CN218513699U - Connection structure for brushless motor and brushless motor - Google Patents

Abstract

The utility model relates to a connection structure for brushless motor, brushless motor includes stator module and rotor subassembly, the stator module includes stator and the three-phase winding of winding on the stator, adopts the star connection between the three-phase winding, connection structure includes three wiring end and is used for bridging the connecting strip of three wiring end; each terminal is intended to be in electrical contact with a coil of a winding of a respective phase, so as to connect together one end of the windings of the respective phase via a connecting strip to form a common terminal; wherein each of the terminals includes a wire breaking portion for breaking an insulating sheath of the coil and a clamping portion for clamping and holding a metal wire of the coil. The utility model discloses still relate to a brushless motor including above-mentioned connection structure. In the less motor structure of size, according to the utility model discloses a connection structure has solved the motor and can't or the inconvenient public end connection problem under the condition of implementing public end welding process because of the space is limited, has saved process and manpower, changes in automated production.

Description

Connection structure for brushless motor and brushless motor

Technical Field

The utility model relates to the technical field of electric machine, specifically relate to a brushless motor who is used for brushless motor's connection structure and includes this kind of connection structure.

Background

With the development of scientific technology, more and more functions are integrated in automobiles in order to meet the needs of automobile users as much as possible and improve the use comfort of the users. In order to achieve these functions, electric motors, in particular brushless dc motors, are widely used in the automotive field.

A brushless electric machine generally includes a stator assembly including a stator and stator windings wound on the stator, and a rotor assembly. The stator windings are typically in the form of three-phase windings, which may be star-connected and delta-connected. In existing brushless motor designs, to achieve star connection of the windings, it is often necessary to weld one end of each phase winding together to form a common terminal, or to solder the single phase windings to a PCB board, and then bridge the three single phase winding coils on the PCB board by metal conductors.

However, when the motor is required to be designed to have a very small size, there are often problems in that: limited by the compact size design of the motor, there is often no space for soldering iron to enter to perform soldering or the soldering procedure cannot be conveniently operated, so that the requirement of soldering the common end of the three-phase winding cannot be met; or when the working current of the motor is relatively large, the requirement of replacing the common end welding of the three-phase winding by using a wiring mode of a PCB (printed circuit board) is difficult to realize. In addition, in the prior art, manual soldering is often needed, so that human resources account for a certain proportion, the operability is poor, the process is relatively complex, the production efficiency is low, and the automatic production is difficult to realize.

Accordingly, there is a need for a new brushless motor structure that overcomes one or more of the problems set forth above and/or other deficiencies in the prior art.

SUMMERY OF THE UTILITY MODEL

The present invention has been made in view of such a background. According to an aspect of the present invention, there is provided a connection structure for a brushless motor, the brushless motor including a stator assembly and a rotor assembly, the stator assembly including a stator and three-phase windings wound on the stator, the three-phase windings being connected in a star shape, the connection structure including three terminals and a connection bar for bridging the three terminals; each of said terminals being intended to be in electrical contact with the coils of the windings of the respective phase so as to connect together one end of the windings of the respective phase via said connecting strip to form a common terminal; wherein each of the terminals includes a wire breaking portion for breaking an insulating sheath of the coil and a clamping portion for clamping and holding a metal wire of the coil.

Advantageously, each of said terminals comprises two contact arms disposed spaced apart from one another, between which a space is defined through which the coil of the winding of the respective phase passes.

Advantageously, a pair of first projections are oppositely provided on the inner edges of the two contact arms facing each other, a first width being defined between the pair of first projections, the first width being smaller than the outer diameter of the coil, so that the insulating sheath is pierced by the pair of first projections when the coil enters into the space.

Advantageously, a pair of second protrusions are oppositely provided on inner edges of the two contact arms facing each other, with a second width defined therebetween, the second width being smaller than the first width, so that the metal wire of the coil is clamped and held by the pair of second protrusions.

Advantageously, a pair of third projections are provided on the terminal, the third projections being intended to be interference-fitted with receiving grooves for receiving the terminals.

Advantageously, said connecting strips extend in the circumferential direction of the stator and span an angle not exceeding 180 °.

Advantageously, the connection structure comprises a fisheye pin extending from the connection bar in a direction away from the terminal, the fisheye pin being adapted to press fit with a pre-made tinning hole in a PCB board arranged at one axial end of the three-phase winding.

According to the utility model discloses an on the other hand, it still provides a brushless motor, brushless motor includes above-mentioned connection structure.

Advantageously, the brushless motor includes a plurality of insulating sleeves provided at one axial end of the three-phase winding, each of the insulating sleeves being opened with a receiving groove, a portion of the coil of each of the three-phase winding passing through one of the receiving grooves.

