Brushless motor, driving mechanism and electric vehicle
By integrating the Hall sensor on the encoder board and installing it on the first end cover of the brushless motor, the cumbersome problem of Hall sensor and magnetic ring replacement in the prior art is solved, and a more efficient maintenance process and lower maintenance costs are achieved.
Patent Information
- Application Number
- CN202311695810.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-11
- Publication Date
- 2025-06-13
AI Technical Summary
When replacing Hall sensors and magnetic rings, existing brushless motors need to remove the motor housing and some parts. The process is cumbersome and easy to damage other parts, resulting in high maintenance costs.
The Hall sensor is integrated on the encoder board and mounted on the first end cover of the brushless motor, and the magnetic ring is mounted on the axial outside of the rotor shaft, corresponding to the Hall sensor position. In this way, during maintenance, you only need to remove the encoder board to replace the Hall sensor, and there is no need to remove the mounting bearings to replace the magnetic ring.
The maintenance and disassembly process of Hall sensors and magnetic rings is simplified, repair efficiency is improved, damage to other parts is reduced, and repair costs are reduced.
Smart Images
Figure CN120150462A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of motors, and particularly to a brushless motor, a drive mechanism and an electric vehicle. Background Art
[0002] A brushless motor consists of a motor main body and a driver, and is a typical mechatronic product. Since the brushless motor operates in a self-controlled manner, it does not require an additional starting winding on the rotor like a synchronous motor under variable-frequency speed regulation during heavy-load starting, nor does it generate oscillations and loss of steps when the load suddenly changes. Therefore, the brushless motor is widely used in electric vehicles as a power output source.
[0003] The brushless motor usually realizes the detection of the rotor position and speed through Hall sensors. In the prior art, the Hall sensors are generally integrated with a circuit board and installed on the stator, and the magnetic rings used in cooperation with the Hall sensors are correspondingly installed between the two mounting bearings of the rotor shaft. When the Hall sensors fail and need to be replaced, the motor housing needs to be opened and some components need to be disassembled, which is a cumbersome process. Or when the magnetic ring loses magnetism and needs to be replaced, the mounting bearings need to be removed, resulting in the bearings being unusable again, making the maintenance cost of the electric vehicle high. Therefore, improvements are needed. Summary of the Invention
[0004] The purpose of the present invention is to overcome the defects of the prior art, and provide a brushless motor, a drive mechanism and an electric vehicle.
[0005] To achieve the above and other purposes, a first aspect of an embodiment of the present invention provides a brushless motor, including a housing, two ends of the housing are respectively connected to a first end cover and a second end cover, and the housing, the first end cover and the second end cover enclose a motor cavity; a stator, arranged circumferentially along the housing in the motor cavity; a rotor shaft, located inside the stator, and a first end of the rotor shaft passes through the first end cover and is connected to the first end cover through a first bearing, a second end of the rotor shaft is connected to the second end cover through a second bearing, and the rotor shaft rotates relative to the stator, the first end cover and the second end cover; an encoder board, detachably installed on an outer side surface of the first end cover; a Hall sensor, arranged on the encoder board; a magnetic ring, sleeved on the rotor shaft, located axially outside the first bearing, and corresponding to the Hall sensor in position, and the magnetic ring rotates synchronously with the rotor shaft.
[0006] Through a brushless motor of the present invention, a Hall sensor is integrated on an encoder board and installed on the first end cover of the brushless motor. Correspondingly, a magnetic ring is installed on the axial outer side of the first bearing. During the maintenance process, only the encoder board needs to be removed from the first end cover, and then the Hall sensor can be repaired or replaced. When replacing the magnetic ring, the first mounting bearing does not need to be disassembled. Thus, the disassembly and assembly process during the maintenance of the Hall sensor and the magnetic ring is simplified, the maintenance efficiency is improved; at the same time, the damage to other components is also reduced, and the cost is saved.
[0007] In some embodiments, the first end cover includes a central through hole through which the rotor shaft passes through the first end cover; a central concave portion is provided around the central through hole, and the encoder board is disposed in the central concave portion and fixedly connected to the first end cover through a fastener.
[0008] In some embodiments, the encoder board includes an encoder board body and a Hall sensor bracket installed on the encoder body. The Hall sensor is installed on the Hall sensor bracket and electrically connected to the encoder.
[0009] In some embodiments, the encoder board body is an annular body, and the Hall sensor bracket is an arc-shaped bracket extending along the circumferential direction of the encoder board body.
[0010] In some embodiments, a flat key is provided on the rotor shaft, and a key groove is provided on the inner circumferential surface of the magnetic ring for mating with the flat key.
[0011] In some embodiments, it includes a circuit board, and the circuit board is fixedly arranged along the circumferential direction at the end of the stator close to the magnetic ring.
[0012] In some embodiments, the magnetic ring includes a magnetic ring body and a magnetic ring sleeve. The magnetic ring body is sleeved on the outer periphery of the magnetic ring sleeve, and a key groove is provided on the inner circumferential surface of the magnetic ring sleeve.
