A brushless motor for driving an automotive cooling fan

Abstract

The present invention discloses a brushless motor for driving a car cooling fan, comprising a controller component, the controller component comprising a housing and a PCBA board, a central axis is arranged on the front of a heat sink, an armature component is installed on the front of the heat sink, an outer rotor assembly is rotatably installed on the central axis, the armature component comprises a stator core, a front insulating end cover and a rear insulating end cover, a stator winding is wound between the front insulating end cover and the rear insulating end cover, three metal hooks are fixed on the rear insulating end cover, the metal hook comprises a hook body, the front end of the hook body is fixed with the rear insulating end cover by plugging, supporting wings are arranged on both sides of the hook body, two hooks are arranged on the outer side of the hook body, a supporting protrusion is arranged on the rear insulating end cover, a supporting groove is arranged on the supporting protrusion, and the rear end of the hook body is inserted into the welding through hole of the PCBA board for welding and fixing. The metal hook of the brushless motor is more firmly fixed, reducing the risk of loosening, and can be better welded with the PCBA board.

Description

Technical Field

[0001] The invention relates to a brushless motor, in particular to an outer rotor brushless motor for driving an automobile cooling fan. Background Art

[0002] Motors are commonly used power devices, used in various industries, and currently brushless motors can be controlled by PCBA boards. Patent No. 201821275298.7 discloses an outer rotor brushless motor, which is smaller in size and thickness than ordinary inner rotor motors, and is very suitable for use in narrow environments on cars. However, this motor still has the following disadvantages:

[0003] 1. The armature assembly and PCBA board of this brushless motor are conductively connected through the conductive connecting rod on the conductive bracket, and the insulating end cover of the armature assembly is embedded with a metal hook, which has a wire harness clamp and a connecting clamp. During installation, one end of the conductive connecting rod needs to be inserted from back to front into the connecting clamp, clamped and welded; and the wire harness of the stator winding is wound according to a specific winding method, and the wire head is wound in the wire harness clamp, tightened and welded. However, this method is firstly troublesome in setting up the conductor connecting rod. Since the conductive connecting rod is bent, there may be some problems with the bending angle. Therefore, in order to ensure that there is no cold soldering, the contact between the connecting piece and the copper ring and the assembly of the copper ring require manual participation, which is very inefficient. In addition, since the number of metal hooks is generally 3 and they are set at a specific position, the end of the wire harness may not correspond exactly to the position of the metal hook after winding, so it is necessary to run the wire in the wiring groove, which makes the wire harness at the end of the stator more messy, and also places higher requirements on the winding personnel and winding methods of the stator winding. At the same time, the metal hook is only embedded in the insulating end cover, and the fixation is not firm, especially when the clamping jaws are clamped under pressure, it is easier to make it loose.

[0004] 2. The central axis is fixed in the middle of the heat sink of the brushless motor in the background technology. After the armature assembly is fixed with the central axis as the center, the outer rotor is mounted on the central axis through the bearing sleeve. However, this structure still brings many inconveniences. First, the heat sink is generally purchased from outside, and the central axis is fixed on the heat sink at the factory. Therefore, the thickness of the heat sink itself is relatively thin, but the overall thickness increases a lot after the central axis is added, resulting in an increase in transportation volume and transportation cost. In addition, a bearing sleeve needs to be provided on the outer rotor assembly, and then the bearing needs to be fixed inside the bearing sleeve, and the outer ring of the bearing needs to be interference fit with the bearing sleeve. In order to increase the fixing firmness of the bearing sleeve, the open end of the bearing sleeve is generally closed after being embedded and fixed to prevent the bearing from falling off. In this way, the fixing of the bearing on the outer rotor is also relatively cumbersome. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide an outer rotor brushless motor for driving an automobile cooling fan, wherein the metal guard hook of the brushless motor is more firmly fixed, reducing the risk of loosening, and can be better welded to a PCBA board.

