Hollow cup brushless motor capable of resisting axial bidirectional impact and manufacturing method thereof

Abstract

The invention discloses a coreless brushless motor resistant to axial bidirectional impact and a manufacturing method thereof. The coreless brushless motor is composed of a top cover (1), a thrust ball bearing (2), an outgoing line (3), a disc spring (4), a Hall plate (5), an armature (6), an iron core ring (7), epoxy resin (8), a flange (9), a shaft (10), a gap adjusting shaft sleeve (11), a balance sheet (12), a magnetic cylinder (13) and a shell (14). And the components are sequentially assembled according to the sequence of electrical assembly, component assembly and structure final assembly. According to the technical scheme, the technical problem of applicability of the high-overload-resistant motor mounting structure for weapon equipment is solved, and the application foundation of an electric steering engine on a high-overload launching platform aircraft is tamped.

Description

Technical Field

[0001] This invention relates to the field of electric motors, and in particular to a hollow cup brushless motor resistant to axial bidirectional impact and its manufacturing method. Background Technology

[0002] Electric servo motors are a new type of actuator in smart munitions, and their core component, the motor, often uses a coreless brushless motor. Especially for small electric servo motors, due to space constraints, servo motors with the same performance specifications require customized motors of different structural specifications depending on their installation orientation. This situation presents new requirements for the diversification of motor installation methods to withstand overload impacts.

[0003] Based on the above research background, this patent proposes a structure and manufacturing method for a DC brushless hollow cup motor resistant to axial bidirectional impact, which solves the technical problem of the applicability of the installation structure of the high overload resistant motor for weapon equipment, and consolidates the application foundation of electric servo motors on high overload launch platform aircraft. Summary of the Invention

[0004] To solve the above-mentioned technical problems, this invention discloses a hollow cup brushless motor resistant to axial bidirectional impact and its manufacturing method.

[0005] A hollow cup brushless motor resistant to axial bidirectional impact is characterized by comprising a stator assembly, a top cover assembly, a flange assembly, a rotor assembly, and an adjusting bushing.

[0006] The stator component consists of lead wires (3), Hall plates (5), armature (6), iron core rings (7), epoxy resin (8), and a housing (14).

[0007] The top cover component consists of a top cover (1), a first thrust ball bearing (2-1), and a disc spring (4).

[0008] The hollow cup brushless motor as described in claim 1 is characterized in that: the flange component is composed of a second thrust ball bearing (2-2), a disc spring (4), and a flange (9).

[0009] The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13).

[0010] A method for manufacturing a hollow cup brushless motor resistant to axial bidirectional impact. The hollow cup brushless motor consists of a top cover (1), a thrust ball bearing (2), a lead wire (3), a disc spring (4), a Hall plate (5), an armature (6), an iron core ring (7), epoxy resin (8), a flange (9), a shaft (10), an adjusting bushing (11), a balance plate (12), a magnetic cylinder (13), and a housing (14); the above components are assembled in the order of electrical assembly, component assembly, and structural assembly.

[0011] The electrical assembly involves welding the Hall element, the capacitor and the lead wire (3) to the Hall plate (5), and then encapsulating the armature (6) and the core ring (7) together with epoxy resin (8) using welding and adhesive to complete the electrical assembly.

[0012] The component assembly is performed according to the following steps: The stator components consist of lead wires (3), Hall plates (5), armature (6), iron core rings (7), epoxy resin (8), and outer shell (14); The top cover (1), thrust ball bearing (2), and disc spring (4) constitute the top cover component; The flange assembly consists of a thrust ball bearing (2), a disc spring (4), and a flange (9); The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13); Stator component assembly: The lead wire (3) is soldered to the armature (6), and then reliably bonded to the outer shell (14) and the core ring (7) with special adhesive. After that, epoxy resin (5) is used to encapsulate it in one piece using a special mold to complete the assembly of the stator component. Assembly of top cover components: Install the top cover (1), disc spring (4) and thrust ball bearing (15) in sequence and reliably; Assembly of flange components: Install the thrust ball bearing (2) and disc spring (4) into the flange (9) in sequence to complete the assembly of the flange components; Rotor component assembly: according to Figure 5 The magnetic cylinder (13) is attached to the shaft (10), and the balance plate (12) is attached to both ends of the magnetic cylinder to form the rotor component.

