High-protection coil assembly structure suitable for automatic production and motor fan adopting high-protection coil assembly structure

Abstract

The utility model relates to the technical field of fans, in particular to a coil assembly, and particularly relates to a high-protection coil assembly structure suitable for automatic production and a motor fan adopting the high-protection coil assembly structure. A high-protection coil assembly structure suitable for automatic production comprises a stator coil assembly, the stator coil assembly is provided with a coil framework for winding a coil, the coil framework is provided with an iron core insertion hole penetrating through the two ends of the coil framework, an insertion piece installation part of an insertion piece is formed on the edge of one side of the coil framework, and the insertion piece is electrically connected with the coil. An insertion sheet protecting cover is sleeved on the insertion sheet; an insulating shell wrapping the coil part and the inserting piece installation part is arranged outside the coil framework in a plastic package mode, the two end faces with the iron core inserting holes are partially or completely exposed out of the insulating shell, and the outermost end face C of the inserting piece protection cover protrudes by the length L relative to the outermost end face D, on the inserting piece installation part, of the insulating shell. According to the coil assembly structure, high protection performance is achieved, low noise is guaranteed, efficient automatic production is achieved, and cost is optimized.

Description

Technical Field

[0001] This utility model relates to the field of fan technology, specifically to a coil assembly, and more particularly to a high-protection coil assembly structure suitable for automated production and a motor fan using the same. Background Technology

[0002] The stator coil of the fan motor in a wall-hung boiler is traditionally wound with enameled wire. During use, factors such as condensation, high humidity, and dust around the coil can damage it. Specifically: During fan operation, temperature differences can cause condensation. If water seeps into the coil, it can lead to short circuits or corrosion. High humidity reduces the insulation performance of the coil, increasing the risk of short circuits, especially in humid areas or poorly ventilated conditions. Dust accumulation hinders heat dissipation, causing the coil to overheat, and conductive particles in the dust can trigger short circuits. When this motor is used in wall-hung boilers and other equipment with fan components, the ambient temperature can reach around 80°C. After the machine stops working, condensation drips onto the coil and gradually seeps into the enameled wire, causing short circuits between turns and ultimately burning out the coil. In harsh environments, excessive dust around the machine can also affect the product's lifespan. For example, patent CN203892213U discloses a gas-fired fireplace fan with enameled wire windings directly wound on the frame, which is highly susceptible to these problems.

[0003] The traditional structure of the coil frame and iron core is prone to electromagnetic vibration due to tolerance accumulation or loose fixing, which in turn generates high-frequency noise; a large gap between the iron core and the coil frame will lead to increased hysteresis loss and cause magnetostrictive noise.

[0004] Using a plastic encapsulation shell to cover the coil and connector joints can achieve high protection and solve some noise problems. However, there is a risk that the encapsulating material may overflow into the connector or core insertion hole during operation. Overflow onto the connector requires manual removal, otherwise it will increase contact resistance; overflow into the core insertion hole will cause noise and jamming, thus hindering efficient automated production, easily leading to quality problems, and increasing costs. In addition, the core is prone to misalignment when inserted into the coil frame, scratching the frame, and is also prone to jamming or misalignment, affecting the yield rate of automated production. Utility Model Content

[0005] The technical problem to be solved by this utility model is: in order to solve the problems in the above-mentioned background technology that traditional enameled wire is easily corroded by condensation, high humidity and dust, resulting in short circuits or burnout; large tolerance between the frame and the iron core causes electromagnetic noise and hysteresis loss; the molding process is prone to overflow, affecting conductivity and assembly efficiency; easy to misalign and scratch the frame; low yield and high cost in automated production, a high protection coil assembly structure suitable for automated production is provided.

[0006] The technical solution adopted by this utility model to solve its technical problem is: a high-protection coil assembly structure suitable for automated production, including a stator coil assembly, wherein the stator coil assembly has a coil frame for winding the coil, and the coil frame has iron core insertion holes penetrating both ends thereof.

[0007] The coil frame has a insert mounting part formed on one side edge, the insert is electrically connected to the coil, and the insert is fitted with an insert cover;

[0008] The coil frame is encased in an insulating shell that covers the coil part and the insert mounting part. The two end faces with iron core insertion holes are partially or completely exposed outside the insulating shell. The outermost end face C of the insert cover protrudes by a length L relative to the outermost end face D of the insulating shell at the insert mounting part. Preferably, the length L is 0.5 to 10 mm.

