Electric tool and electric motor

Abstract

A power tool and an electric motor including a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a central bore that receives the rotor shaft and the stator support portion. The electric motor also includes a bearing having an outer race and an inner race, the outer race supported by the stator core assembly and the inner race supporting the rotor shaft for rotation relative to the stator assembly. The stator core assembly further defines a bearing pocket adjacent the central bore.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 385,884, filed on December 2, 2022, the entire disclosure of which is hereby incorporated by reference. Technical Field

[0003] The present disclosure relates to electric motors and, more particularly, to outer rotor electric motors. Background Art

[0004] An electric motor generally includes a stationary field or stator and a rotatable armature or rotor. The stator is fixedly held by a surrounding motor support structure. The rotor is rotatably supported relative to the stator and the surrounding motor support structure. During operation, the rotor rotates relative to the stator to provide the torque output of the motor.

[0005] In an outer rotor motor design, at least a portion of the rotor is located radially outward from and surrounds the stator. The stator is generally located within or inside the rotor and is fixedly supported relative to the rotor and relative to the surrounding motor support structure. Summary of the invention

[0006] One aspect of the present disclosure provides an electric motor comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a center hole for receiving the rotor shaft and the stator support portion. The electric motor also includes a bearing having an outer ring and an inner ring, the outer ring being supported by the stator core assembly, and the inner ring supporting the rotor shaft for rotation relative to the stator assembly. The stator core assembly further defines a bearing socket adjacent to the center hole and configured to receive the outer ring of the bearing. A step is formed at a location where the bearing socket transitions to the center hole.

[0007] In some aspects, the central bore has a first diameter, and wherein the bearing socket has a second diameter greater than the first diameter.

[0008] Another aspect of the present disclosure provides an electric tool comprising a housing and an electric motor. The electric motor comprises a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also comprises a stator assembly at least partially received within the rotor assembly. The stator assembly comprises a stator mounting member having a stator support portion and a motor support portion. The stator assembly also comprises a stator core assembly fixedly supported by the stator mounting member, the stator core assembly defining a center hole for receiving the rotor shaft and the stator support portion. The electric tool also comprises an adapter configured to be fixedly coupled to the motor support portion, the adapter comprising a first coupling member. The electric tool further comprises a gearbox, the gearbox comprising a second coupling member configured to be received by the first coupling member to detachably couple the adapter to the gearbox.

[0009] Another aspect of the present disclosure provides an electric motor, comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount, the stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount, the stator core assembly including a stator core and an insulator coupled to the stator core, the stator core defining a center hole for receiving the rotor shaft and the stator support portion. The stator assembly further includes a plurality of windings defining a plurality of coils supported on the stator core assembly. The electric motor also includes a printed circuit board assembly attached to the insulator. The insulator defines a plurality of supports protruding axially away from the stator core. The printed circuit board assembly includes a circuit board defining a plurality of through holes, the plurality of through holes being configured to receive the plurality of supports to fix the printed circuit board assembly to the insulator.

[0010] Another aspect of the present disclosure provides an electric motor, comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount, the stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly including a stator core and an insulator coupled to the stator core, the stator core defining a central hole for receiving the rotor shaft and the stator support portion. The stator assembly also includes a plurality of windings, the plurality of windings defining a plurality of coils supported on the plurality of teeth. The stator assembly further includes a terminal arrangement, the terminal arrangement including a plurality of terminals configured to be mechanically and electrically connected to the plurality of windings, the plurality of terminals supported on a cylindrical end wall, the cylindrical end wall protruding axially from the insulator on an inner periphery of the insulator.

[0011] In some aspects, each terminal includes a shank and a connecting portion, wherein the shank is configured to mechanically and electrically connect to at least one winding of the plurality of windings, and the connecting portion is configured to mechanically and electrically connect to a power line to supply power to the at least one winding.

[0012] In some aspects, the tang is a first tang, and wherein each terminal further comprises a second tang.

[0013] Another aspect of the present disclosure provides an electric motor comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly including a stator core and an insulator coupled to the stator core, the stator core defining a central hole for receiving the rotor shaft and the stator support portion, the insulator defining a cylindrical end wall, the cylindrical end wall protruding axially from the stator core on an inner periphery of the insulator. The stator assembly further includes a plurality of windings defining a plurality of coils supported on the plurality of teeth. The stator assembly also includes a terminal arrangement including a commutator ring having a plurality of terminals angularly spaced apart from one another by a plurality of insulating portions, the commutator ring being supported about the cylindrical end wall, the plurality of terminals being configured to be mechanically and electrically connected to the plurality of windings.

[0014] In some aspects, the electric motor further includes the bus bar having an arc shape and electrically connecting a first terminal of the plurality of terminals with a second terminal of the plurality of terminals.

[0015] Another aspect of the present disclosure provides an electric motor comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly including a stator core and an insulator coupled to the stator core, the stator core defining a center hole for receiving the rotor shaft and the stator support portion. The stator assembly further includes a plurality of windings defining a plurality of coils supported on the plurality of teeth. The stator assembly also includes a terminal arrangement including a commutator ring having a plurality of terminals angularly spaced apart from each other by a plurality of insulating portions, the plurality of terminals being configured to be mechanically connected and electrically connected to the plurality of windings. The electric motor also includes a printed circuit board assembly attached to the insulator. The commutator ring is supported around the stator core assembly by the printed circuit board assembly.

