One-piece encapsulated motor

Abstract

This utility model discloses an integrated encapsulated motor, including a stator assembly, a rotor assembly, and a PCBA board. The stator assembly is integrally encapsulated by a plastic shell to form a rotor mounting cavity. The three-phase wiring harness windings of the stator assembly are respectively connected to corresponding phase connecting pieces. The rotor assembly is rotatably mounted in the rotor mounting cavity. A mounting step is provided at the rear end of the shell, and a support platform for fixing the PCBA board is provided within the mounting step. The PCBA board is placed on the mounting step and fixed to the support platform by bolts. The phase connecting pieces are welded to corresponding pins of the PCBA board. A heat dissipation end cover for covering the PCBA board is also fixed at the rear end of the shell. The heat dissipation end cover is insulated with external connection pins that are electrically connected to the PCBA board. The external connection pins are welded and fixed to external wiring harnesses. This encapsulated motor can directly encapsulate the stator assembly through the shell, thereby eliminating the need for conductive supports and simplifying the assembly work.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to an integrated encapsulated motor. Background Technology

[0002] The thermal management cooling fan assembly is mainly used in the thermal management cooling system to dissipate heat. The cooling fan assembly includes a shroud, a drive motor and a fan. The shroud includes a cover and a motor mounting hub inside the cover. The motor mounting hub and the cover are connected by several stiffeners. The drive motor is fixed on the motor mounting hub.

[0003] Current drive motors mainly consist of a motor housing, stator assembly, rotor assembly, and end caps. For example, a novel industrial fan drive motor is disclosed in utility model patent CN 215344169U. This drive motor includes a motor housing, stator, and rotor. The stator needs to be embedded into the motor housing. Therefore, in actual assembly, the motor housing needs to be formed first, then the stator needs to be embedded into the motor housing for assembly, and then subsequent conductive wiring operations are performed. The entire assembly process is complex and cumbersome. Typical three-phase motors use PCBA boards for drive control. For example, the applicant's utility model patent CN210640802U discloses a brushless motor stator assembly for an automotive cooling fan. This motor uses a PCBA board and also utilizes conductive brackets to connect the stator windings to the PCBA board. Therefore, it is necessary to design a motor that minimizes assembly steps and reduces costs. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide an integrated encapsulated motor, which can directly encapsulate the stator assembly through the housing, thereby eliminating the need for conductive supports and simplifying the assembly work.

[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is: an integrated encapsulated motor, including a stator assembly, a rotor assembly, and a PCBA board. The stator assembly is integrally encapsulated by a plastic shell to form a hollow rotor mounting cavity. The three-phase wiring harness windings of the stator assembly are respectively connected to corresponding phase connecting pieces. The rear end of the phase connecting piece extends through the shell and protrudes. The rotor assembly is rotatably mounted in the rotor mounting cavity. The rear end of the shell is provided with a mounting step. A support platform for fixing the PCBA board is provided in the mounting step. The PCBA board is placed on the mounting step and fixed to the support platform by bolts. The phase connecting pieces are welded to the corresponding pins of the PCBA board. A heat dissipation end cover for covering the PCBA board is also fixed to the rear end of the shell. An external connection pin electrically connected to the PCBA board is insulated on the heat dissipation end cover. The external connection pin is welded and fixed to an external wiring harness.

[0006] As a preferred embodiment, the stator assembly includes a stator core, a stator winding, and a stator cladding. The stator cladding covers the entire stator core. The rear end face of the stator cladding is further provided with a plurality of spaced-apart winding guide seats and a plurality of spaced-apart cladding positioning posts. The cladding positioning posts are provided with positioning holes. The stator winding is wound outside the stator cladding according to the winding rules and guided by the winding guide seats. The front end of the phase connecting piece is embedded in the stator cladding.

[0007] As a preferred embodiment, the side wall of the mounting step is further provided with a positioning protrusion for positioning the PCBA board, and the corresponding PCBA board is provided with a positioning groove that cooperates with the positioning protrusion.

