Split type brushless insulated wire holder, stator assembly and brushless motor

Abstract

The split type brushless insulated wire holder comprises an upper wire holder and a lower wire holder, a second connecting part and a first connecting part are connected and can generate relative axial displacement, the first connecting part is provided with a limiting groove for clamping the second connecting part, the inner circumferential wall of the limiting groove is a first wedge-shaped surface, and the inner circumferential wall of the limiting groove is a second wedge-shaped surface. The peripheral wall of the first connecting part is a first wedge-shaped face, the peripheral wall of the second connecting part is a second wedge-shaped face, the first wedge-shaped face abuts against the second wedge-shaped face, the wall thickness of the first connecting part is gradually increased in the direction from the end to the upper frame body, and the wall thickness of the second connecting part is gradually increased in the direction from the end to the lower frame body. The first wedge-shaped surface and the second wedge-shaped surface on the first connecting part and the second connecting part abut against each other and are clamped, so that the upper wire frame and the lower wire frame are connected and positioned, and meanwhile, the first wedge-shaped surface and the second wedge-shaped surface can relatively slide, so that the size of an axial mounting space between the whole insulating wire frames is increased or reduced; the device is suitable for installation of stator cores with different heights.

Description

Technical Field

[0001] This application relates to the technical field of brushless motors, and in particular to a split-type brushless insulated wire frame, stator assembly and brushless motor. Background Technology

[0002] The insulated wire frame is a part of the stator assembly, mainly used to install the stator core and stator windings. The design height of the stator core will vary depending on the requirements of different operating conditions. However, the existing wire frame structure can only accommodate the assembly of stator cores with a fixed height, which limits its application range. Utility Model Content

[0003] In order to accommodate the installation of stator cores and insulation frames of different heights, the primary objective of this application is to provide a split-type brushless insulation frame.

[0004] The technical solution for a split-type brushless insulated wire frame provided in this application is as follows:

[0005] A split-type brushless insulated wire frame, comprising:

[0006] The upper frame includes an upper frame body and a plurality of first protrusions extending outward from one end of the upper frame body and evenly spaced circumferentially, each first protrusion including a first connecting portion located at its end; and

[0007] The lower frame includes a lower frame body and a plurality of second protrusions that extend outward from one end of the lower frame body and are evenly distributed circumferentially. The plurality of second protrusions are the same number as the plurality of first protrusions and are corresponding in position. The second protrusions include a second connecting portion placed at the end.

[0008] The second connecting part is connected to the first connecting part and the two can undergo relative axial displacement. The first connecting part has a limiting groove for the second connecting part to be engaged. The inner peripheral wall of the limiting groove is a first wedge-shaped surface, and the outer peripheral wall of the second connecting part is a second wedge-shaped surface. The first wedge-shaped surface and the second wedge-shaped surface abut against each other. The wall thickness of the first connecting part gradually increases from the end towards the upper frame, and the wall thickness of the second connecting part gradually increases from the end towards the lower frame.

[0009] By adopting the above technical solution, when the upper and lower wire frames are connected, the limiting grooves opened in the second connecting part and the first connecting part engage to complete the connection. After connection, the static friction generated by the contact between the first wedge surface and the second wedge surface provides a relatively locked state between the upper and lower wire frames. When it is necessary to install stator cores of different heights, pulling the upper or lower wire frame causes the first wedge surface and the second wedge surface to slide relative to each other, thereby adjusting the installation space between the entire insulated wire frames. Secondly, the wall thickness of both the first and second connecting parts gradually increases, and the engagement tightness also increases when the upper and lower wire frames are relatively close, improving the connection strength between them.

[0010] Preferably, the first connecting portion further includes a horizontal terminating surface and a first transition surface connecting the horizontal terminating surface and the first wedge-shaped surface, wherein the angle of inclination between the first transition surface and the horizontal surface is greater than the angle of inclination between the first wedge-shaped surface and the horizontal surface; the second connecting portion further includes a second transition surface connected to the second wedge-shaped surface, wherein the angle of inclination between the second transition surface and the horizontal surface is greater than the angle of inclination between the second wedge-shaped surface and the horizontal surface.

