WO2016021804A1

WO2016021804A1 - Stator assembly of motor having hall sensor assembly with improved reliability of electrical connection

Info

Publication number: WO2016021804A1
Application number: PCT/KR2015/003555
Authority: WO
Inventors: Jeong Cheol Jang; Ji Min Lee; Gyeong Sik Yang
Original assignee: New Motech Co., Ltd.
Priority date: 2014-08-08
Filing date: 2015-04-09
Publication date: 2016-02-11
Also published as: KR20160018095A; KR101604917B1

Abstract

Disclose herein is a stator assembly of a motor. The stator assembly includes a stator core having a core base and a plurality of teeth formed radially on the core base. An upper insulator is also provided, which has an upper teeth insulating portion covering upper portions of the teeth of the stator core and an upper base covering an upper portion of the core base. The stator assembly also includes a lower insulator having a lower teeth insulating portion covering lower portions of the teeth of the stator core and a lower base covering a lower portion of the core base. A hall sensor assembly is coupled to the upper insulator and includes a main body that has at least one hall-sensor inserting portion and at least one coil inserting groove formed towards the upper base.

Description

STATOR ASSEMBLY OF MOTOR HAVING HALL SENSOR ASSEMBLY WITH IMPROVED RELIABILITY OF ELECTRICAL CONNECTION

The present invention relates to a stator assembly of a motor. More particularly, the present invention relates to a stator assembly of a motor, which adopts a hall sensor assembly of a new structure, thus improving reliability of electrical connection and durability, in addition to reducing a manufacturing cost thereof.

In general, a motor includes a stator assembly and a rotor assembly. A motor used for an electrical appliance, such as a drum-type washing machine, is configured such that a stator core of the stator assembly is surrounded by an insulator and then is wound by a coil. This coil is electrically connected to a printed circuit board or the like via a hall sensor assembly to apply power.

Such a conventional hall sensor assembly is disclosed in Korean Patent No. 10-1389612. FIG. 1 illustrates a state where the hall sensor assembly is coupled to an upper insulator of a conventional stator assembly. As shown in FIG. 1, the upper insulator 1 is made of insulating resin, and is coupled to an upper portion of a stator core (not shown). A plurality of teeth is radially formed on an outside of the upper insulator 1. A Magmate terminal inserting portion 13 is formed on an upper base 10 of the upper insulator 1 that is an inside of the teeth 11, for the purpose of connecting with an external power connector. A Magmate terminal 14 is inserted into the Magmate terminal inserting portion 13 to be electrically connected to the coil. FIG. 1 shows three Magmate terminal inserting portions 13 that are formed to be connected to power of U, V, and W phases.

In order to connect the external power to the Magmate terminal inserting portions 13, the hall sensor assembly 100 has the Magmate terminal inserting portions 101 at positions corresponding to the Magmate terminal inserting portions 13. A pin (not shown) is provided in the Magmate terminal inserting portion 101 to be connected to each Magmate terminal 14. The pin is electrically connected to a power terminal pin 104 via a lead wire 103. The power terminal pin 104 is located in a power terminal inserting portion 102, and the external power connector is coupled to the power terminal inserting portion 102 to form an electrical connection. Further, a hall sensor (not shown) is located in a side of the hall sensor assembly 100, and an upper portion of the hall sensor is protected by a silicone molding 105. In order to electrically connect the hall sensor with an exterior, a hall sensor connector 106 is formed.

As such, the hall sensor assembly 100 serves to supply external power to the coil wound around the insulator via the lead wire 103, and serves to measure the intensity or polarity of a magnetic field via the hall sensor and then to transmit a measured signal to a controller of a device using the motor.

The external-power connecting method using the conventional hall sensor assembly 100 is problematic in that the electrical connection is realized by press-fitting an end of the coil of the stator assembly into the Magmate terminal 14, so that carbonization may occur at a portion where a film of the coil is undesirably stripped and eliminated, and its assembly is difficult. Further, since the hall sensor assembly 100 is manufactured with the lead wire 103 situated in an insert molding during the manufacture of the hall sensor assembly 100, its manufacture is difficult. Moreover, since the connector should be inserted into each of the power terminal pin 104 and the hall sensor connector 106 to form the electrical connection, it is disadvantageous in terms of the reliability of the electrical connection or durability.