[0013] A second aspect of the embodiments of the present invention provides a driving mechanism, which includes the brushless motor described in the first aspect, and further includes a reduction gearbox. The reduction gearbox includes a reduction gearbox cover plate and a gear reduction structure. The reduction gearbox cover plate and the second cover plate enclose a receiving cavity, and the gear reduction structure is located in the receiving cavity and is power-connected to the rotor shaft.
[0014] In some embodiments, the gear reduction structure includes a transmission pin, a small gear, a large gear, and an output main shaft. The transmission pin is connected to the rotor shaft, the transmission pin connects the small gear, the large gear meshes with the small gear, and the output main shaft is key-connected to the large gear.
[0015] The second aspect of the embodiments of the present invention provides an electric vehicle, which includes the drive mechanism described in the second aspect, and further includes an electronic brake device and a wheel. The output main shaft is connected to the wheel, and the electronic brake device is connected to the first end of the rotor shaft. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 It shows a schematic cross-sectional structure diagram of the drive mechanism and the electronic brake system according to the embodiments of the present invention.
[0017] Figure 2 It shows a schematic partial exploded structure diagram of the drive mechanism according to the embodiments of the present invention.
[0018] Figure 3 It shows a schematic integrated structure diagram of the encoder board and the Hall sensor according to the embodiments of the present invention.
[0019] Figure 4 It shows a schematic structure diagram of the circuit board installation according to the embodiments of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] Please refer to Figures 1 to 4 . The following specific examples illustrate the embodiments of the present invention. Those skilled in the art can easily understand the other advantages and effects of the present invention from the content disclosed in this specification. It should be noted that many specific details are set forth in the following description to fully understand the present invention. However, the present invention can also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited by the specific embodiments disclosed below. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.
[0021] As Figure 1 and Figure 2 shown, a brushless motor in this embodiment includes a housing 10. The two ends of the housing 10 are respectively connected to a first end cover 11A and a second end cover 11B. The housing 10, the first end cover 11A and the second end cover 11B enclose a motor cavity; a stator 12 is arranged circumferentially along the housing 10 in the motor cavity; a rotor shaft 13 is located in the stator 12, and the first end of the rotor shaft 13 passes through the first end cover 11A and is connected to the first end cover 11A through a first bearing 14A. The second end of the rotor shaft 13 is connected to the second end cover 11B through a second bearing 14B. The rotor shaft 13 rotates relative to the stator 12, the first end cover 11A and the second end cover 11B.
[0022] In this embodiment, the brushless motor further includes an encoder board 16, a Hall sensor 17 mounted on the encoder board 16, and a magnetic ring 15 sleeved on the rotor shaft 13 and cooperating with the Hall sensor 17. The encoder board 16 is mounted on the outer side surface of the first end cover 11A and is detachably connected to the first end cover 11A. Thus, the encoder board 16 can be easily detached from the first end cover 11A. For example, mounting holes 163 may be provided on the encoder board 16, and the first end cover 11A is provided with mounting seats 113A. The mounting holes 163 cooperate with the mounting seats 113A and are fastened by fasteners. As Figure 1 shown, the first end cover 11A is provided with a central through hole 111A, and the rotor shaft 13 passes through the first end cover 11A through the central through hole 111A. The first end cover 11A is further provided with a central recess 112A. The central recess 112A is recessed toward the inner side of the brushless motor and is arranged around the central through hole 111A. The mounting seat 113A is arranged in the central recess 112A. The encoder board 16 is mounted in the central recess 112A. The mounting holes 163 cooperate with the mounting seats 113A and are fastened by fasteners.
[0023] The Hall sensor 17 is mounted on the encoder board 16. As an alternative embodiment, as Figure 3 shown, the encoder board 16 includes an encoder board body 161 and a Hall sensor bracket 162 mounted on the encoder body 161. The encoder board body 161 is an annular body, and the Hall sensor bracket 162 is arc-shaped and extends along the circumferential direction of the encoder board body 161. The Hall sensor bracket 162 is provided with a mounting groove. The Hall sensor 17 is inserted into the mounting groove, and the pins are welded to the encoder board 163 to achieve electrical connection with the encoder board 16.
[0024] As Figure 1 and 2As shown, the magnetic ring 15 is sleeved on the rotor shaft 13 and rotates synchronously with the rotor shaft 13. Axially, the magnetic ring 15 is located outside the first bearing 14A. Optionally, the magnetic ring 15 can be in interference fit with the rotor shaft 13. Or the magnetic ring 15 can be in key fit with the rotor shaft 13. Specifically, a flat key 131 is provided on the rotor shaft 13, and a keyway 153 for mating with the flat key 131 is provided on the inner peripheral surface of the magnetic ring 15. As an alternative embodiment, the magnetic ring 15 includes a magnetic ring body 151 and a magnetic ring sleeve 152, and the magnetic ring body 151 is sleeved on the outer periphery of the magnetic ring sleeve 152. For example, the magnetic ring body 151 can be sleeved on the outer periphery of the magnetic ring sleeve 152 by bonding, and a keyway 153 for mating with the flat key 131 is provided on the inner peripheral surface of the magnetic ring sleeve 152.
