A micro motor stator assembly with bus bars

Abstract

This utility model discloses a stator assembly for a micro motor with busbars, characterized in that it includes: a stator core encapsulated in a cylindrical insulating frame, a coil winding wound in a winding slot of the insulating frame, and a busbar with several busbars installed at the end of the insulating frame. The busbars are arranged layer by layer along the axial direction; a connecting terminal connected to the coil winding is provided at the axial end of the radial outer edge of the insulating frame; each tooth extends radially around the inner circumference of the insulating frame, and a positioning part with different axial heights extends axially to position different busbars; each busbar has a positioning opening corresponding to the positioning part along the axial direction; the positioning part passes through the positioning opening and supports the busbar on an axial end face of the positioning part; a welding terminal corresponding to the connecting terminal is provided on the radial outer edge of the busbar; the welding terminal is welded to the connecting terminal to fix the busbar, thus solving the insulation and positioning problems between busbars.

Description

Technical Field

[0001] This utility model relates to a micro motor stator assembly with a busbar containing multiple busbars, which may be classified as H02K 3 / 50 or H01R 25 / 16 by IPC. Background Technology

[0002] Currently, for micro motors that supply power to the motor via a busbar containing multiple busbars at the stator winding end, the busbars are typically fixed by injection molding or by setting a retainer. Traditional designs for the structure and process of this busbar have problems that are not conducive to production, and the insulation, positioning, and size are still not ideal.

[0003] For relevant common knowledge and terminology, please refer to Chinese patents CN116896203A, CN116191147A and CN212648673U, as well as the Mechanical Engineering Handbook and Electrical Engineering Handbook published by Machinery Industry Press from 1978 to 1983 or the 2nd edition in 1997. Utility Model Content

[0004] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a micro-motor stator assembly with a busbar, which can solve the problems described in the background section.

[0005] This utility model provides a stator assembly for a micro motor with a busbar, comprising: a stator core encapsulated in a cylindrical insulating frame, a coil winding wound in a winding slot of the insulating frame, and a busbar with several busbars installed at the end of the insulating frame. The busbars are arranged layer by layer along the axial direction; a connection terminal connected to the coil winding is provided at the axial end of the radial outer edge of the insulating frame; each tooth extending radially around the inner circumference of the insulating frame extends axially to provide positioning portions with different axial heights for positioning different busbars; each busbar has a positioning opening corresponding to the positioning portion along the axial direction; the positioning portion passes through the positioning opening and supports the busbar on the axial end face of the positioning portion; each busbar has a welding terminal corresponding to the connection terminal, and the welding terminal is welded to the connection terminal to fix the busbar.

[0006] The stator assembly according to the embodiments of the present utility model has at least the following beneficial effects: Each bus bar is arranged layer by layer along the axial direction at different heights. By setting corresponding positioning parts with different heights on the tooth parts of the insulating skeleton, positioning ports are provided on each bus bar and respectively positioned and installed with these positioning parts; then, the welding terminals on the bus bar are also used for welding and fixing with the connection terminals for connecting the coil windings, without the need to additionally fix the bus bar by injection molding, which reduces the manufacturing cost while being beneficial to improving the insulation performance and positioning between the bus bars, and the structure is more compact compared with the traditional arrangement of bus bars.

[0007] According to some embodiments of the present utility model, the positioning part is set as a protrusion or a buckle, and the positioning port passes through the protrusion or the positioning port is clamped with the positioning part. When the positioning part is a protrusion, it is mainly used for positioning the bus bar. When the positioning part is a buckle, the bus bar can be further fixed and the installation is more stable.

[0008] According to some embodiments of the present utility model, the bus bar includes a first bus bar, a second bus bar and a third bus bar; the positioning part includes a first positioning part, a second positioning part and a third positioning part; the first positioning part, the second positioning part and the third positioning part respectively pass through the positioning ports of the first bus bar, the second bus bar and the third bus bar, and the horizontal height of the first positioning part is higher than that of the second positioning part; the horizontal height of the second positioning part is higher than that of the third positioning part. This effectively ensures the insulation between the three bus bars.

[0009] According to some embodiments of the present utility model, an avoidance port is further provided on the end face of each bus bar, and the avoidance port allows the positioning part higher than the corresponding bus bar to pass through. This enables the bus bar to avoid the higher positioning part for installation.

