CN114899956A - Winding stator structure, stator assembly and disc type motor - Google Patents

Abstract

The invention provides a winding stator structure, a stator assembly and a disc motor, wherein the winding stator structure comprises a plurality of framework coil units, an iron core unit and a circuit board unit, the iron core unit comprises a plurality of tooth parts, the tooth parts are arranged at intervals in an annular manner, the framework coil unit is sleeved outside each tooth part respectively, the framework coil unit comprises a framework and a coil, the coil is wound outside the framework, two wire outlet heads of the coil are positioned through the framework, the wire outlet heads are electrically connected to the circuit board unit, the framework coil unit, the iron core unit and the circuit board unit are in fixed shapes, the assembly process among the framework coil unit, the iron core unit and the circuit board unit can be automatically completed through equipment, and the assembly is convenient and rapid, the assembly efficiency is effectively improved, the batch automatic production is favorably realized, and the consistency of products is ensured.

Description

Winding stator structure, stator assembly and disc type motor

The present application is a divisional application of an invention patent with the application number of 202110910266X entitled "winding stator structure, stator assembly and disk motor", which was filed on 8/9/2021.

Technical Field

The invention relates to the field of disc motors, in particular to a winding stator structure, a stator assembly and a disc motor.

Background

The motor is an electromagnetic device which realizes electric energy conversion or transmission according to the electromagnetic induction law, and the motor is mainly used for generating driving torque and serving as a power source of electric appliances or various machines. The motor can be classified into a radial magnetic field motor and an axial magnetic field motor, the axial magnetic field motor is also called a disk motor, and the axial magnetic field motor has the characteristics of small volume, light weight, short axial size, high power density and the like, can be used in most thin installation occasions, and is widely used.

The motor comprises a stator and a rotor, wherein the stator is an electric stationary part and mainly comprises an iron core and a winding wound on the iron core, and the stator is used for generating a rotating magnetic field so that the rotor is cut by magnetic lines of force in the magnetic field to generate current.

In the three-phase winding structure, each phase winding is formed by connecting a plurality of coils, and between the plurality of coils of the same phase, it is connected by a bridge wire. The winding is mostly formed by coiling an enameled wire, and the gap bridge wire is flexible, so that the shape of the formed winding is irregular and unfixed, the coil inserting process from the winding to the iron core can be completed only by manual operation, the defects of long time consumption, high cost, poor consistency and the like are caused, and the large-batch automatic production cannot be realized.

Disclosure of Invention

In order to solve the problems, the invention provides a winding stator structure, a stator assembly and a disc motor, which can realize automatic mass production and improve the assembly efficiency and consistency.

According to one aspect of the invention, the invention provides a winding stator structure, which comprises a plurality of framework coil units, an iron core unit and a circuit board unit, wherein the iron core unit comprises a plurality of tooth parts, the tooth parts are annularly arranged at intervals, the framework coil unit is sleeved outside each tooth part respectively, the framework coil unit comprises a framework and a coil, the coil is wound outside the framework, two wire outlet ends of the coil are positioned through the framework, and the wire outlet ends are electrically connected to the circuit board unit.

As the preferred technical scheme, the skeleton includes a body and a first flange, the one end of body is followed periphery and is outwards extended and form first flange, be provided with two spacing platforms on the first flange, spacing platform is located first flange is kept away from one side of body, the coil is around locating outside the body, and make the outlet terminal wear out outside the first flange and be located spacing platform.

As a preferable technical solution, the thickness of the coil at the end far away from the first rib is larger than the thickness of the coil at the end near the first rib.

As a preferred technical solution, after the bobbin coil unit is sleeved on the tooth portion, the circuit board unit and the outlet are relatively held on the circuit board unit, so that the outlet can be electrically connected to the circuit board unit.

As a preferred technical scheme, the circuit board unit is annular and is sleeved on the inner side or the outer side of the annular iron core unit.

As a preferred technical solution, the circuit board unit includes a winding assembly, an insulating structure, and a pad assembly, the winding assembly is encapsulated inside the insulating structure, and the pad assembly is conductively connected to the winding assembly and exposed outside the insulating structure, so that the outlet terminal is soldered to the pad assembly.

As a preferable technical solution, the winding assembly is a three-phase winding, and includes a first phase winding, a second phase winding and a third phase winding stacked from top to bottom, the welding disc assembly comprises a plurality of first welding discs, a plurality of second welding discs and a plurality of third welding discs, the first phase winding comprises a plurality of first bridge wires which are arranged at intervals in a ring shape, the two ends of each first bridge wire are respectively fixed with the first welding discs, the second phase winding comprises a plurality of second bridge wires which are arranged at intervals in a ring shape, the two ends of each second bridge wire are respectively fixed with the second bonding pads, the third phase winding comprises a plurality of third bridge wires which are arranged at intervals in a ring shape, the two ends of each third bridge wire are respectively fixed with the third bonding pads, and the first pad, the second pad and the third pad are arranged along the circumferential direction of the stator in a staggered manner.

According to another aspect of the present invention, the present invention further provides a stator assembly, which includes the winding stator structure of the above embodiment, and further includes a housing, and the winding stator structure is fixed in the housing.

As a preferred technical scheme, the casing includes a bottom plate, be provided with first annular boss and the second annular boss of arranging from outside to inside on the bottom plate, an annular holding tank has been defined between first annular boss and the second annular boss, the iron core unit is located in the annular holding tank, so that the circuit board unit butt in on first annular boss or the second annular boss.

