Novel brushless direct current motor

Abstract

The utility model relates to the technical field of motors, in particular to a novel brushless direct current motor, which comprises a rotor assembly (100), a stator assembly (200), a first end cover (300) and a second end cover (400), the rotor assembly (100) comprises a rotor (101), a rotor shaft sleeve (102) and rotor magnetic steel (103), and the rotor shaft sleeve (102) is made of aluminum materials; the second end cover (400) is provided with a Hall plate (500), and the Hall plate (500) is provided with three surface-mounted Hall elements (501) used for sensing the rotor magnetic steel (103). Due to the adoption of the structural design, the rotor shaft sleeve of the rotor assembly is made of an aluminum material, so that the distribution of magnetic lines of air gaps in the motor is changed, and the problems of large cogging torque and noise of the motor are effectively solved; a Hall element on the Hall plate directly induces motor rotor magnetic steel in a patch mode, so that the reliability of the motor is greatly improved, the structure is simplified, and assembly is facilitated.

Description

Technical Field

[0001] The utility model relates to the technical field of motors, in particular to a novel brushless DC motor. Background Art

[0002] A brushless DC motor (Brushless Direct Current Motor, abbreviated as BLDC motor or brushless motor) is a modern motor design that uses an electronic commutator instead of a traditional mechanical brush and commutator. This design offers many advantages, including higher efficiency, longer service life, lower noise, and better thermal performance. Brushless DC motors are widely used in various fields, such as drones, electric vehicles, precision machinery, household appliances, industrial automation equipment, etc., because they can provide high torque density, fast dynamic response, and precise speed control.

[0003] In the prior art, a Chinese utility model patent with the publication number CN216490125U discloses a Hall circuit board structure, including a Hall circuit board assembly for the installation of Hall components and the transfer between the motor stator and the lead. The Hall circuit board assembly includes a Hall circuit board. The outer side of the Hall circuit board is fixed to a Hall support frame, and a plug-in Hall sensor is fixed outside the Hall support frame. On the other side of the Hall circuit board assembly, a plurality of chip capacitors are fixed, and a power line assembly is fixed outside the Hall circuit board assembly. The Hall elements on its Hall board adopt a plug-in form, which is prone to swing, has low reliability, and has a complex structure that is not conducive to production and assembly. In addition, the rotor shaft sleeve uses a steel material, resulting in a large cogging torque and being not conducive to improving the motor noise.

[0004] Therefore, the prior art needs to be improved and enhanced. Summary of the Utility Model

[0005] The purpose of the utility model is to provide a novel brushless DC motor to solve the above problems existing in the prior art.

[0006] To achieve the above purpose, the technical solution adopted by the utility model is:

[0007] A novel brushless DC motor includes a rotor assembly, a stator assembly sleeved on the outer periphery of the rotor assembly, a first end cover arranged at one end of the stator assembly, and a second end cover arranged at the other end of the stator assembly. The rotor assembly includes a rotor, a rotor shaft sleeve, and a rotor magnet. The rotor shaft sleeve uses an aluminum material. A Hall board is installed on the second end cover, and three patch-type Hall elements for sensing the rotor magnet are arranged on the Hall board.

[0008] As a further solution of the present utility model, a first bolt hole is provided on the second end cover, a second bolt hole is provided on the stator assembly, and the bolt sequentially passes through the first bolt hole and the second bolt hole and is threadedly connected to the first end cover.

[0009] As a further solution of the present utility model, the stator assembly includes a winding, a first wire holder, a second wire holder, and a plurality of stator iron cores sleeved on the outer peripheries of the first wire holder and the second wire holder. Both the first wire holder and the second wire holder include a plurality of positioning teeth. The inner wall of the stator iron core extends towards the axis of the stator iron core to form a plurality of tooth poles, and the tooth poles are inserted into the corresponding positioning teeth of the first wire holder and the second wire holder. Both ends of the winding are respectively wound around the positioning teeth of the first wire holder and the second wire holder and are sleeved around the tooth poles to fix the positioning teeth at both ends of the tooth poles.

[0010] As a further solution of the present utility model, one end of the rotor is rotatably mounted on the first end cover through a first bearing, and the other end is rotatably mounted on the second end cover through a second bearing.

[0011] As a further solution of the present utility model, a washer is provided between the first end cover and the first bearing, and the washer is arranged on the rotor.

[0012] As a further solution of the present utility model, the washer is a corrugated washer.

[0013] As a further solution of the present utility model, a first limit washer and a second limit washer are respectively provided at both ends of the rotor shaft sleeve.

[0014] As a further solution of the present utility model, a notch is provided on the second end cover corresponding to the power supply connection of the Hall plate.

[0015] As a further solution of the present utility model, a wire protection sleeve is provided on the outer wall of the second end cover corresponding to the notch.

