Stator mechanism for brushless motor

Abstract

The utility model discloses a kind of stator mechanisms for brushless motor, belong to brushless motor field. Mainly including stator front end plate, stator lamination and stator rear end plate, two groups of limiting bosses are fixedly installed on stator front end plate circumferential position, guiding space is formed between two groups of limiting bosses, limiting boss is equipped with locating slot;Stator lamination is inserted in stator front end plate, two groups of limiting bosses are slidably inserted with line hook frame, line hook frame is arranged in stator side, line hook frame has butt joint groove, the circumferential position of stator rear end plate is fixedly installed with block structure, block structure has the clamping slot of alignment butt joint groove insertion, to realize the firm assembly of line hook frame between front and rear end plate. A kind of stator mechanism for brushless motor of the application, by line hook frame side placement layout, discard axial extension, form two-way slide insertion locking without screw by means of stator front and rear end plate limiting structure, realize positioning by embedded cooperation, improve motor space utilization, assembly convenience and reliability.

Description

Technical Field

[0001] This utility model relates to the field of brushless motor technology, and in particular to a stator mechanism for a brushless motor. Background Technology

[0002] In modern industry and daily life, brushless motors are widely used in electric vehicles, drones, industrial automation equipment, and home appliances due to their advantages such as high efficiency, long lifespan, and low maintenance requirements. As the core component of a brushless motor, the performance of the stator mechanism directly affects the overall operating efficiency and reliability of the motor. Currently, the stator mechanism of common brushless motors on the market mainly consists of an iron core formed by stacking stator laminations and windings wound around it.

[0003] In brushless motor applications, the electrical connection method of the stator structure has a significant impact on production efficiency and product applicability. Currently, the two mainstream connection methods both have certain drawbacks. Firstly, the method of covering one side of the stator with a circuit board and fixing it with screws, then soldering the stator wires and phase wires to the circuit board, is unusable due to the high temperature of spot welding machines, requiring manual soldering. This not only involves the laborious process of stripping the enameled wire insulation, but also suffers from solder joint detachment due to the small soldering area of ​​the circuit board. The screw fixing further increases workload and cost, and the circuit board increases the overall length of the stator, making it difficult to adapt to narrow spaces. Secondly, the method of inserting and fixing three terminals into the stator end plate is cumbersome in terms of terminal installation and fixation, also increasing the overall length of the stator and product size. Furthermore, the dispersed terminals result in excessively long phase wires, increasing material costs, and additional wiring and fixing are required after soldering, further increasing assembly steps. Therefore, a stator mechanism for brushless motors needs to be designed.

[0004] It should be noted that the information disclosed in this background section is only for understanding the background technology of this application concept, and therefore may include information that does not constitute prior art. Utility Model Content

[0005] This utility model provides a stator mechanism for a brushless motor to solve the problems of low welding efficiency, high cost, and poor adaptability of the two mainstream electrical connection methods of current brushless motor stator structures.

[0006] This utility model embodiment adopts the following technical solution: a stator mechanism for a brushless motor. It includes a stator front end plate, stator laminations, and a stator rear end plate. Two sets of limiting bosses are fixedly installed on the circumference of the stator front end plate, forming a guide space between the two sets of limiting bosses. Positioning slots of a certain depth are provided on the limiting bosses. The stator laminations are inserted into the stator front end plate. A hook frame is slidably inserted between the two sets of limiting bosses. The hook frame is arranged on the side of the stator and has a mating groove. A block structure is fixedly installed on the circumference of the stator rear end plate. The block structure has a slot for aligning with the mating groove for insertion, thereby achieving a stable assembly of the hook frame between the front and rear end plates.

[0007] Furthermore, the hook frame is fixed with three sets of high-temperature resistant connecting pieces by spot welding. One end of each set of connecting pieces extends into a hook claw. The hook claw has a hook-shaped structure, and the hook shape can hook the end of the enameled wire / winding lead-out.

[0008] Furthermore, a connecting portion extends from one end of the connecting piece away from the hook claw, and a phase wire is fixed to the connecting portion by spot welding to achieve electrical connection. The three sets of connecting pieces are arranged in a compact layout to shorten the connection path of the phase wire.

[0009] Furthermore, the stator lamination has a ring-shaped yoke, which serves as the ring-shaped base structure of the stator lamination. The side of the hook frame that is attached to the yoke is an arc-shaped surface, which is suitable for the hook frame to fit tightly against the yoke, thereby quickly realizing the mating groove and the positioning slot of the stator front end plate.