[0025] In this embodiment, the brushless motor further includes a circuit board 18. As Figure 4 shown, the circuit board 18 is annular and is fixedly arranged circumferentially at the end of the stator 12 close to the magnetic ring 15. The circuit board 18 is connected to the coils on the stator 12 through three-phase wires.
[0026] The embodiment of the present application further provides a driving mechanism, which includes the brushless motor described above. As Figure 1 shown, the driving mechanism further includes a reduction gearbox 20. The reduction gearbox 20 includes a reduction gearbox cover 201 and a gear reduction structure 202. The reduction gearbox cover 201 and the second end cover 11B enclose a receiving cavity, and the gear reduction structure 202 is located in the receiving cavity and is power-connected to the rotor shaft 13. Specifically, the gear reduction structure 202 includes a transmission pin 2021, a pinion gear 2022, a large gear 2023 and an output main shaft 2024. The transmission pin 2021 is connected to the rotor shaft 13 and rotates synchronously with the rotor shaft 13. The transmission pin 2021 connects the pinion gear 2022, the large gear 2023 meshes with the pinion gear 2022, and the output main shaft 2024 is key-connected to the large gear 2023. The brushless motor transmits power to the pinion gear 2022 through the transmission pin 2021, the pinion gear 2022 drives the large gear 2023 to rotate, and the large gear 2023 drives the output main shaft 2024 to rotate, finally realizing the output of power.
[0027] The embodiment of the present application further provides an electric vehicle, which includes the driving mechanism described above. The electric vehicle further includes an electronic brake device 30 and wheels. The wheels are connected to the output main shaft 2024 through fasteners, thereby realizing the driving of the wheels. The electronic brake device 30 is connected to the first end of the rotor shaft 13 to realize the braking of the electric vehicle.
[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.
Claims
1. A brushless motor, characterized in that, it includes a housing, two ends of the housing are respectively connected to a first end cover and a second end cover, and the housing, the first end cover and the second end cover enclose a motor cavity; a stator, arranged circumferentially along the housing in the motor cavity; a rotor shaft, located inside the stator, the first end of the rotor shaft passes through the first end cover and is connected to the first end cover through a first bearing, the second end of the rotor shaft is connected to the second end cover through a second bearing, and the rotor shaft rotates relative to the stator, the first end cover and the second end cover; an encoder board, detachably installed on the outer side surface of the first end cover; a Hall sensor, arranged on the encoder board; a magnetic ring, sleeved on the rotor shaft, located axially outside the first bearing, corresponding to the position of the Hall sensor, and the magnetic ring rotates synchronously with the rotor shaft.
2. A brushless motor according to claim 1, characterized in that, the first end cover includes a central through hole, and the rotor shaft passes through the first end cover through the central through hole; a central concave portion, arranged around the central through hole, the encoder board is arranged in the central concave portion and is fixedly connected to the first end cover through a fastener.
3. A brushless motor according to claim 2, characterized in that, the encoder board includes an encoder board body and a Hall sensor bracket installed on the encoder body, the Hall sensor is installed on the Hall sensor bracket and is electrically connected to the encoder.
4. A brushless motor according to claim 3, characterized in that, the encoder board body is an annular body, and the Hall sensor bracket is an arc-shaped bracket extending circumferentially along the encoder board body.
5. A brushless motor according to any one of claims 1-4, characterized in that a flat key is arranged on the rotor shaft, and a key groove for cooperating with the flat key is arranged on the inner peripheral surface of the magnetic ring.
6. A brushless motor according to claim 5, characterized in that, it includes a circuit board, and the circuit board is fixedly arranged circumferentially at an end of the stator close to the magnetic ring.
7. A brushless motor according to claim 5, characterized in that, the magnetic ring includes a magnetic ring body and a magnetic ring sleeve, the magnetic ring body is sleeved on the outer periphery of the magnetic ring sleeve, and a key groove is arranged on the inner peripheral surface of the magnetic ring sleeve.
8. A driving mechanism, including the brushless motor according to any one of claims 1-7, characterized in that, it further includes a speed reduction box, the speed reduction box includes a speed reduction box cover plate and a gear reduction structure, the speed reduction box cover plate and the second cover enclose a containing cavity, and the gear reduction structure is located in the containing cavity and is power-connected to the rotor shaft.
9. A driving mechanism according to claim 8, characterized in that, the gear reduction structure includes a transmission pin, a small gear, a large gear and an output main shaft, the transmission pin is connected to the rotor shaft, the transmission pin connects the small gear, the large gear meshes with the small gear, and the output main shaft is key-connected to the large gear.
10. An electric vehicle, including the driving structure according to any one of claims 6-7, Characterized in that, It further includes an electronic braking device and a wheel, the output main shaft is connected to the wheel, and the electronic braking device is connected to the first end of the rotor shaft.