WO2021051482A1

WO2021051482A1 - Stator assembly, motor, and manufacturing method for stator assembly

Info

Publication number: WO2021051482A1
Application number: PCT/CN2019/113818
Authority: WO
Inventors: 王龙; 玉村周平; 娄志刚; 杨晖; 吴锡; 沈夫
Original assignee: 卧龙电气驱动集团股份有限公司
Priority date: 2019-09-19
Filing date: 2019-10-29
Publication date: 2021-03-25
Also published as: CN110474464A

Abstract

A stator assembly, a motor, and a manufacturing method for a stator assembly. The stator assembly comprises a stator core (1), a plurality of coil windings (2), terminals, thermal shrinkage pipe sleeves (3), and a plastic packaging shell (4); the terminals are disposed on the stator core (1); the terminal comprise conductive ends; the coil windings (2) are wound on the stator core (1); the coil windings (2) comprise outgoing wire heads; the outgoing wire heads (21) are connected to the conductive ends by means of soldering; the thermal shrinkage pipe sleeves (3) are sleeved on the conductive ends and the outgoing wire heads (21); the plastic packaging shell (4) wraps the stator core (1) and the coil windings (2). According to the stator assembly, the motor, and the manufacturing method for the stator assembly, the coil windings (2) are not easily damaged, a high engineering yield is guaranteed, plastic packing does not need to be performed immediately, and slag formed after soldering is not fused with a plastic packaging material, and thus, the use safety of the motor is guaranteed.

Description

Stator assembly, motor and manufacturing method of stator assembly

Technical field

The invention relates to the technical field of electrical equipment, in particular to a stator assembly, a motor and a manufacturing method of the stator assembly.

Background technique

BLDC motor, also known as brushless DC motor, overcomes the inherent defects of brushed DC motor and replaces mechanical commutator with electronic commutator, so brushless DC motor has the characteristics of good speed regulation performance of DC motor. It also has the advantages of simple structure of AC motor, no reversing spark, reliable operation and easy maintenance. The aluminum core wire in the existing BLDC motor often adopts two methods: mechanical peeling paint film welding structure and direct welding peeling paint film welding structure. Because the wire diameter of the aluminum core wire in the motor is relatively small, the mechanical peeling paint film welding is more effective. For the aluminum enameled wire with thin wire diameter, it is easy to damage the aluminum core wire, and the engineering defect rate is relatively high; while the direct welding peeling paint film welding has relatively high reliability, but generally adopts the soldering method of soldering furnace dipping. If plastic sealing is not carried out immediately, there is a risk of oxidation at the welding part of the aluminum core wire. If plastic sealing is directly carried out, the flux residue and solder attached to the solder surface will be fused with the plastic sealing material in the subsequent plastic sealing process, which reduces the safety of the motor insulation and voltage resistance. risk.

Summary of the invention

In view of the above problems, the present invention proposes a method for manufacturing a stator assembly, a motor and a stator assembly, which is not easy to damage the coil windings, guarantees a higher engineering yield, does not need to be plasticized immediately, and the residue after welding is not It will be fused with the plastic packaging material to ensure the safety of the motor.

The technical solutions adopted by the present invention are as follows: The present invention provides a stator assembly, including a stator core, a plurality of coil windings, terminals, a heat shrinkable tube sleeve and a plastic shell, the terminals are provided on the stator core, and The terminal includes a conducting end, the coil winding is wound on the stator core, the coil winding has an outlet end, the outlet end and the conducting end are connected by welding, the conducting end and the A heat shrinkable tube sleeve is arranged on the outer jacket of the outlet head, and the plastic-encapsulated outer shell covers the stator core and the coil winding.

In an embodiment of the present invention, the terminal further includes a leading end, a first connecting portion, and a second connecting portion. The conducting end includes a first conducting end and a second conducting end; The first conductive ends are connected to each other and conducted through the first connecting portion to form a power terminal; a plurality of second conductive ends are connected to each other and conducted through the second connecting portion to form a common terminal.

