Brushless DC motor stator

Abstract

The utility model relates to the technical field of motors, in particular to a brushless direct-current motor stator, in particular to a brushless direct-current motor stator suitable for an ultralow-temperature environment, which comprises a casing and an armature arranged in the casing, and the armature comprises an iron core and a winding wound on the iron core. The winding comprises a main winding and a backup winding, and the main winding and the backup winding are respectively embedded in different grooves of the iron core. Due to the fact that the main winding and the backup winding are arranged, the reliability of the stator is improved, even if one winding breaks down, the other winding can still work continuously, and stable operation of the motor in the ultralow-temperature environment is guaranteed.

Description

A brushless DC motor stator Technical Field

[0001] This utility model relates to the field of motor technology, specifically to a brushless DC motor stator, and more particularly to a brushless DC motor stator suitable for ultra-low temperature environments. Background Technology

[0002] A brushless DC motor (BLDC) is a type of DC motor that uses electronic commutation instead of traditional mechanical commutation. Compared to traditional brushed DC motors, it has no brushes and no mechanical commutator, thus offering higher efficiency, longer lifespan, lower maintenance costs, and better reliability. It is widely used in modern industry and aerospace.

[0003] For some motors that are required to be used in special environments such as -183℃ to +127℃, the motors must be able to work reliably and stably in such environments.

[0004] In ultra-low temperature environments, traditional motor stators often experience performance degradation or failure due to changes in material properties, insulation failure, and winding deformation. For example, rubber-based lead-out sheaths are prone to becoming brittle and cracking at low temperatures, windings loosen due to low-temperature shrinkage, and insulation materials degrade. Existing technologies are insufficient to meet the demands of extreme environments such as lunar or deep space exploration.

[0005] In addition, existing patent applications disclose motor stator structures. For example, patent CN207896759U discloses a motor stator for new energy vehicles, including a stator core, end plates, stator coils, an insulating layer, and a thin film layer. The stator core is composed of stator laminations. Another example is patent application CN109245371A, which discloses a high-reliability winding stator core for a switched reluctance motor, comprising a stator core, stator coils, slot wedges, slot insulation, motor leads, polyurethane-imide non-woven glass fiber tape, polyimide film tape, and a temperature sensor.

[0006] The stators in the aforementioned prior art are all designed according to conventional motor stators and are equipped with a set of windings. In ultra-low temperature environments, the windings are prone to failure, resulting in the motor stator being unable to operate stably in ultra-low temperature environments. Summary of the Invention

[0007] The main objective of this invention is to propose a brushless DC motor stator, which aims to solve the aforementioned technical problems.

[0008] To achieve the above objectives, this utility model proposes a brushless DC motor stator, including a housing and an armature disposed within the housing. The armature includes an iron core and windings wound on the iron core. The windings include a main winding and a backup winding, and the main winding and the backup winding are respectively embedded in different slots of the iron core.

[0009] Preferably, the iron core has 12 slots, the main winding is embedded in slots 1 to 6, and the backup winding is embedded in slots 7 to 12; the main winding and the backup winding are physically isolated by a polyimide film.

[0010] Preferably, the iron core is composed of multiple silicon steel laminations stacked together, and insulating end plates are bonded to both ends of the iron core; the outer circumference of the iron core is formed by laser welding multiple silicon steel laminations into a whole.

[0011] Preferably, the armature further includes slot insulation disposed in the groove of the iron core, the slot insulation being made of polyimide film.

[0012] Preferably, the armature further includes a slot wedge disposed at the slot opening of the iron core, the slot wedge being made of polyamine-imide laminated glass cloth.

[0013] Preferably, the armature is entirely coated with polyester-modified silicone insulating varnish.

[0014] Preferably, at least two pins are radially driven into the middle of the area where the housing contacts the iron core.

[0015] Preferably, the winding is made of polyimide enameled round copper wire.

[0016] Preferably, the winding is connected to an installation wire; the installation wire is soldered to the polyimide enameled copper wire of the winding, and a polytetrafluoroethylene tube is sleeved at the solder joint; the installation wire is tied to the end of the winding by aramid fiber wire; the installation wire is a polyimide composite insulated wire.

[0017] Preferably, a cable outlet hole is provided on the housing, and a hollow bolt is provided at the cable outlet hole, with a nut screwed onto the hollow bolt; the hollow bolt is made of polytetrafluoroethylene; the mounting wire is led out from the central hole of the hollow bolt; and silicone rubber is filled between the mounting wire and the hollow bolt.