[0016] In some aspects, each terminal includes a connecting portion extending in an axial direction of the electric motor, and wherein the printed circuit board assembly includes a circuit board having an arcuate shape and defining a plurality of through holes, and wherein each connecting portion is received in a corresponding through hole of the plurality of through holes.

[0017] In some aspects, each terminal includes a tang configured to mechanically and electrically connect to at least one winding of the plurality of windings.

[0018] In some aspects, the tang is a first tang, and wherein each terminal further comprises a second tang.

[0019] Another aspect of the present disclosure provides an electric motor, comprising a rotor assembly, the rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received in the rotor body. The stator assembly includes a stator mount, the stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly including a stator core and an insulator coupled to the stator core, the stator core defining a central hole for receiving the rotor shaft and the stator support portion. The stator assembly further includes a plurality of windings, the plurality of windings defining a plurality of coils supported on the plurality of teeth. The electric motor also includes a printed circuit board assembly attached to the insulator, the printed circuit board assembly including a circuit board having an annular shape and including an inner periphery and an outer periphery in a radial direction, the circuit board further including a plurality of horn-shaped pieces located on the inner periphery and protruding radially inward, each horn-shaped piece supporting a conductive pad. The plurality of horns are configured to be mechanically and electrically connected to the plurality of windings.

[0020] In some aspects, the printed circuit board assembly includes a plurality of power line connectors and a plurality of conductive traces extending between the conductive pads of each horn and the plurality of power line connectors.

[0021] Other features and aspects of the present disclosure will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of a power tool according to one embodiment of the present disclosure.

[0023] Figure 2 and Figure 3 yes Figure 1 A perspective view of an electric motor of a power tool.

[0024] Figure 4 and Figure 5 yes Figure 2 A partially exploded perspective view of an electric motor.

[0025] Figure 6 and Figure 7 yes Figure 2 A perspective view of a stator of an electric motor.

[0026] Figure 8 yes Figure 7 A partially exploded perspective view of the stator.

[0027] Fig. 9 and Fig.10 yes Figure 2 A perspective view of a rotor of an electric motor.

[0028] Fig.11 yes Fig. 9 Front view of the rotor.

[0029] Fig.12 yes Fig. 9 A partially exploded perspective view of the rotor.

[0030] Fig. 12A According to another embodiment Fig. 9 A perspective view of the rotor frame of a rotor.

[0031] Fig.13 yes Figure 2 The electric motor along Figure 2 A cross-sectional view taken along line 13-13.

[0032] Fig.14 yes Figure 7 A partially exploded stereoscopic view of the various parts of the stator.

[0033] Fig.15A is a perspective view of an electric motor according to another embodiment.

[0034] Fig. 15B yes Fig.15A The electric motor along Fig.15A A cross-sectional view taken along line 15-15.

[0035] Fig.16A is a perspective view of an electric motor according to another embodiment.

[0036] Fig. 16B yes Fig.16A The electric motor along Fig.16A A cross-sectional view taken along line 16-16.

[0037] Fig.17 is the gearbox, adapter plate and Figure 2 A partially exploded perspective view of an electric motor.

[0038] Fig.18A and Fig.18B It's a picture. Fig.17 The adapter plate connects to Figure 2 Electric motor and Fig.17 A three-dimensional view of the gearbox.

[0039] Fig.19 is a partially exploded perspective view of an electric motor and a gear box according to another embodiment.

[0040] Fig. 20A and Fig. 20B yes Fig.19 A three-dimensional diagram of an electric motor and a gear box coupled to each other.

[0041] Fig.21 is a diagram for connecting a printed circuit board assembly (PCBA) to Figure 7 A perspective view of the stator approach.

[0042] Fig.22A yes Fig.21 Front view of the PCBA.

[0043] Fig. 22B is a front view of a PCBA according to another embodiment.

[0044] Fig.23 is a front view of a PCBA according to another embodiment.

[0045] Fig.24A and Fig. 24B 4 are a front view and a rear view of a PCBA according to another embodiment.

[0046] Fig.25 is a rear view of a PCBA according to another embodiment.

[0047] Fig.26 It's a picture. Figure 7 Schematic diagram of the winding arrangement of the stator.

[0048] Fig. 27 yes Figure 7 A three-dimensional diagram of the terminal arrangement of the stator.

[0049] Fig.28 yes Figure 7 A perspective view of a stator mounting of a stator.

[0050] Fig.29 yes Figure 7 A partial three-dimensional view of the stator.

[0051] Fig.30 and Fig.31 They are Fig. 27 Side view and perspective view of the terminal of the terminal arrangement.

[0052] Fig.32 According to another embodiment Fig. 27 A three-dimensional view of the terminals of the terminal arrangement.

[0053] Fig.33 According to another embodiment Figure 7 Partial side view of the terminal arrangement of the stator.

[0054] Fig.34 yes Fig.33 Top view of the terminal arrangement.

[0055] Fig.35 yes Fig.33A three-dimensional view of the terminals of the terminal arrangement.