[0011] By adopting the above technical solution, the inclination of the first transition surface and the second transition surface relative to the two wedge-shaped surfaces is greater, which makes the friction between the two surfaces greater when the first wedge-shaped surface and the second transition surface and the second wedge-shaped surface and the first transition surface come into contact with each other, resulting in better stability after the entire insulated wire frame is engaged.

[0012] Preferably, the upper frame further includes:

[0013] Several first outer blocks arranged at circumferential intervals, each first outer block having a latch on its end face; and

[0014] The first inner block is arranged at several circumferential intervals.

[0015] By adopting the above technical solution, the combination of several first outer blocks and first inner blocks creates a space between them for radial positioning of the winding. Secondly, the snap-fit ​​design facilitates quick snap-fit ​​installation of the circuit board.

[0016] Preferably, it further includes at least one second outer block placed between two adjacent first outer blocks, and the second outer block is provided with a limiting boss on its end face.

[0017] By adopting the above technical solution, when the circuit board is connected to the upper frame, the buckle fixes the circuit board, and the limiting boss and the circuit board further improve the installation stability of the circuit board.

[0018] Preferably, it further includes a Hall plate, wherein the Hall plate has a plurality of first slots and a plurality of second slots at its outer edge, and the second slots are positioned between two adjacent first slots; wherein the buckle is engaged on the first slot, the limiting protrusion is engaged on the second slot and the Hall plate abuts against the limiting protrusion.

[0019] By adopting the above technical solution, the first bayonet and the buckle of the Hall plate are engaged to complete the connection of the Hall plate, while the opening of the second bayonet and the engagement of the limiting boss can further improve the connection stability of the Hall plate. At the same time, the Hall plate can also abut against the limiting boss to achieve axial limitation.

[0020] Preferably, the upper frame has several guide grooves spaced circumferentially on its other end face.

[0021] By adopting the above technical solution, the opening of the guide groove facilitates the subsequent winding component to provide space for clearance and restriction when the phase line connected to the winding, the external power supply enameled sheet electrically connected to the phase line, and the winding are restricted.

[0022] Preferably, the upper frame further includes a plurality of second inner blocks arranged at intervals, the second inner blocks having guide openings that connect to the guide groove.

[0023] By adopting the above technical solution, the second inner stop block can limit the radial positioning of the winding after it is installed on the wire frame, while the opening of the guide opening allows for the insertion and positioning of flexible components such as cable ties.

[0024] Preferably, the lower frame further includes:

[0025] Outer retaining ring; and

[0026] Several third inner blocks arranged at circumferential intervals.

[0027] By adopting the above technical solution, the setting of the outer retaining ring and the third inner retaining block allows for the maximum radial displacement of the limiting winding when it is connected to the insulated wire frame.

[0028] In order to accommodate the installation of stator cores and insulated wire frames of different heights, the second objective of this application is to provide a stator assembly.

[0029] The stator assembly provided in this application adopts the following technical solution:

[0030] A stator assembly includes the aforementioned split-type brushless insulated wire frame, as well as a stator core and windings.

[0031] By adopting the above technical solution, the static friction force generated by the contact between the first wedge surface and the second wedge surface provides a relatively locked state between the upper and lower wire frames. When it is necessary to install stator cores of different heights, pulling the upper or lower wire frame to make the first wedge surface and the second wedge surface slide relative to each other can increase or decrease the installation space between the entire insulated wire frames.

[0032] In order to accommodate the installation of stator cores and insulation frames of different heights, the third objective of this application is to provide a brushless motor.

[0033] The brushless motor provided in this application adopts the following technical solution:

[0034] A brushless motor, including the aforementioned stator assembly.

[0035] By adopting the above technical solution, the static friction force generated by the contact between the first wedge surface and the second wedge surface provides a relatively locked state between the upper and lower wire frames. When it is necessary to install stator cores of different heights, pulling the upper or lower wire frame to make the first wedge surface and the second wedge surface slide relative to each other can increase or decrease the installation space between the entire insulated wire frames.

[0036] In summary, this application includes at least one of the following beneficial technical effects:

[0037] 1. The connection and positioning of the upper and lower wire frames are achieved by the abutting and engaging between the first wedge-shaped surface and the second wedge-shaped surface on the first and second connecting parts. At the same time, the upper and lower wire frames can overcome the static friction between the first and second wedge-shaped surfaces under external force to achieve relative sliding, thereby increasing or decreasing the axial installation space between the entire insulated wire frames. This method is applicable to the installation of stator cores of different heights.

