Stator structure of brushless motor

Abstract

The utility model discloses a stator structure of a brushless motor, which comprises a stator winding assembly, and one end of the stator winding assembly is connected with a collector ring assembly. The collector ring assembly comprises an annular housing and three copper bars of arc-shaped structures, and the annular housing sleeves the outer sides of the three copper bars and is welded and fixed with the stator winding assembly; the three copper bars form a continuous annular structure and are overlapped into two layers; the inner ring side of each copper bar is provided with a plurality of first terminal sheets, and each first terminal sheet is provided with a threading hole for connecting a stator coil; one end of the first terminal sheet extends out of the lower side of the annular housing and is suspended on the inner ring side of the annular housing in a V-shaped bending manner; the outer ring side of each copper bar is provided with a second terminal sheet, and the second terminal sheets are used for connecting a three-phase wire harness. According to the utility model, the axial space of the stator structure is saved, the difficulty of threading operation is reduced, the welding efficiency is improved, and the welding is firmer.

Description

Technical Field

[0001] This utility model relates to the field of motor manufacturing technology, specifically to a stator structure for a brushless motor. Background Technology

[0002] Brushless motors, as a type of motor that is highly efficient, low-noise, and has low maintenance costs, are widely used in modern industrial equipment, home appliances, electric vehicles, and aerospace. The stator structure of a brushless motor is one of its core components, and its design rationality directly affects the motor's performance, size, weight, and manufacturing cost.

[0003] In traditional brushless motor stator structures, the busbar assembly typically employs a multi-layer copper busbar structure to achieve electrical connection between the stator coil windings and the external power supply. However, this multi-layer copper busbar structure has significant drawbacks. In terms of axial space, the multi-layer copper busbar occupies a large amount of space, resulting in a less compact overall structure of the brushless motor, which in turn increases the motor's size and weight, making it extremely unfavorable for applications with strict space and weight requirements.

[0004] Furthermore, the traditional structure also presents numerous inconveniences during stator coil installation. Due to limited installation space, threading the stator coil leads is difficult, increasing installation time, reducing production efficiency, and increasing the risk of lead threading errors, thus affecting motor quality. Moreover, in the traditional structure, the contact area between the lead and the connection point is small when welding the stator coil leads, resulting in weak welds, high welding resistance, and excessive heat generation during welding, which can easily damage the welded area, reduce weld quality, and consequently affect the motor's electrical performance and reliability. Utility Model Content

[0005] The purpose of this invention is to address the problems existing in the prior art by providing a stator structure for a brushless motor that saves axial space in the stator structure, reduces the difficulty of wire threading, improves welding efficiency, and makes the weld more robust.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A stator structure for a brushless motor includes a stator winding assembly, one end of which is connected to a busbar assembly. The busbar assembly includes an annular housing and three arc-shaped copper busbars. The annular housing is fitted over the outside of the three copper busbars and welded to the insulating sleeve of the stator winding assembly. The three copper busbars form a continuous annular structure and are stacked in two layers. Each copper busbar has several first terminal pieces on its inner ring side, and each first terminal piece has a through hole for connecting a stator coil. One end of each first terminal piece extends from the lower side of the annular housing and is suspended in a V-shape on the inner ring side of the annular housing. Each copper busbar has a second terminal piece on its outer ring side for connecting a three-phase wire harness.

[0008] Furthermore, each of the copper busbars has several positioning holes on its outer ring side, and the positioning holes of the upper and lower copper busbars are aligned with each other for positioning during injection molding of the annular shell.

[0009] Furthermore, of the three copper busbars, copper busbar two has a Z-shaped bending structure, copper busbar one is located on the upper side of one end of copper busbar two, and copper busbar three is located on the lower side of one end of copper busbar two.

[0010] Furthermore, the annular housing is provided with three wire-passing holes, which are respectively aligned with three second terminal pieces for introducing three-phase wire harnesses.

[0011] Furthermore, the outer ring of the annular cover is provided with a plurality of welding protrusions, and the annular cover is welded and fixed to the insulating sleeve of the stator winding assembly through the welding protrusions; the welding protrusions are provided with locking pins, which cooperate with the corresponding slots of the insulating sleeve of the stator winding assembly for positioning the welding protrusions.