In an embodiment of the present invention, the stator assembly further includes a bracket, the bracket is provided with a positioning through hole and a positioning slot, the lead end of the power terminal is disposed through the positioning through hole, and the first The conducting end is set through the positioning groove; the bracket is provided in the plastic enclosure corresponding to the power terminal, and the lead end of the power terminal penetrates the plastic enclosure and is exposed to the plastic enclosure. Outside the shell, the first conducting end is located in the plastic shell.

In an embodiment of the present invention, the stator assembly further includes a first insulating end and a second insulating end, and the first insulating end and the second insulating end are respectively sleeved on the stator iron On both end faces of the core, the first insulating end is provided with mounting grooves, and the power terminal and the common terminal are both inserted into the mounting grooves.

In an embodiment of the present invention, the mounting groove has an h-shaped structure, the first connecting portion has a zigzag structure, and the second connecting portion has an in-line structure.

In an embodiment of the present invention, the outlet head is wound on the conducting end and connected by welding; the number of windings is at least three.

In an embodiment of the present invention, the coil winding is a direct-welded aluminum wire enameled wire winding.

The present invention also provides a motor including the above-mentioned stator assembly.

The present invention also provides a method for manufacturing a stator assembly, which is used for the above-mentioned manufacturing of the stator assembly, and includes the following steps:

Step 1: Sleeve the first insulating end portion and the second insulating end portion on the two end surfaces of the stator core, respectively;

Step 2: Insert the power terminal and the common terminal into the installation groove of the first insulating end respectively;

Step 3: The coil winding is automatically wound on the stator core by an automatic winding machine, and the wire outlet of the coil winding is wound on the conducting end and connected by welding;

Step 4: Connect multiple stator cores in sequence to form an in-line stator assembly, and then round the in-line stator assembly to make a ring-shaped stator assembly;

Step 5: The bracket is sleeved on the leading end and the first conducting end of the power terminal through the positioning through hole and the positioning groove structure, so that the bracket is set corresponding to the power terminal;

Step 6: Set the heat-shrinkable tube sleeve outside the conducting end after welding the wire end, and heat and fix it;

Step 7: Plastic seal the ring-shaped stator assembly and bracket in the plastic shell to obtain the stator assembly.

In an embodiment of the present invention, the soldering in the step 3 adopts wave soldering, which includes the following steps: automatically immersing the conductive end wound around the wire head in the first treatment agent for processing, and then automatically immersing it in the high-temperature solder for processing. Paint film removal operation; then automatically immersed in the second treatment agent for processing, and then automatically immersed in high-temperature solder for soldering operation.

In an embodiment of the present invention, the first treatment agent is a soldering flux or a paint remover; the second treatment agent is a soldering flux.

The beneficial effects of the present invention are: the stator assembly, the motor and the method for manufacturing the stator assembly provided by the present invention, the outlet end of the coil winding and the conducting end of the terminal are connected by welding, which is not easy to damage the coil winding and ensures high The engineering yield rate is high, and after the welding connection, the conduction end and the outlet end cover are equipped with heat shrinkable tube sleeves. The heat shrinkable tube sleeve can protect the welding point of the outlet end and the conduction end from being oxidized. It does not need to be plasticized and welded immediately The remaining residue is wrapped in the heat-shrinkable tube sleeve and will not be fused with the plastic packaging material to ensure the safety of the motor.

Description of the drawings

Figure 1 is a schematic view of the structure of the stator assembly of the present invention;

Figure 2 is a first schematic diagram of the internal structure of the stator assembly of the present invention;

Figure 3 is a top view of Figure 2;

Figure 4 is a second schematic diagram of the internal structure of the stator assembly of the present invention;

5 is a schematic diagram of the structure of the power terminal of the present invention with a heat shrinkable tube sleeve;

6 is a schematic diagram of the structure of the power terminal of the present invention without a heat shrinkable tube sleeve;

Figure 7 is a schematic structural view of the common terminal of the present invention covered with a heat shrinkable tube sleeve;

Figure 8 is a schematic structural view of the common terminal of the present invention without a heat shrinkable tube sleeve;

Fig. 9 is a plan view of the first insulating end portion of the present invention.