[0038] 2. By combining the buckle set on the first outer block with the limiting boss set on the second outer block, a quick and detachable positioning connection can be achieved when connecting the Hall plate and the insulating wire frame.

[0039] 3. The guide groove on the upper frame combined with the guide opening on the second inner block facilitates the guiding connection of the flexible parts. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the split-type brushless insulated wire frame in Embodiment 1 from one perspective;

[0041] Figure 2 This is a schematic diagram of the split-type brushless insulated wire frame in Embodiment 1 from another perspective;

[0042] Figure 3This is a cross-sectional view of the split-type brushless insulated wire frame in Embodiment 1;

[0043] Figure 4 for Figure 3 Enlarged view of part A;

[0044] Figure 5 This is a schematic diagram of the stator assembly in Embodiment 2;

[0045] Figure 6 This is an exploded view of the stator assembly in Embodiment 2;

[0046] Figure 7 This is a schematic diagram of the connection between the Hall plate and the insulating wire frame in Example 2;

[0047] Figure 8 This is a schematic diagram of the connection between the winding and the insulating wire frame in Embodiment 2;

[0048] Figure 9 This is a schematic diagram showing the connection between the enameled wire, the winding, and the insulated wire frame in Example 2.

[0049] Explanation of reference numerals in the attached drawings: 10. Upper frame; 11. Upper frame body; 111. Guide groove; 12. First protrusion; 121. First connecting part; 1211. First wedge-shaped surface; 1212. First transition surface; 1213. Horizontal termination surface; 122. Limiting groove; 13. First outer stop block; 14. Buckle; 15. Second outer stop block; 16. Limiting boss; 17. Third outer stop block; 18. First inner stop block ; 19. Second inner stop block; 191. Guide opening; 20. Lower wire frame; 21. Lower frame body; 22. Second protrusion; 221. Second connecting part; 2211. Second wedge-shaped surface; 2212. Second transition surface; 23. Outer retaining ring; 24. Third inner stop block; 30. Hall plate; 31. First bayonet; 32. Second bayonet; 40. Stator core; 50. Winding; 60. Cable tie; 70. Enamelled wire. Detailed Implementation

[0050] The present application will be further described in detail below with reference to the accompanying drawings.

[0051] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly attached to the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0052] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. Example 1

[0053] Figure 1 and Figure 2 The structure of a split-type brushless insulated wire frame is shown, including an upper wire frame 10 and a lower wire frame 20 that can be interlocked, both made of insulating material. The upper wire frame 10 includes a generally circular upper frame body 11, with a plurality of first protrusions 12 evenly distributed circumferentially at intervals on one end face of the upper frame body 11, with gaps between adjacent first protrusions 12. The upper wire frame 10 also includes a generally circular lower frame body 21, with a plurality of second protrusions 22 evenly distributed circumferentially at intervals on one end face of the upper frame body 11. The number of first protrusions 12 and second protrusions 22 is the same, and their positions correspond. The first protrusions 12 can engage with the second protrusions 22 to connect the upper wire frame 10 and the lower wire frame 20. Simultaneously, both the first protrusions 12 and the second protrusions 22 have vertically penetrating channels that are interconnected, providing space for the installation of the winding 50.

[0054] The first protrusion 12 includes a first connecting portion 121 located at its end. The first connecting portion 121 has a limiting groove 122 that forms a connecting channel. The limiting groove 122 forms a stepped surface with the channel in the form of a recess. The second protrusion 22 includes a second connecting portion 221 located at its end. The second connecting portion 221 has an annular groove on its outer peripheral wall and forms a stepped section at the connection. The second connecting portion 221 can be engaged in the limiting groove 122 of the first connecting portion 121 to achieve the connection between the upper wire frame 10 and the lower wire frame 20.

[0055] Combination Figure 3 and Figure 4 The inner peripheral wall of the limiting groove 122 of the first connecting part 121 is a first wedge-shaped surface 1211 with a certain inclination angle. The first connecting part 121 also includes a first transition surface 1212 connecting the first wedge-shaped surface 1211 and a horizontal termination surface 1213 connecting the first transition surface 1212. The inclination angle between the first transition surface 1212 and the horizontal plane is greater than the inclination angle between the first wedge-shaped surface 1211 and the horizontal plane, and the horizontal termination surface 1213 is parallel to the horizontal plane.