[0010] According to some embodiments of the present utility model, the axial end face includes the axial end face of the first limiting boss, the axial end face of the second limiting boss and the axial end face of the third limiting boss. The axial end face of the first limiting boss and the end face of the second positioning part are at the same height; the axial end face of the second limiting boss and the axial end face of the third positioning part are at the same height. The distance between the axial end face of the positioning part and the axial end face is L1, and the thickness of the bus bar is L2, and 1mm < L1 - L2 < 2.5mm. This can shorten the axial height of the stator while meeting the creepage distance.

[0011] According to some embodiments of the present utility model, a welding groove is bent out at the bottom on one side of the connection terminal, and the welding groove is used for welding the lead wire of the coil winding. This enhances the reliability of the connection.

[0012] According to some embodiments of this utility model, the in-phase windings in the coil winding are connected in parallel. Using a parallel connection can appropriately reduce the wire diameter of the coil winding and increase the number of turns, thus greatly reducing the winding difficulty and improving the winding efficiency. Attached Figure Description

[0013] The accompanying drawings are provided to further understand the technical solution of this utility model and constitute a part of the specification. They are used together with the embodiments of this utility model to explain the technical solution of this utility model, and do not constitute a limitation on the technical solution of this utility model.

[0014] Figure 1 This is an overall schematic diagram of a stator assembly provided in one embodiment of the present invention;

[0015] Figure 2 yes Figure 1 A partial exploded view of the stator assembly is shown.

[0016] Figure 3 yes Figure 1 The diagram shown is an overall view of the insulating frame when it is not rolled up.

[0017] Figure 4 yes Figure 3 The front view of the insulating frame is shown;

[0018] Figure 5 yes Figure 2 The diagram shows the overall layout of the busbar.

[0019] Figure 6 yes Figure 4 A magnified view of a portion of the insulating frame A is shown.

[0020] Figure 7 This is a schematic diagram of the connection of a coil winding provided in one embodiment of the present invention;

[0021] Figure 8 This is an overall schematic diagram of a stator assembly provided in another embodiment of the present invention.

[0022] Icon labels:

[0023] Insulating frame 100; winding groove 110; connecting terminal 120; welding groove 121; toothed part 130; positioning part 140; first positioning member 141; second positioning member 142; third positioning member 143; axial end face 150; axial end face 151 of the first limiting boss; axial end face 152 of the second limiting boss; axial end face 153 of the third limiting boss; stator core 200; coil winding 300; lead wire 310; busbar 400; positioning port 410; welding terminal 420; first busbar 430; second busbar 440; third busbar 450; clearance port 460. Detailed Implementation

[0024] The embodiments of this utility model are described in detail below. Examples of these 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 are only used to explain this utility model, and should not be construed as limiting this utility model.

[0025] In the description of this utility model, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings. 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.

[0026] In the description of this utility model, "multiple" refers to two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of technical features or their sequential relationship.

[0027] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0028] Reference Figure 1 and 2 and Figure 7The stator assembly includes: a stator core 200, a coil winding 300, an insulating frame 100, and a busbar 400. The stator core 200 is encapsulated in the insulating frame 100. The coil winding 300 is wound around the winding slots 110 of the insulating frame 100. The busbar 400, containing several busbars 430, 440, and 450, is installed at the end of the insulating frame 100. The axial end of the radial outer edge of the insulating frame 100 is provided with a connection terminal 120 for connecting to the coil winding 300. The insulating frame 100 has teeth 130 extending radially around its inner circumference. Positioning parts 140 with different axial heights extend outward along the axial direction to position different busbars 430, 440, and 450. Each busbar 430, 440, and 450 is provided with a positioning port 410 corresponding to the positioning part 140 along the axial direction. The positioning part 140 passes through the positioning port 410 to support each busbar 430, 440, and 450 on the axial end face 150. The radial outer edge of the busbars 430, 440, and 450 is provided with a welding terminal 420, which is welded to the connecting terminal 120 to fix each busbar 430, 440, and 450. Specifically, since the insulating frame 100 extends into positioning portions 140 at different heights in the axial direction, after the busbar 400 is positioned and installed with the positioning portions 140, each busbar 430, 440, and 450 is placed on the axial end face 150 at different heights. Therefore, each busbar 430, 440, and 450 is axially separated from each other, achieving insulation and positioning between the busbars 430, 440, and 450. Then, the welding terminals 420 of the busbars 430, 440, and 450 are welded to the connecting terminals 120 on the top of the insulating frame 100 to fix each busbar 430, 440, and 450. There is no need to fix the busbar 400 by injection molding, which greatly reduces the manufacturing cost of the stator assembly.