The reference signs in the figure are: 1. Stator core; 2. Coil winding; 3. Heat shrinkable sleeve; 4. Plastic shell; 5. Power terminal; 6. Common terminal; 7. Bracket; 8. 9. An insulating end; 9. The second insulating end; 10. The limit slot; 21. The outlet end; 51. The first conduction end; 52. The lead end; 53, the first connection part; 61. The second conduction. End; 62, the second connecting part; 71, the positioning through hole; 72, the positioning groove; 81, the mounting groove.

detailed description

Hereinafter, the present invention will be described in detail and completely through specific embodiments in conjunction with the drawings.

Please refer to Figures 1-9. The present invention provides a stator assembly, which includes a stator core 1, a plurality of coil windings 2, terminals, a heat shrinkable tube sleeve 3 and a plastic shell 4, and the terminals are arranged on the stator core 1. The terminal includes a conducting end. The coil winding 2 is wound on the stator core 1. The coil winding 2 has an outlet head 21. The outlet head 21 and the conducting end are connected by welding. The conducting end and the outlet head 21 are sheathed with a heat shrinkable tube Cover 3, plastic shell 4 covers stator core 1 and coil winding 2. The outlet head 21 of the coil winding 2 and the conducting end of the terminal are connected by welding, so that the coil winding 2 is not easily damaged, ensuring a high engineering yield, and after the welding connection, the conducting end and the outlet head 21 are covered with heat The shrink tube sleeve 3 and the heat shrink tube sleeve 3 can protect the welding point between the outlet head 21 and the conducting end from being oxidized. It does not need to be plastic sealed immediately, and the residue after welding is wrapped in the heat shrink tube sleeve 3 and will not be sealed with plastic. The materials are fused with each other to ensure the safety of the motor.

The heat-shrinkable tube sleeve 3 contains a hot-melt adhesive structure, which has a good adhesive force, so that the heat-shrinkable tube sleeve 3 can be closely attached to the surface of the welding point between the outlet head 21 and the conducting end. The heat-shrinkable tube sleeve 3 has the advantages of fast shrinkage, short operating time, low cost, and good environmental stress resistance, and can effectively improve the oxidation resistance of the welding point between the outlet head 21 and the conducting end. However, it is not limited to this. The heat shrinkable tube sleeve 3 may not contain hot melt adhesive structure, as long as the heat shrinkable tube sleeve 3 can completely wrap the conducting end, or this kind of heat shrinkable tube sleeve without hot melt adhesive structure inside. 3 Before use, you can brush the three-proof paint on the welding place between the outlet head 21 and the conducting end, which can prevent the oxidation of the welding place between the outlet head 21 and the conducting end, and the residue after welding will not be removed from the heat shrinkable sleeve 3 The purpose of overflowing and fusion with the plastic packaging material is not limited by the present invention.

The terminal also includes a leading end 52, a first connecting portion 53, and a second connecting portion 62. The conductive end includes a first conductive end 51 and a second conductive end 61; the leading end 52 and the first conductive end 51 pass through the first The connecting portions 53 are connected to each other and conducted to form a power terminal 5; a plurality of second conductive ends 61 are connected to and conducted to each other through the second connecting portion 62 to form a common terminal 6. The external power supply leads the current into the stator assembly through the power terminal, and the common terminal is the neutral point terminal of the stator assembly.

The stator assembly further includes a bracket 7, which is provided with a positioning through hole 71 and a positioning slot 72, the leading end 52 of the power terminal 5 is set through the positioning through hole 71, and the first conducting end 51 is set through the positioning slot 72; The bracket 7 is provided in the plastic enclosure 4 corresponding to the power terminal 5, the leading end 52 of the power terminal 5 penetrates the plastic enclosure 4 and is exposed outside the plastic enclosure 4, and the first conducting end 51 is located in the plastic enclosure 4. The positioning through hole 71 and the positioning groove 72 on the bracket 7 correspond to the lead-out end 52 and the first conducting end 51 of the power terminal respectively, which can make the installation positions of the power terminal 5 and the bracket 7 unique, and the positioning on the bracket 7 The through hole 71 and the positioning groove 72 can be used to prevent flashing of the injection molding shell during the injection molding process.

