Three-stage reduction motor with integrated structure

Abstract

This invention discloses an integrated three-stage geared motor, which highly integrates the reduction gear set, power motor, and PCB control board into a sealed housing. This significantly improves the structural compactness, space utilization, and protection capabilities of the geared motor. Furthermore, by integrating a pre-installed grounding terminal on the end cover of the power motor and enabling quick and direct connection with the connector on the PCB control board, the separate grounding wire processing and assembly steps in traditional processes are eliminated. This not only greatly simplifies the production process and improves assembly efficiency and consistency but also ensures the reliability and low impedance of the grounding connection. At the same time, through optimized three-stage reduction transmission, a high reduction ratio and high torque output are achieved while maintaining structural compactness and transmission smoothness. This results in a synergistic improvement in structural strength, process friendliness, environmental adaptability, and long-term reliability, solving the prominent problems of loose structure, insufficient protection, and cumbersome assembly in traditional geared motors.

Description

Technical Field

[0001] This invention belongs to the field of geared motor technology and relates to a new type of geared motor, specifically a three-stage geared motor with an integrated structure. Background Technology

[0002] Gear motors are widely used in automation equipment, smart homes, industrial drives, and other fields. Currently, most mainstream gear motors on the market adopt a separate design for the power motor and the gearbox, or a simple assembly structure, which has the following significant drawbacks: Loose structure and limited performance: Due to the limitations of traditional shape and assembly relationship, it can usually only be adapted to micro power motors with low performance, and often adopts two-stage reduction transmission, resulting in low output torque of the whole machine (usually less than 3Nm), which makes it difficult to meet the application scenarios of heavy load or high dynamic response.

[0003] Low protection level: The power motor is often exposed to the outside, and the overall protection level is usually only around IP50, which cannot effectively prevent dust and water, limiting its use in harsh environments such as humid and dusty environments.

[0004] The assembly process is complex and carries high reliability risks: in particular, the safety grounding connection between the power motor and the PCB control board typically requires additional fabrication of grounding wires, which are then connected separately via welding or screw fastening. This process is inefficient, inconsistent, and the connection points have high impedance and are prone to loosening, affecting both production efficiency and reducing the product's electromagnetic compatibility (EMC) and long-term reliability. Summary of the Invention

[0005] To address the technical problems existing in the background art, the present invention proposes a three-stage geared motor with an integrated structure, which is compact, powerful, reliable in protection, and easy to assemble.

[0006] The objective of this invention can be achieved through the following technical solutions: An integrated three-stage geared motor includes: a protective housing and a reduction gear set, a power motor, and a PCB control board installed inside the protective housing. The output shaft at the front end of the power motor drives and connects to the reduction gear set. The reduction gear set converts the high-speed, low-torque motion input from the power motor into low-speed, high-torque motion before outputting it. The PCB control board is electrically connected to the rear end of the power motor to drive and control the power motor. The rear end cover of the power motor integrates one or more sets of grounding terminals. The PCB control board is equipped with a connector that matches the grounding terminals. The connector is plugged into the grounding terminals to achieve grounding connection between the power motor and the PCB control board.

[0007] Furthermore, the grounding terminal is a metal conductive component pre-embedded in the rear end cover of the power motor. One end of the metal conductive component is in electrical contact with the conductive parts of the electric motor, and the other end forms a connection part for plug-in mating.

[0008] Furthermore, the connecting part of the metal conductive component is a columnar protrusion or a grooved contact surface, and the plug on the PCB control board is a spring clip type female connector or a pin type male connector that matches the connecting part of the metal conductive component.

[0009] Furthermore, the protective housing includes: a gearbox, a motor cylinder, and a control end cover. The reduction gear set is adapted to be installed inside the gearbox, the power motor is completely enclosed inside the motor cylinder, and the PCB control board is adapted to be installed inside the control end cover.

[0010] Furthermore, the gearbox is composed of an upper cover and a lower cover that are sealed together. One end of the motor cylinder is integrally formed with the upper cover of the gearbox, and the control end cover is sealed to the other end of the motor cylinder.

[0011] Furthermore, the gearbox is provided with an output shaft hole, and the control end cover is provided with an electrical interface.

[0012] Furthermore, the reduction gear set includes: a first-stage gear, a second-stage gear, and a third-stage gear with gradually increasing outer diameters. The output shaft at the front end of the power motor drives and connects to the first-stage gear. The first-stage gear drives and connects to the second-stage gear. The second-stage gear drives and connects to the third-stage gear. The third-stage gear is driven and connected to an external load device through the output shaft hole on the reduction gearbox.

[0013] Furthermore, the first-stage gear and the second-stage gear are connected by a worm gear drive. One end of the worm gear meshes with the first-stage gear, and the other end meshes with the second-stage gear. The second-stage gear meshes with the third-stage gear.

[0014] Furthermore, the PCB control board integrates a motor drive circuit and a control chip, and the PCB control board is electrically connected to the external power supply equipment through the electrical interface on the control end cover.