[0056] Fig.36 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0057] Fig.37 and Fig.38 yes Fig.36 A three-dimensional view of the terminals of the terminal arrangement.

[0058] Fig.39 According to another embodiment Fig.36 A three-dimensional view of the terminals of the terminal arrangement.

[0059] Figure 40 to Figure 42 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0060] Fig.43 yes Figure 40 to Figure 42 A perspective view of a bus bar with terminal arrangement.

[0061] Fig.44 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0062] Fig.45 and Fig.46 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0063] Fig.47 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0064] Fig.48 and Fig.49 yes Fig.47 A partial stereogram of the various parts of the PCBA with terminal arrangements.

[0065] Fig.50 According to another embodiment Figure 7 A perspective view of the terminal arrangement of the stator.

[0066] Fig.51 yes Fig.50 A perspective view of the commutator ring with the terminal arrangement.

[0067] Fig.52 yes Fig.50 A partial stereoscopic view of the various parts of the terminal arrangement.

[0068] Fig.53 It's a picture. Figure 2 Flow chart of a method for calibrating an electric motor.

[0069] Fig.54 According to another embodiment Figure 7 A perspective view of a stator core assembly of a stator.

[0070] Fig.55 According to another embodiment Figure 7 A perspective view of a stator core assembly of a stator.

[0071] Fig.56 and Fig.57 According to another embodiment Figure 7 A perspective view of a stator core assembly of a stator.

[0072] Before explaining any embodiments of the present disclosure in detail, it should be understood that the application of the present disclosure is not limited to the details of the construction and arrangement of the components set forth in the following specification or shown in the following figures. The present disclosure can have other embodiments and can be practiced or performed in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive. DETAILED DESCRIPTION

[0073] Figure 1 A power tool 10 is illustrated, such as, for example, a drill, a rotary impact tool, etc. The power tool 10 includes a housing 12 and an electric motor 14. The power tool 10 can operate with a battery pack 16 that is removably coupled to a battery receptacle 18 located at a bottom end of the housing 12. The battery pack 16 includes a plurality of battery cells (not shown) that are electrically connected to provide a desired output (e.g., nominal voltage, current capacity, etc.) of the battery pack 16. When the battery pack 16 is coupled to the battery receptacle 18, the electric motor 14 receives power from the battery pack 16.

[0074] In some embodiments, the power tool 10 may include a power cord for electrically connecting the motor 14 to an AC power source. However, the battery pack 16 is the preferred means of powering the power tool 10 because the cordless power tool may be used in locations where other power sources are unavailable.

[0075] refer to Figures 2 to 5 , the illustrated electric motor 14 is a brushless direct current ("BLDC") electric motor having a stator 20 and a rotor 22 rotatable about an axis 24 relative to the stator 20. The BLDC electric motor 14 is an "outer rotor" BLDC electric motor in which the rotor 22 substantially surrounds the stator 20. Thus, the rotor 22 is an outer rotor 22, and the stator 20 is an inner stator 20 at least partially received within and substantially surrounded by the outer rotor 22.

[0076] refer to Figures 6 to 9The stator 20 includes a stator mount 26, a stator core assembly 28 fixedly supported by the stator mount 26, and a plurality of wires or stator windings 30 defining a plurality of coils 32 ( Fig.12 ). The stator core assembly 28 includes a stator core 34 formed by a stack of laminations in the illustrated configuration and an insulator 36 molded onto the core 34. The stator core 34 includes a central core back 38 and a plurality of teeth 40 protruding outwardly from the core back 38. The coils 32 are formed around the teeth 40 and insulated from the teeth by the insulator 36. The core back 38 defines a core center hole 42 extending longitudinally therethrough. The stator mount 26 includes an elongated stator support portion 44 and a motor support portion 46 located at one longitudinal end of the stator support portion 44. The stator support portion 44 is tubular in shape and supports the stator core assembly 28. More specifically, the core center hole 42 of the stator core 34 receives the stator support portion 44 so that the stator core assembly 28 is rigidly supported around the stator support portion 44. In some examples, the stator core 34 may receive the stator support portion 44 by a press fit or an interference fit. In other examples, the stator support portion 44 can be attached to the stator core 34 via a molding process. The stator mount 26 further defines a mount center hole 48 extending longitudinally therethrough, including through both the stator support portion 44 and the motor support portion 46 .

[0077] refer to Figures 9 to 12 , the rotor 22 includes a central rotor shaft 50, a rotor frame 52, a tubular rotor body 54, and a plurality of permanent magnets 56. The rotor frame 52 is annular in shape and includes a central portion 57A attached to the rotor shaft 50. The peripheral portion 57B of the rotor frame 52 is attached to the rotor body 54. In this way, the rotor frame 52 attaches the rotor body 54 to the rotor shaft 50 for rotation therewith. A plurality of radially and axially extending blades 57C extend between the central portion 57A and the peripheral portion 57B and connect the central portion with the peripheral portion, and define a plurality of airflow apertures 57D between each pair of adjacent blades 57C. The blades 57C operate as a fan to generate airflow, which passes through the airflow apertures, thereby cooling the electric motor 14.

