A motor stator and busbar integrated injection molding structure

Abstract

The utility model relates to a kind of motor stator and busbar integrated injection molding structure, including mould column, mould cover is installed on the upper part of mould column, mould column and mould cover outer periphery are equipped with shell, stator is connected in the middle of shell, stator is connected with lower copper ring, upper copper group connection, upper copper group is installed in mould cover;Pouring potting adhesive between mould column, mould cover, shell;Mould cover middle is equipped with shaft column hole, shaft column hole outside is sequentially distributed glue injection port and mould cover through-hole, one side of mould cover is equipped with boss, vertical slot is equipped in boss. The utility model is completed injection molding in one step process, completely eliminates the risk of stratification, improves structural strength and ensures uniform heat dissipation. At the same time, the original potting process is reduced, and the process time is shortened by more than 40%.

Description

Technical Field

[0001] This utility model belongs to the field of motor manufacturing technology and relates to an integrated injection molding structure of motor stator and busbar. Background Technology

[0002] Currently, in the permanent magnet motor industry, the stator windings and the control board are connected using injection-molded busbars, which consist of a lower copper ring and an upper copper busbar assembly. The stator, with the busbar installed, is then placed into the product housing or a special mold and filled with potting compound for insulation. This process has the following drawbacks: 1. Both potting compound and busbar plastic wrapping serve the purpose of insulation, but they need to be done in separate steps, requiring two molds and multiple positioning processes, making the process complex and expensive. 2. Weak interfacial bonding between processes creates air gaps, leading to uneven heat dissipation and limiting product output power; 3. Due to the different basic properties of the insulating materials of the bus terminals and the potting body, stress cracks are easily generated at the joint, which reduces the service life of the product; 4. Long production cycle (curing + cooling time combined) and low pass rate. Summary of the Invention

[0003] The purpose of this utility model is to provide an integrated injection-molded structure for motor stator and busbar, which can solve the problem, improve the convenience of operation, and has good economic benefits.

[0004] According to the technical solution provided by this utility model: an integrated injection molding structure for a motor stator and busbar includes a mold column, a mold cover installed on the upper part of the mold column, a housing fitted around the mold column and the mold cover, a stator connected in the middle of the housing, the stator connected to a lower copper ring and an upper copper busbar assembly, the upper copper busbar assembly installed in the mold cover; potting compound is poured between the mold column, the mold cover, and the housing; a shaft hole is provided in the middle of the mold cover, and injection ports and through holes of the mold cover are evenly distributed on the outer side of the shaft hole; a boss is provided on one side of the mold cover, and a slot is vertically provided in the boss; the shaft extends out of the shaft hole; the stator includes a stator core pressed into the middle of the housing, a winding is wound inside the stator core, and an insulating frame is provided between the stator core and the winding.

[0005] As a further improvement of this utility model, the mold column is stepped, consisting of a shaft column, a sealing step, and a positioning step from top to bottom; a sealing ring is fitted around the outer periphery of the sealing step, and mold column connection holes are evenly distributed on the positioning step.

[0006] As a further improvement of this utility model, the housing is a hollow barrel, and the upper and lower end faces of the housing are provided with connecting screw holes, which are adapted to the connecting holes of the mold column and the through holes of the mold cover; the upper and lower ends of the housing are connected to the mold cover and the mold column.

[0007] As a further improvement of this utility model, three three-phase lower connecting claws are evenly distributed on the lower copper ring, and the three-phase lower connecting claws are connected to the winding.

[0008] As a further improvement of this utility model, the upper copper busbar assembly consists of three upper copper busbars, namely the first upper copper busbar, the second upper copper busbar, and the third upper copper busbar. The upper part of the first upper copper busbar is a first three-phase lead-out copper plate, and the lower part is a first arc-shaped copper plate, with a three-phase first upper connecting claw at the end of the first arc-shaped copper plate. The upper part of the second upper copper busbar is a second three-phase lead-out copper plate, and the lower part is a second horizontal copper plate, with a three-phase second upper connecting claw at the end of the second arc-shaped copper plate. The upper part of the third upper copper busbar is a third three-phase lead-out copper plate, and the lower part is a third arc-shaped copper busbar. The plate has a three-phase third upper connecting claw at the end of the third arc-shaped copper plate; the first arc-shaped copper plate and the third arc-shaped copper plate are symmetrically arranged with the second horizontal copper plate as the center; the first three-phase lead-out copper plate, the second three-phase lead-out copper plate and the third three-phase lead-out copper plate have pin holes at the top; the boss has three slots vertically arranged, the first three-phase lead-out copper plate, the second three-phase lead-out copper plate and the third three-phase lead-out copper plate are located in the slots, the pin holes on the first three-phase lead-out copper plate, the second three-phase lead-out copper plate and the third three-phase lead-out copper plate extend out of the slots, and the positioning pin is inserted into the pin hole.

[0009] As a further improvement of this utility model, the top of the mold cover is provided with a pin groove, which is semi-circular, and the lower part of the positioning pin is located in the pin groove.

