Stator assembly, method for manufacturing the same, and motor
The stator assembly with connection grooves on the main control board simplifies the connection of stator windings, reducing complexity and cost while improving installation and production efficiency.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-03-21
- Publication Date
- 2026-03-25
Smart Images

Figure 2026509923000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of motors, and specifically to a stator assembly, a motor, and a method for manufacturing a stator assembly.
Background Art
[0002] The connection method of the stator winding of a motor is known. Among them, for the stator winding of a motor, the lead wires of the stator winding are first fixed by one or more copper busbars and then welded. After that, injection molding is performed so that the copper busbars are embedded in an insulator plastic. In this way, the lead wires of the stator winding are connected by the copper busbars. The copper busbars are first crimped to the lead wires of the stator winding and then resistance welded. After that, the copper busbars are overmolded onto a plastic insulation bracket. Such a connection method has the problems that the process is complicated and the cost is high. That is, a method of connecting the windings by a bracket and a copper busbar is adopted, and multiple crimping, welding, and injection molding processes are adopted, resulting in the problems that the processing process is complicated and the material cost is high.
Summary of the Invention
Problems to be Solved by the Invention
[0003] In view of the above defects or deficiencies, the present invention provides a stator assembly, and the stator winding of the stator assembly can simplify the connection structure of the current connection end of the stator winding.
Means for Solving the Problems
[0004] To achieve the above object, the present invention provides a stator assembly, and the specific technical solution is as follows. The stator assembly includes a stator and a main control board provided at the axial outer end of the stator, the stator being formed by joining several stator cores, the stator windings being wound around the stator cores, the stator windings having at least two spaced connection grooves, a first conductive portion being provided on the inner circumferential wall of at least a portion of the connection grooves, the connection end being located within the connection groove, and the connection end being electrically connected to the first conductive portion.
[0005] The connection method used for the stator windings in the above-mentioned stator assembly is easy to install, and the connection structure of the connection ends of the stator windings is relatively simplified.
[0006] The present invention further provides a method for manufacturing a stator assembly, and the method for manufacturing the stator assembly is as follows: The process includes the steps of: insert injection molding a single stator core to form a stator core with an insulating frame; winding stator windings around the stator core with the insulating frame so that each stator winding forms two connection ends; joining the stator cores on which the stator windings are wound along the circumferential direction to form a stator; attaching a main control board with connection grooves to the axial outer end of the stator, and attaching the connection ends to the inside of the connection grooves in a one-to-one correspondence; and electrically connecting the connection ends to the first conductive portion of the inner wall of the connection grooves.
[0007] Stator assemblies manufactured using the above-described method have a simple stator winding connection structure and are easy to install.
[0008] The present invention further provides a motor comprising a stator assembly, a rotor assembly, and a housing, wherein the stator assembly is provided within the housing, and the stator assembly comprises a stator and a main control board provided at the axial outer end of the stator, the stator comprises several stator cores, the stator windings are wound around the stator cores, the stator windings include connection ends, the main control board has at least two spaced connection grooves, at least a portion of the inner wall of the connection grooves is provided with a first conductive portion, the connection ends are located within the connection grooves, and the connection ends are electrically connected to the first conductive portion.
[0009] The stator winding connection structure of the above motor is simple, making it easy to install and relatively improving the motor's production efficiency. [Brief explanation of the drawing]
[0010] [Figure 1] Figure 1 shows a perspective view of the conventional technology. [Figure 2] Figure 2 shows a perspective view of the first embodiment of the stator assembly. [Figure 3] Figure 3 shows an exploded perspective view of Figure 2. [Figure 4] Figure 4 shows a perspective view of the stator core. [Figure 5] Figure 5 shows a front view of a second embodiment of the stator assembly. [Figure 6] Figure 6 shows a front view of the main control board in the second embodiment. [Figure 7] Figure 7 shows a perspective view of a type of stator winding connection method in the second embodiment. [Figure 8] Figure 8 shows a front view of the second embodiment, in which the connection ends are mounted on the main control board. [Figure 9] Figure 9 shows an exploded perspective view of the motor. [Modes for carrying out the invention]
[0011] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be described in further detail below with reference to the drawings and specific embodiments. The embodiments and features of the present invention can be combined with each other, provided they do not conflict.
