Stator connection plate assembly for electric motor

Abstract

The application provides a stator connection plate assembly for motor connection, which comprises an upper shell, a lower shell, a stator connection plate assembly and a locking assembly, the lower shell is internally provided with a cavity, the stator connection plate assembly is embedded in the cavity in the lower shell, the upper shell is seamlessly butted and buckled on the lower shell, and the upper shell is locked on the lower shell through the locking assembly, and the application has the beneficial effects that the stator PCB and the stator connection can be directly installed on the insulation framework through the insulation framework, the processing steps of the assembly are reduced, the installation is convenient, the volume is small, the reliability is high, the reliability and the impact resistance of the stator connection plate are improved, and the use of new energy vehicles is met.

Description

Technical Field

[0001] This invention relates to the field of stator terminal block technology, and more particularly to a stator terminal block assembly for motor connection. Background Technology

[0002] The stator terminal block used for automotive motor connections is a key component inside the motor, primarily responsible for the electrical connections and signal transmission of the motor stator. The injection mold design of the stator terminal block is crucial for the production of new energy vehicle motors, as it ensures the motor's electrical connection and insulation performance. Traditional injection molds typically use water cooling during use. However, the distribution of water cooling pipes is limited, resulting in slow cooling. After the moving and stationary molds separate, the temperature of the molded part and the mold remains high, leading to difficult demolding, poor demolding results, and potential mold damage and deformation.

[0003] A brushless DC motor consists of a motor body and a driver, and is a typical mechatronic product. Because a brushless DC motor operates in a self-controlled manner, it does not require an additional starting winding on the rotor like a synchronous motor that starts under heavy load with frequency conversion speed regulation. It also does not oscillate or lose synchronism when the load changes abruptly. The permanent magnets of small and medium capacity brushless DC motors now mostly use high magnetic energy level rare earth neodymium iron boron (Nd-Fe-B) materials. Therefore, the volume of a rare earth permanent magnet brushless motor is reduced by one frame size compared to a three-phase asynchronous motor of the same capacity.

[0004] New energy vehicles, also known as alternative fuel vehicles, include pure electric vehicles and fuel cell electric vehicles that use all non-petroleum fuels, as well as hybrid electric vehicles and ethanol gasoline vehicles that use some non-petroleum fuels. New energy vehicles need to use brushless motors because they require low voltage, high torque, small size and light weight. However, the current stator assembly of brushless motors has complicated processing steps and is inconvenient to install, which is not conducive to the use of new energy vehicles. Summary of the Invention

[0005] The purpose of this invention is to solve the above-mentioned technical problems by providing a novel stator terminal block assembly for motor connection. The stator PCB board and stator wiring can be directly installed on the insulating frame, reducing the processing steps of the assembly, making it easy to install, small in size, and highly reliable. This improves the reliability and impact resistance of the stator terminal block and meets the requirements of new energy vehicles.

[0006] This invention is achieved through the following technical solution:

[0007] A stator terminal block assembly for motor connection includes an upper housing, a lower housing, a stator terminal block assembly, and a locking assembly. The lower housing has an internal cavity, and the stator terminal block assembly is embedded in the internal cavity of the lower housing. The upper housing seamlessly connects and fastens the stator terminal block assembly to the lower housing, and the locking assembly locks the upper housing onto the lower housing.

[0008] As a further step, the stator terminal block assembly includes an insulating frame, a stator housing, a stator core, a stator winding, a stator PCB board, and stator terminals. The stator housing is fitted onto the outer side of the insulating frame. The inner wall of the stator housing has several core slots. The stator core is located between the insulating frame and the stator housing. The stator core is embedded in the core slots on the inner wall of the stator housing. The insulating frame has several stator winding slots. The stator winding is embedded in the stator winding slots on the insulating frame. The stator PCB board is located above the stator winding. The stator PCB board has a lead-out slot. The tail end of the stator winding has a terminal pin. The terminal pin at the tail end of the stator winding is inserted into the lead-out slot on the stator PCB board. The stator terminals are physically connected to the terminal pin at the tail end of the stator winding and are fixed on the stator PCB board.

[0009] As a further step, the upper housing has a cylindrical through hole in the middle and several ventilation slots on the outer side wall of the upper housing.

[0010] As a further step, the lower housing has a cylindrical through hole in the middle and several ventilation slots on the outer side wall of the lower housing.