[0010] Furthermore, the inner wall of the yoke extends radially with multiple sets of teeth, and stator slots are formed between adjacent teeth. The teeth are radially distributed from the inner wall of the yoke toward the center, serving to separate the stator slots and support the winding. The stator slots, as grooves between adjacent teeth, are used to embed the core area of ​​the enameled wire winding.

[0011] Furthermore, the stator rear end plate is provided with multiple sets of protruding structures along its radial direction. Each set of protruding structures is provided with a step. The stator rear end plate is adapted to be matched with the docking groove of the hook frame through the slot. The protruding structure is simultaneously fitted onto the surface of the tooth, and its step is tightly fitted with the bottom surface of the tooth.

[0012] Furthermore, the stator front end plate is provided with multiple sets of positioning protrusions along its radial direction, and each set of positioning protrusions is provided with a boss. The stator front end plate is adapted to be matched with the docking groove of the hook frame through the positioning slot. The positioning protrusions are simultaneously fitted onto the surface of the tooth, and their bosses are tightly fitted with the bottom surface of the tooth.

[0013] The above-mentioned technical solutions adopted in the embodiments of this utility model can achieve the following beneficial effects:

[0014] A stator mechanism for a brushless motor completely eliminates the axial extension mode of traditional circuit boards or terminals through the side-mounted hook bracket layout. It utilizes the guiding space of the limiting boss on the front end plate of the stator, the positioning slot, and the slot of the plate-like structure at the rear end to form a screwless bidirectional sliding locking structure. At the same time, the embedded cooperation between the mating groove and the slot / slot achieves precise positioning of the hook bracket, avoiding the axial offset problem during traditional terminal installation. This comprehensively improves the space utilization, assembly convenience, and operational reliability of the motor. Attached Figure Description

[0015] The accompanying drawings, which are provided to further illustrate the present invention and constitute a part of the present invention, illustrate exemplary embodiments of the present invention and are used to explain the present invention, but do not constitute an undue limitation of the present invention.

[0016] In the attached diagram:

[0017] Figure 1 This is an overall schematic diagram of a stator mechanism for a brushless motor according to this application;

[0018] Figure 2 for Figure 1 Exploded view;

[0019] Figure 3 for Figure 2 A schematic diagram of the stator front end plate structure;

[0020] Figure 4 for Figure 2 A schematic diagram of the hook frame structure in the middle;

[0021] Figure 5 for Figure 2 A schematic diagram of the stator laminations and stator rear end plate structure;

[0022] Figure label:

[0023] 11. Stator front end plate; 12. Positioning protrusion; 13. Limiting boss; 131. Positioning slot; 21. Stator lamination; 22. Yoke; 23. Tooth; 24. Stator slot; 3. Wire hook bracket; 31. Connecting piece; 32. Butt joint groove; 33. Arc-shaped surface; 34. Wire hook claw; 41. Stator rear end plate; 42. Protruding structure; 43. Block structure; 44. Slot; 61. Enamelled wire; 62. Phase conductor. Detailed Implementation

[0024] To further illustrate the technical means and effects adopted by this utility model in order to achieve the intended utility model purpose, the following detailed description of the specific implementation methods, structure, features and effects of this utility model is provided in conjunction with the accompanying drawings and preferred embodiments.

[0025] The technical solutions provided by the various embodiments of this utility model are described in detail below with reference to the accompanying drawings.

[0026] Reference Figures 1 to 5 As shown, this utility model embodiment provides a stator mechanism for a brushless motor, including a stator front end plate 11, a stator lamination 21 and a stator rear end plate 41. The stator front end plate 11 serves as a front end support structure, and two sets of limiting bosses 13 are fixedly installed on its circumference. A guide space is formed between the two sets of limiting bosses 13, and a positioning slot 131 of a certain depth is provided on the limiting bosses 13.

[0027] The stator laminations 21 are inserted into the stator front end plate 11 and are mainly made of silicon steel sheets (or silicon steel sheets) stacked together to form the core part of the motor magnetic circuit. The stacked structure cooperates with the front end plate. A hook frame 3 is slidably inserted between the two sets of limiting bosses 13. The hook frame 3 is arranged on the side of the stator and serves as a guide and fixing component for the winding circuit. The hook frame 3 has a mating groove 32. A block structure 43 is fixedly installed on the circumference of the stator rear end plate 41. The block structure 43 has a slot 44 for inserting into the mating groove 32 to achieve a stable assembly of the hook frame 3 between the front and rear end plates.