According to another aspect of the present invention there is also provided a disc motor comprising two of the stator assemblies of the above embodiments and a rotor, the housings of the two stator assemblies being assembled relative to each other so that the rotor is retained in both of the winding stator structures and a gap is defined between the rotor and the winding stator structures.

Compared with the prior art, the technical scheme has the following advantages:

the framework coil unit the iron core unit the circuit board unit is fixed shape, wherein the circuit board unit has replaced being flexible bridgewire among the prior art, makes current the relative coil of bridgewire is taken off alone to it forms a shape fixed to gather all bridgewires the circuit board unit, later through with two that draw on the framework coil unit the wire outlet welded fastening can the circuit board unit, and the framework coil unit the iron core unit with assembly process between the circuit board unit can be accomplished by equipment is automatic, and not only convenient assembling is swift, effectively improves assembly efficiency, still does benefit to and realizes batch ground automated production to guarantee the uniformity of product.

The invention is further described with reference to the following figures and examples.

Drawings

FIG. 1 is a schematic structural diagram of a winding stator structure according to the present invention;

FIG. 2 is a schematic view of an assembly process of the winding stator structure of the present invention;

FIG. 3 is a partially enlarged schematic view of a winding stator structure according to the present invention;

FIG. 4 is a schematic structural diagram of a bobbin coil unit according to the present invention;

FIG. 5 is a schematic view of another orientation of the bobbin coil unit of the present invention;

FIG. 6 is a schematic structural view of the framework of the present invention;

FIG. 7 is a cross-sectional view of the armature of the present invention;

FIG. 8 is a schematic view of the skeleton of the present invention in another orientation;

fig. 9 is a schematic structural view of the core unit according to the present invention;

FIG. 10 is a schematic structural diagram of a circuit board unit according to the present invention;

FIG. 11 is a schematic structural view of a winding assembly according to the present invention;

FIG. 12 is a schematic view of an assembly process of the winding assembly of the present invention;

FIG. 13 is an enlarged partial schematic view of the winding assembly;

FIG. 14 is another enlarged partial schematic view of a winding assembly

FIG. 15 is a schematic structural view of a stator assembly according to the present invention;

FIG. 16 is a schematic view of an assembly process of the stator assembly of the present invention;

FIG. 17 is a schematic structural view of the housing of the present invention;

FIG. 18 is a flow chart illustrating an assembly method of the present invention.

In the figure: 100 bobbin coil unit, 110 bobbin, 111 tube, 112 first rib, 1121 limiting jack, 1122 limiting table, 11221 limiting slot, 113 second rib, 120 coil, 121 outlet head, 200 core unit, 210 teeth, 220 yokes, 230 coil slot, 300 circuit board unit, 310 winding assembly, 311 first phase winding, 3111 first gap wire, 31111 first wire portion, 31112 first leg portion, 312 second phase winding, 3121 second gap wire, 31211 second wire portion, 31212 second leg portion, 313 third phase winding, 3131 third gap wire, 31311 third wire portion, 31312 third leg portion, 320 insulation structure, 330 pad assembly, 331 first pad, 332 second pad, 333 third pad, 341 first cylinder, 342 second cylinder, 343 third cylinder, 400 housing, 410 bottom plate, 411 annular receiving groove, 430 inner plate, 420 outer plate, 421 opening, 500 fastener.

Detailed Description

The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments in the following description are given by way of example only, and other obvious variations will occur to those skilled in the art. The basic principles of the invention, as defined in the following description, may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.

As shown in fig. 1 to 3, the winding stator structure includes a plurality of bobbin coil units 100, an iron core unit 200 and a circuit board unit 300, the iron core unit 200 includes a plurality of tooth portions 210, the tooth portions 210 are annularly arranged at intervals, each tooth portion 210 is externally sleeved with one of the bobbin coil units 100, the bobbin coil unit 100 includes a bobbin 110 and a coil 120, the coil 120 is wound outside the bobbin 110, and two wire outlets 121 of the coil 120 are positioned by the bobbin 110, and the plurality of wire outlets 121 are electrically connected to the circuit board unit 300

Each of the skeletons 110 is respectively sleeved on one of the tooth portions 210, so that the coil 120 is relatively fixed to the tooth portion 210, and the skeletons 110 further position the two outlet ends 121 of the coil 120, so that the outlet ends 121 are electrically connected to the circuit board unit 300. Wherein circuit board unit 300 has replaced the flexible bridgewire that is among the prior art, makes current the relative coil of bridgewire is taken off alone to it forms a rigid to gather all bridgewires circuit board unit 300, later with every two on the skeleton coil unit 100 the end outlets 121, equal electric connection in circuit board unit 300 can, solved among the prior art because of the bridgewire is flexible and cause the shape unfixed to and can only artifical time-consuming duration, with high costs, the poor scheduling defect of uniformity that rolls off the production line and bring, it is visible through using circuit board unit 300 not only can realize automated assembly to realize automated production in batches, effectively reduce cost in addition, promote assembly efficiency, and can guarantee the uniformity of product.

As shown in fig. 9, the tooth portion 210 is trapezoidal, the top of the tooth portion 210 is an arc-shaped groove, the bottom of the tooth portion 210 is arc-shaped, the top of the tooth portion 210 and the bottom of the tooth portion 210 are respectively located at two sides of the stator in the radial direction, the top of the tooth portion 210 is located at the inner side, and the bottom of the tooth portion 210 is located at the outer side relative to the top of the tooth portion 210.