[0078] In some embodiments, the rotor frame 52 may be formed of a metal or metal alloy such as, for example, zinc or steel. In other embodiments, the frame 52 may be molded from a resin material.

[0079] The rotor body 54 is tubular in shape and has a radially inner surface 58 defining a central cavity 60. The permanent magnets 56 are fixedly supported on the radially inner surface 58 of the rotor body 54.

[0080] like Fig.13As shown, the rotor body 54 is positioned radially outward from the stator 20 and surrounds portions of the stator 20, including the stator core assembly 28, the coils 32, and a portion of the stator mount 26. Portions of the stator 20, including all or typically a majority of the stator core assembly 28, are received in a central cavity 60 of the rotor body 54.

[0081] Continue to refer Fig.13 , the rotor shaft 50 is rotatably supported relative to the stator 20 by two bearings including a first bearing 62 and a second bearing 64. In this way, the rotor 22 (i.e., including the rotor shaft 50, the rotor frame 52, the rotor body 54 and the magnet 56) rotates relative to the stator 20. When the motor 14 is supported on the power tool 10 ( Figure 1 ), the rotor 22 can rotate relative to both the housing 12 and the stator 20, while the stator 20 does not rotate relative to the housing 12. The rotor shaft 50 extends centrally through the stator 20, passing through both the core center hole 42 and the mounting member center hole 48.

[0082] Fig. 12A A modified rotor frame 52' is shown which may be used in the rotor 22 ( Figure 6 and Figure 7 ) replaces the rotor frame 52. Compared with the rotor frame 52, the modified rotor frame 52' is substantially elongated in the axial direction. The central portion 57A' of the rotor frame 52' defines a recess 68' having a non-circular cross-sectional shape. The recess 68' is capable of receiving the power tool 10 ( Figure 1 ) of a transmission component (not shown) (e.g., by a nominal sliding fit). When the protrusion is inserted into the recess 68', the rotor frame 52' itself can function to transfer torque to the transmission component. In other embodiments (not shown), the rotor frame 52' can alternatively include a non-circular protrusion, and the transmission component can include a non-circular recess configured to receive the protrusion so as to transfer torque therebetween.

[0083] Reference again Figure 3 , the motor 14 further includes an annular printed circuit board assembly (PCBA) 66 attached to the insulator 36 of the stator 20, as will be described in more detail below. The PCBA 66 may include at least one position sensor, such as a Hall effect sensor, operable to detect the position of the permanent magnets 56 of the rotor 22. Additionally or alternatively, the PCBA 66 may include a plurality of switching circuits (e.g., field effect transistors (FETs)) operable to electrically commutate the motor 14.

[0084] like Figure 3As further shown, the rotor shaft 50 includes an output end 70, which, in the illustrated embodiment, protrudes beyond the motor support portion 46 of the stator mount 26. The output end 70 can be fixedly coupled to an output member (e.g., a pinion gear), such as Fig.15A . Pinion 15A may be located on output end 70 of rotor shaft 50 to provide a rotational output for motor 14 adjacent stator mount 26 and away from rotor frame 52. In other embodiments, the motor may alternatively be configured to provide a rotational output adjacent rotor mount, as will be discussed further herein.

[0085] In operation, coils 32 are energized to rotate rotor 22 relative to stator 20. Rotor shaft 50, frame 52, and rotor body 54 rotate together and relative to stator 20 and PCBA 66.

[0086] refer to Figure 8 and Fig.13 , the first bearing 62 is received in a first bearing pocket 74 defined in the motor support portion 46 of the stator mount 26. The outer ring of the first bearing 62 is fixedly held in the first bearing pocket 74 by the motor support portion 46, and the inner ring of the first bearing 62 rotatably supports the rotor shaft 50.

[0087] refer to Fig.13 and Fig.14 In the illustrated embodiment, the second bearing 64 is received in a second bearing socket 76 defined in the stator core 34. The second bearing socket 76 is defined at an axial end of the stator core 34 and is positioned adjacent to the core center hole 42. The second bearing socket 76 and the core center hole 42 both have a circular cross-sectional shape. In the illustrated embodiment, the second bearing socket 76 has a larger diameter than the core center hole so that a shoulder or step 78 is defined therebetween. The outer ring of the second bearing 64 is fixedly held in the second bearing socket 76 by the stator core 34. The inner ring of the second bearing 64 rotatably supports the rotor shaft 50. The outer ring of the second bearing 64 may abut the step 78 so that the step 78 fixes the position of the second bearing 64 in the axial direction.

[0088] Fig.15A and Fig. 15B An alternative embodiment of a motor 14A is illustrated that provides a rotational output adjacent to a rotor frame rather than adjacent to a stator mount. Specifically, the motor 14A is substantially similar to the motor 14 described herein, except that the motor 14A includes a modified rotor 22A having a rotor shaft 50A having an output end 70A that protrudes beyond the rotor frame 52A. The output end 70A may be fixedly coupled to an output member, such as the pinion 72A shown.