[0012] Furthermore, the stator winding assembly includes a plurality of core diaphragms, which form a ring structure. Each core diaphragm is connected to an insulating sleeve, and the stator coil is connected to the inner side of the insulating sleeve.

[0013] Furthermore, the annular shell is provided with several through holes, which are aligned with the positioning holes for positioning during injection molding of the annular shell.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] One of the copper busbars in the busbar assembly adopts a Z-shaped bending structure, so that the three copper busbars are stacked into two layers when forming a continuous ring structure, occupying only the axial space of two layers of copper busbars. Compared with the traditional multi-layer copper busbar structure, it saves the axial space of the stator structure, making the overall structure of the brushless motor more compact.

[0016] One end of the first terminal piece extends from the underside of the annular housing and is suspended in a V-shape on the inner ring side of the annular housing. On the one hand, this increases the installation space, making it easier for the stator coil leads to pass through the corresponding wire holes and reducing the difficulty of the wire threading operation; on the other hand, welding personnel can perform welding operations in a relatively concentrated position, which improves welding efficiency and helps to ensure the consistency of welding quality, thereby improving overall production efficiency.

[0017] Because the first terminal piece is V-shaped and suspended, the contact area between the lead and the wire hole is large when welding the stator coil lead. The larger contact area makes the welding more secure, effectively reducing the welding resistance and ensuring the reliability of the electrical connection between the stator coil winding and the bus ring assembly. Attached Figure Description

[0018] 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 these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure of a brushless motor stator in one embodiment of this application;

[0020] Figure 2 This is an exploded view of the stator of a brushless motor in one embodiment of this application;

[0021] Figure 3 This is an exploded view of the iron-core valve in one embodiment of this application;

[0022] Figure 4 This is an exploded view of a bus ring assembly in one embodiment of this application;

[0023] Figure 5 This is a schematic diagram showing the positional relationship of the three copper busbars in one embodiment of this application;

[0024] In the diagram: 1. Stator winding assembly; 101. Core diaphragm; 2. Bus ring assembly; 3. Annular housing; 301. Wire through hole; 302. Through hole; 4. First terminal piece; 401. Wire through hole; 5. Positioning hole; 6. Second terminal piece; 7. Three-phase wiring harness; 8. Copper busbar two; 9. Copper busbar one; 10. Copper busbar three; 11. Welding boss; 12. Locking pin; 13. Insulating sleeve; 14. Stator coil. Detailed Implementation

[0025] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0026] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0028] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0029] In traditional brushless motor stator structures, the busbar assembly typically employs a multi-layer copper busbar structure to achieve electrical connection between the stator coil windings and the external power supply. However, this multi-layer copper busbar structure has significant drawbacks. In terms of axial space, the multi-layer copper busbar occupies a large amount of space, resulting in a less compact overall structure of the brushless motor, which in turn increases the motor's size and weight, making it extremely unfavorable for applications with strict space and weight requirements.

[0030] Furthermore, the traditional structure also presents numerous inconveniences during stator coil installation. Due to limited installation space, threading the stator coil leads is difficult, increasing installation time, reducing production efficiency, and increasing the risk of lead threading errors, thus affecting motor quality. Moreover, in the traditional structure, the contact area between the lead and the connection point is small when welding the stator coil leads, resulting in weak welds, high welding resistance, and excessive heat generation during welding, which can easily damage the welded area, reduce weld quality, and consequently affect the motor's electrical performance and reliability.

[0031] Regarding the above technical issues, such as Figures 1 to 5 As shown, this application embodiment provides a stator structure for a brushless motor, including a stator winding assembly 1, one end of which is connected to a busbar assembly 2; the busbar assembly 2 includes an annular housing 3 and three arc-shaped copper busbars, the annular housing 3 is fitted over the outside of the three copper busbars and welded to the insulating sleeve of the stator winding assembly 1; the three copper busbars form a continuous annular structure and are stacked in two layers; each copper busbar has several first terminal pieces 4 on its inner ring side, each first terminal piece 4 having a through hole 401 for connecting the stator coil 14; one end of the first terminal piece 4 extends from the lower side of the annular housing 3 and is suspended in a V-shape on the inner ring side of the annular housing 3; each copper busbar has a second terminal piece 6 on its outer ring side for connecting the three-phase wire harness 7.