With continued reference to fig. 9, the core unit 200 further includes an annular yoke portion 220, and a plurality of teeth 210 are annularly and intermittently connected to the yoke portion 220, so that a coil slot 230 for accommodating a coil is formed between two adjacent teeth 210.

As shown in fig. 4 to 8, the frame 110 includes a tube 111 and a first rib 112, one end of the tube 111 extends outwards along a periphery to form the first rib 112, two limiting tables 1122 are disposed on the first rib 112, the limiting tables 1122 are located on one side of the first rib 112 away from the tube 111, and the coil 120 is wound around the tube 111, such that the outlet 121 passes through the first rib 112 and is located on the limiting tables 1122.

Specifically, the tube 111 and the tooth 210 are in the same shape and are both trapezoidal. The size of the bottom of the trapezoid tube 111 is the largest, so that the limiting platform 1122 is located at the bottom of the trapezoid tube 111, so that after the tube 111 is sleeved on the tooth portion 210, the wire outlet 121 located on the limiting platform 1122 is located outside the iron core unit 200, so as to be sleeved on the circuit board unit 300 outside the iron core unit 200 to be electrically connected with the wire outlet 121.

In another embodiment, the limiting platform 1122 is located at the top of the trapezoidal tube 111, so that after the tube 111 is sleeved on the tooth portion 210, the wire outlet 121 on the limiting platform 1122 is located inside the core unit 200, so as to be sleeved on the circuit board unit 300 in the core unit 200 to be electrically connected to the wire outlet 121.

As shown in fig. 6 to 8, the frame 110 further includes a second rib 113, and the other end of the tube 111 extends along the periphery and outwards to form the second rib 113, so that the second rib 113 and the first rib 112 are retained at two ends of the frame 110. The first rib 112 and the second rib 113 are arranged to keep the coil 120 between the first rib 112 and the second rib 113, so as to prevent the coil 120 from sliding out of the end of the framework 110 where the first rib 112 or the second rib 113 is arranged. As shown in fig. 7 and 8, the position-limiting platform 1122 is provided with a position-limiting groove 11221, and the first rib 112 is provided with a position-limiting insertion hole 1121 corresponding to the position-limiting groove 11221, so that the outlet 121 passes through the position-limiting insertion hole 1121 and reaches the position-limiting groove 11221, so as to position the outlet 121 by the position-limiting platform 1122, and facilitate the subsequent electrical connection between the outlet 121 and the circuit board unit 300.

As shown in fig. 4 and 5, after the outlet 121 passes through the position-limiting insertion hole 1121 and reaches the position-limiting groove 11221, the outlet 121 is bent and horizontally disposed so as to facilitate electrical connection with the circuit board unit 300.

As shown in fig. 4, the thickness of the coil 120 at the end close to the second rib 113 is greater than the thickness of the coil 120 at the end close to the first rib 112, that is, the number of winding layers of the coil 120 at the end of the second rib 113 is greater, and the number of winding layers of the coil 120 at the end of the first rib 112 is smaller, when the coil 120 is winding the outermost layer, the outermost layer is close to the second rib 113, and the limiting platform 1122 is located on the first rib 112, so that two of the outlet ends 121 have a longer margin and can be bent to pass through the limiting insertion hole 1121 to the limiting groove 11221, which not only improves the convenience of assembling the outlet ends 121 and the limiting platform 1122, but also makes the structure more compact, thereby improving the full rate of the motor groove and increasing the amount of current passing through the coil.

As shown in fig. 1 to 3, after the tube 111 is sleeved on the tooth 210, the first rib 112 abuts against the yoke 220, and the outlet 121 is located outside the core unit 200, and at this time, the second rib 113 is flush with a side of the tooth 210 away from the yoke 220, and the coil 120 wound outside the tube 111 is accommodated in the coil slot 230.

Specifically, the circuit board unit 300 is sleeved outside the core unit 200, after the tube 111 is sleeved on the tooth portion 210, the first rib 112 abuts against the circuit board unit 300, and the wire outlet 121 is located outside the core unit 200 so that the wire outlet 121 can be electrically connected to the circuit board unit 300, so that the circuit board unit 300 is electrically connected to the wire outlet 121.

More specifically, referring to fig. 2, the bobbin coil unit 100 is sleeved on the tooth portion 210 from the upper portion of the iron core unit 200, and the circuit board unit 300 is sleeved outside the yoke portion 220 from the lower portion of the iron core unit 200, so that the wire outlet head 121 and the circuit board unit 300 can be both located outside the iron core unit 200, and the wire outlet head 121 is electrically connected to the circuit board unit 300 outside the iron core unit 200, and automatic operation can be realized by an assembling device, thereby realizing batch automatic production, improving assembling efficiency and ensuring product consistency.

When the circuit board unit 300 is sleeved inside the core unit 200, the bobbin coil unit 100 is sleeved on the tooth portion 210 from the upper portion of the core unit 200, and the circuit board unit 300 is sleeved inside the yoke portion 220 from the lower portion of the core unit 200, so that the wire outlet 121 and the circuit board unit 300 can be located inside the core unit 200, and the two are welded to each other.