[0009] The plastic-encapsulated insulating shell includes the coil section and the insert mounting section, which is moisture-proof, dust-proof, and avoids condensation corrosion, achieving high protection; the two ends of the coil are partially or completely exposed, which facilitates the insertion of the iron core, reduces the risk of jamming, and also facilitates venting in the plastic encapsulation mold; the insert cover protrudes from the plastic-encapsulated insulating shell to prevent plastic overflow from contaminating the conductive area, and also facilitates automated assembly.

[0010] As one embodiment of this utility model, an automated production clearance part is provided on the end face that partially exposes the insulating shell.

[0011] The automated production clearance section not only ensures the sealing reliability of the molding die to the iron core and prevents the molding material from overflowing into the iron core insertion hole, but also provides space for automated assembly, prevents interference with automated equipment, and ensures high-speed assembly in the future.

[0012] In one embodiment of this utility model, the inner wall E of the core insertion hole near the insert mounting part extends beyond the inner end face F of the insulating shell on that side, and the height H of the extension is 0.5 to 15 mm.

[0013] The inner wall E extends beyond the end face F, which serves two purposes: firstly, to guide the insertion of the iron core and reduce the risk of misalignment; and secondly, to prevent the molding compound from seeping into the iron core insertion hole, thus reducing noise and the probability of jamming.

[0014] In one embodiment of this utility model, the length L1 of the iron core insertion hole is 10-45mm, the width W1 is 10-20mm, and the height H1 is 20-50mm.

[0015] This limitation, with its standardized aperture, reduces the number of specifications and the number of molds required for the frame and core. This not only lowers manufacturing costs but also facilitates efficient core assembly and allows for precise control of core gaps, reducing hysteresis losses and electromagnetic noise.

[0016] As an embodiment of the present utility model, 2 to 4 tension ribs are symmetrically arranged on the inner wall in the width direction of the iron core insertion hole, and the distance d from both ends of each tension rib to the hole opening of the iron core insertion hole is 0.5 mm to H1 / 4.

[0017] The tension ribs make the iron core fit tightly with the hole wall, suppress electromagnetic vibration, and increase the fixation of the iron core to avoid displacement during transportation and operation.

[0018] As an embodiment of the present utility model, the length L2 of the tension rib is H1 / 2 to H1 - 1, the width W2 is 0.5 to 5 mm, and the height H2 is 0.2 to 3 mm.

[0019] The tension ribs with reasonable length ensure the tensioning effect and at the same time avoid excessive resistance during the insertion of the iron core.

[0020] As an embodiment of the present utility model, both ends of the tension rib have inclined guiding parts, and the inclination angle α of the guiding part is 10 to 30°.

[0021] The guiding parts guide the insertion of the iron core, and the inclination angle improves the yield of automatic assembly.

[0022] As an embodiment of the present utility model, an insertion piece slot and a coil end lead-out slot are provided on the insertion piece mounting part, and a slot for the insertion piece to pass through is provided on one end face of the insertion piece cover, and the other end thereof has a notch matching with the insertion piece mounting part.

[0023] The slot and the notch define the position of the insertion piece to avoid reverse installation; the cover and the insertion piece mounting part are tightly fitted to prevent vibration and falling off.

[0024] As an embodiment of the present utility model, the corners of the insulating housing are all provided as arc-shaped.

[0025] The rounded housing reduces air turbulence noise, the arc-shaped corners enhance the strength of the housing to avoid cracking; at the same time, it reduces the wear of the injection mold and is suitable for mass production.

[0026] There is also provided a motor fan using the high-protection coil assembly structure suitable for automatic production described in the above solution, including a volute and a rotor assembly. The rotor assembly is installed on the volute through a connecting member. The rotor assembly includes a rotating shaft and a permanent magnet press-fitted on the rotating shaft. The rotating shaft extends into the volute and is connected to an impeller. A "U"-shaped iron core I is connected to the connecting member. A notch is provided at one end of the iron core I, and an iron core II press-fitted into the iron core insertion hole through interference fit is provided in the notch.

[0027] The iron core I and the iron core II are in interference fit in the notch, reducing the magnetic circuit loss and improving the motor efficiency; the "U"-shaped iron core I optimizes the space layout and adapts to the narrow installation environment of the wall-mounted boiler.

[0028] The beneficial effects of this utility model are:

[0029] (1) High protection: The plastic-sealed outer shell and the insert cover provide double high protection against condensation, dust and high temperature;

[0030] (2) Low noise: The tension ribs and iron core are precisely matched to reduce electromagnetic vibration, and the rounded outer shell reduces air turbulence noise;

[0031] (3) Automated and efficient assembly: protruding insert cover, tension rib guide and automatic machine production clearance part to improve assembly efficiency;

[0032] (4) Cost optimization: Standardized hole positions and anti-overflow structure reduce manual intervention, unified hole diameter reduces the number of specifications, and rounded corners enhance the shell strength and prevent cracking; at the same time, it reduces injection mold wear, resulting in low cost and suitability for large-scale mass production. Attached Figure Description

[0033] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0034] Figure 1 This is a structural schematic diagram of Embodiment 1 of the present invention.