[0018] Due to the adoption of the above technical solution, the beneficial effects of this utility model are as follows:

[0019] (1) The stator of the brushless DC motor provided by this utility model has improved the reliability of the stator by setting the main winding and the backup winding. Even if one winding fails, the other winding can continue to work, ensuring the stable operation of the motor in the ultra-low temperature environment.

[0020] (2) In this utility model, the selected insulation material system can meet the requirements of ultra-low temperature operation, improve the insulation performance of the stator, prevent insulation failure, and thus extend the service life of the motor in ultra-low temperature environment.

[0021] (3) In this utility model, at least two pins are radially driven in the middle of the contact between the housing and the iron core to prevent the armature from loosening and rotating at low temperature, thereby enhancing the structural stability of the stator and ensuring the reliable operation of the motor in ultra-low temperature environment. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0023] Figure 1 is a schematic diagram of the structure of the brushless DC motor stator provided by this utility model;

[0024] Figure 2 is a schematic diagram of the armature structure in this utility model;

[0025] Figure 3 is a schematic diagram of the iron core structure in this utility model;

[0026] Figure 4 is a plan view of a single silicon steel sheet in this utility model;

[0027] Figure 5 is a winding diagram of this utility model.

[0028] Explanation of the reference numerals: 1. Housing; 2. Armature; 2a. Iron core; 2b. Winding; 3. Silicon steel lamination; 4. Insulating end plate; 5. Slot wedge; 6. Pin; 7. Mounting wire; 8. Hollow bolt; 9. Nut. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0031] Referring to Figures 1 to 4, a brushless DC motor stator includes a housing 1 and an armature 2 disposed within the housing 1. The armature 2 includes an iron core 2a and a winding 2b wound on the iron core 2a. The winding 2b includes a main winding and a backup winding, and the main winding and the backup winding are respectively embedded in different slots of the iron core 2a.

[0032] As shown in Figure 5, the motor adopts an 8-pole, 12-slot configuration. Therefore, the iron core 2a has 12 slots. The main winding is embedded in slots 1 to 6, and the backup winding is embedded in slots 7 to 12. The main winding and backup winding are physically isolated by a polyimide film to avoid the risk of short circuits between the windings, thus improving the reliability of the stator. The dual-winding configuration ensures that the main winding and backup winding are completely independent. In the event of a failure in one winding, the other can continue to operate, providing high redundancy and reliability, and ensuring stable operation of the motor in ultra-low temperature environments.

[0033] In this embodiment, the housing 1 is made of titanium alloy TC4 and has an interference fit with the outer diameter of the armature 2. Titanium alloy TC4 has good low-temperature stability, preventing the housing 1 from deforming at ultra-low temperatures. During assembly, the armature 2 is pressed into the housing 1 using a heat-shrink method, and at least two pins 6 are radially driven into the center of the housing 1 where it contacts the iron core 2a for fastening. The heat-shrink assembly method and the fastening with pins 6 prevent the armature 2 from loosening and rotating at low temperatures, enhancing the structural stability of the stator and ensuring reliable operation of the motor in ultra-low temperature environments.

[0034] As shown in Figures 3 and 4, the iron core 2a is composed of multiple silicon steel laminations 3 stacked together, with insulating end plates 4 bonded to both ends of the iron core 2a. The outer circumference of the iron core 2a is formed by laser welding of the multiple silicon steel laminations 3 into a single unit. The insulating end plates 4 are made of polyurethane-polyimide laminated glass cloth insulation board to improve the insulation level of the iron core 2a end face, enhance the insulation performance of the stator, and prevent insulation failure. Silicon steel has high saturation magnetic induction intensity and small loss variation, making it suitable as the material for the iron core 2a.

[0035] In this embodiment, the armature 2 further includes slot insulation disposed within the groove of the iron core 2a, the slot insulation being made of polyimide film 6050. The armature 2 also includes a slot wedge 5 disposed at the slot opening of the iron core 2a for fixing the conductor within the slot, the slot wedge 5 being made of polyamine-imide laminated glass cloth 3253.

[0036] In this embodiment, the armature 2 is coated with polyester-modified silicone insulating varnish. The armature 2 is coated by vacuum impregnation with polyester-modified silicone insulating varnish, and the number of impregnations is not less than two, so as to improve the overall insulation level, heat resistance and rust prevention of the armature 2.

[0037] In this embodiment, the winding 2b is made of polyimide enameled round copper wire QY-2 / 220, and its heat resistance can reach 220℃.

