High performance brushless motor

Abstract

The utility model aims at providing a kind of high-performance brushless motor, it includes casing, stator structure being arranged in casing and rotatory setting in the rotor structure of stator structure, stator structure includes stator base, two insulation end frames, several insulating papers and several winding groups, stator base is set on the inner side wall of casing, the inner side wall of stator base is provided with several partition blocks at equal angle, to make the first wire slot between any two adjacent partition blocks, each insulating paper is respectively set in each first wire slot, two insulation end frames are respectively set on the axial two ends of stator base, and the two ends of each insulating paper are respectively connected with two insulation end frames, each winding group is one-to-one corresponding and is wound on each partition block.

Description

Technical Field

[0001] This utility model relates to the technical field of brushless motors, and in particular to a high-performance brushless motor. Background Technology

[0002] RC remote control cars adhere to strict proportional limitations, and both the size of the car body and the effect during control have a high degree of simulation, which is why they are loved by more and more users.

[0003] As the power source for RC remote control cars, the performance and price of brushless motors have always been key concerns for users. Currently, to design a high-performance motor within certain size and power density requirements, it is necessary to improve the motor's efficiency. The higher the slot fill factor, the more coil turns can be accommodated, thus generating greater output power. Therefore, when designing a high-performance motor, it is necessary to maximize the slot fill factor.

[0004] However, in the current stator structure of brushless motors, the insulation layer between the stator core and the winding is too thick, which greatly affects the slot fill factor of the motor and compresses the winding space. Therefore, in order to increase the number of windings in the motor to improve the slot fill factor and thus improve the motor performance, the high-performance brushless motor of this application is proposed. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a high-performance brushless motor that can effectively improve the slot fill factor.

[0006] The objective of this utility model is achieved through the following technical solution:

[0007] A high-performance brushless motor includes a housing, a stator structure disposed within the housing, and a rotor structure rotatably disposed within the stator structure.

[0008] The stator structure includes a stator base, two insulating end frames, several insulating papers, and several winding groups. The stator base is disposed on the inner side wall of the housing. Several spacers are disposed at equal angles on the inner side wall of the stator base so that a first groove is formed between any two adjacent spacers. Each insulating paper is respectively attached to each of the first grooves. The two insulating end frames are respectively disposed on the two axial ends of the stator base, and both ends of each insulating paper are respectively connected to the two insulating end frames. Each winding group is wound one-to-one on each of the spacers.

[0009] In one embodiment, the end of the spacer away from the stator base extends to both sides toward the first groove to form a spacer wing.

[0010] In one embodiment, a gap is provided between the opposing wings on any two adjacent partitions.

[0011] In one embodiment, the end faces of each spacer away from the stator base collectively form a non-closed inner circular surface.

[0012] In one embodiment, the insulating end frame includes an outer ring and a plurality of end blocks, each end block being disposed at an equal angle on the inner sidewall of the outer ring such that a second groove is formed between any two adjacent end blocks, and each end block abuts against each of the spacers, and each of the second grooves communicates with each of the first grooves.

[0013] In one embodiment, a stop block is provided on the end of the end block near the outer ring and the end block away from the outer ring, so that the end block and the two stop blocks together form a limiting groove.

[0014] In one embodiment, a positioning groove is provided on the outer wall of the stator base, and a positioning post is provided on the outer ring, the positioning post being adapted to be inserted into the positioning groove.

[0015] In one embodiment, a clearance groove is provided on the side of the second groove near the stator base, and one end of the insulating paper is accommodated in the clearance groove.

[0016] In one embodiment, the housing includes a shell, a front cover and a rear cover, the front cover and the rear cover are respectively disposed on the two axial ends of the shell, the outer side wall of the stator base is bonded to the inner side wall of the shell, the two ends of the rotor structure are respectively rotatably connected to the front cover and the rear cover, and one end of the rotor structure protrudes from the front cover.

[0017] In one embodiment, the rotor structure includes a rotating shaft, a rotor core, an aramid membrane, two end plates, and a plurality of magnetic tiles. The two end plates are respectively disposed on both ends of the rotor core. The rotating shaft passes through the rotor core and the two end plates. Each magnetic tile is disposed at an equal angle on the outer side wall of the rotor core, and both ends of each magnetic tile abut against the two end plates. The aramid membrane covers the outer side wall of each magnetic tile.

