Stator assembly structure of integrated integral injection molding

Abstract

The utility model belongs to a motor in the machinery manufacturing industry, and particularly relates to an integrated stator assembly structure formed by integral injection molding. A stator assembly upper annular seam allowance is arranged above the stator assembly shell, and the bottom of the stator assembly upper annular seam allowance is provided with an upper sealing layer, a connector signal pin and a UVW three-phase connector which are integrated with the stator assembly shell. A controller is installed on an upper sealing layer in an upper annular spigot of the stator assembly through a connector power source pin, a connector signal pin and a UVW three-phase connector, the interior of a lower annular spigot of the stator assembly is connected with a boss on the upper portion of the pump body in a sealed mode through a second O-shaped sealing ring, and a self-tapping screw hole is formed in the bottom of a shell of the stator assembly. And the pump cover, the pump body and the stator assembly shell are fastened together by self-tapping screws II through the self-tapping screw holes. The beneficial effects of the utility model are that the stator assembly structure integrated by integral injection molding is highly integrated, the number of parts is reduced by the integral injection molding process, the processing and assembling cost of split components is reduced, and the comprehensive cost is reduced.

Description

Technical Field

[0001] This utility model pertains to motors in the machinery manufacturing industry, and specifically relates to an integrated, injection-molded stator assembly structure. Background Technology

[0002] The existing motor stator assembly structure has the following technical disadvantages:

[0003] Low assembly efficiency: The split design requires separate installation of the stator core assembly and connectors, resulting in cumbersome processes and long cycle times; Insufficient electromagnetic compatibility performance: Traditional stator assembly injection molding structure lacks an integrated grounding circuit, integrating the common-mode inductor on the controller, with the grounding pin only contacting the stator core and not connected to ground. Traditional structures are expensive and have weak electromagnetic interference suppression capabilities; Limited heat dissipation capacity: In the traditional stator assembly injection molding structure, the oil does not contact the stator core and relies on air for heat dissipation, which cannot meet the temperature control requirements of high power density motors; Poor sealing reliability: Split connectors and interfaces are prone to oil leakage, affecting long-term stability. Summary of the Invention

[0004] The purpose of this utility model is to overcome the above-mentioned technical deficiencies and provide a highly integrated, heat dissipation, anti-interference performance, and cost-saving integrated injection-molded stator assembly structure.

[0005] The technical solution adopted by this utility model to solve the technical problem is an integrated injection-molded stator assembly structure, including a stator assembly housing, a stator core, power connector pins, side-out connectors, signal connector pins, bolt bushings, and a grounding pin. The stator core assembly, including the stator core, insulating terminal one, insulating terminal two, windings, power connector pins, signal connector pins, bolt bushings, and grounding pin, is integrally injection-molded from polyphenylene sulfide-based composite material. An annular stop is provided above the stator assembly housing. At the bottom of the annular stop, an upper sealing layer integral with the stator assembly housing is provided. The upper sealing layer has power connector pins, signal connector pins, and a UVW three-phase connector for connection to the side-out connectors. The power connector pins, signal connector pins, and UVW connectors are connected to the upper sealing layer within the annular stop of the stator assembly. The three-phase connector is equipped with a controller. A lower annular stop for the stator assembly is set below the stator assembly housing. The lower annular stop of the stator assembly is sealed to the upper boss of the pump body through an O-ring seal. Self-tapping screw holes are provided at the bottom of the stator assembly housing. The pump cover, pump body and stator assembly housing are fastened together through the self-tapping screw holes with self-tapping screws.

[0006] The beneficial effects of this invention are as follows: the integrated injection-molded stator assembly structure is highly integrated, reducing the number of parts by 50%, shortening assembly cycle time by 40%, and reducing weight by 40%; efficient heat dissipation, with oil directly contacting the stator core, resulting in a temperature rise that is more than 20% lower than traditional air cooling; strong anti-interference performance, effectively suppressing high-frequency electromagnetic interference through a closed-loop grounding circuit design, with electromagnetic compatibility meeting CISPR25 Class 3 standards; high sealing performance, with a radial sealing design of O-ring seals, and a sealing contact pressure safety factor greater than 2. The upper part of the stator assembly meets the IP6K, IP9K, and IPX7 protection levels under the ISO 20653 standard, while the lower part of the stator assembly achieves zero oil leakage, meeting the flow requirements of the electric pump; and reduced processing and assembly costs of separate components, resulting in an overall cost reduction of 25%. Attached Figure Description

[0007] The following description, in conjunction with the accompanying drawings, illustrates specific embodiments.

[0008] Figure 1 This is a front sectional view of the integrated injection-molded stator assembly structure.

[0009] Figure 2 yes Figure 1 Top view of the structure.

[0010] Figure 3 yes Figure 1 Cross-sectional view showing the connection relationship between the controller, controller cover, and oil pump.

[0011] Figure 4 inside Figure 3 Enlarged view of point I in the image.