As shown in fig. 10 to 14, the circuit board unit 300 includes a winding assembly 310, an insulating structure 320, and a bonding pad assembly 330, wherein the winding assembly 310 is encapsulated inside the insulating structure 320, the bonding pad assembly 330 is conductively connected to the winding assembly 310, exposed outside the insulating structure 320, and the outlet terminal 121 is bonded to the bonding pad assembly 330.

The winding assembly 310 may be a three-phase winding, and of course, may also be other phase windings, and hereinafter, a three-phase winding will be taken as an example, specifically, the winding assembly 310 includes a first phase winding 311, a second phase winding 312, and a third phase winding 313, and the first phase winding 311, the second phase winding 312, and the third phase winding 313 are sequentially stacked on the insulating structure 320 from top to bottom and are respectively conducted with the pad assembly 330.

The coil 120 is an enameled wire, and the wire outlet 121 is de-enameled and tinned to prevent rust so as to be welded to the pad assembly 330. Since only the pad assembly 330 of the circuit board unit 300 is exposed to the outside of the insulation structure 320, when the circuit board unit 300 is assembled with the core unit 200 and the like, the insulation structure 320 also has an insulation effect with respect to the core unit 200, and the first phase winding 311, the second phase winding 312, and the third phase winding 313 are also insulated from each other.

Referring to fig. 10, the circuit board unit 300 is in a ring shape, and the pad assembly 330 is exposed to the surface of the circuit board unit 300 by the insulation structure 320, so that the circuit board unit 300 is arranged on the surface of the pad assembly 330, which is opposite to the first rib 112, to enable the outlet head 121 to be soldered to the pad assembly 330. The wire outlet head 121 can be welded to the soldering land assembly 330 by automatic laser soldering equipment, so as to realize automatic welding, thereby achieving the purpose of batch automatic production.

As shown in fig. 11 and 12, the first phase winding 311, the second phase winding 312, and the third phase winding 313 are stacked in this order from top to bottom. The insulating structure 320 includes an insulating material, and is filled among the first phase winding 311, the second phase winding 312, and the third phase winding 313 to achieve an insulating fixation therebetween.

Specifically, the pad assembly 330 includes a plurality of first pads 331, a plurality of second pads 332, and a plurality of third pads 333. The first phase winding 311 includes a plurality of first bridge wires 3111 arranged in a ring shape at intervals, the first pads 331 are respectively fixed to two ends of each of the first bridge wires 3111, the second phase winding 312 includes a plurality of second bridge wires 3121 arranged in a circular interval, the second bonding pads 332 are respectively fixed to both ends of each second bridge wire 3121, the third phase winding 313 includes a plurality of third bridgewire 3131 arranged at intervals in a ring shape, the third bonding pad 333 is fixed to each of two ends of each third bridgewire 3131, the first pad 331, the second pad 332 and the third pad 333 are arranged in a staggered manner along the stator circumferential direction, so that the first pads 331, the second pads 332 and the third pads 333 are arranged in a spaced ring shape, so that the plurality of bobbin coil units 100 arranged in a ring shape are sequentially soldered to the corresponding pads through the wire outlet 121.

More specifically, the first bridge wire 3111 is made of copper foil and is arc-shaped, so that the first bridge wire 3111 forms a ring. The plurality of first bridge wires 3111 are sequentially arranged at intervals, so that a gap exists between two adjacent first bridge wires 3111, in addition, first pads 331 are arranged at two ends of each first bridge wire 3111, and two wire outlets 121 of one framework coil unit 100 are respectively welded to the first bridge wires 3111 which are located at different positions and are adjacent to the first pads 331.

The second and third bridge wires 3121 and 3131 are respectively identical to the first bridge wire 3111, and are made of copper foil and have an arc structure. Similarly, in the second phase winding 312, two adjacent second pads 332 on different second bridge wires 3121 are welded to two wire outlets 121 of one bobbin coil unit 100. And in the third phase winding 313, two adjacent third pads 333 on different third bridge wires 3131 are welded to two wire outlets 121 of one bobbin coil unit 100.

The adjacent three frame coil units 100 are sequentially welded to the third pad 333 which is different from the third bridge wire 3131 and adjacent two, the second pad 332 which is different from the second bridge wire 3121 and adjacent two, and the first bridge wire 3111 which is different from the first pad 331, so that the process is repeated until the welding of the plurality of frame coil units 100 is completed.

With continued reference to fig. 11 and 12, the first gap wire 3111, the second gap wire 3121, and the third gap wire 3131 are arranged in a staggered manner along the stator circumferential direction, thereby enabling the first land 331, the second land 332, and the third land 333 to be arranged at annular intervals.

Specifically, the first gap bridge wire 3111, the second gap bridge wire 3121 and the third gap bridge wire 3131 are sequentially overlapped from top to bottom, wherein the second pads 332 at two ends of the second gap bridge wire 3121 are respectively located on two different and adjacent third gap bridge wires 3131, and the second pads 332 are located between the third pads 333 at two ends of the third gap bridge wire 3131, so that the second pads 332 and the third pads 333 are staggered. The first pads 331 at two ends of the first bridge wire 3111 are respectively located on two different and adjacent second bridge wires 3121 and two different and adjacent third bridge wires 3131, so that the first pads 331, the second pads 332, and the third pads 333 are arranged in a staggered manner in the circumferential direction of the stator.