The stator assembly also includes a first insulating end 8 and a second insulating end 9. The first insulating end 8 and the second insulating end 9 are respectively sleeved on the two end surfaces of the stator core 1. The first insulating end The portion 8 is provided with a mounting slot 81, and the power terminal 5 and the common terminal 6 are inserted into the mounting slot 81. The first conducting end 51, the leading end 52, and the second conducting end 61 are not in direct contact with the stator core 1, so as to avoid a short circuit accident and cause greater losses.

Please refer to Figures 4-9, the mounting groove 81 of the first insulating end 8 has an h-shaped structure, and the first connecting portion 53 of the power terminal 5 connecting the first conductive end 51 and the lead-out end 52 has a Z-shaped structure , The second connecting portion 62 of the common terminal 6 connecting the plurality of second conducting terminals 61 has a straight-line structure, and the mounting groove 81 can be used to install the power terminal 5 and the common terminal 6, so that When the first insulating end 8 is produced, only the specifications can be unified, which is convenient for production. The first connecting portion 53 has a zigzag structure, and the second connecting portion 62 has an in-line structure, so that the second conductive end 61 and the first conductive end 51 of the power terminal 5 can be on the same circumference, thereby making the second conductive end 61 and the first conductive end 51 of the power terminal 5 on the same circle. Both a conducting end 51 and a second conducting end 61 are arranged close to the edge of the plastic enclosure 4 to facilitate the plastic molding of the plastic enclosure 4. However, it is not limited to this. The mounting groove 81 has an H-shaped structure, or the first connecting portion 53 and the second connecting portion 62 may have structures of other shapes. The mounting groove 81 is configured to be used for inserting the first connecting portion 53. It can also be used for the structure of inserting the second connecting portion 62, and can also be used to install the power terminal 5 and the common terminal 6, which is not limited in the present invention.

The distance between the two adjacent second conductive ends 61 of the common terminal 6 is more than 5 mm, which can meet the minimum distance structure of the automatic winding of the winding machine, realize automatic winding, and improve production efficiency.

The number of the second conducting ends 61 in the common terminal 6 is two, and each second conducting end 61 has only one outlet head 21 of the coil winding 2, and it is consistent with the first conducting end 51 to ensure winding Consistency of direction and welding effect. When there are two second conducting ends 61, a single-head winding device is used to perform automatic winding operations. However, it is not limited to this. The number of second conducting ends 61 may also be three, and a three-head winding device is used to perform automatic winding operations, which is not limited in the present invention.

The outlet head 21 is wound on the conducting end and connected by welding; the number of winding turns is at least three turns. The outlet head 21 is first wound on the conducting end and then welded to the conducting end, which can make the connection structure of the outlet head 21 and the conducting end reliable and convenient for welding. When the number of windings reaches three turns, the connection structure between the outlet head 21 and the conducting end is more reliable. When the number of windings is more, the connection structure between the outlet head 21 and the conducting end is more reliable, which can be specifically based on actual needs. The strength of the structure is selected.

The conducting end is also provided with a limit slot 10, the outlet head 21 is wound in the limit slot 10, the free end of the conducting end can be round or triangular, and the free end of the conducting end is larger, which can prevent the outlet head 21 from coming out of the guide. The lead end makes the connection structure between the outlet head 21 and the lead end more reliable.

The coil winding 2 is a straight-welded aluminum wire enameled wire winding. The direct welding aluminum wire enameled wire winding includes an aluminum wire core, the outside of the aluminum wire core is coated with an anti-oxidation protective layer, the outside of the anti-oxidation protective layer is coated with a direct welding paint layer, and the outside of the direct welding paint layer is coated with a self-adhesive layer , Can be welded directly, so that the subsequent automatic welding method can be used. Compared with the welding method of manual soldering furnace dip soldering, the production efficiency is greatly improved, and there is no need for personnel to regularly leave the welding residue in the soldering furnace, which reduces manual operation. Safety risks, and automated welding can reduce man-made controllable risks and avoid losses caused by accidental factors.

The structure of the stator assembly of the present application can adopt fully automated production, which greatly improves the production efficiency, reduces the safety risk of manual operation, and avoids losses caused by accidental factors.