[0010] The positive and progressive effects of this utility model are as follows: 1. This utility model completes injection molding in a single step, completely eliminating the risk of delamination, improving structural strength, and ensuring uniform heat dissipation. It also reduces the original potting process, shortening the process time by more than 40%.

[0011] 2. Compared with the existing stator potting structure, this utility model does not require separate injection molding of the busbar. It only requires welding the winding head and tail to the corresponding copper busbar, then placing the stator into the housing, fixing the position of the copper busbar through the potting mold, and then potting the stator assembly as a whole to achieve the purpose of filling the electrical gap with insulating material and meeting the insulation requirements.

[0012] 3. Compared with the existing stator encapsulation structure, this utility model reduces the number of process steps, simplifies the operation steps, reduces the number of molds, shortens the production cycle, improves the ease of operation, and has good economic benefits. Attached Figure Description

[0013] Figure 1 This is an exploded view of the present invention.

[0014] Figure 2 This is a schematic diagram of the structure of the lower copper ring and the upper copper busbar assembly of this utility model.

[0015] Figure 3 This is a cross-sectional view of the present invention. Detailed Implementation

[0016] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other. The present utility model will now be described in detail with reference to the accompanying drawings and embodiments.

[0017] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0018] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this utility model described herein. Furthermore, terms such as "comprising" and "having" mean that in addition to those already listed in "comprising" and "having," other unlisted contents may also be included; for example, a process, method, system, product, or device may include a series of steps or units, not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to these processes, methods, products, or devices.

[0019] Due to the angle of the drawing, some parts may not be drawn, but their positions and connections can be understood from the text descriptions.

[0020] like Figure 3 As shown, this utility model is an integrated injection-molded structure for a motor stator and busbar, including a mold column 15, a mold cover 12 mounted on the upper part of the mold column 15, a housing 4 sleeved around the outer periphery of the mold column 15 and the mold cover 12, a stator connected in the middle of the housing 4, and the stator connected to a lower copper ring 10 and an upper copper busbar assembly, the upper copper busbar assembly being installed in the mold cover 12. A potting compound 6 is poured between the mold column 15, the mold cover 12, and the housing 4.

[0021] like Figure 1 As shown, the mold column 15 is stepped, consisting of a shaft column 15-1, a sealing step 15-2, and a positioning step 15-3 from top to bottom. A sealing ring 13 is fitted around the outer periphery of the sealing step 15-2, which seals the mold column 15 and the housing 4. Mold column connection holes are evenly distributed on the positioning step 15-3.

[0022] The mold cover 12 has a shaft post hole 12-1 in the middle. Glue injection ports 12-2 and mold cover through holes 12-3 are evenly distributed around the shaft post hole 12-1. A boss 12-4 is provided on one side of the mold cover 12, with a slot vertically positioned within the boss 12-4. The shaft post 15-1 extends out of the shaft post hole 12-1, serving as a simulation of a motor shaft.

[0023] The housing 4 is a hollow barrel. The upper and lower end faces of the housing 4 are provided with connecting screw holes, which are adapted to the connecting holes of the mold column and the through holes 12-3 of the mold cover. The upper and lower ends of the housing 4 are connected to the mold cover 12 and the mold column 15.

[0024] The stator includes a stator core 1 pressed into the middle of the housing 4, a winding 3 wound inside the stator core 1, and an insulating frame 2 provided between the stator core 1 and the winding 3.

[0025] like Figure 2 As shown, three three-phase lower connecting claws 10-1 are evenly distributed on the lower copper ring 10, and the three-phase lower connecting claws 10-1 are connected to the winding 3.

[0026] The upper copper busbar group consists of three upper copper busbars: the first upper copper busbar (7), the second upper copper busbar (8), and the third upper copper busbar (9). The first upper copper busbar (7) has a first three-phase lead-out copper plate (7-1) at the top and a first arc-shaped copper plate (7-2) at the bottom, with a three-phase first upper connecting claw (7-3) at the end of the first arc-shaped copper plate. The second upper copper busbar (8) has a second three-phase lead-out copper plate (8-1) at the top and a second horizontal copper plate (8-2) at the bottom, with a three-phase second upper connecting claw (8-3) at the end of the second arc-shaped copper plate. The third upper copper busbar (9) has a third three-phase lead-out copper plate (9-1) at the top and a third arc-shaped copper plate (9-2) at the bottom, with a three-phase third upper connecting claw (9-3) at the end of the third arc-shaped copper plate. The first arc-shaped copper plate (7-2) and the third arc-shaped copper plate (9-2) are symmetrically arranged with the second horizontal copper plate (8-2) as the center. The first three-phase lead-out copper plates 7-1, 8-1, and 9-1 have pin holes on their upper parts. The winding 3 has six leads, which connect to three lower three-phase connecting claws 10-1 and the first, second, and third upper three-phase connecting claws 7-3, 8-3, and 9-3, respectively. The boss 12-4 has three vertical slots. The first three-phase lead-out copper plates 7-1, 8-1, and 9-1 are located in these slots. The pin holes on these plates extend out of the slots, and the positioning pin 14 is inserted into the pin holes to connect the upper copper busbar assembly to the mold cover 12. To prevent the positioning pin 14 from wobbling, the top of the mold cover 12 has a pin groove, which is semi-circular, and the lower part of the positioning pin 14 is located in the pin groove.