[0008] As a preferred embodiment, the front end of the housing is further provided with a forward-protruding central cylinder, a bearing is embedded in the central cylinder, the front end of the rotor shaft of the rotor assembly is rotatably mounted in the central cylinder through the bearing and passes through the central cylinder, and the rear end of the rotor shaft is rotatably mounted on the heat dissipation end cover through another bearing.

[0009] As a preferred embodiment, a number of reinforcing ribs are provided between the front end face of the shell and the outer side wall of the central cylinder.

[0010] As a preferred embodiment, the front end of the external connection pin is inserted into the corresponding pin of the PCBA board and soldered to fix it. An insulating pad is fitted on the external connection pin. The insulating pad is located between the heat dissipation end cover and the PCBA board. The insulating pad is provided with a number of rearwardly protruding sealing protrusions. The heat dissipation end cover is provided with a number of embedding holes to facilitate the sealing fit of the sealing protrusions. The external connection pins pass through the sealing protrusions one by one and their rear ends are exposed.

[0011] As a preferred embodiment, the heat dissipation end cover is also provided with a sealing box, the external connection pin is located inside the sealing box, and the sealing box is provided with a dust cover.

[0012] As a preferred embodiment, the housing is provided with a plurality of supporting connecting ears, and the heat dissipation end cover is provided with end cover connecting ears corresponding to the connecting ears. The end cover connecting ears and the supporting connecting ears are fixed together by bolts, and each supporting connecting ear is also provided with a fixing connecting hole for easy motor fixing.

[0013] After adopting the above technical solution, the effect of this utility model is as follows: Since the stator assembly is integrally covered by a plastic shell to form a hollow rotor mounting cavity, the three-phase wiring harness windings of the stator assembly are respectively connected to corresponding phase connecting pieces. The rear end of the phase connecting piece protrudes through the shell. The rotor assembly is rotatably mounted in the rotor mounting cavity. A mounting step is provided at the rear end of the shell, and a support platform for fixing the PCBA board is provided within the mounting step. The PCBA board is placed on the mounting step and fixed to the support platform with bolts. The phase connecting piece is soldered to the corresponding pin of the PCBA board. The rear end of the shell is also fixed with a PCB... The heat dissipation end cover of the A-board cover has insulated external connection pins that are electrically connected to the PCBA board. These external connection pins are welded and fixed to the external wiring harness. Therefore, after the housing covers the stator assembly, no additional stator assembly assembly is required. Secondly, the molded housing can form an installation step, which facilitates the assembly of the PCBA board directly using a support platform. Furthermore, the integrally covered phase connection piece can achieve the conductive connection between the PCBA board and the stator windings. Through the above structure, not only can the PCBA board be used to control the motor conveniently, but other conductive supports for connecting the stator assembly and PCBA are also eliminated, thereby simplifying the motor structure and reducing costs. This covered motor adopts an integral injection molding concept, covering (fixing) the stator assembly with a plastic housing. The housing uses plastic instead of aluminum, eliminating conductive supports and heat fitting processes, thus simplifying the production and assembly process.

[0014] Furthermore, since the stator assembly includes a stator core, stator windings, and a stator enclosure, with the stator enclosure covering the entire stator core, and the rear end face of the stator enclosure further provided with several spaced-apart winding guide seats and several spaced-apart enclosure positioning posts, each with positioning holes, and the stator windings being wound according to winding rules outside the stator enclosure and guided by the winding guide seats, and the front end of the phase connecting piece being embedded in the stator enclosure, the stator assembly is directly covered by the stator enclosure. This eliminates the need for the conventional forming and installation of the insulating front end cover and insulating rear end cover. After the entire stator enclosure covers the stator core, the winding guide seats are directly formed to facilitate the winding of the stator windings. At the same time, the positioning holes on the enclosure positioning posts facilitate the positioning of the stator assembly during enclosure, ensuring accurate positioning during enclosure.