Advantageously, the terminal of the connection structure is intended to be press-fitted in the receiving groove, so that the insulating sheath of the coil is pierced by the wire-breaking portion and the metal wire of the coil is clamped and held by the clamping portion during the press-in process.

Compared with the prior art, adopt and according to the utility model discloses a brushless motor for brushless motor's connection structure and including this connection structure can realize one of following technological effect at least: the problem of common end connection of the three-phase winding can be solved under the condition that a common end welding process cannot be implemented or a PCB wiring mode is not easy to realize due to the limited size and space of the motor; the reliable connection of the circuit can be realized, and the structure requirements of different working currents can be met; the method saves a common end welding process or a tin soldering process between the winding coil and the PCB, has good operability and relatively simple process, and is easy for automatic production.

Drawings

The above and other features and advantages of the present invention will become more readily understood from the following description with reference to the accompanying drawings, in which:

fig. 1 shows a schematic perspective view of a connection structure for a brushless motor according to the present invention;

FIG. 2a shows a schematic front view of the connection in FIG. 1; FIG. 2b shows an enlarged detail view of the circled portion in FIG. 2 a;

fig. 3a shows a schematic perspective view of a brushless motor (without a PCB board mounted thereon) according to the present invention; figure 3b shows a schematic perspective view of a brushless motor (with a PCB board mounted thereon) according to the present invention;

figure 4a shows, in cross-section, in part, an insulating sleeve provided at one axial end of a winding of the brushless motor shown in figures 3a and 3 b; fig. 4b is a schematic view showing one of the terminals of the connection structure shown in fig. 1 as being press-fitted in an insulating housing; and

fig. 5 shows the clamping relationship between the winding coil and the connection structure (partially showing one of the terminals).

All the figures are purely diagrammatic and not drawn to scale, and moreover they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely mentioned. That is, the present invention may include other components in addition to those shown in the drawings.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention to those skilled in the art. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. The following aspects, features, embodiments and advantages are merely illustrative and should not be considered elements or limitations of the claims except where explicitly recited in a claim. Terms such as "first," "second," and the like are used hereinafter to describe elements of the present application and are used only to distinguish one element from another without limiting the nature, sequence, order, or number of such elements. In addition, it is to be noted that in the present description, identical and/or functionally identical technical features are provided with the same or similar reference signs.

The motor can be classified into a direct current motor and an alternating current motor according to the type of a working power supply, wherein the direct current motor generally comprises a brush direct current motor and a brushless direct current motor, wherein the brush direct current motor adopts mechanical commutation, an external magnetic pole is fixed, an internal coil is movable, when the motor works, a commutator and the coil rotate together, a carbon brush and magnetic steel are not movable, and then the commutator and the carbon brush generate friction to complete current direction switching; the brushless DC motor is electronically commutated without commutator and carbon brush, and is composed of permanent magnet rotor, multi-pole winding stator, position sensor, etc. the position sensor energizes adjacent stator coil according to the position of magnetic pole of rotor, and the stator generates magnetic pole attracted with rotor to attract rotor to rotate, so repeating to drive motor to rotate.

The coupling structure according to the present invention (to be discussed in detail hereinafter) is mainly applied to a brushless motor. The stator windings of brushless motors are typically three-phase windings, which may be star-connected and delta-connected. To achieve a star connection of the windings, it is often necessary to weld one end of each phase winding together to form a common terminal. As mentioned in the background section, there are often situations where the common terminal welding process is impractical or inconvenient to implement due to the limited size space of the machine, which makes a reliable and efficient way to implement common terminal connection of windings in a star connection desirable.

To this end, the utility model provides an improved structure, it relates to a connection structure who is used for brushless motor's winding especially, and it can realize the common port connection of three-phase winding reliably under the condition that the common port welding process can't be implemented or inconvenient implementation.

Specifically, as shown in fig. 1, the connection structure 100 may be formed as a metal connecting piece (e.g., C19010 or a copper sheet material such as tin bronze, etc.) including three terminals 110 and a connecting strip 120 for bridging the three terminals 110. Each of the terminals 110 is intended to be in electrical contact with the coils 400 of the windings of the respective phase so as to connect one end of the windings of the respective phase together via the connecting strip 120 to form a common terminal. The connecting bars 120 extend in the circumferential direction of the stator and span an angle (see fig. 3 a). The angle is preferably designed to not exceed 180 ° so that unnecessary interference between the connection structure 100 and other parts in the motor can be effectively avoided.