Therefore, in order to solve the above-mentioned problems, the inventors propose a stator assembly, which adopts a hall sensor assembly of a new structure excluding the electrical connecting structure using the Magmate.

An embodiment of the present invention is directed to a stator assembly of a motor, which adopts a hall sensor assembly of a new structure.

Another embodiment of the present invention is directed to a stator assembly of a motor, which is improved in durability and reliability of electrical connection.

A further embodiment of the present invention is directed to a stator assembly of a motor, which is improved in assemblability.

The above and other objects of the present invention will be easily achieved by the following detailed description.

According to an aspect of the present invention, a stator assembly of a motor includes a stator core having a core base and a plurality of teeth formed radially on the core base; an upper insulator having an upper teeth insulating portion covering upper portions of the teeth of the stator core, and an upper base covering an upper portion of the core base; a lower insulator having a lower teeth insulating portion covering lower portions of the teeth of the stator core, and a lower base covering a lower portion of the core base; and a hall sensor assembly coupled to the upper insulator and including a main body, the main body having at least one hall-sensor inserting portion and at least one coil inserting groove formed towards the upper base.

According to another aspect of the present invention, the stator assembly may further include a coil wound around the upper and lower teeth insulating portions, an end of the coil being inserted into and guided by the coil inserting groove.

According to a further aspect of the present invention, the coil guided by the coil inserting groove may be surrounded by a cable secured to the main body and may be extended to be connected to an external power source.

According to still another aspect of the present invention, the cable may be held by a cable clamp that may be fastened to a clamp fastening portion provided on the main body.

According to another aspect of the present invention, a molding space may be defined above the hall-sensor inserting portion, and an inserting groove may be formed at a predetermined position in the molding space so that a wire holding member may be inserted into the inserting groove.

It should be understood that different embodiments of the invention, including those described under different aspects of the invention, are meant to be generally applicable to all aspects of the invention. Any embodiment may be combined with any other embodiment unless inappropriate. All examples are illustrative and non-limiting.

According to the present invention, the stator assembly of the motor adopts the hall sensor assembly of the new structure, which is improved in durability, reliability of electrical connection, and assemblability.

FIG. 1 is a perspective view showing a stator assembly of a motor equipped with a conventional hall sensor assembly;

FIG. 2 is a perspective view showing a stator assembly equipped with a hall sensor assembly according to the present invention;

FIG. 3 is an exploded perspective view showing the stator assembly of the motor according to the present invention;

FIG. 4 is an enlarged perspective view showing the hall sensor assembly coupled to the stator assembly of the motor according to the present invention; and

FIG. 5 is an exploded perspective view showing the hall sensor assembly applied to the stator assembly of the motor according to the present invention.

Exemplary embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. The present invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Throughout the disclosure, like reference numerals refer to like parts throughout the various figures and embodiments of the present invention.

FIG. 2 is a perspective view showing a stator assembly 5 equipped with a hall sensor assembly 4 according to the present invention, and FIG. 3 is an exploded perspective view showing the stator assembly 5 of the motor according to the present invention.

As shown in FIGS. 2 and 3, the stator assembly 5 according to the present invention includes an upper insulator 1, a lower insulator 2, a stator core 3, and a hall sensor assembly 4.

An upper insulator 1 and a lower insulator 2 are coupled to an upper portion and a lower portion of the stator core 3, respectively, thus insulating a surface of the stator core 3. The stator core 3 includes a circular core base 30 and a plurality of teeth 31 that are formed radially from the circular core base 30. An upper base 10 of the upper insulator 1 and a lower base 20 of the lower insulator 2 cover an upper portion, a lower portion and/or an inner surface of the core base 30 of the stator core 3, respectively, thus insulating them. At least one locking protrusion 12 is provided on the upper base 10 of the upper insulator 1 so that the hall sensor assembly 4 is coupled thereto. In FIG. 3, two locking protrusions 12 are illustrated.

A plurality of fastening portions 22 is provided on an inside of the lower insulator 2. Each fastening portion 22 is a portion through which a fastening means, such as a bolt, passes to fasten the stator assembly 5 to a motor set (not shown). Although the fastening portions 22 are not limited to a specific number, at least three fastening portions are preferred for the purpose of robust and stable coupling. A rivet 6 is inserted into a hole formed in each fastening portion 22.