[0018] Compared with the prior art, the present invention has at least the following advantages:

[0019] When each winding group is wound onto each spacer in a corresponding manner, the winding group and the spacer / stator base are isolated and insulated by insulating paper and insulating end frames. Since the insulating paper is thin, it occupies little space. Therefore, in the case of a stator base / spacer of the same volume, compared with the existing structure in which a plastic insulating layer is installed in the first slot, the structure of this application can greatly save the space of insulating material, thereby increasing the number of windings in the winding group and effectively improving the slot fill factor. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of a high-performance brushless motor according to one embodiment of the present invention;

[0022] Figure 2 for Figure 1 An exploded view of the high-performance brushless motor shown.

[0023] Figure 3 This is a schematic diagram of the stator structure according to one embodiment of the present invention;

[0024] Figure 4 for Figure 3 A partial structural schematic diagram of the stator structure is shown.

[0025] Figure 5 This is a schematic diagram of the stator base according to one embodiment of the present invention;

[0026] Figure 6 This is a cross-sectional structural diagram of an insulating end frame according to one embodiment of the present invention;

[0027] Figure 7 for Figure 4 A partial enlarged structural diagram of A;

[0028] Figure 8 This is a schematic diagram of the rotor structure according to one embodiment of the present invention.

[0029] Explanation of reference numerals in the attached figures:

[0030] 10. High-performance brushless motor; 100. Housing; 200. Stator structure; 300. Rotor structure; 210. Stator base; 220. Insulating end frame; 230. Insulating paper; 240. Winding assembly; 251. Spacer block; 211. First slot; 252. Spacer wing; 221. Outer ring; 222. End block; 223. Second slot; 224. Stop block; 225. Material limiting slot; 212. Positioning slot; 226. Positioning column; 227. Clearance slot; 110. Housing; 120. Front cover; 130. Rear cover; 310. Shaft; 320. Rotor core; 330. Aramid film; 340. End plate; 350. Magnet tile; 140. Insulating partition. Detailed Implementation

[0031] The embodiments of this utility model are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the embodiments of this utility model, and should not be construed as limiting the utility model.

[0032] In the description of the embodiments of this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of 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.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0035] To facilitate understanding of this utility model, a more comprehensive description will be provided below with reference to the accompanying drawings. The drawings illustrate preferred embodiments of this utility model.

[0036] like Figures 1 to 5 As shown, a high-performance brushless motor 10 includes a housing 100, a stator structure 200 disposed within the housing 100, and a rotor structure 300 rotatably disposed within the stator structure 200. The stator structure 200 includes a stator base 210, two insulating end frames 220, a plurality of insulating papers 230, and a plurality of winding groups 240. The stator base 210 is disposed on the inner side wall of the housing 100. A plurality of spacers 251 are disposed at equal angles on the inner side wall of the stator base 210 so that a first groove 211 is formed between any two adjacent spacers 251. Each insulating paper 230 is respectively attached to each first groove 211. The two insulating end frames 220 are respectively disposed on the two axial ends of the stator base 210, and both ends of each insulating paper 230 are respectively connected to the two insulating end frames 220. Each winding group 240 is wound one-to-one on each spacer 251.

[0037] It should be noted that the stator structure 200 is installed inside the housing 100, and the rotor structure 300 is rotatably installed inside the stator structure 200, with the rotor structure 300 rotatably connected to the housing 100. Further, the stator base 210 is installed on the inner wall of the housing 100, and multiple spacers 251 are equally spaced on the inner wall of the stator base 210, each spacer 251 being integrally formed with the stator base 210. Thus, a first groove 211 is formed between any two adjacent spacers 251, resulting in multiple first grooves 211 on the inner wall of the stator base 210. An insulating paper 230 is fitted into each first groove 211, and two insulating end brackets 220 are respectively installed at both ends of the stator base 210, such that both ends of each insulating paper 230 are connected to two insulating end brackets 220. Thus, when each winding group 240 is wound one-to-one on each spacer 251, the winding group 240 and the spacer 251 / stator base 210 are isolated and insulated by insulating paper 230 and insulating end frame 220. Since the insulating paper 230 is thin, it occupies little space. Therefore, in the case of the same volume stator base 210 / spacer 251, compared with the existing structure of installing a plastic insulating layer in the first wire slot 211, the structure of this application can greatly save the space of insulating material, thereby increasing the number of windings of the winding group 240 and effectively improving the slot fill factor.