[0035] Figure 2 yes Figure 1 A structural diagram from another perspective.

[0036] Figure 3 yes Figure 2 A structural diagram from another perspective.

[0037] Figure 4 yes Figure 1 Exploded view.

[0038] Figure 5 This is a schematic diagram of the coil frame in Embodiment 1 of this utility model.

[0039] Figure 6 This is a cross-sectional view of Embodiment 1 of this utility model.

[0040] Figure 7 This is a structural schematic diagram of Embodiment 2 of this utility model.

[0041] Figure 8 This is a structural schematic diagram of Embodiment 3 of this utility model.

[0042] In the diagram: 1. Coil frame; 11. Core insertion hole; 12. Laminate mounting part; 121. Laminate slot; 122. Coil end lead-out slot; 13. Tensioning rib; 131. Guide part; 14. Automated production clearance part; 2. Coil; 3. Insulating shell; 4. Laminate; 5. Laminate cover; 51. Slot; 52. Slot opening; 7. Core II; 8. Core I; 9. Rotor assembly; 10. Volute. Detailed Implementation

[0043] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0044] Example 1

[0045] like Figures 1-4 As shown, this high-protection coil assembly structure suitable for automated production includes a stator coil assembly. The stator coil assembly has a coil frame 1 for winding the coil 2. The coil frame 1 is H-shaped, with a crossbeam in the middle for winding the coil 2. The coil frame 1 has iron core insertion holes 11 that pass through both ends. One side edge of the coil frame 1 forms a insert mounting part 12 for insert 4. Due to the insert mounting part 12, the thickness is greatest at this point. After the insert 4 is inserted into the insert mounting part 12, the coil is wound. After winding, the two ends of the coil 2 are welded to the insert 4 to achieve electrical connection. Insert cover 5 is fitted onto the insert 4, forming an insulating shell 3 by plastic sealing. The insulating shell 3 encapsulates the coil 2 and the insert mounting part 12, forming an integrated stator coil assembly. Preferably, the corners of the insulating shell 3 are all rounded. Specifically, this serves several purposes: right-angle corners are prone to stress cracking due to injection molding cooling shrinkage or external impact; the rounded design disperses stress, preventing shell cracking and improving mechanical strength; high-frequency vibrations during motor operation can accumulate fatigue damage at sharp corners; the rounded structure extends the shell's lifespan; rounded corners allow for smoother flow of molding compound within the mold, reducing incomplete filling or porosity defects and improving yield; they prevent stress concentration in the mold caused by right angles, reducing mold wear and making them suitable for mass production; the rounded corners eliminate dead angles, making it difficult for dust or condensate to accumulate, reducing the risk of insulation failure due to dirt buildup; they prevent sharp corners from scratching operators or assembly line equipment, and can also reduce edge radiation of high-frequency electromagnetic fields, reducing interference with surrounding circuits. Simultaneously, the rounded corner shell reduces air turbulence noise.

[0046] like Figure 1 As shown, since the insert mounting part 12 is the thickest part on the coil frame 1, the outer surface A of the insulating shell 3 at this point is higher than the end face B of the coil frame 1. The upper edge of the insulating shell 3 is also higher, which can also provide protection for the coil frame 1.

[0047] like Figure 2 As shown, both ends of the coil frame 1 with the core insertion hole 11 are partially exposed from the insulating shell 3. The outermost end face C of the insert cover 5 protrudes by a length L of 0.5–10 mm relative to the outermost end face D of the insert mounting portion 12 relative to the insulating shell 3. The protrusion length L of the outermost end face C of the insert cover 5 forms a distinct physical feature (as shown in Table 1), facilitating precise gripping and positioning by robotic arms or automated equipment, thus improving assembly efficiency. The insulating shell 3 does not completely cover both ends of the coil frame 1, which is beneficial for sealing the core insertion hole 11 by the molding die and for mold venting, preventing the molding die overflow from obstructing the core insertion, while also providing operating space for automated equipment. The protruding insert cover 5 covers the insert mounting portion 12, preventing the molding die overflow from contaminating the conductive area of ​​the insert and ensuring reliable electrical connection. The partially exposed end face of the core insertion hole 11 is directly exposed, facilitating visual or sensor calibration during core insertion and reducing the risk of misalignment.