The teeth 31 of the stator core 3 are covered by both an upper teeth insulating portion 11 and a lower teeth insulating portion 21, with a coil (not shown) wound around each of the upper and lower

teeth insulating portions

11 and 21. An end of the wound coil is guided to the hall sensor assembly 4 to be connected to an external power source. A detailed configuration will be described with reference to FIG. 4. Meanwhile, the teeth 31 are radially formed on an outside of the core base 30 in FIGS. 2 and 3. Such a structure is applied to an outer rotor motor, namely, a motor configured such that a rotor is rotatably located outside the stator. The present invention is not limited to such an outer rotor motor, but the teeth 31may be formed on an inside of the core base 30. In this case, the upper teeth insulating portion 11 and the lower teeth insulating portion 21 are also formed on the inside to correspond to the shape of the teeth.

FIG. 4 is an enlarged perspective view showing the hall sensor assembly 4 coupled to the stator assembly 5 of the motor according to the present invention.

Referring to FIG. 4, a main body 40 of the hall sensor assembly 4 according to the present invention is coupled to a locking protrusion 212 formed on the upper base 10 of the upper insulator 1. Although a screw coupling method is shown in FIG. 4 as the coupling method, it is possible to use a hook coupling method, a coupling method using an adhesive, or other known coupling methods.

An end of the coil 7 wound around the teeth of the stator assembly 5 is guided by a coil inserting groove 42 formed at a predetermined position of the main body 40, is bound to an interior of the cable 70 and then is drawn out to the external power source. In the case of 3-phase winding, the coil 7 is formed such that its ends have three strands as shown in FIG. 4. However, the number of the ends may be changed depending on the structure of the motor or the like. An example wherein three ends of the coil are drawn out to the cable 70 will be described herein.

As described above, the coil 7 is guided towards the cable 70 while being inserted into the coil inserting groove 42. A surface of the coil 7 is preferably surrounded by an insulating tube (not shown) or shrink tube (not shown) so as to protect the coil 7. A portion surrounded by the insulating tube or the like may be preferably applied before the coil is inserted into the coil inserting groove 42.

In order to prevent the coil 7 guided through the coil inserting groove 42 from moving upwards, it is preferable to guide an upper portion of the coil 7 by means of an upper coil holding portion 43. Subsequently, the coil 7 is surrounded by the cable 70 to be drawn out to the external power source. The cable 70 utilizes an insulating cable that is universally used, and is secured to the main body 40 of the hall sensor assembly 4 via a cable clamp 71. The number or position of the cable clamp 71 is not limited to a specific number or position. For example, it is possible to apply two cable clamps 71 as shown in FIG. 4 so as to ensure reliable securing.

A hall sensor (not shown) is located at an upper portion of the main body 40 and an upper portion of the upper teeth insulating portion 11, and an upper portion of the hall sensor is treated by silicone molding 9. Of course, although the term "silicone molding" is used herein, molding treatment using materials other than silicone is also possible. That is, the term "silicone molding" used herein covers all types of molding using a resin, an adhesive, etc. A wire (not shown) for transmitting an electrical signal of the hall sensor to a controller (not shown) is drawn out to an outside through a wire holding member 8. The drawn wire may be bound to the cable 70 together to be guided, or may be electrically coupled to the controller, in a similar manner as a connector, to form electrical connection.

FIG. 5 is an exploded perspective view showing the hall sensor assembly 4 applied to the stator assembly 5 of the motor according to the present invention.

As shown in FIG. 5, the hall sensor assembly 4 of the present invention may include a fastening portion 41 defined in the main body 40, a coil inserting groove 42, an upper coil holding portion 43, a loss-in-weight space 44, a clamp fastening portion 45, an anti-rotation guide 46, a hall-sensor inserting portion 47, a molding space 48, and an inserting groove 49.

