One-piece injection molding overmolded structure of brushless motor

Abstract

This utility model discloses an integrated injection-molded structure for a brushless motor, relating to the field of motor design. It includes a motor drive board with a stator fixedly mounted on it. A rotor is rotatably mounted on the stator, and the stator drives the rotor to rotate when energized. The stator comprises a base frame, an iron core, and a top frame. The base frame is fixedly mounted on the upper side of the motor drive board and has an inlay groove formed thereon. The iron core is fitted into the inlay groove with a clearance fit. The top frame is injection-molded and positioned above the base frame and iron core. The base frame and top frame enclose the iron core, forming an integrated injection-molded structure. Several protruding edges are formed on the bottom side of the base frame, and pins are fixedly mounted on the bottom side of these protruding edges. Several welding holes are formed on the motor drive board, and the pins are welded and fixed into these welding holes. This utility model utilizes a secondary injection molding process to manufacture an integrated stator, which is then fixed by inserting pins into the welding holes, ensuring motor reliability and saving space.

Description

Technical Field

[0001] This utility model relates to the field of motor design, and in particular to an integrated injection-molded overmolded structure for brushless motors. Background Technology

[0002] A brushless DC motor consists of a motor body and a driver, and is a typical mechatronic product. Because a brushless DC motor operates in a self-controlled manner, it does not require an additional starting winding on the rotor like a synchronous motor that starts under heavy load with frequency conversion speed regulation, nor does it experience oscillation or loss of synchronism during sudden load changes.

[0003] In current brushless motors, the PCBA control board of the motor stator is used to control the energizing direction of the copper wire windings. Together with the magnetic field of the permanent magnet ring on the rotor, it drives the rotor to rotate at high speed. The motor control board on the market is generally locked in the motor bracket with screws.

[0004] Screw assembly is cumbersome and has a high failure rate. Moreover, this design can cause the motor control board to tilt during operation, which can cause the Hall effect sensors inside the motor to shift, resulting in large differences in the forward and reverse rotation performance of the motor and unstable operation.

[0005] Therefore, it is necessary to design an integrated injection molding and overmolding structure for brushless motors to avoid tilting during assembly, thereby ensuring the probability of good quality and the service life of the motor. Utility Model Content

[0006] To overcome the shortcomings mentioned above, this utility model provides a technical solution that can solve the above problems.

[0007] The brushless motor has an integrated injection-molded structure, including a motor drive board, on which a stator is fixedly mounted, and a rotor is rotatably mounted on the stator. When the stator is energized, it drives the rotor to rotate. The stator includes a base frame, an iron core, and a top frame. The base frame is fixedly installed on the upper side of the motor drive board. An inlay groove is formed on the base frame. The iron core is installed in the inlay groove with clearance fit. The top frame is injection molded and set above the base frame and the iron core. The base frame and the top frame wrap around the iron core and form an injection molded integrated structure. The base frame has several bottom edges formed on its bottom side, and the bottom edges of the several bottom edges all abut against the motor drive plate, and the height of the several bottom edges is set to be the same.

[0008] Furthermore: the bottom side of the base frame is formed with several protruding edges, which are separated from the motor drive board by vertical separation. PIN pins are fixedly installed on the bottom side of the protruding edges, and several welding holes are formed on the motor drive board, in which the PIN pins are welded and fixed.

[0009] Furthermore: the outer side of the iron core is formed with several winding slots, and copper wire windings are electrically connected and installed on the PIN pins. The copper wire windings are wound and installed between the base frame and the top frame, and the copper wire windings are located in the several winding slots of the iron core. Several insulating edges are formed on both the base frame and the top frame, and the copper wire windings and the winding slots of the iron core are insulated and separated by several insulating edges.

[0010] Furthermore: a positioning pin is formed on the bottom side of the bottom edge, and several pin holes are formed on the motor drive plate, with the positioning pins being inserted into the pin holes in a one-to-one clearance fit.

[0011] Furthermore: both the stator and the motor drive board have through holes formed in their middle portions; a bottom cover is fixedly installed on the bottom side of the motor drive board; a positioning cylinder is formed in the middle of the upper side of the bottom cover; and the through holes of the stator and the motor drive board are fitted together with the positioning cylinder on the outside with clearance fit.

[0012] Furthermore: the rotor includes a rotating cover, a rotating shaft, and a permanent magnet ring. The rotating cover is mounted on the stator, the rotating shaft is fixedly mounted in the middle of the rotating cover, and the lower end of the rotating shaft is rotatably mounted in the positioning cylinder. The permanent magnet ring is fixedly mounted on the inner wall of the rotating cover, and the permanent magnet ring is located on the outer side of the iron core.

[0013] Furthermore, a rolling bearing is fitted between the positioning cylinder and the rotating shaft.

[0014] Furthermore: the bottom cover is formed with a clearance slot, and a connector is fixedly installed on the bottom side of the motor drive board. The connector is installed in the clearance slot with a clearance fit, and the connector supplies power to the copper wire winding through the motor drive board and PIN pins.