[0028] Specifically, the hook frame 3 is fixed with three sets of high-temperature resistant connecting pieces 31 by spot welding. One end of each connecting piece 31 extends into a hook claw 34, which has a hook-shaped structure. This hook shape can directly hook the end of the enameled wire 61 or the winding lead-out, and prevent the enameled wire 61 from shifting or loosening due to mechanical movement during winding and welding by physical limiting, thus ensuring the stability of the winding structure. At the same time, when the winding machine winds the enameled wire 61 into the stator slot 24, the hook claw 34 provides an initial fixed anchor point for the winding, guiding the enameled wire 61 to wind neatly layer by layer according to the design path, avoiding winding chaos caused by loosening at the starting end, and improving the consistency and standardization of the winding arrangement.

[0029] Specifically, a connecting portion (not shown in the figure) extends from one end of the connecting piece 31 away from the hook claw 34. A phase wire 62 is fixed to the connecting portion by spot welding, thereby realizing electrical connection, ensuring stable current transmission, and providing a basis for the normal operation of the motor. The three sets of connecting pieces 31 are arranged in a compact layout (with small spacing) to shorten the connection path of the phase wire 62, and at the same time reduce the amount of wire material used to save manufacturing costs.

[0030] Specifically, the stator lamination 21 has a ring-shaped yoke 22, which serves as the ring-shaped base structure of the stator lamination 21. Meanwhile, the side of the hook frame 3 that is attached to the yoke 22 is an arc-shaped surface 33. The arc-shaped surface 33 is suitable for the hook frame 3 to be tightly attached to the yoke 22, thereby achieving faster engagement between the mating groove 32 and the positioning slot 131 of the stator front end plate 11.

[0031] Specifically, the inner wall of the yoke 22 extends radially into multiple sets of teeth 23, with stator slots 24 formed between adjacent teeth 23. The yoke 22 serves as the annular base structure of the stator laminations 21, forming a closed path for the motor's magnetic circuit. It primarily conducts magnetic lines of force, enabling efficient flow of the alternating magnetic field within the motor, while also providing mechanical support for the stacked structure of the teeth 23 and the stator laminations 21.

[0032] The teeth 23 radiate outward from the inner wall of the yoke 22 towards the center, serving not only to separate the stator slots 24 but also to support the windings. The stator slots 24, as grooves between adjacent teeth 23, are the core area for embedding the enameled wire 61 windings.

[0033] Specifically, the stator rear end plate 41 is provided with multiple sets of protruding structures 42 along its radial direction, and each set of protruding structures 42 has a step. When the stator rear end plate 41 is fitted with the docking groove 32 of the hook frame 3 through the slot 44, the protruding structure 42 is simultaneously fitted onto the surface of the tooth 23, and its step is tightly fitted with the bottom surface of the tooth 23, thereby achieving positioning and support of the tooth 23 through mechanical limiting, ensuring the stability of the stator lamination 21 stacking structure, and preventing the tooth 23 from radially displacing or deforming during motor operation.

[0034] Specifically, the stator front end plate 11 is provided with multiple sets of positioning protrusions 12 along its radial direction. Each set of positioning protrusions 12 is provided with a boss. When the stator front end plate 11 is adapted to the docking groove 32 of the hook frame 3 through the positioning slot 131, the positioning protrusion 12 is simultaneously fitted onto the surface of the tooth 23, and its boss is tightly fitted with the bottom surface of the tooth 23. Thus, the positioning and support of the tooth 23 are achieved through mechanical limiting, ensuring the stability of the stator lamination 21 stacking structure and preventing the tooth 23 from radially displacing or deforming during motor operation.

[0035] In summary: During assembly and use, the stator front end plate 11 is first inserted into the stator slot 24 of the stator lamination 21 according to multiple sets of positioning protrusions 12. The stator front end plate 11 itself forms a tight fit connection by utilizing its own plasticity. Axial and radial dual positioning can be achieved without additional fasteners, ensuring the concentricity and stability of the stacked structure. The hook frame 3 is quickly aligned with the positioning slot 131 of the stator front end plate 11 through the docking slot 32, and is completely fixed by the slot 44 of the stator rear end plate 41, forming a two-way clamping structure of the front and rear end plates for the hook frame 3, which effectively limits the displacement of the hook frame 3 during winding and motor operation. Finally, the entire stator is placed into the winding machine to wind the enameled wire 61, then placed into the spot welding machine for spot welding, and finally the phase conductors 62 are manually welded to form the stator.