[0016] Compared with the prior art, the beneficial effects of the present utility model are as follows:

[0017] Due to the above structural design, the rotor shaft sleeve of the rotor assembly is made of aluminum material, which changes the distribution of the air gap magnetic force lines inside the motor, effectively improving the problems of large cogging torque and noise of the motor; the Hall elements on the Hall plate directly sense the magnetic steel of the motor rotor in a patch form, greatly improving the reliability of the motor and making the structure simpler and more conducive to assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. Figure 1 is a schematic structural diagram of an embodiment of the present utility model;

[0019] FIG. Figure 2Schematic cross-sectional structure diagram of an embodiment of the present utility model;

[0020] Appendix Figure 3 Schematic exploded structure diagram of an embodiment of the present utility model;

[0021] Appendix Figure 4 Schematic exploded structure diagram of the stator assembly of an embodiment of the present utility model.

[0022] Each label in the figure is respectively:

[0023] 100 - Rotor assembly, 200 - Stator assembly, 300 - First end cover, 400 - Second end cover, 500 - Hall plate, 600 - Bolt;

[0024] 101 - Rotor, 102 - Rotor bushing, 103 - Rotor magnet;

[0025] 501 - Surface mount Hall element;

[0026] 401 - First bolt hole, 402 - Notch, 403 - Cable protection sleeve;

[0027] 201 - Second bolt hole, 202 - First wire frame, 203 - Second wire frame, 204 - Stator iron core sheet;

[0028] 2021 - Positioning tooth;

[0029] 2041 - Tooth pole;

[0030] 1011 - First bearing, 1012 - Second bearing, 1013 - Washer, 1014 - First limit spacer, 1015 - Second limit spacer. Detailed implementation manners

[0031] This part will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the drawings. The role of the drawings is to supplement the description in the text part of the specification, enabling people to intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but it should not be construed as a limitation on the protection scope of the present utility model.

[0032] In the description of the present utility model, it should be understood that for the orientation description, such as the orientation or position relationship indicated by up, down, front, back, left, right, etc., is based on the orientation or position relationship shown in the drawings. It is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the present utility model.

[0033] In the description of the present utility model, the meaning of "a number of" is one or more, the meaning of "a plurality of" is more than two, and understandings such as "greater than", "less than", "exceeding", etc. do not include the corresponding number, while understandings such as "above", "below", "within", etc. include the corresponding number. If there is a description of "first" and "second", it is only for the purpose of distinguishing technical features and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features or implicitly specifying the sequence relationship of the indicated technical features.

[0034] In the description of the present utility model, unless otherwise clearly defined, terms such as "arrangement", "installation", "connection", etc. should be understood in a broad sense, and those skilled in the art can reasonably determine the specific meaning of the above terms in the present utility model in combination with the specific content of the technical solution.

[0035] Embodiment:

[0036] As Figures 1-4 shown, a new type of brushless DC motor of the present application includes a rotor assembly 100, a stator assembly 200 sleeved on the outer periphery of the rotor assembly 100, a first end cover 300 arranged at one end of the stator assembly 200, and a second end cover 400 arranged at the other end of the stator assembly 200. The rotor assembly 100 includes a rotor 101, a rotor shaft sleeve 102, and a rotor magnet 103. The rotor shaft sleeve 102 is made of aluminum material, which changes the distribution of air-gap magnetic field lines inside the motor and effectively improves the problems of large cogging torque and noise of the motor. A Hall plate 500 is installed on the second end cover 400, and three surface-mounted Hall elements 600 for sensing the rotor magnet 103 are arranged on the Hall plate 500. Since the Hall elements on the Hall plate 500 directly sense the rotor magnet of the motor in a surface-mounted form, the reliability of the motor is greatly improved and the structure is simpler and more conducive to assembly.

[0037] Specifically, a first bolt hole 401 is arranged on the second end cover 400, a second bolt hole 201 is arranged on the stator assembly 200, and a bolt 600 sequentially passes through the first bolt hole 401 and the second bolt hole 201 and is threadedly connected to the first end cover 300, thereby fixing the second end cover, the stator assembly, and the first end cover together.

[0038] Specifically, the stator assembly 200 includes a winding, a first wire holder 202, a second wire holder 203, and a number of stator iron cores 204 sleeved on the outer perimeters of the first wire holder 202 and the second wire holder 203. Both the first wire holder 202 and the second wire holder 203 include a number of positioning teeth 2021. Inner walls of the stator iron cores 204 extend towards the axis of the stator iron cores to form a number of tooth poles 2041. The tooth poles 2041 are inserted into corresponding positioning teeth 2021 of the first wire holder 202 and the second wire holder 203. Two ends of the winding are respectively wound around the positioning teeth 2021 of the first wire holder 202 and the second wire holder 203, and are sleeved around the outer perimeters of the tooth poles 2041 to fix the positioning teeth 2021 at both ends of the tooth poles 2041. That is, fixation between the first wire holder 202, the second wire holder 203, and the number of stator iron cores 204 is achieved through the wire group.