[0012] Many specific details will be described below in order to fully understand the present invention, but the present invention may be carried out in other forms different from those described herein, and therefore the scope of protection of the present invention is not limited to the specific embodiments disclosed below.
[0013] The present invention will be further described below with reference to the drawings and embodiments.
[0014] A known connection method for motor stator windings involves first fixing the lead wires of the stator windings with one or more copper busbars 15, then welding them, and subsequently injection molding the copper busbars 15 so that they are embedded in insulating plastic. As shown in Figure 1, the connection ends 121 of the motor stator windings 12 are connected to the copper busbars 15, the copper busbars 15 and connection ends 121 are first crimped and then resistance welded, and then the copper busbars 15 are overmolded onto the insulating bracket 16. However, this connection method has the problem of being complex and costly. Specifically, by adopting a method of connecting the stator windings 12 with the insulating bracket 16 and copper busbars 15, and employing multiple crimping, welding, and injection molding processes, the processing is complex and the material costs are high.
[0015] To solve the problems of the prior art described above, the present invention provides a stator assembly 100, and a specific technical proposal is as follows: The stator assembly 100 includes a stator 1 and a main control board 2 provided at the axial outer end of the stator 1. The stator 1 is formed by joining several stator cores 11, each of which is wound with a stator winding 12, and the stator winding 12 includes a connection end 121. The main control board 2 has at least two spaced connection grooves 21, and at least a portion of the inner circumferential wall of each connection groove 21 is provided with a first conductive portion 211. The connection end 121 is located within the connection groove 21 and is electrically connected to the first conductive portion 211, thereby enabling conductivity between the stator winding 12 and the circuit on the main control board 2. The method for achieving the electrical connection can be welding, and the welding method can be soldering or laser welding. This proposed technology simplifies the current connection structure of the stator winding ends because it only requires electrically connecting the connection end 121 of the stator winding 12 to the first conductive portion 211 in the connection groove 21, eliminating the need to connect the stator winding using an insulating bracket and a copper busbar. Specifically, the stator winding 12 is wound around each stator core 11, and each stator winding 12 includes two connection ends 121, each of which is electrically connected to a corresponding connection groove 21. At least two of the connection grooves 21 are provided on the outer periphery of the main control board 2, spaced apart along the circumferential direction of the main control board 2, and the connection grooves 21 open outward along the radial direction of the main control board 2 and correspond one-to-one with the connection ends 121.
[0016] Furthermore, in actual applications, the winding ends of motors have high wiring requirements. There are motors with low power that use stator windings with thin wire diameters, which are extremely prone to breaking when pulled, and it is not easy to install the connection end 121 of the stator winding 12 inside the connection groove 21, and it is inconvenient to weld it to the first conductive part 211 on the inner wall of the connection groove 21 for electrical connection. To support and stabilize the connection end 121 of the stator winding 12, the stator 1 may be further provided with pins 13, and the material of the pins 13 may be metal or insulating material. Viewed from the end direction of the stator 1, these pins 13 are arranged equidistant along the circumferential direction, the stator 1 further includes an insulating frame 14, the insulating frame 14 is fitted onto the axial outer end of the stator core 11, one end of the pins 13 is inserted into the insulating frame 14 and the other end is recessed in the connection groove 21, the connection end 121 is located in the connection groove 21 and the connection end 121 is wrapped around at least a portion of the outside of the pins 13. By recessing the pins 13 into the connection groove 21, the height of the ends of the stator assembly 100 can be relatively reduced, and the axial dimension of the motor can be shortened, ensuring a small volume and light weight for the motor 10.
[0017] The material of pin 13 in the present invention may be a metal material with good conductivity, such as copper material, aluminum material, etc., or may be an insulating material, such as plastic. Of course, the pin 13 made of metal material has greater strength than the pin 13 made of insulating material, can support the connection end portion 121 of the stator winding 12 more firmly, and is more advantageous for improving the welding strength and the reliability of electrical connection in the welding process. When the pin 13 is made of metal material, a second conductive portion 122 is provided on the connection end portion 121, a third conductive portion 131 is provided on the pin 13, and the first conductive portion 211, the second conductive portion 122, and the third conductive portion 131 are electrically connected by welding. When the pin 13 is made of insulating material, the pin 13 only plays a role of supporting and stabilizing the connection end portion and does not participate in electrical connection. In this case, a second conductive portion 122' is provided on the connection end portion 121, and the first conductive portion 211 and the second conductive portion 122' are electrically connected by welding.
