are both made of plastic.

7. A BLDC high voltage motor stator structure as claimed in claim 5, wherein: The support frame (6) and the head connector fixing bracket (7) are manufactured as one piece.

8. A BLDC high voltage motor stator structure as claimed in claim 5, wherein: The conductive piece (62) is a copper sheet.

9. A BLDC motor comprising a stator assembly and a rotor assembly, characterized by: The stator assembly adopts the BLDC high-voltage motor stator structure as described in any one of claims 1 to 8.

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