[0038] Referring to Figures 1 and 2, the winding 2b is connected to an installation wire 7. The installation wire 7 is soldered to the polyimide enameled round copper wire of the winding 2b, and a polytetrafluoroethylene tube is sleeved at the solder joint. The installation wire 7 is bound to the end of the winding 2b by aramid fiber wire. The installation wire 7 is made of polyimide composite insulated wire, which is lightweight, flame-retardant at low temperatures, resistant to chemical corrosion, and has high mechanical strength. The selected installation wire 7 has excellent performance, can adapt to ultra-low temperature environments, improves the reliability and safety of the motor, and ensures stable operation of the motor under extreme conditions.

[0039] A cable outlet hole is provided on the housing 1, and a hollow bolt 8 is provided at the cable outlet hole. A nut 9 is screwed onto the hollow bolt 8. Specifically, the hollow bolt 8 is threaded into the cable outlet hole, and then locked by the nut 9. After the nut 9 is locked, the threads of the hollow bolt 8 are broken by a soldering iron to prevent loosening. The hollow bolt 8 is made of polytetrafluoroethylene (PTFE). The mounting wire 7 is led out from the central hole of the hollow bolt 8 to form a lead wire. Silicone rubber is filled between the mounting wire 7 and the hollow bolt 8. The silicone rubber serves both as a seal and as a good protector for the root of the lead wire. This structure solves the problem of rubber cable outlet sheaths becoming brittle and cracking at extremely low temperatures, effectively protecting the lead wire, preventing scratches and damage to the lead wire, and improving the insulation and reliability of the motor in ultra-low temperature environments.

[0040] In this embodiment, the mounting wires of the main winding and the backup winding are both led out from the same slot and cannot contact the inner wall of the housing 1. The binding part of the mounting wire 7 must also be protected with polytetrafluoroethylene tubing.

[0041] The brushless DC motor stator provided in this embodiment improves structural reliability, enhances the insulation system, strengthens motor reliability, and extends the motor's service life in ultra-low temperature environments compared to existing technologies.

[0042] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the concept of the present utility model and using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included in the patent protection scope of the present utility model.

Claims

1. A brushless DC motor stator, comprising a housing (1) and an armature (2) disposed within the housing (1), the armature (2) comprising an iron core (2a) and a winding (2b) wound on the iron core (2a); characterized in that, The winding (2b) includes a main winding and a backup winding, and the main winding and the backup winding are respectively embedded in different slots of the iron core (2a).

2. The brushless DC motor stator as described in claim 1, characterized in that, The iron core (2a) has 12 slots, the main winding is embedded in slots 1 to 6, and the backup winding is embedded in slots 7 to 12; the main winding and the backup winding are physically isolated by a polyimide film.

3. A brushless DC motor stator as claimed in claim 1, wherein, The iron core (2a) is made of multiple silicon steel laminations (3) stacked together, and insulating end plates (4) are bonded to both ends of the iron core (2a); the outer circle of the iron core (2a) is welded together by laser welding multiple silicon steel laminations (3) into a whole.

4. A brushless DC motor stator as claimed in claim 1, wherein, The armature (2) also includes slot insulation disposed in the groove of the iron core (2a), the slot insulation being made of polyimide film.

5. The brushless DC motor stator as described in claim 1, characterized in that, The armature (2) also includes a slot wedge (5) disposed at the slot opening of the iron core (2a), the slot wedge (5) being made of polyamine-imide laminated glass cloth.

6. The brushless DC motor stator as described in claim 1, characterized in that, The armature (2) is coated with polyester-modified silicone insulating varnish.

7. A brushless DC motor stator as claimed in claim 1, wherein, At least two pins (6) are radially driven into the middle of the housing (1) where it contacts the iron core (2a).

8. The brushless DC motor stator as described in claim 1, characterized in that, The winding (2b) is made of polyimide enameled round copper wire.

9. A brushless DC motor stator as described in claim 8, characterized in that, The winding (2b) is connected to an installation wire (7); the installation wire (7) is soldered to the polyimide enameled round copper wire of the winding (2b), and a polytetrafluoroethylene tube is sleeved at the solder joint; the installation wire (7) is tied to the end of the winding (2b) by aramid fiber wire; the installation wire (7) is a polyimide composite insulated wire.

10. A brushless DC motor stator as described in claim 9, characterized in that, A cable outlet hole is provided on the housing (1), and a hollow bolt (8) is provided at the cable outlet hole. A nut (9) is screwed onto the hollow bolt (8). The hollow bolt (8) is made of polytetrafluoroethylene. The mounting wire (7) is led out from the center hole of the hollow bolt (8). Silicone rubber is filled between the mounting wire (7) and the hollow bolt (8).

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