[0006] In order to solve the above technical problems, the technical solution of the present invention is: a brushless motor for driving a cooling fan of an automobile, comprising a controller component, the controller component comprising a shell composed of a heat sink and a rear end cover, a PCBA board is arranged in the shell, a central axis is arranged on the front of the heat sink, an armature component is installed on the front of the heat sink, an outer rotor assembly is rotatably installed on the central axis, the armature component comprises a stator core and a front insulating end cover and a rear insulating end cover respectively fixed to the front end and rear end of the stator core, a stator winding is wound between the front insulating end cover and the rear insulating end cover, and a stator winding is wound between the front insulating end cover and the rear insulating end cover. There are three metal hooks, the stator winding is wound according to the winding rule and crosses the metal hooks and is clamped and welded to the metal hooks, so that the stator winding forms a three-phase winding; the metal hook includes a hook body, the front end of the hook body is fixed with the rear insulating end cover, supporting wings are arranged on both sides of the hook body, and two hooks are arranged on the outer side of the hook body for convenient winding, the rear insulating end cover is provided with a supporting protrusion corresponding to the supporting wing, and the supporting protrusion is provided with a supporting groove, and the rear end of the hook body extends backward and is inserted into the welding through hole of the PCBA board for welding and fixing.

[0007] As a preferred solution, the protective hook body includes a front end insertion part, a rear end insertion part, a left supporting wing part and a right supporting wing part, and the front end insertion part, the rear end insertion part, the left supporting wing part and the right supporting wing part constitute a cross structure, and the two hook parts are respectively arranged in the middle of the left supporting wing part and the right supporting wing part.

[0008] As a preferred solution, the rear insulating end cover is also provided with a plurality of wire combing structures for facilitating wire winding and combing.

[0009] As a preferred solution, the number of the combing wire structures is three, and the combing wire structure includes two spaced combing wire protrusions, each of which is provided with a combing groove for facilitating the wire to pass through, and one of the hook portions of the protective hook body is located in the space between the two combing wire protrusions.

[0010] As a preferred solution, a raised ring protruding forward is provided in the middle of the front insulating end cover.

[0011] As a preferred solution, the outer rotor assembly includes a rotor shell and a magnetic steel arranged inside the rotor shell, a plug-in hole is provided in the middle of the rotor shell, the front end of the center shaft is inserted into the plug-in hole and has an interference fit; a front bearing close to the plug-in hole is installed on the center shaft, a through hole is provided at the center of the stator core, and a front bearing groove and a rear bearing groove are provided at the front and rear ends respectively, the center shaft is inserted into the through hole and the front bearing is placed in the front bearing groove, a rear bearing is fixed at the rear end of the center shaft, and an outer ring of the rear bearing is embedded and fixed in the rear bearing groove.

[0012] As a preferred solution, an elastic gasket is arranged in the embedding groove of the front bearing, and the elastic gasket is in contact with the outer ring of the front bearing.

[0013] As a preferred solution, the heat sink is provided with a blind hole for accommodating the central axis.

[0014] As a preferred solution, the rear section of the central shaft is provided with a retaining ring groove, in which a retaining ring is mounted, and the retaining ring is squeeze-fitted with the inner ring of the rear bearing.

[0015] After adopting the above technical scheme, the effect of the present invention is: since the metal hook includes a hook body, the front end of the hook body is fixed with the rear insulating end cover, supporting wings are provided on both sides of the hook body, and two hooks are provided on the outer side of the hook body for convenient winding, and the rear insulating end cover is provided with a supporting protrusion that supports the supporting wings in a one-to-one correspondence, and the supporting protrusion is provided with a supporting groove, and the rear end of the hook body extends backward and is inserted into the welding through hole of the PCBA board for welding and fixing. Therefore, after the front end of the hook body is fixed, the supporting wing is used to support the supporting protrusion, so that the metal hook is not easy to loosen during welding and wire clamping operations. At the same time, two hooks are provided on the hook body, which makes it more convenient to clamp the wire end during winding, reduces excessive winding and makes the wiring harness neater. The rear end of the metal hook directly extends and is inserted into the soldering through hole of the PCBA board, and there is no need to use a conductive connecting rod. This makes it more reliable and reduces manual involvement. It only requires the soldering through hole and the rear end of the metal hook to be aligned and pressed down, making assembly simpler and more suitable for automatic assembly.

[0016] As a preferred solution, the protective hook body includes a front insertion part, a rear insertion part, a left supporting wing part and a right supporting wing part, and the front insertion part, the rear insertion part, the left supporting wing part and the right supporting wing part form a cross-shaped structure, and the two hook parts are respectively arranged in the middle of the left supporting wing part and the right supporting wing part. This protective hook body is not only convenient for insertion, but also the two hook parts are actually formed by opening a groove on the left supporting wing part and the right supporting wing part and bending outward, which makes the molding simpler, and also fully separates the positions of the two hook parts, which is more convenient for the selection of clamping wires. Moreover, in the background technology, one clamping claw may clamp three wire ends, which increases the difficulty of welding and is also prone to cold welding. In this solution, since there are many optional positions and distribution points for the hook part, the above problems can be avoided.