[0048] Table 1

[0049]

[0050] like Figure 3 As shown, an automated production clearance section 14 is provided on the end face of the partially exposed insulating shell 3 to prevent the molding compound from interfering with the automated equipment and ensure subsequent high-speed assembly. Specifically, the inner wall E of the core insertion hole 11 near the insert mounting section 12 extends beyond the inner end face F of the insulating shell 3 on that side, with a protrusion height H of 0.5–15 mm. The inner wall E extending beyond the end face F forms a physical guiding structure, providing initial alignment guidance when the core is inserted, avoiding insertion angle deviations caused by the molding compound covering it, and reducing the risk of jamming during automated assembly. The protruding design of the inner wall E ensures that the contact area between the core and the hole wall completely avoids the coverage area of ​​the molding compound, preventing residual injection molding compound from affecting the smoothness of core insertion. The height H is accommodating core dimensional tolerances; even if there are minor machining errors in the core, the protruding inner wall can still ensure effective guidance, improving the production yield.

[0051] like Figure 4 As shown, the length L1 of the iron core insertion hole 11 is 10–45 mm, the width W1 is 10–20 mm, and the height H1 is 20–50 mm. Figure 6As shown, 2 to 4 tension ribs 13 are symmetrically arranged on the inner wall of the core insertion hole 11 in the width direction. The distance d between the two ends of each tension rib 13 and the opening of the core insertion hole 11 is 0.5 mm to H1 / 4. Preferably, the length L2 of the tension rib 13 is H1 / 2 to H1-1, the width W2 is 0.5 to 5 mm, and the height H2 is 0.2 to 3 mm. The two ends of the tension rib 13 have inclined guide portions 131, and the inclination angle α of the guide portions 131 is preferably 10 to 30°. The symmetrically arranged 2 to 4 tension ribs 13 form an interference fit with the core through elastic / partial plastic deformation, eliminating the tolerance gap between the core and the hole wall and avoiding noise caused by electromagnetic vibration. The radial pressure of the tension ribs 13 ensures that the core does not shift under high temperature or vibration conditions, maintaining the stability of the magnetic circuit. The guide portion 131 with an inclination angle α guides the core to be inserted smoothly, reducing the resistance during robot assembly and improving production efficiency. Meanwhile, the 10-30° inclined structure avoids hard contact between the iron core's sharp edges and the tension rib 13, preventing the risk of corrosion caused by wear of the silicon steel sheet coating. The length L1, width W1, and height H1 of the iron core insertion hole 11 match the iron core dimensions to ensure no shaking after insertion, while also allowing for thermal expansion. The distance d between the two ends of the tension rib 13 and the opening of the iron core insertion hole 11 controls the effective range of the tension rib 13, preventing it from being too close to the opening and affecting the initial alignment of the iron core. The length L2 of the tension rib 13 ensures that it covers the effective magnetic circuit area of ​​the iron core, balancing the tightening force and assembly smoothness.

[0052] like Figure 4 and Figure 5 As shown, the insert mounting part 12 has an insert slot 121 and a coil end lead-out slot 122. One end face of the insert cover 5 has a slot 51 for insertion through which the insert passes, and the other end has a slot 52 that mates with the insert mounting part 12. The separate design of the insert slot 121 and the coil end lead-out slot 122 enables precise positioning of the insert 4 and the coil terminal, avoids the copper wire from twisting under force during soldering, and prevents the risk of short circuit caused by solder overflow. The setting of the slot 51 and the slot 52 provides a three-dimensional positioning reference, and the insertion depth of the insert 4 is controllable.

[0053] The high-protection coil assembly structure suitable for automated production in this embodiment, through the systematic coupling design of geometric features: the inner wall E protrudes beyond the end face F, the tension rib 13 and the outermost end face C of the insert cover 5 protrude beyond the outermost end face D of the insert mounting part 12, transforming the compromise solution that originally required sacrificing a certain aspect of performance into an integrated solution that simultaneously achieves high protection, low noise and mass production compatibility.

[0054] Example 2

[0055] like Figure 7As shown, the difference from Embodiment 1 is that: the end face of the coil frame 1 with the iron core insertion hole 11 is exposed to the insulating shell 3, and the other end face of the coil frame 1 with the iron core insertion hole 11 is completely exposed to the insulating shell 3. That is, only one insert mounting part 12 is provided, which reduces one insert mounting part 12 and related protective cover structure, reduces the amount of molding compound, simplifies the mold complexity, and improves the mold life; the single-sided structure shortens the axial dimension, reduces the weight, eliminates the step of selecting the installation direction of the insert 4, and shortens the automation cycle time.