It is understood that a plurality of the third bridgewire 3131 are arranged at a spaced distance in a ring shape; the second bridge wires 3121 are arranged in a ring shape at intervals, and are stacked on the third bridge wire 3131, and the second pads 332 are rotated clockwise by a first angle along the stator circumferential direction with respect to the third pads 333, so that the second pads 332 at both ends of the second bridge wire 3121 are respectively located on two different and adjacent third bridge wires 3131; the plurality of first bridge wires 3111 are arranged in a ring shape at intervals, and stacked on the second bridge wire 3121, and the first pads 331 are rotated clockwise by a second angle along the stator circumferential direction with respect to the third pads 333, so that the first pads 331 at both ends of the first bridge wire 3111 are respectively located on two different and adjacent second bridge wires 3121 and two different and adjacent third bridge wires 3131, and the first angles, the second angles, and the radians of the third bridge wires are sequentially increased, so that two second pads 332 located on two different and adjacent second bridge wires 3121 are arranged between two third pads 333 on the same third bridge wire 3131, and two first pads 331 located on two different and adjacent first bridge wires 3111 are arranged, so that three adjacent skeleton coil units 100 are sequentially welded to the third three-phase winding 313 through the wire outlet head 121, The second phase winding 312 and the first phase winding 311 reciprocate in this way to complete the electrical connection between the plurality of bobbin coil units 100 and the circuit board unit 300.

As shown in fig. 11 and 12, the first bridge wire 3111 includes a first wire portion 31111 and two first branch portions 31112, the first wire portion 31111 is arc-shaped, two ends of the first wire portion 31111 extend to one side of the protrusion to form the first branch portion 31112, the first pad 331 is fixed on the first branch portion 31112, when the first bridge wires 3111 are arranged in a ring shape at intervals, the first wire portions 31111 are arranged in a ring shape, so that the first pad 331 is located outside the ring shape formed by the first wire portions 31111, so as to weld the outlet head 121 on the first pad 331.

Similarly, the second jumper wire 3121 includes a second wire portion 31211 and two second branch portions 31212, and the second pad 332 is fixed to the second branch portion 31212, so that the second pad 332 is located outside the loop formed by the plurality of second wire portions 31211. The third bridge wire 3131 includes a third wire 31311 and two third branches 31312, and the third pad 333 is fixed on the third branch 31312, such that the third pad 333 is located outside an annular shape formed by the third wire 31311.

In addition, the first phase winding 311 is reserved with two adjacent first pads 331 located on different first bridge lines 3111 for connecting to an external circuit, the second phase winding 312 is reserved with two adjacent second pads 332 located on different second bridge lines 3121 for connecting to an external circuit, the third phase winding 313 is also reserved with two adjacent third pads 333 located on different third bridge lines 3131 for connecting to an external circuit, and the two second pads 332 connected to an external circuit are located on two first pads 331 connected to an external circuit and two third pads 333 connected to an external circuit, and the distance between the first bridge line 3111, the second bridge line 3121 and the third bridge line 3131 is reduced by changing the shapes of the first bridge line 3111, the second bridge line 3121 and the third bridge line 3131, and a centralized arrangement is realized, that is, see fig. 11.

Taking the first bridge wire 3111 as an example, the first wire portion 31111 is reduced in size, and the first branch portion 31112 is extended, so that the first pad 331 connected to an external circuit extends outward for a certain distance, so as to facilitate soldering and routing.

As shown in fig. 13 to 14, the first pad 331, the second pad 332, and the third pad 333 are all located on the same horizontal plane, so that the wire outlet 121 is easily soldered to the first pad 331, the second pad 332, and the third pad 333.

Specifically, the first gap line 3111, the second gap line 3121 and the third gap line 3131 are overlapped from top to bottom, after the circuit board unit 300 is sleeved on the iron core unit 200, the first gap line 3111 is close to the first rib 112, and the second gap line 3121 and the third gap line 3131 are sequentially far away from the first gap line 3111. Wherein the circuit board unit 300 further includes a first cylinder 341, a second cylinder 342, and a third cylinder 343, the first cylinder 341 is connected between the first flying lead 3111 and the first pad 331, the second cylinder 342 is connected between the second flying lead 3121 and the second pad 332, the third cylinder 343 is connected between the third flying lead 3131 and the third pad 333, and the first cylinder 341, the second cylinder 342, and the third cylinder 343 are gradually enlarged to maintain the first pad 331, the second pad 332, and the third pad 333 on the same horizontal plane.

In summary, each of the skeletons 110 is respectively sleeved on one of the tooth portions 210, so that the coil 120 is relatively fixed to the tooth portion 210, and the skeletons 110 further position the two wire outlets 121 of the coil 120, so that the wire outlets 121 are electrically connected to the circuit board unit 300. The circuit board unit 300 replaces a flexible bridge wire in the prior art, so that the existing opposite coils of the bridge wire are taken down independently, all the bridge wires are gathered to form a rigid circuit board unit 300, and then the two wire outlet heads 121 on each framework coil unit 100 are electrically connected to the circuit board unit 300, thereby overcoming the defects that the shape is not fixed due to the flexibility of the bridge wire and the time consumption, the cost is high, the consistency is poor and the like caused by manual wire inserting only in the prior art, and not only can automatic assembly be realized by using the circuit board unit 300 so as to realize batch automatic production, but also effectively reduce the cost, improve the assembly efficiency and ensure the consistency of products.