[0017] As a preferred solution, the rear insulating end cover is also provided with a plurality of combing conductor structures for facilitating the combing of the winding, and the combing conductor structures can comb the wire bundle to improve the neatness.

[0018] As a preferred solution, the number of the combing wire structures is three, and the combing wire structures include two spaced combing wire protrusions, and the combing wire protrusions are provided with combing grooves for convenient wire passing. One of the hook portions of the protective hook body is located in the space between the two combing wire protrusions. In this way, one of the hook portions of the protective hook body is located in the space between the two combing wire protrusions, so that there is no need to add additional space. At the same time, the wire harness just passes through the hook portion during the combing process, so that the operation is simpler.

[0019] Furthermore, since a protruding ring protruding forward is provided in the middle of the front insulating end cover, the protruding ring can facilitate the routing and combing of the wire harness at the front end.

[0020] Furthermore, since the outer rotor assembly includes a rotor shell and a magnetic steel arranged inside the rotor shell, an insertion hole is arranged in the middle of the rotor shell, and the front end of the central shaft is inserted into the insertion hole and has an interference fit; a front bearing close to the insertion hole is installed on the central shaft, a through hole is arranged at the center of the stator core, and a front bearing embedding groove and a rear bearing embedding groove are respectively arranged at the front and rear ends, the central shaft is inserted into the through hole and the front bearing is placed in the front bearing embedding groove, and a rear bearing is fixed at the rear end of the central shaft, and the outer ring of the rear bearing is embedded and fixed in the rear bearing embedding groove, so that the central shaft of the brushless motor is directly fixed on the rotor shell of the outer rotor assembly, and the thickness of the purchased heat sink is very thin, so that packaging and transportation are very convenient.

[0021] Furthermore, since an elastic gasket is arranged in the groove of the front bearing, the elastic gasket is in contact with the outer ring of the front bearing, and the elastic gasket can push the outer ring of the front bearing, thereby causing a slight displacement of the central axis. The slight displacement of the central axis will lead to a slight displacement of the inner rings of the front bearing and the rear bearing, thereby making the running track of the ball more stable. The presence of the elastic gasket can make the operation of the bearing more stable and the service life longer. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0023] Figure 1 is a front view of a brushless motor according to an embodiment of the present invention;

[0024] Figure 2 yes Figure 1 Sectional view at AA;

[0025] Figure 3 yes Figure 2 An enlarged schematic diagram at B;

[0026] Figure 4 is a perspective view of the armature assembly;

[0027] Figure 5 yes Figure 4 An enlarged schematic diagram at C;

[0028] Figure 6 is a front view of the armature assembly;

[0029] In the attached drawings: 1. outer rotor assembly; 11. rotor shell; 12. insertion hole; 13. insertion sleeve; 14. magnet; 2. armature assembly; 21. stator core; 22. stator winding; 23. front insulating end cover; 231. raised ring; 24. rear insulating end cover; 241. insertion protrusion; 242. combing wire protrusion; 243. combing groove; 244. support protrusion 4; 245. support groove; 25. front bearing embedding groove; 3. heat sink; 31. accommodating blind hole; 4. PCBA board; 5. center shaft; 6. front bearing; 7. rear bearing; 8. elastic gasket; 9. metal protective hook; 91. front end insertion part; 92. rear end insertion part, 93. right support wing; 94. left support wing; 95. hook. DETAILED DESCRIPTION

[0030] The present invention is further described in detail below through specific examples.

[0031] The front mentioned in this embodiment refers to the side of the brushless motor used to install the cooling fan, that is, Figure 2 The front is above, and the cooling fan is fixed on the outer rotor assembly 1.