[0015] The beneficial effects of this invention are as follows: The geared motor provided by this invention, through its integrated and modular structural design, highly integrates the reduction gear set, power motor, and PCB control board into a sealed housing, significantly improving the structural compactness, space utilization, and protection capabilities of the geared motor. This allows it to better adapt to complex and harsh application environments. Furthermore, by integrating a pre-installed grounding terminal on the end cover of the power motor and enabling quick and direct connection with the connector on the PCB control board, the separate grounding wire processing and assembly steps in traditional processes are completely eliminated. This not only greatly simplifies the production process and improves assembly efficiency and consistency but also ensures the reliability and low impedance of the grounding connection, effectively suppressing electromagnetic interference and enhancing the stability and safety of the geared motor operation. At the same time, through optimized three-stage reduction transmission, high reduction ratio and high torque output are achieved while maintaining structural compactness and transmission smoothness. The overall design achieves synergistic improvement in structural strength, process friendliness, environmental adaptability, and long-term reliability, comprehensively solving the prominent problems of loose structure, insufficient protection, and cumbersome assembly in traditional geared motors. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of the present invention.

[0017] Figure 2 This is a schematic diagram of the internal structure of the protective housing of the present invention.

[0018] Figure 3 This is a schematic diagram of the assembly of the power motor and the PCB control board of the present invention.

[0019] Figure 4 This is a schematic diagram of the protective shell of the present invention.

[0020] Figure 5 This is a schematic diagram of the transmission of the reduction gear set of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] like Figures 1-2As shown, this invention provides a three-stage geared motor with an integrated structure, comprising: a protective housing 1 and a reduction gear set 2, a power motor 3, and a PCB control board 4 sequentially installed at the front, middle, and rear positions inside the protective housing 1. The output shaft at the front end of the power motor 3 is directly connected to the input end of the reduction gear set 2. The power input to the power motor 3 is reduced by the reduction gear set 2, changing from high-speed, low-torque motion to low-speed, high-torque motion, and is output from the output end of the reduction gear set 2. The PCB control board 4 is fixedly installed at the rear end of the power motor 3 via an insulating support plate 7. The PCB control board 4 is electrically connected to the power motor 3 via wires or interfaces, and is responsible for providing drive power to the power motor 3 and executing control logic to drive and control the power motor 3.

[0023] Among them, such as Figure 3 As shown, three sets of grounding terminals 5 are integrated on the end cover at the rear end of the power motor 3, evenly distributed along the circumference. Correspondingly, three sets of connectors 6 are provided on the PCB control board 4, matching the shape and position of the grounding terminals 5. During the assembly of the geared motor, when the PCB control board 4 is installed in its predetermined position, the connectors 6 on it will automatically align with the grounding terminals 5 on the end cover at the rear end of the power motor 2 and complete the insertion and engagement, thereby realizing the grounding connection between the power motor 3 and the PCB control board 4. This completely eliminates the need for separately processed and installed grounding wires in traditional processes. The reliable electrical connection between the power motor 3 and the grounding layer of the PCB control board 4 is achieved synchronously in the single action of installing the PCB control board 4, greatly simplifying the assembly process, improving production efficiency, and ensuring the reliability and consistency of the grounding connection, which is beneficial to improving the electromagnetic compatibility of the geared motor.

[0024] Specifically, the end cap at the rear end of the power motor 3 is typically made of insulating engineering plastic. The grounding terminal 5 is a metal conductive component, such as a copper insert, pre-embedded in the end cap at the rear end of the power motor 3. During the injection molding of the end cap, the metal conductive component is encapsulated and fixed in one go. One end of the metal conductive component maintains stable electrical contact with conductive components such as the stator core or housing of the electric motor 2, while the other end forms a connection portion exposed on the surface of the end cap for insertion and mating with the connector 6.

[0025] Specifically, the connecting part of the metal conductive component can be in the form of a columnar protrusion or a grooved contact surface. Correspondingly, the plug-in 6 on the PCB control board 4 is a spring clip female connector (corresponding to the columnar protrusion) or a pin male connector (corresponding to the grooved contact surface) that matches the connecting part of the metal conductive component. This plug-in mating method allows for quick, tool-free operation, low contact resistance, and a stable connection.

[0026] In a geared motor, such as Figure 4As shown, the protective housing 1 adopts a modular design, including: a gearbox 11, a motor cylinder 12, and a control end cover 13. The reduction gear set 2 is precisely assembled in the internal cavity of the gearbox 11. The power motor 3 is completely enclosed and protected inside the cylindrical motor cylinder 12. The PCB control board 4 is sealed and installed at one end of the motor cylinder 12 through the control end cover 13. Specifically, the gearbox 11 is composed of an upper cover and a lower cover fastened with screws and supplemented with sealing gaskets to ensure that the gear lubricating grease does not leak. One end of the motor cylinder 12 and the upper cover of the gearbox 11 are integrally cast to form a robust overall structure, and the overall protection level meets IP54. The control end cover 13 is detachably sealed to the other end of the motor cylinder 12 through screws and sealing rings, which facilitates the maintenance or replacement of the PCB control board 4.