[0018] The main control board 2 includes a first wall 22 and a second wall 23. The first wall 22 and the second wall 23 are provided opposite to each other. The connection groove 21 is located between the first wall 22 and the second wall 23. Along the radial direction of the stator assembly, the farthest distance between the first wall 22 and the second wall 23 is D1, the connection end portion 121 is columnar, and the maximum outer diameter of the connection end portion 121 is L1. However, D1 is larger than L1. Along the axial direction of the stator assembly, the extending length of the connection end portion 121 is H1, and along the axial direction of the stator assembly, the extending length of the connection groove 21 is H2. H1 is smaller than H2.
[0019] As shown in Figures 3 and 4, the main control board 2 is provided with a first wall 22 and a second wall 23, which are arranged opposite each other along the radial direction of the stator assembly, and which are the walls forming the connection groove 21. Along the radial direction of the stator assembly, the furthest distance between the first wall 22 and the second wall 23 is D1, that is, the maximum length of the radial width of the connection groove 21 is D1. The connection end 121 is provided in a columnar shape, and the maximum outer diameter of the columnar connection end 121 is L1, that is, the maximum radial width of the connection end 121 is L1, and the maximum radial width D1 of the connection groove 21 is greater than the maximum radial width L1 of the connection end 121. Thus, when the connection end 121 is located in the connection groove 21, a gap exists between the outside of the connection end 121 and the wall of the connection groove 21. This allows solder to easily penetrate into the connection groove 21 during welding between the connection end 121 and the first conductive part 211 in the connection groove 21, thereby ensuring welding strength. Along the axial direction of the stator assembly, the extended length H1 of the connection end 121 is the height of the connection end 121, and the extended length H2 of the connection groove 21 is the height of the connection groove 21. The height H1 of the connection end 121 is less than the height H2 of the connection groove 21. Thus, when the connection end 121 is located within the connection groove 21, it can be completely hidden within the connection groove 21. This prevents the connection end 121 from interfering with other axially positioned parts and prevents the problem of excessively short creepage distance. For a stator winding 12 with a large wire diameter, the winding machine cannot wind the copper wire onto the pins 13, and this operation is not possible even manually. Therefore, motors using windings with a large wire diameter cannot use the main control board 2. Moreover, to ensure connection reliability, the stator winding 12 of a motor usually needs to be wound onto the pins 13 at least three times. This increases the axial distance of the main control board 2 relative to the end face of the stator core 11, and increases the overall length of the motor. Furthermore, this solution requires an increase in the material of the pins 13, and further increases the number of steps. Therefore, the present invention provides a stator assembly 100 with yet another structure in which it is not necessary to use the pins 13 to support and stabilize the connection end 121. The connection end 121 can be supported and engaged by the structure of the connection groove 21 of the main control board 2 itself.
[0020] Specifically, the connection groove 21 has a first groove portion 212, a second groove portion 213, and a third groove portion 214. A fourth conductive portion 215 is provided on at least a part of the inner wall of the first groove portion 212, a fifth conductive portion 216 is provided on at least a part of the inner wall of the second groove portion 213, and a sixth conductive portion 217 is provided on at least a part of the inner wall of the third groove portion 214. The connection end portion 121 is electrically connected to at least one of the fourth conductive portion 215, the fifth conductive portion 216, and the sixth conductive portion 217. Thereby, the communication of the circuit between the stator winding 12 and the main control board 2 is realized. Specifically, the connection end portion 121 is first locked to the first groove portion 212 or the second groove portion 213 or the third groove portion 214 by a jig, and then the connection end portion 121 is welded and connected to the first groove portion 212 by welding. Or, the connection end portion 121 is welded and connected to the second groove portion 213. Or, the connection end portion 121 is welded and connected to the third groove portion 214. The welding method can adopt laser welding or soldering, and a solder dip process can be adopted during soldering. Of course, the connection end portion 121 is first locked to the first groove portion 212 or the second groove portion 213 or the third groove portion 214, but it does not have to be welded, and a press fit can be made between the connection end portion 121 and the first groove portion 212 or the second groove portion 213 or the third groove portion 214. However, compared with the press fit method, the welding connection method is more reliable.