Unlike the prior art, the connection structure 100 of the present invention can eliminate the welding process of the common end portion of the winding coil. Specifically, each of the terminals 110 includes a wire breaking portion for breaking an insulating sheath of the coil and a clamping portion for clamping and holding a metal wire of the coil. As such, in the process of pressing the respective terminals 110 of the connection structure 100 into the plurality of insulation sleeves 300 (which are opened with the receiving grooves 301, see fig. 4 a) formed at the axial ends of the stator winding, for example, the insulation sheath of the coil will be first punctured by the wire-broken portion, and the exposed metal conductive wire (e.g., copper wire) will be finally clamped and held by the clamping portion. The breaking line part and the clamping part can have various different structural forms as long as the functions can be realized.

According to the exemplary embodiment shown in fig. 1, each terminal 110 comprises two contact arms 111 spaced apart from each other and preferably symmetrically arranged, the two contact arms 111 extending from the connection strip 120 towards a direction away from the connection strip 120, and a space 112 is defined between the two contact arms 111 through which the winding coil passes. A pair of first protrusions 111a are oppositely or symmetrically provided on inner edges of the two contact arms 111 facing each other, and a first width W1 is defined between the pair of first protrusions 111a, the first width W1 being smaller than an outer diameter of the coil, so that an insulating sheath of the coil is pierced by the pair of first protrusions 111a when the corresponding coil is initially pressed into the space 112.

In addition, as the coil of the winding is continuously pressed into the space 112 with respect to the two contact arms 111, the metal wire of the coil that has been pierced will be clamped by a pair of second protrusions 111b that are oppositely or symmetrically disposed on the inner edges of the two contact arms 111 facing each other. Specifically, a second width W2 is defined between the pair of second protrusions 111b, and the second width W2 is smaller than the outer diameter of the coil and the first width W1, thereby allowing the metal wire of the coil to be clamped and held by the pair of second protrusions 111b (see fig. 2b and 5).

To achieve power transmission of the motor, the coils of each phase winding are electrically connected to the PCB board 200 at one of the axial ends of the stator winding. Specifically, in the brushless motor having star-connected windings as shown in fig. 3a to 3b, in addition to the connection structure 100 for realizing the common terminal connection according to the present invention, three connection structures 100' for electrically connecting the coils of the windings of the respective phases with the PCB board 200 are provided. This connection structure 100' includes similar wire-breaking portions and clamping portions as the terminal 110 in the aforementioned connection structure 100, so that a soldering process between the winding coil and the PCB board can be omitted.

It should be appreciated that the connection structure 100 according to the present invention may be selected for use with the PCB board 200 or may be used alone. For example, in case it is desired to take the current signals of the common ends of the three-phase windings, the connection structure 100 may comprise a fisheye pin 130 extending from the connection strip 120 in a direction away from the terminal 110, the fisheye pin 130 being adapted to be press-fitted into a pre-formed tin-plated hole 201 of a PCB board 200 arranged at one axial end of the three-phase windings (see fig. 3 b). According to the utility model discloses a width A (see fig. 2 a) of fisheye contact pin 130 among the connection structure can be selected according to the size of the operating current of motor to the structure demand that allows to adapt to different operating current sizes. Accordingly, the size of the pre-plated holes 201 on the PCB 200 intended to mate with the fisheye pins 130 may be selected according to the width a to ensure a press-fit relationship between the two.

However, the fish-eye pin configuration may be omitted, for example, in the case where it is not necessary to take a common terminal current signal.

With continued reference to fig. 3a-3b, the brushless motor may include a plurality of insulating sleeves 300 disposed at one axial end of the stator windings, and the insulating sleeves 300 may be integrally formed or separately formed. Each insulating sheath 300 is formed with a receiving slot 301, and a portion of the coil of the corresponding phase winding of the stator winding passes through one of the receiving slots 301.

Each terminal 110 of the connecting structure is intended to be press-fitted into the receiving groove 301 of the corresponding insulating sheath 300. As the terminal 110 is pressed inward toward the receiving groove 301, the insulating sheath of the coil 400 is pierced by the wire-broken portion (first projection 111 a), and the exposed metal wire is then clamped and held by the clamping portion (first projection 111 b) (see fig. 5).

When the pressing-in process of the terminal 110 is finished, the lower side edge 121 of the connecting strip 120 will stop on the insulating sleeve 300.

In order to enable the connection structure 100 to be stably held in the receiving groove 301, a pair of third protrusions 111c may be further provided on each terminal 110. Specifically, a pair of third projections in the form of barbs defining a third width W3 that is greater than the inner bore diameter of the receiving groove 301 (see fig. 4 b) are provided on the outer edges of the two contact arms 111 that are remote from each other, thus ensuring that the connection structure can be interference-fitted in the receiving groove with the third projections.