[0032] like Figures 1 to 6 As shown, a brushless motor for driving a cooling fan of an automobile includes a controller component, the controller component includes a shell composed of a heat sink 3 and a rear end cover, a PCBA board 4 is arranged in the shell, a central axis 5 is arranged on the front of the heat sink 3, an armature component 2 is installed on the front of the heat sink 3, an outer rotor assembly 1 is rotatably installed on the central axis 5, the armature component 2 includes a stator core 21 and a front insulating end cover 23 and a rear insulating end cover 24 respectively fixed to the front end and rear end of the stator core 21, and the stator core 21 is detachably fixed to the front end face of the heat sink 3 by bolts; The stator winding 22 is wound between the front insulating end cover 23 and the rear insulating end cover 24. Three metal hooks 9 are fixed on the rear insulating end cover. The stator winding 22 is wound according to the winding rules and crosses the metal hooks 9 to be clamped and welded to the metal hooks 9, so that the stator winding 22 forms a three-phase winding. The metal hook 9 includes a hook body, and the front end of the hook body is plugged and fixed to the rear insulating end cover 24. Specifically, the rear insulating end cover 2 is provided with a plug-in protrusion 241, and a slot is provided in the plug-in protrusion 241 to facilitate the insertion of the hook body. The hook body can be provided with inverted teeth to increase the firmness of the fixation. Support wings are provided on both sides of the hook body, and two hooks 95 are provided on the outer side of the hook body for easy winding. The metal hook 9 is made of the same material with good electrical conductivity. The rear insulating end cover 24 is provided with a supporting protrusion 244 corresponding to the supporting wing portion one by one, and the supporting protrusion 244 is provided with a supporting groove 245. The rear end of the protective hook body extends backward and is inserted into the welding through hole of the PCBA board 4 for welding and fixing.

[0033] like Figure 5 As shown, the protective hook body includes a front end insertion portion 91, a rear end insertion portion 92, a left support wing portion 94 and a right support wing portion 93. The left support wing portion 94 and the right support wing portion 93 in this embodiment are in relative positions. Figure 5 The position is determined, and the right side of the drawing is defined as right.

[0034] The front insertion part 91, the rear insertion part 92, the left support wing 94 and the right support wing 93 form a cross-shaped structure, and the two hooks 95 are respectively arranged in the middle of the left support wing 94 and the right support wing 93. This kind of hook body is not only convenient for insertion, but also the two hooks 95 are actually formed by opening a groove on the left support wing 94 and the right support wing 93 and bending outward, which is simpler to form, and the positions of the two hooks 95 are fully separated, which is more convenient for selecting the clamping position. The clamping position has a variety of options, which can reduce the number of wires clamped by each hook 95. In the background technology, it is easy to clamp three wire ends in one clamping claw, which increases the difficulty of welding and is also easy to cause cold welding. In this solution, since there are many optional positions and distribution points of the hook 95, the above problems can be avoided.

[0035] The rear insulating end cap 24 is also provided with a plurality of wire combing structures for facilitating the winding and combing. The number of the wire combing structures is three, and the wire combing structures include two spaced wire combing protrusions 242, and the wire combing protrusions 242 are provided with combing grooves 243 for facilitating the wire to pass through, and one of the hook parts 95 of the protective hook body is located in the space between the two wire combing protrusions 242. In this way, one of the hook parts 95 of the protective hook body is located in the space between the two wire combing protrusions 242, so that there is no need to add additional space, the structure is more compact, and the wire harness just passes through the hook part 95 during the combing process, so that the operation is simpler.

[0036] A protruding ring 231 protruding forward is provided in the middle of the front insulating end cover 23 to facilitate the winding of the front end wiring harness.

[0037] like Figure 2 As shown, the outer rotor assembly 1 includes a rotor shell 11 and a magnetic steel 14 arranged inside the rotor shell 11. The middle part of the rotor shell 11 is provided with an insertion hole 12, and the front end of the center shaft 5 is inserted into the insertion hole 12 with interference fit. In this embodiment, in order to increase the contact area of ​​the interference fit, the insertion hole 12 is actually the inner hole of the protruding insertion sleeve 13, and the contact area between the center hole and the inner hole of the insertion sleeve 13 is large, which is more firm.