[0021] Specifically, the third groove portion 214 extends along the axial direction of the stator assembly. Along the radial direction of the stator assembly, the first groove portion 212 and the second groove portion 213 extend in opposite directions respectively, and the first groove portion 212, the second groove portion 213, and the third groove portion 214 communicate with each other. The main control board 2 includes a third wall 24 and a fourth wall 25, the third wall 24 and the fourth wall 25 are provided opposite to each other, the third groove portion 214 is located between the third wall 24 and the fourth wall 25, and along the radial direction of the stator assembly, the farthest distance between the third wall 24 and the fourth wall 25 is D2, the connection end portion 121 is columnar, and the maximum outer diameter of the connection end portion 121 is L2. D2 is less than or equal to L2.
[0022] As shown in Figures 5 to 8, the first groove 212 and the second groove 213 extend along the radial direction of the stator assembly, and the third groove 214 extends along the axial direction of the stator assembly, with the first groove 212, the second groove 213, and the third groove 214 arranged in a T-shape. The main control substrate 2 is provided with a third wall 24 and a fourth wall 25, which are opposite each other, and the third groove 214 is located between the third wall 24 and the fourth wall 25, and the third wall 24 and the fourth wall 25 belong to the walls that form the third groove 214. Along the radial direction of the stator assembly, the furthest distance between the third wall 24 and the fourth wall 25 is D2, that is, the maximum length of the radial width of the third groove 214 is D2. The connection end 121 is provided in a columnar shape, and the maximum outer diameter of the columnar connection end 121 is L2. That is, the maximum radial width of the connection end 121 is L2, and the maximum radial width D2 of the third groove 214 is less than or equal to the maximum radial width L2 of the connection end 121. In this way, the connection end 121 is locked into the third groove 214, and the connection end 121 is tightly fitted into the third groove 214. The first groove 212 and the second groove 213, which are provided extending in the radial direction, are used to create a space for solder to drip. Moreover, by providing the first groove 212, the second groove 213, and the third groove 214 to communicate with each other, the connection between the connection end 121 located in the third groove 214 and the conductive part in the connection groove 21 and the solder can be guaranteed, and the welding strength between the connection end and the main control board can be further guaranteed.
[0023] The present invention provides a first embodiment of a method for manufacturing a stator assembly 100, the specific steps being as follows: A single stator core 11 is insert-injected to form a stator core with an insulating skeleton 14. Stator windings 12 are wound around the stator core 11 with the insulating frame 14, and each of the stator windings 12 forms two connection ends 121. A stator 1 is formed by joining together a single stator core 11 on which the stator winding 12 is wound along the circumferential direction. The main control board 2 with connection grooves 21 is attached to the axial outer end of the stator 1, and the connection ends 121 are attached in a one-to-one correspondence within the connection grooves 21. The connection end 121 and the first conductive portion 211 on the inner wall of the connection groove 21 are electrically connected.
[0024] The method for manufacturing the stator assembly in this embodiment can be used for stator windings 12 of various wire diameters, and the connection ends 121 can be manually placed inside the connection grooves 21, thus it can also be implemented manually.
[0025] The present invention further provides a second embodiment of a method for manufacturing a stator assembly 100, the specific steps being as follows: A single stator core 11 is insert-injected together with pins 13 to form a stator core 11 with an insulating skeleton 14. Stator windings 12 are wound around the stator core 11 with the insulating frame 14, and each of the stator windings 12 forms two connection ends 121, and these connection ends 121 are wound around the outside of the pin 13. A single stator core 11 on which the stator winding 12 is wound is joined along the circumferential direction of the stator assembly 100 to form a stator 1. The main control board 2 with connection grooves 21 is attached to the axial outer end of the stator 1, and the connection ends 121 are attached in a one-to-one correspondence within the connection grooves 21. The second conductive portion 122 of the connection end 121, the first conductive portion 211 of the inner wall of the connection groove 21, and the third conductive portion 131 of the pin 13 are electrically connected. Alternatively, the second conductive portion 122' of the connection end 121 and the first conductive portion 211 of the inner wall of the connection groove 21 are electrically connected.