[0089] Fig.16Aand Fig. 16B Another alternative embodiment of a motor 14B is illustrated which, like motor 14A, provides a rotational output adjacent to the rotor frame, rather than adjacent to the stator mount. Motor 14B is substantially similar to motor 14A described herein, and generally similar to motor 14 described herein, except that motor 14B includes a second bearing 64B that is not located within stator core 34B. Instead, the inner race of second bearing 64B is positioned around the outer diameter of output member or pinion 72B. The outer race of second bearing 64B may be formed by the power tool 10 ( Figure 1 ) is fixedly supported.

[0090] refer to Fig.17 And turning again to the electric motor 14 described herein, in the illustrated embodiment, the motor support portion 46 includes two radially projecting tabs 80 positioned opposite each other about the axis 24, and two corresponding screw holes 82 formed in the tabs 80. The screw holes 82 can receive screws (not shown) to secure the stator mount 26 directly to a separate motor support structure, thereby supporting the motor 14.

[0091] refer to Figures 17 to 18B The motor 14 may also include a modular adapter plate 84 that is removably coupled to the motor support portion 46 of the stator mount 26 (eg, via threaded fasteners). The adapter plate 84 is further configured to be removably coupled to a fixed component, such as Fig.17 86 is shown. The adapter plate 84 includes a base plate 87 and two annular external bayonet couplings 88 formed at the periphery of the base plate 87 and positioned generally opposite each other relative to the axis 24. The base plate 87 defines a central aperture 90 that allows a portion of the rotor shaft 50 to pass therethrough. In the illustrated embodiment, the base plate 87 also defines two fastener apertures 92 that correspond to the two screw holes 82 formed on the stator mount 26. The external bayonet coupling 88 defines a slot 94. The gearbox 86 includes two outwardly projecting tabs 96 corresponding to the two bayonet couplings 88. The slots 94 of the bayonet coupling 88 receive the tabs 96 of the gearbox 86 to secure the adapter plate 84 to the gearbox 86, thereby coupling the stator mount 26 to the gearbox 86.

[0092] refer to Figures 19 to 20B, an alternative embodiment of the motor 14 may include a modified stator mount 26A having a modified motor support portion 46A. That is, the modified stator mount 26A may include a stator support portion 44 that is identical to the stator support portion of the stator mount 26, but the modified motor support portion 46A is configured to be mounted to an alternative gearbox 86A by different means. The motor support portion 46A is disc-shaped and includes two apertures 98A extending transverse to the axis 24 and parallel to each other in the illustrated embodiment. The two apertures 98A receive two corresponding pins 100A therein. In some embodiments, the pins 100A may be spring pins 100A that are retractable and extendable along their length. The gearbox 86A includes a front opening 102A that receives the disc-shaped motor support portion 46A (e.g., by a nominal sliding fit). The gearbox 86A further includes a pin boss 104A that is shaped and positioned to receive an end portion of the pin 100A. The pin 100A extends through the aperture 98A and into the pin boss 104A to releasably secure the motor support portion 46A to the gear case 86A.

[0093] Fig.21 A two-step process for securing the PCBA 66 to the insulator 36 of the stator core assembly 28 is illustrated. Fig.21 and Figure 8 As shown, the insulator 36 includes a plurality of axially extending posts or supports 106 (e.g., five supports 106 in the illustrated embodiment) protruding at a first axial end 108 thereof. That is, the stator core assembly 28 includes a first axial end 108 and a second axial end 110 ( Figure 8 ), wherein the PCBA 66 is coupled to the first axial end 108. The PCBA 66 includes a circuit board 112 having a plurality of corresponding through holes 114 (e.g., five through holes 114 in the illustrated embodiment) that receive the standoff 106 of the insulator 36. The standoff 106 is located at the outermost periphery of the insulator 36 and extends from a post 116 having a diameter greater than the standoff 106. Thus, a shoulder 117 ( Figure 8 and Fig. 27 ). The shoulder 117 abuts the first surface of the PCBA 66 to axially position the PCBA 66 relative to the insulator 36. Fig.21As shown, during assembly, the PCBA 66 may first be placed on the insulator 36, wherein the standoff 106 extends through the through-hole 114 and beyond the opposite second surface of the PCBA 66. Thereafter, the protruding end of the standoff 106 may then be compressed or stamped to deform and abut against the second surface of the PCBA 66. The deformed end of the standoff 106 becomes a flange having a larger diameter than the through-hole 114 to hold the PCBA 66 in place against the insulator 36. The standoff 106 and the corresponding through-hole 114 may be oriented in a certain pattern (e.g., an asymmetric pattern) so that the through-hole 114 will receive the standoff 106 in the only possible orientation of the PCBA 66 relative to the insulator 36. This pattern arrangement of the standoff 106 and the through-hole 114 will synchronize the PCBA 66 relative to the insulator 36 to ensure proper installation during assembly.

[0094] refer to Fig.22A In one embodiment, the circuit board 112 of the PCBA 66 has an annular arc shape that is open in the center and extends about 315 degrees around its origin or around the axis 24 when the PCBA 66 is coupled to the stator 20. The PCBA 66 also includes three position sensors 118 (e.g., magnetic sensors such as Hall effect sensors) that are disposed on a first surface of the circuit board 112 and angularly spaced apart from each other at equal intervals of 120 mechanical degrees. The five through holes 114 also extend through the circuit board 112 in an asymmetrical pattern.