As shown in fig. 15 to 17, the stator assembly includes the winding stator structure of the above embodiment, and further includes a housing 400, and the winding stator structure is fixed in the housing 400. Because the stator assembly adopts the winding stator structure of the above embodiment, the stator assembly refers to the above embodiment for the beneficial effects brought by the winding stator structure.

As shown in fig. 17, the housing 400 includes a bottom plate 410, an inner side plate 430 and an outer side plate 420, the bottom plate 410 is annular, and the inner and outer edges of the bottom plate 410 extend in the same direction to form the inner side plate 430 and the outer side plate 420. Referring to fig. 16, the winding stator structure is assembled inside the housing 400 along the stator axis from above the housing 400, and the yoke 220 abuts on the bottom plate 410, the winding stator structure in a ring shape is held between the inner side plate 430 and the outer side plate 420, and then a fastening member 500 is screwed with the yoke 220 through the bottom plate 410 from below the bottom plate 410, so as to fix the two, wherein the fastening member 500 may be a bolt or the like.

As shown in fig. 17, a first annular boss 412 and a second annular boss 413 are disposed on the bottom plate 410, the first annular boss 412 and the second annular boss 413 are disposed from the outside, wherein the first annular boss 412 is disposed along the inner periphery of the outer plate 420, the second annular boss 413 is disposed along the outer periphery of the inner plate 430, and an annular receiving groove 411 is defined between the first annular boss 412 and the second annular boss 413, so that the yoke portion 220 is positioned and fixed in the annular receiving groove 411, thereby improving the fixing effect and positioning of the winding stator structure in the housing 400. When the annular circuit board unit 300 is sleeved outside the core unit 200, the circuit board unit 300 is held between the yoke 220 and the outer plate 420, and b abuts against the first annular boss 412, and when the circuit board unit 300 is sleeved inside the core unit 200, the circuit board unit 300 is held between the yoke 220 and the inner plate 430 and abuts against the second annular boss 413, so that it can be seen that the core unit 200 and the circuit board unit 300 directly contact the bottom plate 410, so as to perform corresponding heat dissipation through the bottom plate 410.

Preferably, heat dissipation ribs are disposed outside the bottom plate 410 or the outer side plate 420, so as to further improve heat dissipation performance.

As shown in fig. 15 to 17, the outer plate 420 is opened with an opening 421, so that the first bonding pad 331, the second bonding pad 332 and the third bonding pad 333 which are collectively disposed and used for connecting an external circuit are located in the opening 421, so as to connect the external circuit.

The invention also provides a disc motor which comprises a rotor and two stator assemblies of the above embodiments, wherein the rotor is held between the two stator assemblies and coaxially arranged, so that a double-stator structure is formed. When assembled, the two stator assembly housings 400 are assembled in opposition with the rotor and the two winding stators held between the two housings 400. Wherein the rotor and the winding stator structure are spaced along a disc motor axis and a gap is defined between the rotor and the winding stator structure in which a magnetic flux of the disc motor is in an axial direction.

When the two housings 400 are assembled, the inner side plate 430 and the outer side plate 420 of the two housings 400 are respectively abutted against each other and fastened and fixed by a fastener.

As shown in fig. 1 to 18, the assembling method includes the steps of:

(a) providing a plurality of bobbin coil units 100, wherein the bobbin coil unit 100 comprises a bobbin 110 and a coil 120, the coil 120 is wound outside the bobbin 110, and two wire outlets 121 of the coil 120 are positioned by the bobbin 110;

(b) sleeving the plurality of bobbin coil units 100 on the tooth portions 210 of the core units 200 one by one;

(c) providing a circuit board unit 300, wherein the circuit board unit 300 comprises a winding assembly 310, an insulating structure 320 and a pad assembly 330, the winding assembly 310 is packaged inside the insulating structure 320, and the pad assembly 330 is conductively connected to the winding assembly 310 and exposed outside the insulating structure 320;

(d) assembling the circuit board unit 300 on the core unit 200 with the pad assembly 330 facing the outlet head 121;

(e) the outlet header 121 is welded to the weld plate assembly 330 to assemble a winding stator structure.

Circuit board unit 300 has replaced the bridging line that is flexible among the prior art, makes current the relative coil of bridging line is taken off alone to it forms a rigid to summarize all bridging lines circuit board unit 300 can have earlier skeleton coil unit 100 cover of coil 120 is located on tooth portion 210, then will circuit board unit 300 with coil 120's outlet end 121 places relatively, will at last outlet end 121 electric connection in on the circuit board unit 300, not only assembly convenience is swift, effectively improves assembly efficiency, still does benefit to and realizes automated production in batches to guarantee the uniformity of product.

According to an embodiment of the present invention, in the step (a), the winding of the coil 120 on the bobbin 110 may be automatically completed by a winding device, and two outlet ends 121 of the coil 120 are automatically positioned on the position-limiting table 1122 and then are conveyed to the core unit 200 by a conveyor belt or a robot, and in the step (b), the bobbin coil units 100 are sequentially sleeved on the tooth portion 210 of each core unit 200 by using the robot or the like, and at the same time, the first blocking edge 112 positioning the outlet end 121 is ensured to abut against the yoke portion 220 of the core unit 200, so that the outlet end 121 faces the outside of the core unit 200 to be electrically connected with the circuit board unit 300 in the step (c).