The fastening portion 41 serves to fasten the main body 40 to the locking protrusion 12 of the upper insulator 1, and is formed as a screw groove in FIG. 5. It is possible to apply various fastening structures other than the screw-type fastening structure, as described above. The coil inserting groove 42 serves to guide the end of the coil wound around the teeth, and allows the coil 7 to be inserted therein and guided. The number of coil inserting grooves 42 depends on the number of coils. In FIG 5, three coil inserting grooves are shown. The shape or position of the coil inserting groove 42 may be different from that of FIG. 5. The upper coil holding portion 43 slightly presses the upper portions of the three coils guided by the coil inserting grooves 42, thus preventing the coils from being dislodged

The loss-in-weight space 44 is provided in the main body 40 to reduce the amount of resin molding required for the main body 40, and may be applied to positions other than a position of FIG. 5, as necessary. For example, a plurality of loss-in-weight spaces may also be formed even in a portion where the cable 70 is situated.

The clamp fastening portion 45 serves to fasten the cable clamp 71 for holding the cable to the main body 40. Various numbers of clamp fastening portions 45 are possible. In FIG. 5, two clamp fastening portions 45 are formed. Although FIG. 5 shows that the clamp fastening portion 45 has the shape of a hole for screw-type coupling, it may have various coupling structures using a groove or hook for hook-type coupling, an adhesive, etc. without being limited thereto. The anti-rotation guide 46 is provided at a position adjacent to the clamp fastening portion 45, thus preventing the cable clamp 71 from being removed from a preset position due to rotation.

The hall-sensor inserting portion 47 is located above ends of the teeth when the main body 40 is coupled to the upper insulator 1. The hall-sensor inserting portion 47 is formed in a lower portion of the main body 40. An end of the hall-sensor inserting portion 47 may be supported or secured to abut on an end of the upper teeth insulating portion 11. The molding space 48 is a portion where molding is formed by silicone or the like.

The inserting groove 49 is formed at a position adjacent to the molding space, so that the wire holding member 8 is inserted into the inserting groove 49. A plurality of wire withdrawing portions 49a is formed on opposite sides of the inserting groove 49 in a longitudinal direction thereof, while wire inserting portions 80 are formed in the wire holding member 8 at positions corresponding to those of the wire withdrawing portions 49a. In order to transmit an electrical signal from the hall sensor (not shown) inserted into the hall-sensor inserting portion 47 to the controller, the wire (not shown) forms an electrical connection from the hall sensor to the controller. The wire is guided while being seated in the wire withdrawing portion 49a, and is fixed by the wire inserting portions 80 while the wire holding member 8 is inserted into the inserting groove 49.

Preferably, a width of each wire withdrawing portion 49a is equal or slightly larger than a width or diameter of the wire. In order to stably hold the wire, preferably, the width of each wire inserting portion 80 is equal or slightly smaller than a width or diameter of the wire. The wire holding member 8 is preferably made of a high-strength material by resin molding. The reason is because the use of a flexible material such as rubber may cause a reduction in strength, deformation or removal. Further, hooks 81 may be provided on opposite sides of the wire holding member 8. Such a protruding shape allows the wire holding member 8 to be conveniently and firmly inserted into the inserting groove 49.

While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.

Claims

A stator assembly of a motor, comprising:

a stator core having a core base and a plurality of teeth formed radially on the core base;

an upper insulator having an upper teeth insulating portion covering upper portions of the teeth of the stator core, and an upper base covering an upper portion of the core base;

a lower insulator having a lower teeth insulating portion covering lower portions of the teeth of the stator core, and a lower base covering a lower portion of the core base; and

a hall sensor assembly coupled to the upper insulator and including a main body, the main body having at least one hall-sensor inserting portion and at least one coil inserting groove formed towards the upper base.
The stator assembly of claim 1, further comprising:

a coil wound around the upper and lower teeth insulating portions, an end of the coil being inserted into and guided by the coil inserting groove.
The stator assembly of claim 2, wherein the coil guided by the coil inserting groove is surrounded by a cable secured to the main body and is extended to be connected to an external power source.
The stator assembly of claim 3, wherein the cable is held by a cable clamp that is fastened to a clamp fastening portion provided on the main body.
The stator assembly of claim 1, wherein a molding space is defined above the hall-sensor inserting portion, an inserting groove is formed at a predetermined position in the molding space so that a wire holding member is inserted into the inserting groove.