[0026] The method for manufacturing the stator assembly in this embodiment is relatively often applied to motors with relatively small stator winding wire diameters, and the pins 13 can, to some extent, support and stabilize the stator windings.
[0027] Stator assemblies manufactured using the above-described method have a simple stator winding connection structure and are easy to install.
[0028] The present invention further provides a motor 10 which includes a stator assembly 100 provided by any of the above designs, and thus has all the beneficial effects of the stator assembly, specifically, the connection structure of the stator windings is simple and easy to install, and the production efficiency of the motor can be relatively improved.
[0029] Furthermore, the motor 10 further includes a housing 300 and a rotor assembly 200, the stator assembly 100 is provided inside the housing 300, the stator assembly 100 includes a stator 1 and a main control board 2 provided at the axial outer end of the stator 1, the stator 1 is made up of several stator cores 11 joined together, each stator core 11 has a stator winding 12 wound around it, the stator winding 12 has a connection end 121, the main control board 2 has a plurality of spaced connection grooves 21, at least a portion of the inner circumferential wall of each connection groove 21 has a first conductive portion 211, the connection end 121 is located inside the connection groove 21 and the connection end 121 is electrically connected to the first conductive portion 211, thereby enabling conductivity between the stator winding 12 and the circuit on the main control board 2.
[0030] In this invention, the term "plural" refers to two or more unless otherwise specifically defined. The terms "attachment," "connection," "bonding," and "fixing" should all be understood in a broad sense. For example, "connection" may be a fixed connection, a removable connection, or an integral connection, and "connection" may be a direct connection or an indirect connection via an intermediate medium. Those skilled in the art will be able to understand the specific meaning of the above terms in this invention depending on the specific situation.
[0031] The above description is merely a preferred embodiment of the present invention and is not intended to limit it. Those skilled in the art can make various modifications and changes to the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be within the scope of protection of the present invention. [Explanation of symbols]
[0032] The correspondence between the symbols and part names in Figures 1 to 8 is as follows:
[0033] 100, Stator assembly; 1, Stator; 2, Main control board; 11, Stator core; 12, Stator winding; 121, Connection end; 21, Connection groove; 211, First conductive part; 13, Pin; 14, Insulating frame; 122, Second conductive part; 122', Second conductive part; 131, Third conductive part; 212, First groove; 213, Second groove; 214, Third groove; 215, Fourth conductive part; 216, Fifth conductive part; 217, Sixth conductive part; 200, Rotor assembly; 15, Copper busbar; 16, Insulating bracket; 10, Motor; 300, Housing; 22, First wall; 23, Second wall; 24, Third wall; 25, Fourth wall.
Claims
1. A stator assembly (100), The stator assembly (100) includes a stator (1) and a main control board (2) provided at the axial outer end of the stator (1). The stator (1) includes several stator cores (11), the stator cores (11) are wound with stator windings (12), and the stator windings (12) include connection ends (121). The stator assembly is characterized in that the main control board (2) has at least two connection grooves (21) provided at intervals, a first conductive portion (211) is provided on the inner circumferential wall of at least a portion of the connection groove (21), the connection end (121) is located within the connection groove (21), and the connection end (121) is electrically connected to the first conductive portion (211).
2. The stator assembly according to claim 1, characterized in that at least two connection grooves (21) are provided on the outer periphery of the main control board (2) at intervals along the circumferential direction of the main control board (2), the connection grooves (21) open outward along the radial direction of the main control board (2) and correspond one-to-one with the connection end (121).
3. The stator assembly according to claim 2, wherein the stator (1) further comprises some pins (13) and an insulating frame (14), the material of the pins (13) being a metal or insulating material, the insulating frame (14) being fitted onto the axial outer end of the stator core (11), one end of the pins (13) being inserted into the insulating frame (14) and the other end being recessed in the connection groove (21), the connection end (121) being located in the connection groove (21), and the connection end (121) being wrapped around the outside of at least some of the pins (13).