Please refer to Figures 1-9. The present invention also provides a method for manufacturing a stator assembly, which is used for the above-mentioned manufacturing of the stator assembly, including the following steps:

Step 1: Sleeve the first insulating end 8 and the second insulating end 9 on the two end faces of the stator core 1 respectively;

Step 2: Insert the power terminal 5 and the common terminal 6 into the installation groove 81 of the first insulating end 8 respectively;

Step 3: The coil winding 2 is automatically wound on the stator core 1 by an automatic winding machine, and the wire outlet 21 of the coil winding 2 is wound on the conducting end and connected by welding;

Step 4: Multiple stator cores 1 are connected in sequence to form an in-line stator assembly, and then the in-line stator assembly is rounded to form a ring-shaped stator assembly;

Step 5: The bracket 7 is sleeved on the leading end 52 and the first conducting end 51 of the power terminal 5 through the positioning through hole 71 and the positioning groove 72, so that the bracket 7 is set corresponding to the power terminal 5;

Step 6: Set the heat-shrinkable tube sleeve 3 outside the conducting end after welding the wire head 21, and heat and fix it;

Step 7: Plastic seal the ring-shaped stator assembly and the bracket 7 in the plastic shell 4 to obtain the stator assembly.

In the method for manufacturing the stator assembly of the present application, the outlet head 21 of the coil winding 2 and the conducting end of the terminal are connected by welding, so that the coil winding 2 is not easily damaged, ensuring a high engineering yield, and after the welding connection, the lead The heat-shrinkable tube sleeve 3 is provided on the outer end and the outlet head 21. The heat-shrinkable tube sleeve 3 can protect the welding part of the outlet head 21 and the conducting end from being oxidized. It does not need to be plastic sealed immediately, and the residue after welding is wrapped in the heat The shrink tube sleeve 3 will not be fused with the plastic packaging material to ensure the safety of the motor.

The plastic shell 4 is formed by injection molding, which can completely seal the welding part of the outlet head 21 and the terminal conduction end, which further improves the reliability of the welding part. The plastic shell 4 is formed by BCM plastic sealing, and the manufactured product has good mechanical properties, high dimensional stability, good surface finish, water resistance, oil resistance, corrosion resistance, heat resistance, and electrical properties.

The soldering in step 3 adopts wave soldering, which includes the following steps: automatically immerse the conducting end of the winding head 21 in the first treatment agent for processing, and then automatically immerse it in the high-temperature solder to remove the paint film; and then automatically immerse it in the first treatment agent. After treatment in the second treatment agent, it is automatically immersed in high-temperature solder again for soldering operations. During wave soldering, the solder is fluid. Compared with the static soldering method, it can reduce the risk of poor solder caused by problems such as the easy oxidation of the solder surface and the residual solder residue on the solder surface, ensuring the soldering effect, improving the processability and quality stability. Sex. Wave soldering has the advantages of environmental protection, good reliability, low energy consumption, saving the use of flux and greatly reducing the generation of tin dross, which can ensure that the solder connection structure is more reliable. Among them, the solder temperature during the soldering operation is higher than the solder temperature during the paint film removal operation.

The first treatment agent is a flux or paint remover; the second treatment agent is a flux. Flux has a certain paint stripping performance and soldering performance. When the paint film on the outer layer of the coil winding 2 is a single-layer structure, the flux can be used to achieve the purpose of paint stripping; when the paint film on the outer layer of the coil winding 2 has a double-layer structure, the paint remover needs to be used to achieve the peeling. The purpose of the paint.

The present invention also provides a motor, including the above-mentioned stator assembly or the stator assembly made by the above-mentioned stator assembly manufacturing method. The outlet head 21 of the coil winding 2 and the conducting end of the terminal are connected by welding, so that the coil winding 2 is not easily damaged, ensuring a high engineering yield, and after the welding connection, the conducting end and the outlet head 21 are covered with heat The shrink tube sleeve 3 and the heat shrink tube sleeve 3 can protect the welding point between the outlet head 21 and the conducting end from being oxidized. It does not need to be plastic sealed immediately, and the residue after welding is wrapped in the heat shrink tube sleeve 3 and will not be sealed with plastic. The materials are fused with each other to ensure the safety of the motor. The motor has a high degree of automation during manufacture and is safe and reliable in use.