[0013] The assembly of the structure is carried out in the following steps: the rotor is installed inside the stator, and then the adjusting bushing (11) is installed at both ends of the rotor. The top cover component and the flange component are installed at both ends of the stator. At the same time, the rotor shaft (10) passes through the top cover component and the flange component. The axial clearance of the motor is adjusted by adjusting the height of the adjusting bushing (11) at both ends. After the clearance is adjusted, the stator, flange component and top cover component are connected into one piece by laser welding.

[0014] Beneficial effects: This invention solves the technical problem of the applicability of the mounting structure of the high overload resistant motor for weapon equipment, and consolidates the application foundation of electric servo motors on high overload launch platform aircraft. Attached Figure Description

[0015] Figure 1 Product structure composition diagram; Figure 2 Stator component structural composition diagram; Figure 3 Top cover component structural composition diagram; Figure 4 Flange component structural composition diagram; Figure 5 Rotor component structural composition diagram; Figure 6 Real photos of a hollow cup brushless motor resistant to axial bidirectional impact; Figure 7 Disc spring (4) displacement distribution cloud map; Figure 8 Overall structural stress distribution cloud map of the product; Figure 9 Product displacement distribution cloud map; Figure 10 Overall structural stress distribution cloud map of the product; Figure 11 Product displacement distribution cloud map; Figure 12 Axial clearance before product impact; Figure 13 Axial clearance after product impact; Figure 14 Hall effect signal output before product impact; Figure 15 Hall output signal after product impact; Figure 16 Axial clearance before product impact; Figure 17 Axial clearance of the product after impact; Figure 18 Hall effect signal output before product impact; Figure 19 Hall output signal after product impact; Figure 20 The electric servo motor of this patented motor has an outdoor flight test curve (+20000g). Figure 21 The electric servo motor of this patent has an outdoor flight test curve (-20000g). Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be described in complete and clear form below with reference to the accompanying drawings.

[0017] See structural composition Figure 1 The product is mainly composed of a top cover (1), a thrust ball bearing (2), a lead wire (3), a disc spring (4), a Hall plate (5), an armature (6), an iron core ring (7), epoxy resin (8), a flange (9), a shaft (10), an adjusting bushing (11), a balance plate (12), a magnetic cylinder (13), and a housing (14).

[0018] The stator components consist of lead wires (3), Hall plates (5), armatures (6), core rings (7), epoxy resin (8), and housing (14) (see...). Figure 2 ).

[0019] The top cover (1), the first thrust ball bearing (2-1), and the disc spring (4) constitute the top cover component (see Figure 3 ).

[0020] The flange assembly consists of a second thrust ball bearing (2-2), a disc spring (4), and a flange (9) (see...). Figure 4 ).

[0021] The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13) (see...). Figure 5 ).

[0022] The product consists of stator components, top cover components, flange components, rotor components, and adjusting bushings (11).

[0023] Top cover (1): Provides a support structure for the top cover component.

[0024] Thrust ball bearing (2): bears the axial impact force of part of the rotor components.

[0025] Lead-out line (3): Provides electrical input / output interface.

[0026] Disc spring (4): Unloads the main force of axial impact on the rotor components.

[0027] Hall plate (5): senses the rotational position of the rotor components, thereby controlling the rotor rotation.

[0028] Armature (6): Generates electromagnetic torque.

[0029] Iron core ring (7): The permanent magnet provides a low magnetic resistance closed loop.

[0030] Epoxy resin (8): The outer shell (14), iron core ring (7), and armature (6) are encapsulated in an integrated structure using a packaging mold to form a stator component to withstand axial overload impact.

[0031] Flange (9): Provides the mounting reference and mechanical connection interface for the product.

[0032] Shaft (10): is the mechanical interface for the product's power output.

[0033] Adjusting bushing (11): Adjusts the axial clearance of the product.

[0034] Balance plate (12): Adjusts the dynamic balance of rotor components.

[0035] Magnetic cylinder (13): Provides a constant main magnetic field.

[0036] Shell (14): Provides basic structural support for the product.