[0095] Fig. 22B Another embodiment of PCBA 66' is shown, which is substantially similar to Fig.22A The PCBA 66 of the present invention is shown in FIG. 6A , but the position sensor 118′ is positioned differently compared to the PCBA 66. Specifically, the position sensor 118′ is shifted by three mechanical degrees compared to the position sensor 118 or relative to the through hole 114′. Since the stator 20 of the motor 14 includes twelve coils 32 and three phases, this three-degree mechanical shift of the position sensor 118′ is equivalent to a fifteen-degree electrical phase shift.

[0096] Fig.23 Another embodiment of a PCBA 66" operable with the motor 14 is illustrated. The PCBA 66" includes an annular, arcuate circuit board 112" that extends approximately 170 degrees about its origin or about the axis 24 when the PCBA 66" is coupled to the stator 20. The PCBA 66" also includes three position sensors 118" and through holes 114", which are angularly spaced apart from each other at intervals of approximately 60 degrees.

[0097] Fig.24A and Fig. 24BAnother embodiment of a PCBA 66'' operable with the motor 14 is illustrated. The PCBA 66'' includes an annular curved circuit board 112'' that extends approximately 115 degrees about its origin or about the axis 24 when the PCBA 66'' is coupled to the stator 20. In other embodiments, the PCBA 66'' may extend less than 180 degrees about the axis 24 to maintain a compact arrangement. The PCBA 66'' also includes three position sensors 118'' ( Fig.24A ) and are angularly spaced apart from each other at intervals of approximately 24 mechanical degrees. In addition, the circuit board 112"' includes a support for receiving two of the support 106 ( Fig.21 ) of the two through holes 114 '. Since the angular range of the circuit board 112 ' is relatively short, the space is limited compared to the circuit boards 112, 112 ' and 112 ' described herein. Therefore, the circuit board 112 ' does not include pads for receiving and connecting to voltage lines, ground lines and / or signal lines, such as FIG. 22A to FIG. 23 The pads shown in . Fig. 24B The second side of the circuit board 112'" includes a plurality of soldered through-hole (SMT) pads 120'" (eg, five SMT pads 120'" in the illustrated embodiment) for connecting to individual wires.

[0098] Fig.25 A second side of an alternative PCBA 66"" is illustrated that is substantially similar to PCBA 66"' but does not include SMT pads on its second side. Instead, PCBA 66"" includes an SMT connector 120A"" coupled to the second side of circuit board 112"" that can be selectively and removably coupled to a corresponding wire connector (not shown).

[0099] Fig.26 The three-phase winding arrangement 121 of the stator 20 according to an embodiment of the present disclosure is schematically illustrated. Each of the twelve teeth 40 is assigned to represent a coil 32 ( Figure 8 ) are 1-12 in counterclockwise order. Fig.26As shown, tooth 1 supports coil 1, tooth 2 supports coil 2, and so on, tooth 12 supports coil 12. The twelve coils 1-12 are formed by three windings W1, W2 and W3, and each winding W1-W3 forms four coils in the coils 1-12 respectively. For example, coils 1, 2, 7 and 8 located on teeth 1, 2, 7 and 8 respectively are formed by the first winding W1. Winding W1 represents one or more continuous insulated wires, which start from the starting wire U and continuously form coils 8, 7, 2 and 1 in sequence, and then terminate at the ending wire U'. Similarly, winding W2 starts from the starting wire V and continuously forms coils 4, 3, 10 and 9, and then terminates at the ending wire V'. Winding W3 starts from the starting wire W and continuously forms coils 12, 11, 6 and 5, and then terminates at the ending wire W'. Each winding W1-W3 includes some connecting sections or cross-over portions C1-C3, which extend circumferentially around a portion of the stator 20 to connect the relatively positioned coils. For example, the winding W1 includes a crossover portion C1 that extends around a portion of the inner circumference of the stator 20 to connect the coil 7 with the coil 2 .

[0100] In the embodiment shown, each winding W1-W3 is actually formed by two continuous strands of wire, which extend substantially beside or above / below each other when they form the corresponding coil 1-12. For example, winding W1 is formed by two wires, each of which extends separately but continuously to form coil 8, coil 7, crossover portion C1, coil 2 and coil 1. Therefore, the starting wire U actually includes two wire ends or wires in each of the two continuous strands, and the ending wire U' also includes two different wires. Therefore, Fig.26 The entire winding arrangement 121 of the depicted stator 20 includes twelve wires, four each of the starting wire U and ending wire V', the starting wire V and ending wire W', and the starting wire W and ending wire U'. By utilizing two separate and continuous strands to form each winding W1-W3, small diameter wires can be used, which allows for more efficient use of the space between and around the teeth 40.

[0101] refer to Figure 27 to Figure 29 , the stator 20 may include a coil 32 (including Fig.26 The start and end wires (U, U', V, V', W and W') shown in FIG are connected to a terminal arrangement 122 of one or more power sources. The terminal arrangement 122 includes three conductive terminals 124 supported by the insulator 36 at the first axial end 108 of the stator core assembly 28.