[0039] Specifically, one end of the rotor 101 is rotatably mounted on the first end cover 300 through a first bearing 1011, and the other end is rotatably mounted on the second end cover 400 through a second bearing 1012. The first bearing 1011 and the second bearing 1012 adopt ball bearings, which play a role in supporting the rotation of the rotor assembly and bearing radial and axial loads. [[ID=(4)]]

[0040] Specifically, a washer 1013 disposed on the rotor 101 is provided between the first end cover 300 and the first bearing 1011. The washer 1013 is a corrugated washer, which is used to adjust the axial movement of the motor. One week of the corrugated washer has three wave peaks and three wave valleys. The advantages of the three wave peaks and three wave valleys are that the contacts between the corrugated washer and the first bearing and the first end cover are all three points, and three points form a plane to ensure stable contact of these two contact surfaces.

[0041] Specifically, a first limit washer 1014 and a second limit washer 1015 are respectively provided at both ends of the rotor shaft sleeve 102. The axial movement clearance of the rotor 101 is jointly limited within an allowable range through the first limit washer 1014 and the second limit washer 1015.

[0042] Specifically, the second end cover 400 is provided with a notch 402 corresponding to the power supply connection of the Hall plate 500 for the power supply wire of the Hall plate to pass through. A wire protection sleeve 403 is provided on the outer wall of the second end cover 400 corresponding to the notch 402 to prevent the power supply wire of the Hall plate from being worn and extend its service life.

[0043] In summary, through the above structural design, the present utility model solves the deficiencies in the prior art and has the characteristics of reasonable structure and strong practicability.

[0044] The above are only the specific embodiments of the present utility model, but the protection scope of the present utility model is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present utility model can easily think of changes or substitutions, which should all be covered within the protection scope of the present utility model. Therefore, the protection scope of the present utility model shall be subject to the protection scope of the said claims.

Claims

1. A novel brushless DC motor, comprising a rotor assembly (100), a stator assembly (200) sleeved on the outer periphery of the rotor assembly (100), a first end cover (300) disposed at one end of the stator assembly (200), and a second end cover (400) disposed at the other end of the stator assembly (200), characterized in that: The rotor assembly (100) includes a rotor (101), a rotor bushing (102), and a rotor magnet (103). The rotor bushing (102) is made of aluminum material. A Hall plate (500) is mounted on the second end cover (400), and three surface-mounted Hall elements (501) for sensing the rotor magnet (103) are arranged on the Hall plate (500).

2. The novel brushless DC motor according to claim 1, characterized in that: The second end cover (400) is provided with a first bolt hole (401), and the stator assembly (200) is provided with a second bolt hole (201). A bolt (600) sequentially passes through the first bolt hole (401) and the second bolt hole (201) and is threadedly connected to the first end cover (300).

3. The novel brushless DC motor according to claim 2, characterized in that: The stator assembly (200) includes a winding, a first wire frame (202), a second wire frame (203), and a plurality of stator iron core sheets (204) sleeved on the outer peripheries of the first wire frame (202) and the second wire frame (203). Both the first wire frame (202) and the second wire frame (203) include a plurality of positioning teeth (2021). Tooth poles (2041) are formed by extending the inner wall of the stator iron core sheet (204) towards the axis of the stator iron core sheet. The tooth poles (2041) are inserted into the corresponding positioning teeth (2021) of the first wire frame (202) and the second wire frame (203). Both ends of the winding are respectively wound around the positioning teeth (2021) of the first wire frame (202) and the second wire frame (203) and are sleeved around the tooth poles (2041) to fix the positioning teeth (2021) at both ends of the tooth poles (2041).

4. The novel brushless DC motor according to claim 3, wherein: One end of the rotor (101) is rotatably mounted on the first end cover (300) through a first bearing (1011), and the other end is rotatably mounted on the second end cover (400) through a second bearing (1012).

5. The novel brushless DC motor according to claim 4, wherein: A washer (1013) arranged on the rotor (101) is provided between the first end cover (300) and the first bearing (1011).

6. The novel brushless DC motor according to claim 5, characterized in that: The washer (1013) is a corrugated washer.

7. The novel brushless DC motor according to claim 6, wherein: A first limit washer (1014) and a second limit washer (1015) are respectively arranged at both ends of the rotor bushing (102).

8. The novel brushless DC motor according to claim 7, characterized in that: A notch (402) is provided on the second end cover (400) corresponding to the power supply connection of the Hall plate (500).

9. The novel brushless DC motor according to claim 8, characterized in that: A wire protection sleeve (403) is provided on the outer wall of the second end cover (400) corresponding to the notch (402).

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