[0027] The working process of this utility model is as follows: Apply release agent to the middle of mold column 15, and inject potting compound 6 into the housing 4 through injection port 12-2. After potting is completed, remove mold column 15 and mold cover 12. This facilitates the subsequent installation of motor shaft and motor end cover.

[0028] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of this utility model, and the utility model is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of this utility model, and these modifications and improvements are also considered to be within the protection scope of this utility model.

Claims

1. An integrated injection-molded structure for a motor stator and busbar, characterized in that, The mold includes a mold column (15), a mold cover (12) installed on the upper part of the mold column (15), a housing (4) fitted around the outer periphery of the mold column (15) and the mold cover (12), a stator connected in the middle of the housing (4), the stator connected to the lower copper ring (10) and the upper copper busbar assembly, the upper copper busbar assembly installed in the mold cover (12); potting compound (6) is poured between the mold column (15), the mold cover (12) and the housing (4); the mold cover (12) has a shaft hole (12-1) in the middle, and the shaft hole (12-1) is... -1) The outer side is evenly distributed with injection ports (12-2) and mold cover through holes (12-3). A boss (12-4) is provided on one side of the mold cover (12). A slot is provided vertically in the boss (12-4). The shaft (15-1) extends out of the shaft hole (12-1). The stator includes a stator core (1) pressed in the middle of the housing (4). The stator core (1) is wound with a winding (3) inside. An insulating skeleton (2) is provided between the stator core (1) and the winding (3).

2. The integrated injection-molded structure of motor stator and busbar as described in claim 1, characterized in that, The mold column (15) is stepped, and from top to bottom are the shaft column (15-1), the sealing step (15-2), and the positioning step (15-3); the sealing step (15-2) is fitted with a sealing ring (13) on its outer periphery, and the mold column connection holes are evenly distributed on the positioning step (15-3).

3. The integrated injection-molded structure of motor stator and busbar as described in claim 2, characterized in that, The housing (4) is a hollow barrel. The upper and lower end faces of the housing (4) are provided with connecting screw holes, which are adapted to the mold column connecting hole and the mold cover through hole (12-3). The upper and lower ends of the housing (4) are connected to the mold cover (12) and the mold column (15).

4. The integrated injection-molded structure of motor stator and busbar as described in claim 1, characterized in that, Three three-phase lower connecting claws (10-1) are evenly distributed on the lower copper ring (10), and the three-phase lower connecting claws (10-1) are connected to the winding (3).

5. The integrated injection-molded structure of motor stator and busbar as described in claim 4, characterized in that, The upper copper busbar group consists of three upper copper busbars, namely the first upper copper busbar (7), the second upper copper busbar (8), and the third upper copper busbar (9). The upper part of the first upper copper busbar (7) is the first three-phase lead-out copper plate (7-1), and the lower part is the first arc-shaped copper plate (7-2). The end of the first arc-shaped copper plate is provided with the first three-phase upper connecting claw (7-3). The upper part of the second upper copper busbar (8) is the second three-phase lead-out copper plate (8-1), and the lower part is the second horizontal copper plate (8-2). The end of the second arc-shaped copper plate is provided with the second three-phase upper connecting claw (8-3). The upper part of the third upper copper busbar (9) is the third three-phase lead-out copper plate (9-1), and the lower part is the third arc-shaped copper plate (9-2). The end of the third arc-shaped copper plate is provided with the third three-phase upper connecting claw (9-3). The upper connecting claw (9-3); the first arc-shaped copper plate (7-2) and the third arc-shaped copper plate (9-2) are symmetrically arranged with the second horizontal copper plate (8-2) as the center; the first three-phase lead-out copper plate (7-1), the second three-phase lead-out copper plate (8-1), and the third three-phase lead-out copper plate (9-1) are provided with pin holes on the upper part; the boss (12-4) is provided with 3 slots vertically, the first three-phase lead-out copper plate (7-1), the second three-phase lead-out copper plate (8-1), and the third three-phase lead-out copper plate (9-1) are located in the slots, the pin holes on the first three-phase lead-out copper plate (7-1), the second three-phase lead-out copper plate (8-1), and the third three-phase lead-out copper plate (9-1) extend out of the slots, and the positioning pin (14) is inserted into the pin hole.

6. The integrated injection-molded structure of motor stator and busbar as described in claim 5, characterized in that, The top of the mold cover (12) is provided with a pin groove, which is semi-circular, and the lower part of the positioning pin (14) is located in the pin groove.

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