[0102] refer to Fig.30 and Fig.31, each terminal 124 is formed of a conductive material (e.g., a metal or a metal alloy) and includes a base portion 128, a tang 130 protruding from the base portion 128, and a connecting portion 132 extending from the base portion 128. In some embodiments, the terminal 124 can be formed as a stamping cut from a metal sheet and bent into shape. Each connecting portion 132 extends away from the base portion 128 in the axial direction, and when arranged on the stator 20, each tang 130 extends away from the base portion 128 in the axial direction and the radial direction. Each terminal 124 can include a thickness of approximately 0.6 millimeters (mm), and each tang can include a length of approximately 3.0 mm.

[0103] like Fig. 27 As shown, the insulator 36 of the stator core assembly 28 includes a cylindrical end wall 126 extending around the inner circumference of the insulator 36 and protruding axially outward at the first axial end 108. The end wall 126 is located radially inward from the teeth 40 and supports the terminals 124 mounted thereto. In the illustrated embodiment, the base portion 128 of each terminal 124 is attached to an annular mount 140, and the mount 140 is attached to a portion of the end wall 126. In other embodiments (not shown), the terminals 124 can be mounted directly to the end wall 126 itself, such as via a molding process.

[0104] As combined Fig.26 As discussed, each winding W1-W3 includes two continuous wires, each continuous wire having a starting conductor and an ending conductor, for a total of four conductors per winding W1-W3, and a total of twelve conductors in the winding arrangement 121. The tang 130 of each terminal 124 receives and electrically connects four respective conductors of the windings W1-W3.

[0105] refer to Fig.28 and Fig.29 , the terminal 124 protrudes axially outward beyond the end wall 126 and toward the motor support portion 46 of the stator mount 26. Therefore, the motor support portion 46 may include a plurality of cutouts 134 corresponding to the positions of the terminals 124 to provide clearance for the axial extension of the terminals 124. Fig.29 As shown, the power line 136 can be electrically connected to the connecting portion 132 of the terminal 124 in an area generally located within the cutout 134. Fig.29 As further shown, the circuit board 112 of the PCBA 66 is annular in shape and extends about the axis 24. The circuit board 112 is located radially outward from the terminals 124. In addition, the circuit board 112 extends around at least two of the terminals 124.

[0106] Fig.32An alternative embodiment of a terminal 124' is shown that can be used in place of terminal 124 in terminal arrangement 122. Terminal 124' is similar to terminal 124, having a base portion 128' and a tang 130', but includes a connecting portion 132' that projects laterally away from base portion 128' rather than axially away from the base portion. In addition, connecting portion 132' includes a through hole 138' that can receive a power cord (such as power cord 136 ( Fig.29 ))'s wire end to make it easier to solder to it.

[0107] Figure 33 to Figure 35 Another embodiment of a terminal arrangement 122a for connecting the coil 32 to one or more power sources is illustrated. The terminal arrangement 122a is similar to the terminal arrangement 122, but differs in the shape of the three terminals 124a. That is, each terminal 124a includes not one but two base portions 128a, and a tang 130a extends away from each base portion 128a, so that each terminal 124a has a total of two tangs 130a. The connecting portion 132a extends axially away from only one of the two base portions 128a, so that each terminal 124a includes only one connecting portion 132a. The two base portions 128a are connected to each other by a bridging portion 142a. The three terminals 124a are mounted to the end wall 126 of the insulator 36 in a manner similar to that described above with respect to the terminal arrangement 122.

[0108] Each terminal 124a includes two tangs 130a, so that there are a total of six tangs 130a in the terminal arrangement 122a. Fig.26 In the winding arrangement 121 shown in FIG, each tang 130a in the terminal arrangement 122a receives and electrically connects to two corresponding wires of the windings W1-W3. Compared to the terminal arrangement 122, this simplifies the winding process by requiring fewer wire connections per tang 130a.

[0109] Fig.36 and Fig.37 Another embodiment of a terminal arrangement 122b for connecting the coil 32 to one or more power sources is illustrated. The terminal arrangement 122b is similar to the terminal arrangement 122a, but differs in the shape of the three terminals 124b. Specifically, each terminal 124b includes a base portion 128b and two tangs 130b, which initially protrude axially downward from the base portion 128b, then simultaneously bend radially outward and return axially upward, and then terminate at their distal ends. Each of these terminals 124b further includes a single connecting portion 132b extending axially upward from the base portion 128b opposite to the tang 130b. The three terminals 124b are mounted to the end wall 126 of the insulator 36 in a manner similar to that described above with respect to the terminal arrangement 122.

[0110] Each terminal 124b includes two tangs 130b, so that there are a total of six tangs 130b in the terminal arrangement 122b. Fig.26 In the winding arrangement 121 shown in FIG, each tang 130b in the terminal arrangement 122b receives and electrically connects to two corresponding wires of the windings W1-W3. Compared to the terminal arrangement 122, this simplifies the winding process by requiring fewer wire connections per tang 130b.

[0111] Fig.38 The stamping 144b is shown, which may be cut from a sheet of metal and then bent into shape to form Fig.37 Specifically, the leg 146b of the stamping 144b can be along Fig.38 The tang 130b is bent in the direction of the arrow shown.