[0029] refer to Figures 2 to 6, the bus bar 400 includes a first bus bar 430, a second bus bar 440, and a third bus bar 450. The positioning part 140 includes a first positioning member 141, a second positioning member 142, and a third positioning member 143. The axial end face 150 includes the axial end face 151 of the first limiting boss, the axial end face 152 of the second limiting boss, and the axial end face 153 of the third limiting boss. The first positioning member 141, the second positioning member 142, and the third positioning member 143 respectively pass through the positioning holes 410 of the first bus bar 430, the second bus bar 440, and the third bus bar 450 to achieve positioning and installation; the horizontal height of the first positioning member 141 is higher than that of the second positioning member 142, and the horizontal height of the second positioning member 142 is higher than that of the third positioning member 143. The axial end face 151 of the first limiting boss and the axial end face of the second positioning member 142 are at the same height; the axial end face 152 of the second limiting boss and the axial end face of the third positioning member 143 are at the same height. Specifically, the first positioning member 141, the second positioning member 142, and the third positioning member 143 are respectively arranged in a plurality along the circumferential direction, and the corresponding positioning holes 410 on the first bus bar 430, the second bus bar 440, and the third bus bar 450 are also provided in a plurality to perform positioning and installation on the bus bar 400. It can be understood that since the first bus bar 430, the second bus bar 440, and the third bus bar 450 are respectively positioned and installed with the first positioning member 141, the second positioning member 142, and the third positioning member 143 with different heights, each bus bar 430, 440, 450 is installed at different heights on the top of the stator assembly, so that each bus bar 430, 440, 450 is staggered in the axial direction, ensuring that each bus bar 430, 440, 45 is independent of each other and achieving insulation. When installing the bus bar 400, the positioning hole 410 of the third bus bar 450 passes through the third positioning member 143 and is placed on the axial end face 153 of the third limiting boss. Then, the positioning hole 410 of the second bus bar 440 passes through the second positioning member 142 and is placed on the axial end face 152 of the second limiting boss. Finally, the positioning hole 410 of the first bus bar 430 passes through the first positioning member 141 and is placed on the axial end face 151 of the first limiting boss, thereby achieving the preliminary installation and positioning of the bus bars 430, 440, 450. Then, by welding the welding terminals 420 on the bus bars 430, 440, 450 and the connection terminals 120 on the top of the insulating skeleton 100, the complete fixation of the bus bars 430, 440, 450 can be achieved. More specifically, the distance between the axial end face of the positioning part 140 and the axial end face 150 is L1, and the thickness of each bus bar 430, 440, 450 is L2, and 1mm < L1 - L2 < 2.5mm. Therefore, it can meet the creepage distance of international 12V, and at the same time, it can also shorten the axial height of the stator assembly. In this application, L1 - L2 is preferably 1.5mm.

[0030] Furthermore, each busbar 430, 440, and 450 has a clearance opening 460 on its end face, which allows the positioning part 140, which is higher than the second busbar 440 or the third busbar 450, to pass through. Specifically, when the third busbar 450 is installed, the first positioning member 141 and the second positioning member 142 pass through the clearance opening 460 of the third busbar 450; when the second busbar 440 is installed, the first positioning member 141 passes through the clearance opening 460 of the second busbar 440.

[0031] Understandably, the number of the first positioning element 141, the second positioning element 142, and the third positioning element 143 can be set according to the number of slots in the winding groove 110, and the corresponding positioning ports 410 of the busbars 430, 440, and 450 are also set accordingly, without specific limitations here. For example, when the winding groove 110 has 12 slots, the number of the first positioning element 141, the second positioning element 142, and the third positioning element 143 is 4, and the number of positioning ports 410 is also set to 4.

[0032] In addition, further reference Figure 1 and Figure 8 The positioning part 140 can be configured as a protrusion or a snap fastener. When the positioning part 140 is a protrusion, it is mainly used to position the busbars 430, 440, and 450. When the positioning part 140 is a snap fastener, it can further fix the busbars 430, 440, and 450, axially limit the busbars 430, 440, and 450, prevent the busbars 430, 440, and 450 from axially dislodging, and make the installation more stable.