[0056] The second wedge-shaped surface 2211 and the second transition surface 2212 are connected to the outer peripheral wall of the second connecting portion 221. The angle of inclination between the second transition surface 2212 and the horizontal plane is greater than the angle of inclination between the second wedge-shaped surface 2211 and the horizontal plane. The first wedge-shaped surface 1211 can abut against the second wedge-shaped surface 2211, and the two are in a transition fit to maintain the relative locking between the upper wire frame 10 and the lower wire frame 20. In addition, in this embodiment, the wall thickness of both the first connecting portion 121 and the second connecting portion 221 gradually increases from the end in the axial direction away from the end. As a result, when the first wedge-shaped surface 1211 and the wedge-shaped surface move towards each other and approach each other, the frictional force between them gradually increases. Meanwhile, in this embodiment, the length of the first wedge surface 1211 is less than the length of the second wedge surface 2211, so that the second wedge surface 2211 can slide onto the first transition surface 1212, thereby increasing the bending deformation of the second connecting part 221 and increasing the friction between the first connecting part 121 and the second connecting part 221. When the end face of the first connecting part 121 abuts against the horizontal termination surface 1213, the upper wire frame 10 and the lower wire frame 20 are at the maximum stroke position of sliding towards each other. When the first wedge surface 1211 and the second wedge surface 2211 slide away from each other, the upper wire frame 10 and the lower wire frame 20 separate from each other, thereby changing the installation space between the upper frame body 11 and the lower frame body 21. This installation space can be used for the installation of stator cores 40 of different heights.

[0057] The upper frame 11 has several circumferentially arranged and spaced-apart first outer blocks 13, second outer blocks 15, and third outer blocks 17 on its other end face. The first outer blocks 13, second outer blocks 15, and third outer blocks 17 are arranged sequentially and on the same circumference. The first outer block 13 has a buckle 14 on its end face, and the buckle 14 has a buckle groove. The second outer block 15 has a limiting boss 16 on its end face. The limiting boss 16 is stepped and has a limiting surface.

[0058] On the other end face of the upper frame 11, a plurality of first inner blocks 18 and second inner blocks 19 are arranged at intervals. The plurality of first inner blocks 18 and second inner blocks 19 are arranged at intervals and are all on the same circumference. There is a gap between the first outer block 13 and the first inner block 18 for the installation limit of one end of the winding 50. At the same time, a plurality of guide grooves 111 are also provided at intervals on the end face of the upper frame 11. Both ends of the guide grooves 111 are open. The second inner block 19 has a guide opening 191 that communicates with the guide grooves 111.

[0059] The lower frame 21 is provided with an outer retaining ring 23 and several circumferentially spaced third inner blocks 24 on the other end face. The several third inner blocks 24 are all on the same circumference, and there is a gap between the outer retaining ring 23 and the third inner blocks 24 to allow for the installation limit of the other end of the winding 50. Example 2

[0060] Figure 5 and Figure 6 A stator assembly structure is shown, including a split brushless insulated wire frame as in Embodiment 1, a Hall plate 30, a stator core 40, and a winding 50. The stator core 40 is positioned between the upper frame 11 and the lower frame 21, and the vertical distance between the upper frame 11 and the lower frame 21 can be adjusted by adjusting the relative position between the upper frame 10 and the lower frame 20 for different stator core 40 heights.

[0061] Combination Figure 7 The Hall plate 30 has several first latches 31 and several second latches 32 at its outer edge. The second latches 32 are positioned between two adjacent first latches 31. The Hall plate 30 can be snapped into the latching groove of the buckle 14 to achieve quick installation with the insulating frame. Specifically, the buckle 14 can be snapped into the first latches 31, and the limiting protrusion can be snapped into the second latches 32. When the latching groove is engaged with the Hall plate 30, the end face of the Hall plate 30 abuts against the limiting surface of the limiting protrusion.