[0011] As a further step, the locking assembly includes a locking connecting rod, a first locking bearing, a second locking bearing, and a locking nut. The locking connecting rod has a limiting block in the middle. The upper end of the locking connecting rod passes through a cylindrical through hole in the middle of the lower housing and connects to the insulating frame. It is locked to the insulating frame by the second locking bearing. The lower end of the locking connecting rod extends outside the lower housing. The cylindrical through hole in the middle of the upper housing is inserted into the upper end of the locking connecting rod. The upper housing is fixed to the insulating frame by the first locking bearing. The locking nut locks the first locking bearing to the upper housing.

[0012] As a further step, the lower part of the locking connecting rod is provided with external threads, the top of the locking connecting rod is provided with a through hole, and the locking nut passes through the through hole at the top of the locking connecting rod and locks itself onto the upper housing.

[0013] As a further step, a washer is provided between the locking nut and the first locking bearing.

[0014] Furthermore, the physical method is laser welding or ultrasonic welding.

[0015] The beneficial effects of this invention are as follows:

[0016] (1) The stator PCB board and stator wiring can be directly installed on the insulating frame, which reduces the processing steps of the components, is easy to install, small in size, and highly reliable, and improves the reliability and impact resistance of the stator wiring board, thus meeting the needs of new energy vehicles.

[0017] (2) The stator wiring can be soldered into the wire slot on the stator PCB board, thereby improving the stability of the wiring. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the stator terminal block assembly for motor connection according to the present invention;

[0019] Figure 2 This is an exploded view of the stator terminal block assembly for motor connection according to the present invention.

[0020] Figure 3 This is a schematic diagram of the stator terminal block assembly structure of the present invention;

[0021] Figure 4 This is an exploded view of the stator terminal block assembly of the present invention;

[0022] Figure 5 This is a schematic diagram of the locking assembly structure of the present invention;

[0023] Figure 6 This is a schematic diagram of the exploded structure of the locking assembly of the present invention;

[0024] Reference numerals: 1. Upper housing; 11. Cylindrical through hole; 12. Ventilation slot; 2. Lower housing; 21. Cavity; 22. Cylindrical through hole; 3. Stator terminal block assembly; 31. Insulating frame; 32. Stator housing; 320. Core slot; 33. Stator core; 34. Stator winding; 340. Terminal pin; 35. Stator PCB board; 350. Outlet slot; 36. Stator wiring; 4. Locking assembly; 41. Locking connecting rod; 410. Limiting block; 411. External thread; 412. Through hole; 42. First locking bearing; 43. Second locking bearing; 44. Locking nut; 45. Washer. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0026] 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 application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application; the terms "comprising" and "having," and any variations thereof, in the specification, claims, and foregoing drawings of this application are intended to cover non-exclusive inclusion. The terms "first," "second," etc., in the specification, claims, or foregoing drawings of this application are used to distinguish different objects, not to describe a particular order.

[0027] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0028] For reference Figures 1-6 As shown, a stator terminal block assembly for motor connection includes an upper housing 1, a lower housing 2, a stator terminal block assembly 3, and a locking assembly 4. The lower housing 2 has a cavity 21 inside, and the stator terminal block assembly 3 is embedded in the cavity 21 inside the lower housing 2. The upper housing 1 seamlessly connects and fastens the stator terminal block assembly 3 to the lower housing 2, and the locking assembly 4 locks the upper housing 1 to the lower housing 2.

[0029] Preferably, the stator terminal block assembly 3 includes an insulating frame 31, a stator housing 32, a stator core 33, a stator winding 34, a stator PCB board 35, and stator terminals 36. The stator housing 32 is fitted onto the outer side of the insulating frame 31. The inner wall of the stator housing 32 has a plurality of core slots 320. The stator core 33 is disposed between the insulating frame 31 and the stator housing 32, and the stator core 33 is embedded in the core slots 320 of the inner wall of the stator housing 32. The insulating frame 31 has a plurality of stator winding slots. The stator winding 34 is embedded in the stator winding slot on the insulating frame 31. A stator PCB board 35 is provided above the stator winding 34. The stator PCB board 35 is provided with a wire outlet slot 350. The stator winding 34 is provided with a wiring pin 340 at its tail end. The wiring pin 340 at the tail end of the stator winding 34 is inserted into the wire outlet slot 350 on the stator PCB board 35. The stator wire 36 is physically connected to the wiring pin 340 at the tail end of the stator winding 34 and is fixed on the stator PCB board 35.

[0030] Preferably, the upper housing 1 has a cylindrical through hole 11 in the middle and a plurality of ventilation slots 12 on the outer side wall of the upper housing 1.