[0037] Manufacturing method: The product is assembled in the order of electrical assembly, component assembly, and structural assembly.

[0038] Electrical assembly: The Hall element, resistor and capacitor and lead wire (3) are welded to the Hall plate (5), and then the armature (6) is integrated with the iron core ring (7) by welding and gluing and encapsulation with epoxy resin (8) to complete the electrical assembly.

[0039] Component assembly: The stator assembly consists of lead wires (3), Hall plates (5), armature (6), core rings (7), epoxy resin (8), and housing (14) (see...). Figure 2 ).

[0040] The top cover (1), thrust ball bearing (2), and disc spring (4) constitute the top cover assembly (see Figure 3 ).

[0041] The flange assembly consists of a thrust ball bearing (2), a disc spring (4), and a flange (9) (see...). Figure 4 ).

[0042] The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13) (see...). Figure 5 ).

[0043] Stator component assembly: The lead wire (3) is soldered to the armature (6), and then reliably bonded to the housing (14) and core ring (7) with special adhesive. Afterwards, it is encapsulated in one piece with epoxy resin (5) using a special mold to complete the assembly of the stator component (see Figure 2 ).

[0044] Top cover assembly: according to Figure 3 Install the top cover (1), disc spring (4) and thrust ball bearing (15) in sequence reliably.

[0045] Flange component assembly: according to Figure 4 The thrust ball bearing (2) and disc spring (4) are sequentially installed into the flange (9) to complete the assembly of the flange components.

[0046] Rotor component assembly: according to Figure 5 The magnetic cylinder (13) is attached to the shaft (10), and the balance plate (12) is attached to both ends of the magnetic cylinder to form the rotor component.

[0047] Structural assembly: according to Figure 1The rotor is installed inside the stator, and then the adjusting bushing (11) is installed at both ends of the rotor. The top cover and flange components are installed at both ends of the stator, and the rotor shaft (10) passes through the top cover and flange components. The axial clearance of the motor is adjusted by adjusting the height of the adjusting bushing (11) at both ends. After the clearance is adjusted, the stator, flange components and top cover components are connected into one unit by laser welding.

[0048] Structural simulation analysis: After the product is subjected to axial impact along the X-axis, the rotor component will generate impact force on the disc springs (4) and thrust ball bearings at both ends of the product along the X-axis. The disc springs (4) at both ends are the main force-bearing parts for impact resistance, and the push-pull ball bearings are the secondary force-bearing parts. Figure 7 The image shows the deformation contour plot of the disc springs (4) at both ends under an overload impact of ±20000g. It shows that the maximum resultant displacement of one disc spring (4) is 0.0466mm, and the total deformation is 0.0932mm. The maximum deformation of the disc spring (4) is 0.15mm. Therefore, the disc springs can withstand an overload impact of 20000g. The simulation results of the entire product under an overload impact of +20000g are shown in [the image]. Figure 8 and Figure 9 .

[0049] Simulation results show that when the product is subjected to an overload impact of +20000g, the maximum resultant displacement is 0.003584mm. Excluding stress concentration points caused by mesh generation, the structural stress does not exceed 220MPa (the allowable stress of the part is about 250MPa). Therefore, the product can withstand an overload impact of 20000g.

[0050] Simulation results of the product under an overload impact of -20000g are shown below. Figure 10 and Figure 11 .

[0051] Simulation results show that when the product is subjected to an overload impact of -20000g, the maximum resultant displacement is 0.00427mm. Excluding stress concentration points caused by mesh generation, the structural stress does not exceed 216MPa (the allowable stress of the part is about 250MPa). Therefore, the product can withstand an overload impact of 20000g.

[0052] ±20000 overload impact test verification: Table 1 shows the product's technical specifications before and after the +20000g impact test, and all parameters meet the requirements. The actual axial clearance changes before and after the test are shown in [Table 1]. Figure 12 , Figure 13 Its axial clearance variation is 0.03, which is almost unchanged and meets the requirements.

[0053] Table 1 Comparison of Test Indicators Before and After the +20000g Impact Test of the Product Table 2 shows the product's technical specifications before and after the -20000g impact test, and all parameters meet the requirements. The actual axial clearance changes before and after the test are shown in Table 2. Figure 16 , Figure 17 Its axial clearance variation is 0.03, which is almost unchanged and meets the requirements.