[0038] The central shaft 5 is provided with a front bearing 6 near the insertion hole 12. The center of the stator core 21 is provided with a through hole and the front bearing groove 25 and the rear bearing groove are provided at the front and rear ends respectively. The central shaft 5 is inserted into the through hole and the front bearing is placed in the front bearing groove 25, which is not tightly fitted. The rear end of the central shaft 5 is fixed with the rear bearing 7, and the outer ring of the rear bearing 7 is embedded and fixed in the groove of the rear bearing 7. The rear end of the central shaft 5 contacts the heat sink. An elastic gasket 8 is provided in the front bearing groove 25, and the elastic gasket 8 contacts and matches with the outer ring of the front bearing 6. The elastic gasket 8 can push the outer ring, thereby generating a slight displacement of the central shaft 5. The slight displacement of the central shaft 5 makes the running track of the balls of the front bearing 6 and the rear bearing 7 more stable. In this way, the existence of the elastic gasket 8 can make the operation of the bearing more stable and the service life longer. The rear section of the central shaft 5 is provided with a retaining ring groove, and a retaining ring is clamped in the retaining ring groove, and the retaining ring contacts and matches with the inner ring of the rear bearing 7. The heat sink is provided with a blind hole 31 for accommodating the central shaft 5 , and the central shaft 5 does not need to be plugged into and matched with the blind hole 31 .

[0039] The above-described embodiments are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Various modifications and alterations to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A brushless motor for driving a cooling fan of an automobile, comprising a controller assembly, the controller assembly comprising a housing composed of a heat sink and a rear end cover, a PCBA board being arranged in the housing, a central axis being arranged on the front of the heat sink, an armature assembly being mounted on the front of the heat sink, an outer rotor assembly being rotatably mounted on the central axis, the armature assembly comprising a stator core and a front insulating end cover and a rear insulating end cover respectively fixed to the front end and the rear end of the stator core, a stator winding being wound between the front insulating end cover and the rear insulating end cover, three metal hooks being fixed on the rear insulating end cover, the stator winding being wound according to a winding rule and crossing the metal hooks to be clamped and welded therewith, so that the stator winding forms a three-phase winding; Features: The metal hook comprises a hook body, the front end of which is fixedly inserted into a rear insulating end cover, support wings are arranged on both sides of the hook body, two hooks for convenient winding are arranged on the outer side of the hook body, a support protrusion which supports the support wings in a one-to-one correspondence is arranged on the rear insulating end cover, a support groove is arranged on the support protrusion, and the rear end of the hook body extends backward and is inserted into a welding through hole of the PCBA board for welding and fixing.

2. A brushless motor for driving a car cooling fan as claimed in claim 1, Features: The protective hook body includes a front end insertion part, a rear end insertion part, a left supporting wing part and a right supporting wing part, and the front end insertion part, the rear end insertion part, the left supporting wing part and the right supporting wing part constitute a cross structure, and the two hook parts are respectively arranged in the middle part of the left supporting wing part and the right supporting wing part.

3. A brushless motor for driving a car cooling fan as claimed in claim 2, Features: The rear insulating end cover is also provided with a plurality of wire combing structures for facilitating wire winding and combing.

4. A brushless motor for driving a car cooling fan as claimed in claim 3, Features: The number of the combing wire structures is three, and the combing wire structures include two spaced combing wire protrusions, each of which is provided with a combing groove for convenient wire passing, and one of the hook parts of the protective hook body is located in the space between the two combing wire protrusions.

5. A brushless motor for driving a car cooling fan as claimed in claim 4, Features: A protruding ring protruding forward is arranged in the middle of the front insulating end cover.

6. A brushless motor for driving an automobile cooling fan according to any one of claims 1 to 5, Features: The outer rotor assembly includes a rotor shell and a magnetic steel arranged inside the rotor shell. An insertion hole is arranged in the middle of the rotor shell, and the front end of the center shaft is inserted into the insertion hole and has an interference fit; a front bearing close to the insertion hole is installed on the center shaft, a through hole is arranged at the center of the stator core, and a front bearing embedding groove and a rear bearing embedding groove are respectively arranged at the front and rear ends, the center shaft is inserted into the through hole and the front bearing is placed in the front bearing embedding groove, and a rear bearing is fixed at the rear end of the center shaft, and the outer ring of the rear bearing is embedded and fixed in the rear bearing embedding groove.

7. A brushless motor for driving a car cooling fan as claimed in claim 6, Features: An elastic gasket is arranged in the front bearing groove, and the elastic gasket is in contact and cooperation with the outer ring of the front bearing.

8. A brushless motor for driving an automotive radiator fan according to claim 7, characterized in that: A receiving blind hole for receiving the central shaft is arranged on the heat dissipation seat.

9. A brushless motor for driving an automotive radiator fan according to claim 8, characterized in that: A snap ring groove is arranged at the rear section of the central shaft, a snap ring is clamped in the snap ring groove, and the snap ring is in extrusion contact with the inner ring of the rear bearing.

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