Therefore, the connecting structure not only can puncture the insulating sheath by virtue of the pressing action, but also can be stably kept in the receiving groove under the condition of ensuring the electric contact between the connecting structure and the exposed metal lead, so that a public end welding procedure is replaced by a simple operation step, and the public end connection problem under the condition that the public end welding procedure cannot be implemented or is inconvenient to implement is solved.

As an improvement point of the utility model, because the utility model discloses a connection structure need not to rely on the public end that welding process realized three-phase winding to connect, consequently can use the motor operating current of multiple size. For example, it is often not possible to accommodate large operating currents when the common terminal connections are made in the prior art using PCB board wiring (i.e., by soldering the single phase windings to the PCB board and then bridging the three single phase winding coils on the PCB board by metal conductors). Since large operating currents result in the need for large-sized metal conductors to bridge the winding coils, it is not possible or difficult to achieve common-end connections by soldering on a PCB board in small-sized motors where the size space is particularly limited. However, the connection structure according to the present invention solves or avoids this technical problem.

Will be according to the utility model discloses a connection structure impresses when insulating cover's accepting groove, the insulating crust through broken wire portion puncture coil and through the clamping part centre gripping and the metal wire who stably keeps the coil, make the public end welding process of three-phase winding coil that can replace brushless motor, this is in the less compact motor structure of size, the public end connection problem of motor under the condition because of the space is limited and can't or inconvenient implementation welding process, because it has saved butt-joint welding or soldering tin process, has fine maneuverability, the process has been saved, the manpower, change in automated production.

It should be noted that the above-described embodiments should be regarded as merely exemplary, and the present invention is not limited to these embodiments. Upon consideration of the present specification, those skilled in the art can make various changes and modifications without departing from the scope or spirit of the present invention. The true scope of the invention is defined by the following claims and their equivalents.

Claims (10)

1. A connection structure (100) for a brushless motor comprising a stator assembly and a rotor assembly, the stator assembly comprising a stator and three-phase windings wound on the stator, the three-phase windings being connected in a star-like connection, characterized in that the connection structure comprises three terminals (110) and a connection bar (120) for bridging the three terminals (110); each of said terminals (110) is intended to be in electrical contact with the coils of the windings of the respective phase, so that one end of the windings of the respective phases can be connected together via said connection bars to form a common terminal; wherein each of the terminals (110) includes a wire breaking portion for breaking an insulating sheath of the coil and a clamping portion for clamping and holding a metal wire of the coil.

2. The connection structure (100) according to claim 1, wherein each of the terminals (110) includes two contact arms (111) disposed apart from each other, the two contact arms (111) defining a space (112) therebetween through which a coil of a winding of a corresponding phase passes.

3. The connection structure (100) according to claim 2, wherein a pair of first protrusions (111 a) are oppositely disposed on inner edges of the two contact arms (111) facing each other, a first width (W1) is defined between the pair of first protrusions (111 a), the first width (W1) being smaller than an outer diameter of the coil such that the insulating sheath is pierced by the pair of first protrusions (111 a) when the coil enters into the space (112).

4. The connection structure (100) according to claim 3, wherein a pair of second protrusions (111 b) are oppositely disposed on inner edges of the two contact arms (111) facing each other, a second width (W2) is defined between the pair of second protrusions (111 b), the second width (W2) being smaller than the first width (W1) so that the metal wire of the coil is clamped and held by the pair of second protrusions (111 b).

5. The connection structure (100) according to any one of claims 1 to 4, wherein a pair of third projections (111 c) are provided on the terminal (110), the third projections being intended to be interference-fitted with a receiving groove (301) for receiving the terminal.

6. The connection structure (100) according to any one of claims 1 to 4, wherein the connection bars (120) extend in a circumferential direction of the stator and span an angle not exceeding 180 °.

7. The connection structure (100) according to any one of claims 1 to 4, wherein the connection structure (100) comprises a fisheye pin (130) extending from the connection strip (120) towards a direction away from the terminals, the fisheye pin being adapted to be press-fitted with a pre-made tinning hole (201) on a PCB board (200) arranged at one axial end of the three-phase winding.

8. A brushless electric machine, characterized in that it comprises a connection structure (100) according to any one of claims 1 to 7.

9. The brushless motor of claim 8, comprising a plurality of insulating sleeves (300) disposed at one axial end of the three-phase winding, each insulating sleeve being opened with a receiving slot (301), a portion of the coil of each phase winding of the three-phase winding passing through one of the receiving slots (301).

10. The brushless electric machine according to claim 9, characterized in that the terminal (110) of the connection structure (100) is intended to be press-fitted in the receiving groove (301) such that the insulating sheath of the coil is pierced by the wire-breaking portion and the metal wire of the coil is clamped and held by the clamping portion during the press-in process.

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