[0062] Combination Figure 8 and Figure 9 Each winding 50 passes through the conductive channel between two adjacent first protrusions 12 and second protrusions 22. The enameled wire 70, electrically connected to the winding 50, is connected to the phase lead of the winding 50 and then fixed by a flexible element. In this embodiment, the flexible element is a cable tie 60. One end of the cable tie 60 passes through the guide groove 111 and connects to the other end of the cable tie 60, enabling quick connection between the winding 50, the phase lead of the winding 50, and the enameled wire 70. Simultaneously, a portion of the cable tie 60 is confined within the guide opening 191 to achieve horizontal positioning. The connection structure of the cable tie 60 replaces the existing adhesive bonding method used for phase lead fixing, facilitating disassembly and maintenance. Example 3

[0063] A brushless motor includes the stator assembly as described in Embodiment 2.

[0064] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A split-type brushless insulated wire frame, characterized in that, include: The upper frame (10) includes an upper frame body (11) and a plurality of first protrusions (12) extending outward from one end of the upper frame body (11) and evenly spaced circumferentially, each first protrusion (12) including a first connecting portion (121) at its end; and The lower frame (20) includes a lower frame body (21) and a plurality of second protrusions (22) extending outward from one end of the lower frame body (21) and evenly distributed in the circumferential direction. The plurality of second protrusions (22) are the same number as the plurality of first protrusions (12) and are corresponding in position. The second protrusions (22) include a second connecting part (221) placed at the end. The second connecting part (221) is connected to the first connecting part (121) and the two can undergo relative axial displacement. The first connecting part (121) has a limiting groove (122) for the second connecting part (221) to be engaged. The inner peripheral wall of the limiting groove (122) is a first wedge-shaped surface (1211), and the outer peripheral wall of the second connecting part (221) is a second wedge-shaped surface (2211). The first wedge-shaped surface (1211) and the second wedge-shaped surface (2211) abut against each other. The wall thickness of the first connecting part (121) gradually increases from the end toward the upper frame (11), and the wall thickness of the second connecting part (221) gradually increases from the end toward the lower frame (21).

2. The split-type brushless insulated wire frame according to claim 1, characterized in that, The first connecting part (121) further includes a horizontal termination surface (1213) and a first transition surface (1212) connecting the horizontal termination surface (1213) and the first wedge surface (1211). The angle of inclination between the first transition surface (1212) and the horizontal surface is greater than the angle of inclination between the first wedge surface (1211) and the horizontal surface. The second connecting part (221) further includes a second transition surface (2212) connected to the second wedge surface (2211). The angle of inclination between the second transition surface (2212) and the horizontal surface is greater than the angle of inclination between the second wedge surface (2211) and the horizontal surface.

3. The split-type brushless insulated wire frame according to claim 1, characterized in that, The upper frame (11) also includes: A plurality of first outer blocks (13) arranged at circumferential intervals, wherein each first outer block (13) is provided with a buckle (14) on its end face; and Several circumferentially spaced first inner blocks (18).

4. The split-type brushless insulated wire frame according to claim 3, characterized in that, It also includes at least one second outer block (15) placed between two adjacent first outer blocks (13), and the second outer block (15) is provided with a limiting boss (16) on its end face.

5. The split-type brushless insulated wire frame according to claim 4, characterized in that, It also includes a Hall plate (30), which has a plurality of first slots (31) and a plurality of second slots (32) at its outer edge. The second slots (32) are placed between two adjacent first slots (31). The buckle (14) is engaged on the first slot (31), and the limiting boss (16) is engaged on the second slot (32) and the Hall plate (30) abuts against the limiting boss (16).

6. The split-type brushless insulated wire frame according to claim 1, characterized in that, The upper frame (11) has several guide grooves (111) spaced circumferentially on its other end face.

7. The split-type brushless insulated wire frame according to claim 6, characterized in that, The upper frame (11) also includes a number of second inner blocks (19) arranged at intervals, and the second inner blocks (19) are provided with guide ports (191) that connect to the guide groove (111).

8. The split-type brushless insulated wire frame according to claim 1, characterized in that, The lower frame (21) also includes: Outer retaining ring (23); and Several third inner blocks (24) are arranged at circumferential intervals.

9. A stator assembly, characterized in that, Includes the split-type brushless insulated wire frame as described in any one of claims 1-8, as well as the stator core (40) and windings (50).

10. A brushless motor, characterized in that, Includes the stator assembly as described in claim 9.

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