[0015] Compared with the prior art, the beneficial effects of this utility model are: the integrated stator is manufactured by secondary injection molding of mold, which has a good insulation effect. At the same time, several bottom edges of the base frame can be stably abutted against the motor drive board to complete precise assembly, and then fixed by inserting pins into the welding holes. There will be no phenomenon of unreliable fixation or tilting, which ensures the reliability of the motor, saves extra space, and improves the rationality of the overall motor mechanism design.

[0016] Before the improvement, the drawbacks were that the motor drive board could be damaged or not installed properly during operation, resulting in large differences in forward and reverse performance and unstable operation.

[0017] Advantages of the improvement: The installation position of the motor drive board is guaranteed by PIN pins and solder holes, which makes the operation simple, the position is fixed and secure and will not tilt, thus ensuring the reliability of the motor, saving extra space, and improving the overall rationality of the motor mechanism design.

[0018] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a structural schematic diagram from another perspective of the present invention; Figure 3 This is an exploded structural diagram of the present invention; Figure 4 yes Figure 3 A schematic diagram of the explosion structure from another perspective; Figure 5 This is an exploded structural diagram of the stator of this utility model.

[0021] The following components are shown in the diagram: 1. Motor drive board; 2. Stator; 21. Base frame; 22. Iron core; 23. Top frame; 3. Rotor; 31. Rotating cover; 32. Rotating shaft; 33. Permanent magnet ring; 4. Inlay groove; 5. Bottom edge; 6. Raised edge; 7. PIN pin; 8. Solder hole; 9. Winding groove; 10. Insulating edge; 11. Positioning pin; 12. Pin hole; 13. Through hole; 14. Bottom cover; 15. Positioning cylinder; 16. Rolling bearing; 17. Clear slot; 18. Connector. Detailed Implementation

[0022] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0023] The components of the present invention embodiments described and shown in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0024] Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0025] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0026] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0027] like Figure 1-5 As shown, the integrated injection-molded structure of the brushless motor of this utility model includes a motor drive board 1, on which a stator 2 is fixedly installed, and a rotor 3 is rotatably installed on the stator 2, and the stator 2 drives the rotor 3 to rotate when energized. The stator 2 includes a base frame 21, an iron core 22, and a top frame 23. The base frame 21 is fixedly installed on the upper side of the motor drive plate 1. An inlay groove 4 is formed on the base frame 21. The iron core 22 is installed in the inlay groove 4 with a clearance fit. The top frame 23 is injection molded and set above the base frame 21 and the iron core 22. The base frame 21 and the top frame 23 wrap around the iron core 22 and form an injection molded integrated structure. The bottom side of the base frame 21 is formed with a plurality of bottom edges 5, the bottom edges of the plurality of bottom edges 5 all abut against the motor drive plate 1, and the plurality of bottom edges 5 are set at the same height. The principle is as follows: the base frame 21 is pre-processed by injection molding, and then the iron core 22 is placed into the inlay groove 4 of the base frame 21. After that, it is placed into the injection mold for secondary molding, and then the top frame 23 is formed. At this time, the iron core 22 is wrapped between the base frame 21 and the top frame 23, which has a good insulation effect. At the same time, several bottom edges 5 of the base frame 21 can be stably abutted against the motor drive plate 1 to complete precise assembly. There will be no phenomenon of unstable fixation or tilting, which ensures the reliability of the motor, saves extra space, and improves the rationality of the overall motor mechanism design.

[0028] Furthermore, the bottom side of the base frame 21 is formed with several protruding edges 6, which are vertically separated from the motor drive board 1. PIN pins 7 are fixedly installed on the bottom side of the protruding edges 6. Several welding holes 8 are formed on the motor drive board 1, and the PIN pins 7 are welded and fixed in the welding holes 8. The PIN pins 7 can be installed into the welding holes 8 of the motor drive board 1 by welding, thereby completing the precise positioning of the motor drive board 1 on the bottom side of the base frame 21. The motor will not tilt during operation, ensuring the reliability of the motor.

[0029] Furthermore: the outer side of the iron core 22 is formed with several winding slots 9, and copper wire windings are electrically connected and installed on the PIN pins 7. The copper wire windings are wound and installed between the base frame 21 and the top frame 23, and the copper wire windings are located in the several winding slots 9 of the iron core 22. Several insulating edges 10 are formed on both the base frame 21 and the top frame 23. The copper wire windings and the winding slots 9 of the iron core 22 are insulated and separated by several insulating edges 10. The base frame 21 and the top frame 23 can be used to achieve full insulation when the copper wire windings are wound on the iron core 22, which can realize the operation of precision winding and improve the yield of brushless motor production.

[0030] Furthermore, the bottom side of the bottom edge 5 is formed with a positioning pin 11, and the motor drive plate 1 is formed with a plurality of pin holes 12. The positioning pin 11 is inserted into the pin hole 12 with a one-to-one gap fit; this makes the installation of the base frame 21 on the motor drive plate 1 more stable and prevents displacement, thus ensuring the stability of the motor operation.