[0027] In a geared motor, the reduction gear set 2 is the core component for achieving torque increase and speed reduction, such as... Figure 5 As shown, the reduction gear set 2 includes a first-stage gear 21, a second-stage gear 22, and a third-stage gear 23, with progressively increasing outer diameters and load-bearing capacities. The output shaft at the front end of the power motor 3 drives the first-stage gear 21 to rotate via a key connection or other means. The first-stage gear 21 transmits power to the second-stage gear 22, which further transmits power to the final third-stage gear 23. After three stages of reduction, the output speed is significantly reduced, and the torque is greatly increased, achieving a total transmission ratio greater than 100:1. By equipping it with a high-performance power motor 2, the stall torque can be stably greater than 4 Nm, meeting the application requirements for heavy-load starting. The reduction gearbox 11 is provided with an output shaft hole 14. Finally, the output shaft of the third-stage gear 33 is supported by a bearing and passes through the output shaft hole 14 to drive the connected external load equipment. Specifically, the first-stage gear 21 and the second-stage gear 22 are connected by a worm gear 24. One end of the worm gear 24 meshes with the first-stage gear 21, and the other end meshes with the second-stage gear 22. This worm gear transmission structure is compact, can achieve a large single-stage reduction ratio, and has a reverse self-locking characteristic under certain conditions, enhancing the safety of the drive system. The second-stage gear 22 and the third-stage gear 23 adopt a common parallel shaft gear meshing method, optimizing the space occupied by the reduction gear set 2.

[0028] In the geared motor, the PCB control board 4 serves as the control core, integrating the motor drive circuit and microprocessor control chip. The motor drive circuit typically includes a bridge circuit composed of power MOSFETs or IGBTs. The control end cover 13 is equipped with a standard electrical interface 15, which uses a waterproof aviation plug, terminal block, or cable outlet. Power lines, control signal lines, or communication buses from external power supply equipment are all connected to the electrical interface 15 and connected to the corresponding circuits on the PCB control board 4, thereby realizing comprehensive intelligent control of the geared motor, including power supply, start-up, stop, speed regulation, direction adjustment, and status monitoring.

[0029] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A three-stage geared motor with an integrated structure, characterized in that, include: The protective housing (1) and the reduction gear set (2), power motor (3) and PCB control board (4) installed in the protective housing (1) are connected to the output shaft of the front end of the power motor (3). The reduction gear set (2) converts the high-speed low-torque motion input by the power motor (3) into low-speed high-torque motion and outputs it. The PCB control board (4) is electrically connected to the rear end of the power motor (3) to drive and control the power motor (3). One or more sets of grounding terminals (5) are integrated on the rear end cover of the power motor (3). The PCB control board (4) is provided with a connector (6) that matches the grounding terminal (5). The connector (6) is plugged into the grounding terminal (5) to realize the grounding connection between the power motor (3) and the PCB control board (4).

2. The geared motor according to claim 1, characterized in that, The grounding terminal (5) is a metal conductive component pre-embedded in the end cover of the rear end of the power motor (3). One end of the metal conductive component is in electrical contact with the conductive component of the electric motor (2), and the other end forms a connection part for plug-in mating.

3. The geared motor according to claim 2, characterized in that, The connecting part of the metal conductive component is a columnar protrusion or a grooved contact surface. The plug (6) on the PCB control board (4) is a spring clip female connector or a pin male connector that matches the connecting part of the metal conductive component.

4. The geared motor according to claim 1, characterized in that, The protective housing (1) includes: a gearbox (11), a motor barrel (12) and a control end cover (13). The gearbox (2) is adapted to be installed inside the gearbox (11). The power motor (3) is completely enclosed inside the motor barrel (12). The PCB control board (4) is adapted to be installed inside the control end cover (13).

5. The geared motor according to claim 4, characterized in that, The gearbox (11) is composed of an upper cover and a lower cover that are sealed together. One end of the motor cylinder (12) is integrally formed with the upper cover of the gearbox (11), and the control end cover (13) is sealed to the other end of the motor cylinder (12).

6. The geared motor according to claim 4, characterized in that, The gearbox (11) is provided with an output shaft hole (14), and the control end cover (13) is provided with an electrical interface (15).

7. The geared motor according to claim 6, characterized in that, The reduction gear set (2) includes: a first-stage gear (21), a second-stage gear (22), and a third-stage gear (23) with gradually increasing outer diameters. The output shaft at the front end of the power motor (3) drives and connects to the first-stage gear (21). The first-stage gear (21) drives and connects to the second-stage gear (22). The second-stage gear (22) drives and connects to the third-stage gear (23). The third-stage gear (23) drives and connects to the external load device through the output shaft hole (14) on the reduction gearbox (11).

8. The geared motor according to claim 7, characterized in that, The first gear (21) and the second gear (22) are connected by a worm (24). One end of the worm (24) meshes with the first gear (21), and the other end meshes with the second gear (22). The second gear (22) meshes with the third gear (23).

9. The geared motor according to claim 6, characterized in that, The PCB control board (4) integrates a motor drive circuit and a control chip. The PCB control board (4) is electrically connected to an external power supply device through the electrical interface (15) on the control end cover (13).

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