[0015] Furthermore, since the side wall of the mounting step is also provided with positioning protrusions for positioning the PCBA board, and the corresponding PCBA board is provided with positioning grooves that cooperate with the positioning protrusions, the positioning of the PCBA board can be facilitated, and the phase connector can be accurately inserted into the corresponding pin of the PCBA board.

[0016] Furthermore, since the front end of the housing is provided with a forward-protruding central cylinder, and a bearing is embedded in the central cylinder, the front end of the rotor shaft of the rotor assembly is rotatably mounted in the central cylinder through the bearing and passes through the central cylinder, and the rear end of the rotor shaft is rotatably mounted on the heat dissipation end cover through another bearing, the rotor assembly can be assembled more conveniently using the central cylinder, making installation easier.

[0017] Furthermore, since several reinforcing ribs are provided between the front end face of the shell and the outer side wall of the central cylinder, these reinforcing ribs can effectively increase the connection strength between the front end face of the shell and the central cylinder.

[0018] Furthermore, since the front end of the external connection pin is inserted into the corresponding pin on the PCBA board and soldered in place, an insulating pad is fitted onto the external connection pin. This insulating pad is located between the heat sink and the PCBA board, and it has several rearward-protruding sealing protrusions. The heat sink has several insertion holes for easy sealing of the sealing protrusions. The external connection pin passes through each of these sealing protrusions, with its rear end exposed. In this way, the external connection pin is isolated from the heat sink by the sealing protrusions, providing insulation and facilitating soldering to external wiring harnesses.

[0019] Furthermore, since the heat dissipation end cover is also equipped with a sealing box, the external connection pin is located inside the sealing box, and the sealing box is equipped with a dust cover. The sealing box can be used to facilitate protection when soldering external wire harnesses and external connection pins. After soldering, waterproof glue can be filled into the sealing box for waterproofing, and then the dust cover can be used for dust prevention.

[0020] Furthermore, since the housing is provided with several supporting connecting ears, and the heat dissipation end cover is provided with end cover connecting ears corresponding to the connecting ears, the end cover connecting ears and the supporting connecting ears are fixed together by bolts. Each supporting connecting ear is also provided with a fixing connecting hole for easy motor fixing. Therefore, the fixing connecting holes on the supporting connecting ears of the housing can easily fix the motor to other components. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] Figure 1 This is a three-dimensional structural view of an embodiment of the present utility model;

[0023] Figure 2 This is a perspective view of an embodiment of the present invention with the dust cover hidden.

[0024] Figure 3 This is a perspective view of an embodiment of the present invention with the heat dissipation end cap hidden.

[0025] Figure 4 This is a three-dimensional structural view of the stator assembly encased in the shell according to an embodiment of the present utility model;

[0026] Figure 5 This is a three-dimensional structural view of the front end face of an embodiment of this utility model;

[0027] Figure 6 It is a three-dimensional view of the rotor assembly and stator assembly;

[0028] In the attached diagram: 1. Housing; 11. Support connecting ear; 12. Fixing connecting hole; 13. Bolt hole; 14. Mounting step; 15. Support platform; 16. Central cylinder; 17. Reinforcing rib; 18. Positioning protrusion; 2. Heat dissipation end cover; 21. End cover connecting ear; 3. Dust cover; 4. External wiring harness; 5. Sealing box; 6. External connection pin; 7. Insulating pad; 71. Sealing protrusion; 8. PCBA board; 9. Rotor assembly; 91. Rotor shaft; 10. Stator assembly; 101. Stator enclosure; 102. Covering positioning post; 103. Positioning hole; 104. Stator winding; 105. Winding guide seat; 106. Phase connecting piece. Detailed Implementation

[0029] The present invention will be further described in detail below through specific embodiments.

[0030] like Figures 1 to 6 As shown, the integrated encapsulated motor includes a stator assembly 10, a rotor assembly 9, and a PCBA board 8. The stator assembly 10 is integrally encapsulated by a plastic shell 1 to form a hollow rotor mounting cavity.