[0032] The lead wire of the stator coil 14 passes through the wire hole 401 on the first terminal piece 4 and is welded and fixed to the first terminal piece 4, thereby realizing the electrical connection between the stator coil winding and the bus ring assembly 2.

[0033] like Figure 4 and 5 As shown, the ring structure composed of three copper busbars provides a current flow path for the stator coil windings, enabling each stator coil winding to be connected in a three-phase double-branch delta configuration to form a complete circuit.

[0034] Each copper busbar has a second terminal piece 6 on its outer ring side, which is used to connect the three-phase wiring harness 7. In this way, the bus ring assembly 2 electrically connects the series-connected stator coil windings to the three-phase wiring harness 7, realizing the electrical connection between the brushless motor stator and the external power supply.

[0035] When the three-phase wiring harness 7 is connected to the power supply, the current enters the bus ring assembly 2 through the second terminal piece 6, and then is transmitted to the corresponding stator coil 14 through the first terminal piece 4, thereby generating a rotating magnetic field and driving the brushless motor to run.

[0036] One of the copper busbars in the busbar assembly 2 adopts a Z-shaped bending structure, so that when the three copper busbars form a continuous ring structure, they are stacked into two layers, occupying only the axial space of two layers of copper busbars. Compared with the traditional multi-layer copper busbar structure, it saves the axial space of the stator structure, making the overall structure of the brushless motor more compact, which helps to reduce the size and weight of the motor.

[0037] One end of the first terminal piece 4 extends from the lower side of the annular housing 3 and is suspended in a V-shape on the inner ring side of the annular housing 3. When installing the stator coil 14, the V-shaped suspension design facilitates the passage of the stator coil 14 leads through the corresponding wire-passing hole 401. Because the V-shape increases the installation space, the wire-passing operation is easier, reducing installation difficulty and improving production efficiency.

[0038] Furthermore, because the first terminal piece 4 is suspended in a V-shape, the contact area between the lead and the through hole 401 is large when welding the lead of the stator coil 14. The larger contact area makes the weld stronger, reduces the welding resistance, reduces the heat generated during the welding process, and improves the welding quality.

[0039] Furthermore, the first terminal pieces 4 are concentrated on the inner ring side of the annular housing 3, arranged in a ring shape. This layout makes welding operations more convenient. Welders can perform welding operations in a relatively concentrated position, improving welding efficiency and helping to ensure consistent welding quality.

[0040] In some embodiments, each copper busbar has a plurality of positioning holes 5 on its outer ring side, and the positioning holes 5 of the upper and lower copper busbars are aligned with each other for positioning when injection molding the annular shell 3.

[0041] In some embodiments, among the three copper busbars, copper busbar 2 8 has a Z-shaped bending structure, copper busbar 1 9 is disposed on the upper side of one end of copper busbar 2, and copper busbar 3 10 is disposed on the lower side of one end of copper busbar 2 8.

[0042] Copper busbar 28 adopts a Z-shaped bending structure, copper busbar 19 is located on the upper side of one end of copper busbar 28, and copper busbar 310 is located on the lower side of one end of copper busbar 28. The three copper busbars cooperate with each other in this layout to form a continuous ring structure and are stacked into two layers, saving axial space.

[0043] In some embodiments, the annular housing 3 is provided with three wire passage holes 301, which are respectively aligned with three second terminal pieces 6 for introducing three-phase wire harnesses 7.

[0044] The three wire-passing holes 301 on the annular housing 3 provide an entry path for the three-phase wiring harness 7. Since the wire-passing holes 301 are aligned with the second terminal piece 6, the three-phase wiring harness 7 can smoothly pass through the annular housing 3 along the wire-passing holes 301 and directly connect to the corresponding second terminal piece 6, realizing the electrical connection between the stator coil winding and the external power supply. This installation method can greatly shorten the installation time and improve production efficiency.