[0012] In the diagram: 1-Stator assembly housing; 1-1-Upper annular stop of stator assembly; 1-2-Lower annular stop of stator assembly; 1-3-Side connector; 1-4-Upper sealing layer; 1-5-Self-tapping screw hole; 2-Insulating terminal one; 3-Stator core; 4-Insulating terminal two; 5-Winding; 6-Connector power pin; 7-Connector signal pin; 8-Grounding pin; 9-Bolt bushing; 10-Controller cover; 11-Controller; 12-Self-tapping screw one; 13-O-ring seal one; 14-O-ring seal two; 15-Hollow shaft; 15-1-Hollow shaft oil passage; 15-2-Oil outlet; 16-Self-tapping screw two; 17-Pump cover; 18-Inner rotor; 19-Outer rotor; 20-Pump body; 21-Oil; A-Oil circulation direction; B-Stator core heat dissipation circulation oil chamber; C-Pump cover circulation oil chamber. Detailed Implementation

[0013] Example, see attached document Figure 1-4The integrated injection-molded stator assembly structure is formed by injection molding the stator core 3, insulating terminal 1 2, insulating terminal 2 4, winding 5, side-out connector 1-3, power pin 6, signal pin 7, bolt bushing 9, and grounding pin 8 into a sealed, lightweight, integrated structure using polyphenylene sulfide-based composite material. An annular stop 1-1 is located above the stator assembly housing 1. At the bottom of the annular stop 1-1, an upper sealing layer 1-4, integral with the stator assembly housing 1, is located. The upper sealing layer 1-4 has a power pin 6, a signal pin 7, and a UVW three-phase connector connected to the side-out connector 1-3. A bolt bushing 9 and a grounding pin 8 are located on the outer circumference of the stator assembly housing 1. One end of the grounding pin 8 is connected to the bolt bushing 9, and the other end extends to the controller connector power supply for direct connection to the controller. A controller 11 is mounted on the upper sealing layer 1-4 within the annular stop 1-1 of the stator assembly via connector power pin 6, connector signal pin 7, and a UVW three-phase connector. Above the controller 11, the controller cover 10 is mounted via an O-ring seal 13 between the inner circumferential surface of the annular stop 1-1 of the stator assembly and the controller cover 10, with a clearance fit. The controller cover 10 is fixed to the stator assembly housing 1 with self-tapping screws 12. The pump body 20 of the hydraulic pump is sealed to the inner circumferential surface of the lower annular stop 1-2 of the stator assembly via an O-ring seal 14 between the upper boss of the pump body 20 and the lower annular stop 1-2 of the stator assembly. A hollow shaft 15 is centrally located within the pump body 20 and the stator assembly housing 1, and a hollow shaft oil passage 15-1 is located at the axis of the hollow shaft 15. A pump cover 17 is connected to the lower end face of the pump body 20 via a stop-type connection. The pump cover 17 and the pump body 20 are fastened together by self-tapping screws 16 through self-tapping pin holes 1-5 on the lower end face of the stator assembly housing 1. An inner rotor 18 is installed around the hollow shaft 15 inside the pump body 20, and an outer rotor 19 is provided around the inner rotor 18. A stator core cooling circulation oil chamber B is set inside the stator core housing 1, and a pump cover circulation oil chamber C is set in the pump cover 17. Oil 21 flows from the stator core cooling circulation oil chamber B along the oil circulation direction A to the pump cover circulation oil chamber C, flows out from the center hole of the pump cover 17 into the hollow shaft oil passage 15-1, and flows out from the oil outlet hole 15-2 above the hollow shaft 15 into the stator core cooling circulation oil chamber B to form a circulation.

[0014] The working principle of this utility model is as follows: The integrated injection-molded stator assembly structure, formed by the one-time injection molding of the stator core assembly and other related components using polyphenylene sulfide-based composite material, creates a sealed, lightweight, integrated structure that suppresses electromagnetic compatibility and interference. The pump body oil chamber is connected to the internal cavity of the stator assembly. The oil pump drives the oil 21 to be drawn into the cavity, flows through the stator core 3, and then returns, achieving direct contact and efficient cooling. The side connectors 1-3 of the stator assembly allow the UVW three-phase connector, the power pin 6, the signal pin 7, and the grounding pin 8 to extend from the top of the stator assembly. The top of the stator assembly is closed, isolating the controller 11, which does not contact the oil 21. The connection between the controller 11 and the pump body 20 and the stator assembly is sealed with an O-ring to ensure zero leakage of the oil 21, meeting the flow requirements of the electric pump.

Claims

1. An integrated, injection-molded stator assembly structure, comprising a stator assembly housing (1), a stator core (3), a power connector pin (6), side-mounted connectors (1-3), a signal connector pin (7), a bolt bushing (9), and a grounding pin (8), characterized in that, The stator core assembly includes a stator core (3), insulating terminal one (2), insulating terminal two (4), winding (5), connector power pin (6), connector signal pin (7), bolt bushing (9), and grounding pin (8), all of which are injection molded from polyphenylene sulfide-based composite material in one piece. An upper annular stop (1-1) is provided above the stator assembly housing (1). At the bottom of the upper annular stop (1-1) is an upper sealing layer (1-4) integral with the stator assembly housing (1). A connector power pin (6) connected to the side-out connector (1-3) is provided on the upper sealing layer (1-4). The connector signal pin... The controller is installed on the upper sealing layer (1-4) inside the annular stop (1-1) of the stator assembly via the connector power pin (6), connector signal pin (7) and UVW three-phase connector. The stator assembly lower annular stop (1-2) is set below the stator assembly housing (1). The stator assembly lower annular stop (1-2) is sealed to the upper boss of the pump body (20) through the O-ring seal (14). A self-tapping screw hole is provided at the bottom of the stator assembly housing (1). The pump cover (17), pump body (20) and stator assembly housing (1) are fastened together through the self-tapping screw hole with self-tapping screw (16).

Images