According to an embodiment of the present invention, the winding assembly 310 may be a three-phase winding, and of course, other phase windings are also possible, and the following will be taken as an example of the three-phase winding, and the winding assembly 310 includes a first phase winding 311, a second phase winding 312, and a third phase winding 313, so that the step (c) further includes the following steps:

(c1) and overlapping the first phase winding 311, the second phase winding 312 and the third phase winding 313 from top to bottom, and packaging the overlapping in the insulating structure 320.

According to an embodiment of the present invention, the insulating structure 320 is filled with the insulating material, so that the step (c1) further comprises the steps of:

an insulating material is filled between the first phase winding 311, the second phase winding 312, and the third phase winding 313 to assemble the circuit board unit 300.

According to an embodiment of the present invention, the pad assembly 330 includes a plurality of first pads 331, a plurality of second pads 332, and a plurality of third pads 333, the first phase winding 311 includes a plurality of first bridge wires 3111, both ends of each of the first bridge wires 3111 are respectively fixed with the first pads 331, the second phase winding 312 includes a plurality of second bridge wires 3121, both ends of each of the second bridge wires 3121 are respectively fixed with the second pads 332, the third phase winding 313 includes a third bridge wire 3131, both ends of each of the third bridge wires 3131 are respectively fixed with the third pads 333, and the step (c) further includes the steps of:

arranging a plurality of the third bridgewire 3131 in a ring shape at a spaced distance;

a plurality of the second bridge wires 3121 are arranged in a ring shape at intervals and are stacked on the third bridge wire 3131, and the second land 332 is rotated clockwise by a first angle along the stator circumferential direction with respect to the third land 333;

the plurality of first bridge lines 3111 are arranged in a ring shape at intervals, and are stacked on the second bridge line 3121, and the first land 331 is rotated clockwise relative to the third land 333 along the stator circumferential direction by a second angle, and the radians of the first angle, the second angle, and the third bridge line increase in order.

Since the first gap bridge wire 3111 and the third gap bridge wire 3131 and the second gap bridge wire 3121 are arranged in a staggered manner in the stator circumferential direction, the first land 331, the second land 332, and the third land 333 are also arranged in a staggered and spaced ring shape. In detail, two adjacent third pads 333 different from the third bridge line 3131, two adjacent second pads 332 different from the second bridge line 3121, and two adjacent first pads 331 different from the first bridge line 3111 are sequentially arranged along the stator circumferential direction at intervals. Refer to fig. 11. When the subsequent welding is performed with the bobbin coil units 100, the adjacent three bobbin coil units 100 are welded to the third phase winding 313, the second phase winding 312 and the first phase winding 311 sequentially through the wire outlet 121, and the steps are repeated so as to complete the electrical connection between the plurality of bobbin coil units 100 and the circuit board unit 300. Namely, the coils corresponding to three adjacent teeth are sequentially welded to the two adjacent third pads 333 positioned on the different third jumper 3131, the two adjacent second pads 332 positioned on the different second jumper 3121, and the two adjacent first pads 331 positioned on the different first jumper 3111 through wire outlets, and the process is repeated until the welding of the coils corresponding to the teeth is completed. The insulating structure 320 may be formed simultaneously with the overlapping of the first phase winding 311, the second phase winding 312 and the third phase winding 313, for example, an insulating material is first laid, then the first phase winding 311 is placed, and then the insulating material is laid on the first phase winding 311, and so on, so that the insulating material filled between the first phase winding 311, the second phase winding 312 and the third phase winding 313 forms the insulating structure 320, and at the same time, the first bonding pad 331, the second bonding pad 332 and the third bonding pad 333 are ensured to be exposed to the outside by the insulating structure.

It should be noted that, the circuit board unit 300 may also be automatically assembled by an apparatus and then transported to the core unit 200 to perform the step (d).

In the step (d), referring to fig. 1 to 3, the circuit board unit 300 may be relatively moved with respect to the core unit 200 by using a device, so that the circuit board unit 300 is held around the outer periphery of the yoke portion 220, and the side of the circuit board unit 300 with the pad assembly 330 is abutted against the first rib 112, so that the outlet head 121 positioned on the first rib 112 is opposed to the pad assembly 330, and at this time, the outlet head 121 and the circuit board unit 300 are both located outside the core unit 200, and then welding is performed in the step (e).

Of course, the outlet 121 and the circuit board unit 300 may also be located inside the core unit 200 and disposed opposite to each other.

According to an embodiment of the present invention, the step (e) further comprises the steps of:

and sequentially welding the adjacent three framework coil units to the third bridging line and the adjacent two third pads, the second bridging line and the adjacent two second pads, and the first bridging line and the adjacent two first pads, wherein the third bridging line and the adjacent two third pads are different from each other, and the third bridging line and the adjacent two second pads are different from each other, so that the welding of the framework coil units is completed in a circulating manner.

In step (e), the outlet head 121 is welded to the welding disc assembly 330 by using an automatic laser soldering device to assemble a winding stator structure.

According to an embodiment of the present invention, the method further comprises the following steps after the step (e):

(f) fitting the winding stator structure within the housing 400;

(g) the housing 400 is potted and cured to assemble the stator assembly.

Referring to fig. 16, the winding stator structure is assembled inside the housing 400 along the stator axis from above the housing 400 with the yoke 220 embedded in the annular receiving groove 411 of the base plate 410, and the circuit board unit 300 is abutted on the base plate 410, and then the fastener 500 is inserted from below the base plate 410 and screwed with the yoke 220 to lock the winding stator structure inside the housing 400.