[0038] like Figure 5 As shown, in one embodiment, the end of the spacer 251 away from the stator seat 210 extends to both sides in a direction close to the first groove 211 to form a spacer wing 252 respectively.

[0039] It should be noted that by forming partition wings 252 on both sides of the partition block 251, the first wire groove 211 formed is a non-closed annular structure, so that the winding group 240 can be stably wound on the partition block 251.

[0040] In one embodiment, a gap is provided between the opposing partition wings 252 on any two adjacent partitions 251. In this way, the first groove 211 formed between any two adjacent partitions 251 is a non-closed annular structure.

[0041] In one embodiment, the end faces of each spacer 251 away from the stator base 210 collectively form a non-closed inner circular surface. In this way, the rotor structure 300 can pass through the inner circular surface intermittently to rotate stably relative to each winding group 240.

[0042] like Figure 4 and Figure 6 As shown, in one embodiment, the insulating end frame 220 includes an outer ring 221 and a plurality of end blocks 222. Each end block 222 is disposed at an equal angle on the inner sidewall of the outer ring 221 so that a second groove 223 is formed between any two adjacent end blocks 222. Each end block 222 abuts against each spacer 251 in a one-to-one correspondence, and each second groove 223 is connected to each first groove 211 in a one-to-one correspondence.

[0043] It should be noted that each end block 222 abuts against each spacer 251 in a corresponding manner. In this way, the end blocks 222 separate the two ends of the spacer 251, and the insulating paper 230 separates the two sides of the spacer 251, thereby ensuring reliable insulation between the winding assembly 240 and the spacer 251 / stator base 210. In one embodiment, the end block 222 and the outer ring 221 are integrally formed plastic structures.

[0044] like Figure 2 and Figure 6 As shown, in one embodiment, a stop block 224 is provided on the end of the end block 222 near the outer ring 221 and the end of the end block 222 away from the outer ring 221, so that the end block 222 and the two stop blocks 224 together form a limiting groove 225.

[0045] It should be noted that the two stops 224 together with the end block 222 form a limiting groove 225, which allows the winding assembly 240 to stably pass around the end block 222 without slipping.

[0046] like Figure 6 As shown, in one embodiment, a positioning groove 212 is provided on the outer side wall of the stator base 210, and a positioning post 226 is provided on the outer ring 221, the positioning post 226 being adapted to be inserted into the positioning groove 212.

[0047] Thus, by fitting the positioning pins 226 into the positioning slots 212, the entire insulating end frame 220 can be quickly and accurately assembled onto the end of the stator base 210, facilitating the installation of the stator structure 200. In one embodiment, two positioning pins 226 are provided, and two positioning slots 212 are formed. The two positioning pins 226 are respectively inserted into the two positioning slots 212 to achieve positioning and prevent mistaken identification.

[0048] like Figure 7 As shown, in one embodiment, a clearance groove 227 is provided on the side of the second wire groove 223 near the stator base 210, and one end of the insulating paper 230 is accommodated in the clearance groove 227.

[0049] It should be noted that the clearance groove 227 is stepped within the second wire groove 223. Therefore, the portion of the insulating paper 230 that extends beyond both ends of the stator base 210 will fall into the clearance groove 227. This ensures that the insulating paper 230 is tightly connected to the insulating end frame 220, thereby ensuring reliable insulation between the winding assembly 240 and the stator base 210 / spacer block 251.

[0050] like Figure 2 As shown, in one embodiment, the housing 100 includes a housing 110, a front cover 120 and a rear cover 130. The front cover 120 and the rear cover 130 are respectively disposed on the two axial ends of the housing 110. The outer side wall of the stator seat 210 is bonded to the inner side wall of the housing 110. The two ends of the rotor structure 300 are rotatably connected to the front cover 120 and the rear cover 130 respectively, and one end of the rotor structure 300 extends out from the front cover 120.

[0051] It should be noted that the outer wall of the stator base 210 is glued to the inner wall of the housing 110, the front cover 120 is also glued to one end of the housing 110, and the rear cover 130 is screwed to the other end of the housing 110. The rotor structure 300 is rotatably connected to the front cover 120 and the rear cover 130 respectively.