[0045] In some embodiments, the outer ring of the annular housing 3 is provided with a plurality of welding protrusions 11, and the annular housing 3 is welded and fixed to the insulating sleeve of the stator winding assembly 1 by the welding protrusions 11; the welding protrusions 11 are provided with locking pins 12, which cooperate with the corresponding slots of the insulating sleeve of the stator winding assembly 1 for positioning the welding protrusions 11.

[0046] The locking pin 12 on the welding boss 11 cooperates with the corresponding slot of the stator winding assembly 1. When the annular cover 3 is installed on the stator winding assembly 1, the locking pin 12 is accurately inserted into the slot of the stator winding assembly 1, accurately determining the position of the welding boss 11 relative to the stator winding assembly 1, thereby ensuring the accurate positioning of the annular cover 3 and the stator winding assembly 1 before welding.

[0047] like Figure 3 As shown, in some embodiments, the stator winding assembly 1 includes a plurality of core diaphragms 101, which form an annular structure. Each core diaphragm 101 is connected to an insulating sleeve 13, and the inner side of the insulating sleeve 13 is connected to the stator coil 14.

[0048] Several iron core diaphragms 101 form a ring structure. When the stator coil 14 is energized, a magnetic field is generated in the iron core diaphragms 101. The insulating sleeve 13 serves to insulate and electrically isolate, preventing electrical short circuits between the stator coil 14 and the iron core diaphragms 101, and facilitating the installation of the stator coil 14, making the winding and fixing of the coil easier.

[0049] In some embodiments, the annular housing 3 is provided with a plurality of through holes 302, which are aligned one by one with the positioning holes 5 for positioning during injection molding of the annular housing 3.

[0050] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A stator structure for a brushless motor, characterized in that, It includes a stator winding assembly (1), one end of which is connected to a busbar assembly (2); The busbar assembly (2) includes an annular housing (3) and three arc-shaped copper busbars. The annular housing (3) is fitted around the outside of the three copper busbars and is welded and fixed to the insulating sleeve of the stator winding assembly (1). The three copper busbars form a continuous ring structure and are stacked into two layers; Each of the copper busbars has several first terminal pieces (4) on its inner ring side, and each first terminal piece (4) has a wire hole (401) for connecting the stator coil (14). One end of the first terminal piece (4) extends from the lower side of the annular shell (3) and is suspended in a V-shape on the inner ring side of the annular shell (3); Each of the copper busbars has a second terminal piece (6) on its outer ring side, which is used to connect the three-phase wire harness (7).

2. The stator structure of a brushless motor according to claim 1, characterized in that, Of the three copper busbars, copper busbar two (8) has a Z-shaped bending structure, copper busbar one (9) is located on the upper side of one end of copper busbar two, and copper busbar three (10) is located on the lower side of one end of copper busbar two (8).

3. The stator structure of a brushless motor according to claim 1, characterized in that, The annular housing (3) is provided with three wire passage holes (301), which are respectively aligned with three second terminal pieces (6) for introducing three-phase wire harnesses (7).

4. The stator structure of a brushless motor according to claim 1, characterized in that, The outer ring of the annular shell (3) is provided with a plurality of welding bosses (11), and the annular shell (3) is welded and fixed to the insulating sleeve of the stator winding assembly (1) through the welding bosses (11). The welding boss (11) is provided with a locking pin (12), which engages with the corresponding slot of the insulating sleeve of the stator winding assembly (1) to position the welding boss (11).

5. The stator structure of a brushless motor according to claim 1, characterized in that, The stator winding assembly (1) includes a plurality of core diaphragms (101), which form an annular structure. Each core diaphragm (101) is connected to an insulating sleeve (13), and the inner side of the insulating sleeve (13) is connected to a stator coil (14).

6. The stator structure of a brushless motor according to claim 1, characterized in that, Each of the copper busbars has several positioning holes (5) on its outer ring side. The positioning holes (5) of the upper and lower copper busbars are aligned with each other for positioning when the annular shell (3) is injection molded.

7. The stator structure of a brushless motor according to claim 6, characterized in that, The annular shell (3) is provided with a plurality of through holes (302), which are aligned one by one with the positioning holes (5) for positioning during injection molding of the annular shell (3).

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