[0033] refer to Figure 1 , Figure 2 and Figure 8 A welding groove 121 with an upward opening is bent out at the bottom of one side of the connecting terminal 120. The welding groove 121 is used to weld the lead wire 310 of the coil winding 300. The lead wire 310 is embedded in the welding groove 121, and the welding groove 121 supports the lead wire 310, making the electrical connection between the lead wire 310 and the connecting terminal 120 more reliable.

[0034] refer to Figure 7 The in-phase windings in coil winding 300 are connected in parallel. Specifically, coil winding 300 is wound by a winding machine using a single-branch winding method. The coil wire diameter is very thick, and the winding machine cannot withstand the winding tension, resulting in slow or no winding, low winding efficiency, and the need to increase power, which greatly increases electricity costs. However, this application adopts a parallel method. In order to ensure that the output has the same back EMF as a single branch, the number of turns of coil winding 300 needs to be increased. Therefore, the coil wire diameter can be reduced to increase the number of turns of coil winding 300, thereby greatly reducing the winding tension, reducing the winding difficulty, improving winding efficiency, and saving costs.

[0035] Understandably, the number of welding terminals 420 and connecting terminals 120 is set according to the connection method of the coil winding 300 and the number of winding slots 110. For example, if the stator assembly has 12 slots, there are a total of 4 parallel branches, and the number of welding terminals 420 and connecting terminals 120 is 13.

[0036] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model.

Claims

1. A micro motor stator assembly including a busbar (400), comprising: The stator core (200) is encapsulated in a cylindrical insulating frame (100), the coil winding (300) is wound in a winding slot (110) of the insulating frame (100), and the busbar (400) with several busbars (430, 440, 450) is installed at the end of the insulating frame (100). The busbars are arranged layer by layer along the axial direction; the axial end of the radial outer edge of the insulating frame (100) is provided with a connecting terminal (120) connected to the coil winding (300); the insulating frame (100) has teeth (130) extending radially around its inner circumference, extending axially to position different busbars and with axial height. The positioning parts (140) are of different degrees. Each busbar (430, 440, 450) is provided with a positioning port (410) corresponding to the positioning part (140) along the axial direction. The positioning part (140) passes through the positioning port (410) and supports the busbar (430, 440, 450) on the axial end face (150) of the positioning part (140). The busbar (430, 440, 450) is provided with a welding terminal (420) corresponding to the connecting terminal (120). The welding terminal (420) is welded to the connecting terminal (120) to fix the busbar (430, 440, 450).

2. The stator assembly according to claim 1, characterized in that, The positioning part (140) is configured as a protrusion or a snap fastener, and the positioning port (410) passes through the protrusion or the positioning port (410) and engages with the positioning part (140).

3. The stator assembly according to claim 1, characterized in that, The busbar (400) includes a first busbar (430), a second busbar (440), and a third busbar (450); the positioning part (140) includes a first positioning element (141), a second positioning element (142), and a third positioning element (143); the first positioning element (141), the second positioning element (142), and the third positioning element (143) pass through the positioning openings (410) of the first busbar (430), the second busbar (440), and the third busbar (450), respectively, and the horizontal height of the first positioning element (141) is higher than that of the second positioning element (142); the horizontal height of the second positioning element (142) is higher than that of the third positioning element (143).

4. The stator assembly according to claim 1, characterized in that, Each busbar (430, 440, 450) is also provided with a clearance opening (460) on its end face, the clearance opening (460) allowing the positioning part (140) which is higher than the corresponding busbar (430, 440, 450) to pass through.

5. The stator assembly according to claim 3, characterized in that, The axial end face (150) includes an axial end face (151) of a first limiting boss, an axial end face (152) of a second limiting boss, and an axial end face (153) of a third limiting boss. The axial end face (151) of the first limiting boss is at the same height as the axial end face of the second positioning member (142); the axial end face (152) of the second limiting boss is at the same height as the axial end face of the third positioning member (143). The distance between the axial end face of the positioning part (140) and the axial end face (150) is L1. The thickness of each busbar (430, 440, 450) is L2, and 1mm. <L1—L2<2.5mm。 6. The stator assembly according to claim 1, characterized in that, A welding groove (121) is bent out at the bottom of one side of the connecting terminal (120), and the welding groove (121) is used to weld the lead wire (310) of the coil winding (300).

7. The stator assembly according to claim 1, characterized in that, The in-phase windings in the coil winding (300) are connected in parallel.

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