[0052] like Figure 8 As shown, in one embodiment, the rotor structure 300 includes a rotating shaft 310, a rotor core 320, an aramid membrane 330, two end plates 340, and a plurality of magnetic tiles 350. The two end plates 340 are respectively disposed on both ends of the rotor core 320. The rotating shaft 310 passes through the rotor core 320 and the two end plates 340. Each magnetic tile 350 is disposed at equal angles on the outer side wall of the rotor core 320, and both ends of each magnetic tile 350 abut against the two end plates 340 respectively. The aramid membrane 330 covers the outer side wall of each magnetic tile 350.

[0053] It should be noted that the rotating shaft 310 passes through and is fixed at the axial position of the rotor core 320. The two end plates 340 are located at both ends of the rotor core 320, and each magnet 350 is installed at an equal angle on the outer side wall of the rotor core 320. Then, an aramid film 330 is used to cover the outer peripheral wall of each magnet 350. This forms the integral rotor structure 300. Furthermore, the two ends of the rotating shaft 310 are rotatably connected to the front cover 120 and the rear cover 130 respectively through bearings.

[0054] like Figure 2 As shown, in one embodiment, an insulating partition 140 is further provided between the stator structure 200 and the front end cover 120. This improves the insulation performance of the stator structure 200.

[0055] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A high-performance brushless motor, comprising a housing, a stator structure disposed within the housing, and a rotor structure rotatably disposed within the stator structure, characterized in that: The stator structure includes a stator base, two insulating end frames, several insulating papers, and several winding groups. The stator base is disposed on the inner side wall of the housing. Several spacers are disposed at equal angles on the inner side wall of the stator base so that a first groove is formed between any two adjacent spacers. Each insulating paper is respectively attached to each of the first grooves. The two insulating end frames are respectively disposed on the two axial ends of the stator base, and both ends of each insulating paper are respectively connected to the two insulating end frames. Each winding group is wound one-to-one on each of the spacers.

2. The high-performance brushless motor according to claim 1, characterized in that, The spacer extends from the end away from the stator base toward both sides toward the first groove to form a spacer wing.

3. The high-performance brushless motor according to claim 2, characterized in that, A gap is provided between the opposing winglets on any two adjacent partitions.

4. The high-performance brushless motor according to claim 3, characterized in that, The end faces of each of the spacers away from the stator base together form a non-closed inner circular surface.

5. The high-performance brushless motor according to claim 1, characterized in that, The insulating end frame includes an outer ring and a plurality of end blocks. Each end block is disposed at an equal angle on the inner sidewall of the outer ring so that a second groove is formed between any two adjacent end blocks. Each end block abuts against each spacer block, and each second groove is connected to each first groove.

6. The high-performance brushless motor according to claim 5, characterized in that, A stop block is provided on the end of the end block near the outer ring and the end block away from the outer ring, so that the end block and the two stop blocks together form a limiting groove.

7. The high-performance brushless motor according to claim 5, characterized in that, A positioning groove is provided on the outer wall of the stator base, and a positioning post is provided on the outer ring, the positioning post being adapted to be inserted into the positioning groove.

8. The high-performance brushless motor according to claim 5, characterized in that, The second groove has a clearance groove on the side near the stator base, and one end of the insulating paper is accommodated in the clearance groove.

9. The high-performance brushless motor according to claim 1, characterized in that, The housing includes a shell, a front cover and a rear cover. The front cover and the rear cover are respectively disposed on the two axial ends of the shell. The outer side wall of the stator base is glued to the inner side wall of the shell. The two ends of the rotor structure are rotatably connected to the front cover and the rear cover respectively, and one end of the rotor structure protrudes from the front cover.

10. The high-performance brushless motor according to claim 9, characterized in that, The rotor structure includes a rotating shaft, a rotor core, an aramid membrane, two end plates, and several magnetic tiles. The two end plates are respectively disposed on both ends of the rotor core. The rotating shaft passes through the rotor core and the two end plates. Each magnetic tile is disposed at an equal angle on the outer side wall of the rotor core, and both ends of each magnetic tile abut against the two end plates. The aramid membrane covers the outer side wall of each magnetic tile.

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