[0031] The front end of the housing 1 is provided with a forward-protruding central cylinder 16. A bearing is embedded in the central cylinder 16. The front end of the rotor shaft 91 of the rotor assembly 9 is rotatably mounted in the central cylinder 16 through the bearing and passes through the central cylinder 16. The rear end of the rotor shaft 91 is rotatably mounted on the heat dissipation end cover 2 through another bearing. Several reinforcing ribs 17 are also provided between the front end face of the housing 1 and the outer wall of the central cylinder 16. Several supporting connecting ears 11 are provided on the housing 1. The heat dissipation end cover 2 is provided with end cover connecting ears 21 corresponding to the connecting ears. The end cover connecting ears 21 and the supporting connecting ears 11 are fixed together by bolts. Bolt holes 13 are provided on the end cover connecting ears 21 and the supporting connecting ears 11. The end cover connecting ears 21 and the supporting connecting ears 11 are fixed together by bolts installed in the bolt holes 13. Each supporting connecting ear 11 is also provided with a fixing connecting hole 12 for easy motor fixing.

[0032] like Figure 4 and 6As shown, the three-phase wire harness windings of the stator assembly 10 are respectively connected to the corresponding phase connecting pieces 106, and the rear end of the phase connecting piece 106 extends through the housing 1 and protrudes.

[0033] The stator assembly 10 includes a stator core, a stator winding 104, and a stator cover 101. The stator cover covers the entire stator core. The rear end face of the stator cover is further provided with several spaced-apart winding guide seats 105 and several spaced-apart cover positioning posts 102. Positioning holes 103 are provided on the cover positioning posts 102. The stator winding 104 is wound according to a winding rule outside the stator cover and guided by the winding guide seats 105. The front end of the phase connecting piece 106 is embedded in the stator cover. In this embodiment, the phase connecting piece 106 is embedded during the stator cover covering process. The number of winding guide seats 105 and cover positioning posts 102 is multiple and they are located at the ends of the stator cover.

[0034] The rotor assembly 9 is rotatably mounted in the rotor mounting cavity. The rear end of the housing 1 is provided with a mounting step 14. A support platform 15 for fixing the PCBA board 8 is provided in the mounting step 14. The PCBA board 8 is disposed on the mounting step 14 and fixed to the support platform 15 by bolts. The phase connection piece 106 is welded to the corresponding pin of the PCBA board 8. The rear end of the housing 1 is also fixed with a heat dissipation end cover 2 to cover the PCBA board 8. An external connection pin 6 electrically connected to the PCBA board 8 is provided on the heat dissipation end cover 2. The external connection pin 6 is welded and fixed to the external wiring harness 4.

[0035] In this embodiment, the side wall of the mounting step 14 is also provided with a positioning protrusion 18 for positioning the PCBA board 8, and the corresponding PCBA board 8 is provided with a positioning groove that cooperates with the positioning protrusion 18. The number of positioning protrusions 18 is at least one, which facilitates the determination of the PCBA board 8.

[0036] The front end of the external connection pin 6 is inserted into the corresponding pin of the PCBA board 8 and soldered in place. An insulating pad 7 is fitted onto the external connection pin 6, and the insulating pad 7 is located between the heat dissipation end cover 2 and the PCBA board 8. The insulating pad 7 has several rearwardly protruding sealing protrusions 71. The heat dissipation end cover 2 has several embedding holes for easy sealing and mating of the sealing protrusions 71. The external connection pin 6 passes through the sealing protrusions 71 one by one and its rear end is exposed. The heat dissipation end cover 2 is also provided with a sealing box 5, and the external connection pin 6 is located inside the sealing box 5. A dust cover 3 is provided on the sealing box 5.

[0037] During installation, the insulating pad 7 is first placed over the external connection pin 6, and then the heat dissipation end cap 2 is assembled. The insertion hole of the heat dissipation end cap 2 facilitates the insertion of the protruding part, while the external connection pin 6 is also inside the sealing box 5. This provides some protection when the external wiring harness 4 is soldered to the external connection pin 6. After soldering, the dust cover 3 is then fixed to the sealing box 5. The sealing box 5 can be filled with sealant for sealing.