[0056] The insert mounting part 12 in Embodiment 1 has two parts, one above the other, which is highly versatile: it supports bidirectional insert mounting for speed-regulating motors and is compatible with different motor winding directions or different power supply wiring methods; if the insert 4 at one end fails to be installed, it can be quickly switched to the other end to continue assembly, reducing the risk of production interruption and reducing rework caused by incorrect orientation of insert 4 in automated production.

[0057] Example 3

[0058] like Figure 8 As shown, the motor fan with a high-protection coil assembly structure suitable for automated production, as described in Embodiment 1 or Embodiment 2, includes a volute 10 and a rotor assembly 9. The rotor assembly 9 is mounted on the volute 10 via a connector. The rotor assembly 9 includes a shaft and a permanent magnet (not shown) press-fitted onto the shaft. The shaft extends into the volute 10 and connects to an impeller (not shown). A "U"-shaped iron core I8 is connected to the connector. One end of the iron core I8 has a notch, and an iron core II7 is press-fitted into the iron core insertion hole 11 within the notch through an interference fit. Thus, while ensuring motor performance, it perfectly adapts to automated production and significantly reduces the total life cycle cost, making it particularly suitable for demanding applications such as wall-hung boiler fans that require long-term tolerance to high temperatures and humidity.

[0059] 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 high-protection coil assembly structure suitable for automated production, including a stator coil assembly. The stator coil assembly has a coil skeleton (1) around which a coil (2) is wound. The coil skeleton (1) is provided with an iron core insertion hole (11) penetrating through both ends thereof. It is characterized in that: On one side edge of the coil skeleton (1), there is a tab mounting portion (12) for a tab (4). The tab (4) is electrically connected to the coil (2), and a tab cover (5) is sleeved on the tab (4); The coil skeleton (1) is externally encapsulated with an insulating shell (3) that wraps the coil portion and the tab mounting portion (12). Part or all of the two end faces with the iron core insertion hole (ll) are exposed from the insulating shell (3). The outermost end face C of the tab cover (5) protrudes from the outermost end face D of the insulating shell at the tab mounting portion (12) by a length L.

2. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: The length L is 0.5 - 10 mm.

3. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: The end face partially exposed from the insulating shell (3) is provided with an automated production relief portion (14).

4. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: On one inner wall E of the iron core insertion hole (11) close to the tab mounting portion (12), it exceeds the inner end face F of the insulating shell (3) on this side, and the exceeded height H is 0.5 - 15 mm.

5. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: The length L1 of the iron core insertion hole (11) is 10 - 45 mm, the width W1 is 10 - 20 mm, and the height H1 is 20 - 50 mm.

6. The high-protection coil assembly structure suitable for automated production according to claim 5, characterized in that: On the inner walls in the width direction of the iron core insertion hole (11), 2 - 4 tension ribs (13) are symmetrically arranged. The distance d from both ends of each tension rib (13) to the hole opening of the iron core insertion hole (11) is 0.5 mm - H1 / 4.

7. The high-protection coil assembly structure suitable for automated production according to claim 5, characterized in that: The length L2 of the tension rib (13) is H1 / 2 - H1 - 1, the width W2 is 0.5 - 5 mm, and the height H2 is 0.2 - 3 mm.

8. The high-protection coil assembly structure suitable for automated production according to claim 5, characterized in that: Both ends of the tension rib (13) have inclined guiding portions (131), and the inclination angle α of the guiding portion (131) is 10 - 30°.

9. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: The tab mounting portion (12) is provided with a tab slot (121) and a coil end lead-out slot (122). One end face of the tab cover (5) is provided with a slot (51) for the tab (4) to insert and pass through, and the other end thereof has a notch (52) that matches the tab mounting portion (12).

10. The high-protection coil assembly structure suitable for automated production according to claim 1, characterized in that: The corners of the insulating shell (3) are all set to be arc-shaped.

11. A motor fan employing a high-protection coil assembly structure suitable for automated production according to any one of claims 1 to 10, comprising a volute (10) and a rotor assembly (9), characterized in that: The rotor assembly (9) is installed on the volute (10) through a connecting member. The rotor assembly (9) includes a rotating shaft and a permanent magnet press-fitted on the rotating shaft. The rotating shaft extends into the volute (10) and is connected to an impeller. A U-shaped iron core I (8) is connected to the connecting member. One end of the iron core I (8) is provided with a notch, and an iron core II (7) press-fitted into the iron core insertion hole (11) by interference fit is arranged in the notch.

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