4. The stator assembly according to claim 3, characterized in that the material of the pin (13) is a metal material, a second conductive part (122) is provided at the connection end (121), a third conductive part (131) is provided on the pin (13), and the three parts, the first conductive part (211), the second conductive part (122), and the third conductive part (131), are electrically connected.
5. The stator assembly according to claim 3, characterized in that the material of the pin (13) is an insulating material, a second conductive portion (122') is provided at the connection end (121), and the first conductive portion (211) and the second conductive portion (122') are electrically connected.
6. The stator assembly according to any one of claims 1 to 5, characterized in that the main control board (2) includes a first wall (22) and a second wall (23), the first wall (22) and the second wall (23) are provided opposite to each other, the connecting groove (21) is located between the first wall (22) and the second wall (23), the furthest distance between the first wall (22) and the second wall (23) along the radial direction of the stator assembly is D1, the connection end (121) is columnar, the maximum outer diameter of the connection end (121) is L1, and D1 is greater than L1.
7. The stator assembly according to claim 6, characterized in that the extending length of the connection end (121) along the axial direction of the stator assembly is H1, the extending length of the connection groove (21) along the axial direction of the stator assembly is H2, and H1 is less than or equal to H2.
8. The connecting groove (21) has a first groove (212), a second groove (213), and a third groove (214), with a fourth conductive portion (215) provided on the inner wall of at least a portion of the first groove (212), a fifth conductive portion (216) provided on the inner wall of at least a portion of the second groove (213), and a sixth conductive portion (217) provided on the inner wall of at least a portion of the third groove (214). The stator assembly according to claim 1, characterized in that the connection end (121) is electrically connected to at least one of the fourth conductive part (215), the fifth conductive part (216), and the fifth conductive part (216).
9. The stator assembly according to claim 8, characterized in that the third groove (214) extends along the axial direction of the stator assembly, and the first groove (212) and the second groove (213) extend in opposite directions along the radial direction of the stator assembly, and the first groove (212), the second groove (213), and the third groove (214) are in communication with each other.
10. The stator assembly according to claim 9, characterized in that the main control board (2) includes a third wall (24) and a fourth wall (25), the third wall (24) and the fourth wall (25) are provided opposite to each other, the third groove (214) is located between the third wall (24) and the fourth wall (25), the furthest distance between the third wall (24) and the fourth wall (25) along the radial direction of the stator assembly is D2, the connection end (121) is columnar, the maximum outer diameter of the connection end (121) is L2, and D2 is L2 or less.
11. The stator assembly according to any one of claims 1 to 5, characterized in that each stator core (11) is wound with a stator winding (12), and each stator winding (12) has two connection ends (121), each of which is electrically connected to a corresponding connection groove (21).
12. The stator assembly according to claim 7, characterized in that the connection end (121) and the first conductive part (211) are electrically connected by soldering or laser welding.
13. A method for manufacturing a stator assembly (100), A method for manufacturing a stator assembly, comprising the steps of: insert injection molding a single stator core (11) to form a stator core (11) with an insulating frame (14); winding stator windings (12) around the stator core (11) with the insulating frame (14) so that each of the stator windings (12) forms a connection end (121); joining the single stator cores (11) on which the stator windings (12) are wound along the circumferential direction to form a stator (1); attaching a main control board (2) with a connection groove (21) to the axial outer end of the stator (1), and attaching the connection end (121) to the inside of the connection groove (21) in a one-to-one correspondence; and welding the connection end (121) to a first conductive portion (211) of the inner wall of the connection groove (21) to electrically connect them.
14. It is a motor, The motor includes a stator assembly (100), a rotor assembly (200), and a housing (300), the stator assembly (100) being housed within the housing (300), the stator assembly (100) including a stator (1) and a main control board (2) provided at the axial outer end of the stator (1), the stator (1) including several stator cores (11), and the stator cores (11) containing stator windings A motor characterized in that a (12) is wound around the stator winding (12), the stator winding (12) includes a connection end (121), the main control board (2) has at least two spaced-apart connection grooves (21), a first conductive portion (211) is provided on the inner wall of at least a portion of the connection groove (21), the connection end (121) is located within the connection groove (21), and the connection end (121) is electrically connected to the first conductive portion (211).