[0038] Compared to conventional structures, this motor simplifies the assembly process and eliminates the need for conductive supports. The PCBA board 8 is directly fixed to the mounting step 14 of the housing 1, thus reducing the number of parts and lowering costs. This motor is ideal for low-power applications with low heat dissipation requirements. This integrated encapsulated motor can be used in cooling fan assemblies to drive fan impellers, making it suitable for a variety of applications.

[0039] The above-described embodiments are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Any modifications and alterations to the technical solution of the present utility model without departing from its design spirit shall fall within the protection scope defined by the claims of the present utility model.

Claims

1. An integrated encapsulated motor, comprising a stator assembly, a rotor assembly, and a PCBA board, characterized in that: The stator assembly is integrally encased in a plastic shell to form a hollow rotor mounting cavity. The three-phase wiring harness windings of the stator assembly are respectively connected to corresponding phase connecting pieces. The rear end of the phase connecting piece extends through the shell and protrudes. The rotor assembly is rotatably mounted in the rotor mounting cavity. The rear end of the shell is provided with a mounting step, and a support platform for fixing the PCBA board is provided within the mounting step. The PCBA board is placed on the mounting step and fixed to the support platform with bolts. The phase connecting piece is soldered to the corresponding pin of the PCBA board. A heat dissipation end cover for covering the PCBA board is also fixed to the rear end of the shell. The heat dissipation end cover is insulated with external connection pins that are electrically connected to the PCBA board. The external connection pins are soldered and fixed to the external wiring harness.

2. The integrated encapsulated motor as described in claim 1, characterized in that: The stator assembly includes a stator core, a stator winding, and a stator cladding. The stator cladding covers the entire stator core. The rear end face of the stator cladding is provided with a plurality of spaced-apart winding guide seats and a plurality of spaced-apart cladding positioning posts. The cladding positioning posts are provided with positioning holes. The stator winding is wound outside the stator cladding according to the winding rules and guided by the winding guide seats. The front end of the phase connecting piece is embedded in the stator cladding.

3. The integrated encapsulated motor as described in claim 2, characterized in that: The side wall of the mounting step is also provided with a positioning protrusion for positioning the PCBA board, and the corresponding PCBA board is provided with a positioning groove that cooperates with the positioning protrusion.

4. The integrated encapsulated motor as described in claim 3, characterized in that: The front end of the housing is also provided with a forward-protruding central cylinder, in which a bearing is embedded. The front end of the rotor shaft of the rotor assembly is rotatably mounted in the central cylinder through the bearing and passes through the central cylinder. The rear end of the rotor shaft is rotatably mounted on the heat dissipation end cover through another bearing.

5. The integrated encapsulated motor as described in claim 4, characterized in that: Several reinforcing ribs are also provided between the front end face of the shell and the outer wall of the central cylinder.

6. The integrated encapsulated motor as described in claim 5, characterized in that: The front end of the external connection pin is inserted into the corresponding pin of the PCBA board and soldered to fix it. An insulating pad is fitted on the external connection pin. The insulating pad is located between the heat dissipation end cover and the PCBA board. The insulating pad is provided with a number of rearwardly protruding sealing protrusions. The heat dissipation end cover is provided with a number of embedding holes to facilitate the sealing fit of the sealing protrusions. The external connection pin passes through the sealing protrusions one by one and the rear end is exposed.

7. The integrated encapsulated motor as described in claim 6, characterized in that: The heat dissipation end cover is also provided with a sealing box, the external connection pin is located inside the sealing box, and the sealing box is provided with a dust cover.

8. The integrated encapsulated motor as described in claim 7, characterized in that: The housing is provided with a plurality of supporting connecting ears, and the heat dissipation end cover is provided with end cover connecting ears corresponding to the connecting ears. The end cover connecting ears and the supporting connecting ears are fixed together by bolts. Each supporting connecting ear is also provided with a fixing connecting hole for easy motor fixing.

Images