The above descriptions are only the preferred embodiments of the present invention, which do not limit the scope of patent protection of the present invention. Any equivalent structural transformations made using the contents of the description and drawings of the present invention are directly or indirectly applied to other related technical fields. The same principles are included in the protection scope of the present invention.

Claims

A stator assembly, characterized in that it comprises a stator iron core, a plurality of coil windings, terminals, a heat shrinkable tube sleeve and a plastic casing, the terminal is arranged on the stator iron core, the terminal includes a conducting end, and the The coil winding is wound on the stator core, the coil winding has an outlet end, the outlet end and the conducting end are connected by welding, and the conducting end and the outlet end are sheathed with heat shrink A pipe sleeve, and the plastic shell covers the stator core and the coil windings.
The stator assembly of claim 1, wherein the terminal further includes a lead-out end, a first connecting portion, and a second connecting portion, and the conductive end includes a first conductive end and a second conductive end The leading end and the first conducting end are connected to each other and conducted through a first connecting portion to form a power terminal terminal; a plurality of the second conducting ends are connected to each other and conducted through a second connecting portion, To form a common terminal.
The stator assembly of claim 2, further comprising a bracket, the bracket is provided with positioning through holes and positioning slots, the lead-out ends of the power terminal terminals are disposed through the positioning through holes, and the The first conducting end is provided through the positioning groove; the bracket is provided in the plastic housing corresponding to the power terminal, and the lead end of the power terminal passes through the plastic housing and is exposed to the outside. Outside the plastic enclosure, the first conducting end is located in the plastic enclosure.
The stator assembly of claim 2, further comprising a first insulating end portion and a second insulating end portion, the first insulating end portion and the second insulating end portion are respectively sleeved on the On both end surfaces of the stator core, the first insulating end is provided with mounting slots, and the power terminal and the common terminal are both inserted into the mounting slots.
5. The stator assembly of claim 4, wherein the mounting slot has an h-shaped structure, the first connecting portion has a zigzag structure, and the second connecting portion has an in-line structure.
The stator assembly of claim 1, wherein the wire outlet is wound on the conducting end and connected by welding; the number of windings is at least three; the coil winding is of a direct welding type Aluminum wire enameled wire winding.
A motor, characterized by comprising the stator assembly of any one of claims 1-6.
A method for manufacturing a stator assembly, characterized in that it is used for the manufacture of the stator assembly according to any one of claims 1-6, comprising the following steps:

Step 1: Sleeve the first insulating end portion and the second insulating end portion on the two end surfaces of the stator core, respectively;

Step 2: Insert the power terminal and the common terminal into the installation groove of the first insulating end respectively;

Step 3: The coil winding is automatically wound on the stator core by an automatic winding machine, and the wire outlet of the coil winding is wound on the conducting end and connected by welding;

Step 4: Connect multiple stator cores in sequence to form an in-line stator assembly, and then round the in-line stator assembly to make a ring-shaped stator assembly;

Step 5: The bracket is sleeved on the leading end and the first conducting end of the power terminal through the positioning through hole and the positioning groove structure, so that the bracket is set corresponding to the power terminal;

Step 6: Set the heat-shrinkable tube sleeve outside the conducting end after welding the wire end, and heat and fix it;

Step 7: Plastic seal the ring-shaped stator assembly and bracket in the plastic shell to obtain the stator assembly.
The method for manufacturing a stator assembly according to claim 8, wherein the soldering in the third step adopts wave soldering tin, which includes the following steps: automatically immersing the conducting end of the winding head in the first treatment agent for processing After that, it is automatically immersed in high-temperature solder to remove the paint film; then it is automatically immersed in the second treatment agent for processing, and then automatically immersed in the high-temperature solder for soldering operations.
9. The method for manufacturing a stator assembly according to claim 9, wherein the first treatment agent is a flux or paint remover; and the second treatment agent is a flux.