[0054] Table 2 Comparison of Test Indicators Before and After Product-20000g Impact Test Field flight test verification: The electric servo motor using this product completed field flight tests on the aircraft carrier, with an actual overload impact of ≥20000g, and the flight process and results were normal. (See the operating curve of the electric servo motor.) Figure 20 (+20000g) Figure 21 (-20000g). The electric servo motor works normally, proving that this product meets the requirements for bidirectional axial impact, and this patented solution is valid.

[0055] Product simulation, impact testing, and field flight testing have all demonstrated that it can function normally after undergoing high overload impacts, proving the effectiveness of the patented method.

Claims

1. A hollow cup brushless motor resistant to axial bidirectional impact, characterized in that: It consists of stator components, top cover components, flange components, rotor components, and adjusting bushings.

2. The hollow cup brushless motor as described in claim 1, characterized in that: The stator component consists of lead wires (3), Hall plates (5), armature (6), iron core rings (7), epoxy resin (8), and a housing (14).

3. The hollow cup brushless motor as described in claim 1, characterized in that: The top cover component consists of a top cover (1), a first thrust ball bearing (2-1), and a disc spring (4).

4. The hollow cup brushless motor as described in claim 1, characterized in that: The flange assembly consists of a second thrust ball bearing (2-2), a disc spring (4), and a flange (9).

5. The hollow cup brushless motor as described in claim 1, characterized in that: The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13).

6. A method for manufacturing a hollow cup brushless motor resistant to axial bidirectional impact, characterized in that: The hollow cup brushless motor consists of a top cover (1), a thrust ball bearing (2), a lead wire (3), a disc spring (4), a Hall plate (5), an armature (6), an iron core ring (7), epoxy resin (8), a flange (9), a shaft (10), an adjusting bushing (11), a balance plate (12), a magnetic cylinder (13), and a housing (14); the above components are assembled in the order of electrical assembly, component assembly, and structural assembly.

7. A method for manufacturing a hollow cup brushless motor according to claim 6, characterized in that: The electrical assembly involves welding the Hall element, the capacitor and the lead wire (3) to the Hall plate (5), and then encapsulating the armature (6) and the core ring (7) together with epoxy resin (8) using welding and adhesive to complete the electrical assembly.

8. A method for manufacturing a hollow cup brushless motor according to claim 6, characterized in that, The component assembly is performed according to the following steps: The stator components consist of lead wires (3), Hall plates (5), armature (6), iron core rings (7), epoxy resin (8), and outer shell (14); The top cover (1), thrust ball bearing (2), and disc spring (4) constitute the top cover component; The flange assembly consists of a thrust ball bearing (2), a disc spring (4), and a flange (9); The rotor assembly consists of a shaft (10), a balance plate (12), and a magnetic cylinder (13); Stator component assembly: The lead wire (3) is soldered to the armature (6), and then reliably bonded to the outer shell (14) and the core ring (7) with special adhesive. After that, epoxy resin (5) is used to encapsulate it in one piece using a special mold to complete the assembly of the stator component. Assembly of top cover components: Install the top cover (1), disc spring (4) and thrust ball bearing (15) in sequence and reliably; Assembly of flange components: Install the thrust ball bearing (2) and disc spring (4) into the flange (9) in sequence to complete the assembly of the flange components; Rotor assembly: The magnetic cylinder (13) is bonded to the shaft (10), and the balance plate (12) is bonded to both ends of the magnetic cylinder to form the rotor assembly.

9. A method for manufacturing a hollow cup brushless motor according to claim 6, characterized in that, The assembly of the structure is carried out in the following steps: the rotor is installed inside the stator, and then the adjusting bushing (11) is installed at both ends of the rotor. The top cover component and the flange component are installed at both ends of the stator. At the same time, the rotor shaft (10) passes through the top cover component and the flange component. The axial clearance of the motor is adjusted by adjusting the height of the adjusting bushing (11) at both ends. After the clearance is adjusted, the stator, flange component and top cover component are connected into one piece by laser welding.

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