With continued reference to fig. 15, the first bonding pad 331, the second bonding pad 332, and the third bonding pad 333, which are collectively disposed and used for connecting an external circuit, are located in the opening 421 so as to facilitate connecting the external circuit.

According to an embodiment of the present invention, the method further comprises the following steps after the step (g):

(h) a rotor is provided and held between the two stator assemblies and the housings 400 of the two stator assemblies are assembled and secured relative to each other so that the rotor and the winding stator structure are spaced along the axis of the disc motor and a gap is defined between the rotor and the winding stator structure.

In summary, the bobbin coil unit 100, the iron core unit 200, and the circuit board unit 300 are all in a fixed shape, wherein the circuit board unit 300 replaces a flexible gap bridge wire in the prior art, so that the gap bridge wire in the prior art is taken down separately relative to the coil, and all the gap bridge wires are collected to form the circuit board unit 300 in a fixed shape, and then two wire outlet heads 121 led out from the bobbin coil unit 100 are welded and fixed to the circuit board unit 300, and the assembly process between the bobbin coil unit 100, the iron core unit 200, and the circuit board unit 300 can be automatically completed by equipment, so that the assembly is convenient and fast, the assembly efficiency is effectively improved, the batch automatic production is facilitated, and the consistency of products is ensured.

The above-mentioned embodiments are only for illustrating the technical ideas and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the contents of the present invention and to implement the same, and the scope of the present invention is not limited by the embodiments, i.e. all equivalent changes or modifications made in the spirit of the present invention are still within the scope of the present invention.

Claims (10)

1. The utility model provides a winding stator structure, its characterized in that includes a plurality of skeleton coil units (100), an iron core unit (200) and a circuit board unit (300), iron core unit (200) include a plurality of tooth portion (210), and are a plurality of tooth portion (210) are annular interval arrangement, each tooth portion (210) are equipped with one outward respectively the cover skeleton coil unit (100), skeleton coil unit (100) include a skeleton (110) and a coil (120), coil (120) are around locating outside skeleton (110), and pass through skeleton (110) location two leading-out terminals (121) of coil (120), it is a plurality of equal electric connection in leading-out terminal (121) circuit board unit (300).

2. The winding stator structure according to claim 1, wherein the bobbin (110) includes a tube (111) and a first rib (112), one end of the tube (111) extends along a circumference and outwards to form the first rib (112), two limiting tables (1122) are disposed on the first rib (112), the limiting tables (1122) are located on one side of the first rib (112) away from the tube (111), the coil (120) is wound outside the tube (111), and the outlet head (121) penetrates out of the first rib (112) and is located on the limiting tables (1122).

3. The winding stator structure of claim 2, characterized in that the thickness of the coil (120) at the end remote from the first rib (112) is greater than the thickness of the coil (120) at the end near the first rib (112).

4. The winding stator structure according to claim 1, wherein after the bobbin coil unit (100) is sleeved on the tooth portion (210), the circuit board unit (300) is held on the circuit board unit (300) opposite to the outlet (121) so that the outlet (121) can be electrically connected to the circuit board unit (300).

5. The winding stator structure according to claim 4, wherein the circuit board unit (300) is annular and is sleeved inside or outside the annular core unit (200).

6. The winding stator structure according to claim 1, wherein the circuit board unit (300) comprises a winding assembly (310), an insulating structure (320), and a bonding pad assembly (330), the winding assembly (310) is encapsulated inside the insulating structure (320), and the bonding pad assembly (330) is conductively connected to the winding assembly (310) and exposed outside the insulating structure (320) so that the outlet terminal (121) is welded to the bonding pad assembly (330).

7. The winding stator structure according to claim 6, wherein the winding assembly (310) is a three-phase winding including a first phase winding (311), a second phase winding (312) and a third phase winding (313) stacked from top to bottom, the pad assembly (330) includes a plurality of first pads (331), a plurality of second pads (332) and a plurality of third pads (333), the first phase winding (311) includes a plurality of first bridge wires (3111) arranged in a circular interval, both ends of each first bridge wire (3111) are respectively fixed with the first pads (331), the second phase winding (312) includes a plurality of second bridge wires (3121) arranged in a circular interval, both ends of each second bridge wire (3121) are respectively fixed with the second pads (332), the third phase winding (313) includes a plurality of third bridge wires (3131) arranged in a circular interval, the third bonding pads (333) are respectively fixed to two ends of each third bridge wire (3131), and the first bonding pads (331), the second bonding pads (332), and the third bonding pads (333) are arranged in a staggered manner along the circumferential direction of the stator.

8. A stator assembly comprising a winding stator structure according to any of claims 1 to 7, further comprising a housing (400), said winding stator structure being secured within said housing (400).

9. The stator assembly according to claim 8, wherein the housing (400) comprises a bottom plate (410), the bottom plate (410) is provided with a first annular boss (412) and a second annular boss (413) arranged from outside to inside, an annular receiving groove (411) is defined between the first annular boss (412) and the second annular boss (413), and the core unit (200) is positioned in the annular receiving groove (411) so that the circuit board unit (300) abuts against the first annular boss (412) or the second annular boss (413).

10. A disc machine comprising two stator assemblies according to claim 8 or 9 and further comprising a rotor, the housings (400) of the two stator assemblies being assembled relative to one another so that the rotor is retained between the two winding stator structures and a gap is defined between the rotor and the winding stator structures.

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