[0031] Furthermore, both the stator 2 and the motor drive plate 1 have through holes 13 formed in their middle portions. A bottom cover 14 is fixedly installed on the bottom side of the motor drive plate 1. A positioning cylinder 15 is formed in the middle of the upper side of the bottom cover 14. The through holes 13 of the stator 2 and the motor drive plate 1 are fitted together with the positioning cylinder 15 with clearance fit. This allows the motor drive plate 1 and the stator 2 to be stably assembled onto the positioning cylinder 15, ensuring the overall reliability of the motor.

[0032] Furthermore, the rotor 3 includes a rotating cover 31, a rotating shaft 32, and a permanent magnet ring 33. The rotating cover 31 is installed on the stator 2, the rotating shaft 32 is fixedly installed in the middle of the rotating cover 31, and the lower end of the rotating shaft 32 is rotatably fitted inside the positioning cylinder 15. The permanent magnet ring 33 is fixedly installed on the inner wall of the rotating cover 31, and the permanent magnet ring 33 is located outside the iron core 22. When the motor drive board 1 energizes the copper wire winding, the magnetic field of the permanent magnet ring 33 can drive the rotating cover 31 and the rotating shaft 32 to rotate at high speed, which can ensure the stable operation of the motor.

[0033] Furthermore, a rolling bearing 16 is fitted between the positioning cylinder 15 and the rotating shaft 32, so that the rotating shaft 32 will not wobble when it is running at high speed.

[0034] Furthermore: the bottom cover 14 is formed with a clearance slot 17, and a connector 18 is fixedly installed on the bottom side of the motor drive board 1. The connector 18 is installed in the clearance slot 17 with clearance fit. The connector 18 supplies power to the copper wire winding through the motor drive board 1 and the PIN pin 7. The setting of the connector 18 can facilitate the wiring and use of the brushless motor.

[0035] This embodiment does not impose any limitation on the shape, material, structure, etc. of this utility model. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this utility model shall fall within the protection scope of this utility model.

Claims

1. An integrated injection-molded overmolded structure for a brushless motor, including a motor drive board, on which a stator is fixedly mounted, and a rotor is rotatably mounted on the stator, and the stator drives the rotor to rotate when energized; Its features are: The stator includes a base frame, an iron core, and a top frame. The base frame is fixedly installed on the upper side of the motor drive board. An inlay groove is formed on the base frame. The iron core is installed in the inlay groove with clearance fit. The top frame is injection molded and set above the base frame and the iron core. The base frame and the top frame wrap around the iron core and form an injection molded integrated structure. The bottom side of the base frame has several protruding edges, and pins are fixedly installed on the bottom side of the protruding edges. The motor drive board has several welding holes, and the pins are welded and fixed in the welding holes.

2. The integral injection-molded overmolded structure of the brushless motor according to claim 1, characterized in that: The outer side of the iron core is formed with several winding slots. A copper wire winding is electrically connected and installed on the PIN pin. The copper wire winding is wound and installed between the base frame and the top frame, and the copper wire winding is located in the several winding slots of the iron core. Several insulating edges are formed on both the base frame and the top frame. The copper wire winding and the winding slots of the iron core are insulated and separated by several insulating edges.

3. The integral injection-molded overmolded structure of the brushless motor according to any one of claims 1-2, characterized in that: The base frame has several bottom edges formed on its bottom side, and the bottom edges of the several bottom edges all abut against the motor drive plate, and the height of the several bottom edges is set to be the same.

4. The integral injection-molded overmolded structure of the brushless motor according to claim 3, characterized in that: The bottom edge has a positioning pin formed on its bottom side, and the motor drive plate has several pin holes formed on its bottom side. The positioning pins are inserted into the pin holes with a clearance fit.

5. The integrated injection-molded overmolded structure of the brushless motor according to claim 2, characterized in that: Both the stator and the motor drive board have through holes formed in the middle. A bottom cover is fixedly installed on the bottom side of the motor drive board. A positioning cylinder is formed in the middle of the upper side of the bottom cover. The through holes of the stator and the motor drive board are fitted with the positioning cylinder with clearance fit.

6. The integral injection-molded overmolded structure of the brushless motor according to claim 5, characterized in that: The rotor includes a rotating cover, a rotating shaft, and a permanent magnet ring. The rotating cover is mounted on the stator, the rotating shaft is fixedly mounted in the middle of the rotating cover, and the lower end of the rotating shaft is rotatably fitted inside the positioning cylinder. The permanent magnet ring is fixedly mounted on the inner wall of the rotating cover and is located on the outer side of the iron core.

7. The integral injection-molded overmolded structure of the brushless motor according to claim 6, characterized in that: A rolling bearing is fitted between the positioning cylinder and the rotating shaft.

8. The integral injection-molded overmolded structure of the brushless motor according to claim 7, characterized in that: The bottom cover has a recessed slot, and a connector is fixedly installed on the bottom side of the motor drive board. The connector is installed in the recessed slot with a clearance fit, and the connector supplies power to the copper wire winding through the motor drive board and PIN pins.

9. The integral injection-molded overmolded structure of the brushless motor according to claim 1, characterized in that: The protruding edge and the motor drive board are arranged vertically and vertically separated from each other.

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