[0036] Among them, the three sets of high-temperature resistant connecting pieces 31 of the hook frame 3 adopt spot welding process to replace the traditional manual welding. The welding point quality is more reliable and the production efficiency is improved. The compact distribution design shortens the length of the phase conductor 62 and reduces material costs.

[0037] The docking structure between the stator rear end plate 41 and the slot 44 of the hook frame 3 provides stable support for the winding machine, ensures the winding accuracy of the enameled wire 61, reduces the risk of wire breakage due to vibration, and further improves the production yield.

[0038] The hook bracket 3 is arranged on the side of the stator to avoid axial extension, shorten the overall length of the motor, and make the motor more suitable for applications in narrow spaces. Furthermore, the mechanical positioning of the hook bracket 3 is achieved by utilizing the structural features of the stator front end plate 11, stator lamination 21, and stator rear end plate 41, eliminating the need for additional fixing screws, reducing the number of parts and assembly processes, and lowering material and labor costs.

[0039] The deep contact design of the positioning slot 131 enhances the fit strength with the hook bracket 3 docking slot 32, making it less likely to fall off during assembly; at the same time, the mechanical limiting structure avoids the risk of loosening during long-term operation and extends the motor life.

[0040] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A stator mechanism for a brushless motor, comprising a stator front end plate (11), stator laminations (21), and a stator rear end plate (41), characterized in that: Two sets of limiting bosses (13) are fixedly installed on the circumference of the stator front end plate (11), and a guide space is formed between the two sets of limiting bosses (13). A positioning slot (131) of a certain depth is opened on the limiting bosses (13). The stator lamination (21) is inserted into the stator front end plate (11). A hook frame (3) is slidably inserted between the two sets of limiting bosses (13). The hook frame (3) is arranged on the side of the stator. The hook frame (3) has a mating groove (32). A block structure (43) is fixedly installed on the circumference of the stator rear end plate (41). The block structure (43) has a slot (44) for inserting into the mating groove (32) to achieve a stable assembly of the hook frame (3) between the front and rear end plates.

2. The stator mechanism for a brushless motor according to claim 1, characterized in that: The hook frame (3) is fixed with three sets of high-temperature resistant connecting pieces (31) by spot welding. One end of each set of connecting pieces (31) extends into a hook claw (34). The hook claw (34) has a hook-shaped structure and the hook shape can hook the end / winding wire of the enameled wire (61).

3. The stator mechanism for a brushless motor according to claim 2, characterized in that: The connecting piece (31) extends from one end away from the hook claw (34) to form a connecting part. A phase wire (62) is fixed to the connecting part by spot welding to achieve electrical connection. The three sets of connecting pieces (31) are arranged in a compact layout to shorten the connection path of the phase wire (62).

4. The stator mechanism for a brushless motor according to claim 3, characterized in that: The stator lamination (21) has a ring-shaped yoke (22), which serves as the ring-shaped base structure of the stator lamination (21). The side of the hook frame (3) that is attached to the yoke (22) is an arc-shaped surface (33). The arc-shaped surface (33) is suitable for the hook frame (3) to fit tightly against the yoke (22), thereby quickly realizing the engagement of the mating groove (32) with the positioning slot (131) of the stator front end plate (11).

5. The stator mechanism for a brushless motor according to claim 4, characterized in that: The inner wall of the yoke (22) extends radially into multiple sets of teeth (23), and stator slots (24) are formed between adjacent teeth (23). The teeth (23) are radially distributed from the inner wall of the yoke (22) towards the center, used to separate the stator slots (24) and support the winding. The stator slots (24) serve as grooves between adjacent teeth (23) for embedding the core area of ​​the enameled wire (61) winding.

6. The stator mechanism for a brushless motor according to claim 5, characterized in that: The stator rear end plate (41) is provided with multiple sets of protruding structures (42) along its radial direction. Each set of protruding structures (42) is provided with a step. The stator rear end plate (41) is adapted to be matched with the docking groove (32) of the hook frame (3) through the slot (44). The protruding structure (42) is simultaneously fitted onto the surface of the tooth (23), and its step is tightly fitted with the bottom surface of the tooth (23).

7. The stator mechanism for a brushless motor according to claim 5, characterized in that: The stator front end plate (11) is provided with multiple sets of positioning protrusions (12) along its radial direction. Each set of positioning protrusions (12) is provided with a boss. The stator front end plate (11) is adapted to be matched with the docking groove (32) of the hook frame (3) through the positioning slot (131). The positioning protrusions (12) are simultaneously fitted onto the surface of the tooth (23), and their bosses are tightly fitted with the bottom surface of the tooth (23).

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