[0031] Preferably, the lower housing 21 has a cylindrical through hole 22 in the middle and a plurality of ventilation slots 23 on the outer side wall of the lower housing 21.

[0032] Preferably, the locking assembly 4 includes a locking connecting rod 41, a first locking bearing 42, a second locking bearing 43, and a locking nut 44. The locking connecting rod 41 has a limiting block 410 in the middle. The upper end of the locking connecting rod 41 passes through the cylindrical through hole 22 in the middle of the lower housing 2 and is connected to the insulating frame 31. It is locked to the insulating frame 31 by the second locking bearing 43. The lower end of the locking connecting rod 41 extends outside the lower housing 2. The cylindrical through hole 11 in the middle of the upper housing 1 is inserted into the upper end of the locking connecting rod 41. The upper housing 1 is fixed to the insulating frame 41 by the first locking bearing 42. The locking nut 44 locks the first locking bearing 42 to the upper housing 1.

[0033] Preferably, the locking connecting rod 41 has an external thread 411 at its lower part and a through hole 412 at its top. The locking nut 44 passes through the through hole 412 at the top of the locking connecting rod 41 and locks itself onto the upper housing 1.

[0034] Preferably, a washer 45 is provided between the locking nut 44 and the first locking bearing 42.

[0035] Preferably, the physical method is laser welding or ultrasonic welding.

[0036] Based on the disclosure and teachings of the foregoing specification, those skilled in the art can make appropriate changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments disclosed and described above, and some modifications and changes to the present invention should also fall within the protection scope of the claims of the present invention. Furthermore, although some specific terms are used in this specification, these terms are only for convenience of explanation and do not constitute any limitation on the present invention.

Claims

1. A stator terminal block assembly for motor connection, characterized in that: The device includes an upper housing, a lower housing, a stator terminal block assembly, and a locking assembly. The lower housing has an internal cavity, and the stator terminal block assembly is embedded in the cavity inside the lower housing. The upper housing seamlessly connects and fastens the stator terminal block assembly to the lower housing, and the locking assembly locks the upper housing onto the lower housing.

2. The stator terminal block assembly for motor connection according to claim 1, characterized in that: The stator terminal block assembly includes an insulating frame, a stator housing, a stator core, stator windings, a stator PCB board, and stator terminals. The stator housing is fitted onto the outer side of the insulating frame. The inner wall of the stator housing has several core slots. The stator core is located between the insulating frame and the stator housing and is embedded in the core slots on the inner wall of the stator housing. The insulating frame has several stator winding slots, and the stator windings are embedded in the stator winding slots on the insulating frame. The stator PCB board is located above the stator windings and has a lead-out slot. The tail of the stator windings has a terminal pin, which is inserted into the lead-out slot on the stator PCB board. The stator terminals are physically connected to the terminal pins at the tail of the stator windings and are fixed to the stator PCB board.

3. The stator terminal block assembly for motor connection according to claim 1, characterized in that: The upper housing has a cylindrical through hole in the middle and several ventilation slots on the outer side wall of the upper housing.

4. The stator terminal block assembly for motor connection according to claim 1, characterized in that: The lower housing has a cylindrical through hole in the middle and several ventilation slots on the outer side wall of the lower housing.

5. The stator terminal block assembly for motor connection according to claim 4, characterized in that: The locking assembly includes a locking connecting rod, a first locking bearing, a second locking bearing, and a locking nut. The locking connecting rod has a limiting block in the middle. The upper end of the locking connecting rod passes through a cylindrical through hole in the middle of the lower housing and connects to the insulating frame. It is locked to the insulating frame by the second locking bearing. The lower end of the locking connecting rod extends outside the lower housing. The cylindrical through hole in the middle of the upper housing is inserted into the upper end of the locking connecting rod. The upper housing is fixed to the insulating frame by the first locking bearing. The locking nut locks the first locking bearing to the upper housing.

6. The stator terminal block assembly for motor connection according to claim 5, characterized in that: The lower part of the locking connecting rod is provided with external threads, and the top of the locking connecting rod is provided with a through hole. The locking nut passes through the through hole at the top of the locking connecting rod and locks itself onto the upper housing.

7. The stator terminal block assembly for motor connection according to claim 5, characterized in that: A washer is provided between the locking nut and the first locking bearing.

8. The stator terminal block assembly for motor connection according to claim 2, characterized in that: The physical method is either laser welding or ultrasonic welding.

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