[0112] Fig.39 An alternative embodiment of a terminal 124b' is shown that can replace the terminal 124b in the terminal arrangement 122b. The terminal 124b' differs from the terminal 124b in that the connecting portion 132b' is larger than the connecting portion 132b and defines a through hole 138b' that can receive the end of a power cord (such as the power cord 136 ( Fig.29 )) to facilitate soldering to it.

[0113] Figure 40 to Figure 43 Another embodiment of a terminal arrangement 122c for connecting the coil 32 to one or more power sources is illustrated. The terminal arrangement 122c includes a commutator ring 148c that includes a plurality of terminals 124c arranged in an annular structure and spaced apart from each other at equal intervals. Specifically, the commutator ring 148c includes twelve terminals 124c that are connected to each other by twelve insulating segments 150c so that the terminals 124c and the insulating segments 150c together form an annular shape. In other embodiments (not shown), the terminal A may be supported by a continuous molded ring, or alternatively, the terminal 124c may be supported by the end wall 126 itself. In the illustrated embodiment, the commutator ring 148c is attached to the outer surface of the end wall 126, wherein each terminal 124c is aligned with a corresponding tooth 40. Although not shown in Figure 40 to Figure 43 , but when the PCBA 66 is coupled to the insulator 36, the circuit board 112 is positioned radially outward from the commutator ring 148c including the terminals 124c. In addition, the circuit board 112 extends around at least two of the terminals 124c.

[0114] Each terminal 124c includes a shank 130c and a base portion 128c coupled to an adjacent insulating segment 150c. The shank 130c initially protrudes axially downward from the base portion 128c, then simultaneously bends radially outward and returns axially upward, before terminating at its distal end. Fig.41 As shown, each terminal 124c further includes a single connecting portion 132c extending axially upward from the base portion 128c opposite the tang 130c.

[0115] The commutator ring 148c includes a total of twelve tangs 130c. Fig.26 In the winding arrangement 121 shown in FIG, each tang 130c in the terminal arrangement 122c receives and electrically connects to a corresponding wire of the winding W1-W3. Compared to the terminal arrangement 122, this simplifies the winding process by requiring fewer wire connections per tang 130c.

[0116] Fig.41 A bus bar 152c of the terminal arrangement 122c is also illustrated. The bus bar 152c is arc-shaped and includes four terminal connectors 154c, each of which is connected to a corresponding connection portion 132c of four of the terminals 124c. Specifically, two of the terminal connectors 154c are connected to two terminals 124c positioned adjacent to each other on one side of the commutator ring 148c, and the other two terminal connectors 154c are connected to two opposite terminals 124c that are adjacent to each other and positioned opposite to the first two terminals 124c relative to the center axis 24. Although Fig.41 Only one bus bar 152c is shown, but Fig.42 The terminal arrangement 122c is schematically illustrated to include three bus bars 152c, each bus bar 152c connecting four terminals 124c including two opposing pairs of terminals 124c. Fig.41 Each terminal connector 154c of the bus bar 152c is further illustrated as protruding radially outward from the central arc segment 156c and including a through hole 138c. The through hole 138c receives the connecting portion 132c of the corresponding terminal 124c to form an electrical connection between the terminal 124c and the bus bar 152c. Each bus bar 152c further includes a power connector 158c, which protrudes radially outward from the arc segment 156c and defines a power through hole 159c. The power through hole 159c can receive a power line (such as the power line 136( Fig.29 ))'s wire end to make it easier to solder to it.

[0117] Fig.43 The diagram shows Fig.40 Another embodiment of a bus bar 152c' that operates in conjunction with the commutator ring 148c shown in FIG. The bus bar 152c' is similar to Fig.42The busbars 152c of the present invention are similar to those of the present invention, but include modified terminal connectors 154c' that do not include through holes. Instead, the terminal connectors 154c' project axially so that when the busbars 152c' are coupled to the commutator ring 148c, the terminal connectors 154c' are in face-to-face contact with the base portions 128c of the corresponding terminals 124c of the commutator ring 148c. Each busbar 152c' further includes a power connector 158c' that projects radially outward from the arc segments 156c' and defines a power through hole 159c'.

[0118] Fig.44 An alternative embodiment of a terminal arrangement 122c' is illustrated. The terminal arrangement 122c is substantially similar to the terminal arrangement 122c and uses the same commutator ring 148c. However, the terminal arrangement 122c' differs from the terminal arrangement 122c in the orientation of the terminals 124c relative to the teeth 40 of the stator core assembly 28. That is, in the terminal arrangement 122c', the commutator ring 148c is rotationally displaced relative to the terminal arrangement 122c so that the terminals 124c of the terminal arrangement 122c' are each aligned between two adjacent teeth 40. That is, the terminals 124c are aligned with the slot space defined between two adjacent teeth 40. Compared to the terminal arrangement 122c, when the terminal arrangement 122c' is used, this simplifies the winding process of the stator 20 and provides more space for accommodating the coils 32.

[0119] Fig.45 and Fig.46 Another embodiment of a terminal arrangement 122d for connecting the coil 32 to one or more power sources is shown. The terminal arrangement 122d is similar to Figures 27 to 31 12 and uses the same terminals 124. However, the terminal arrangement 122d differs from the terminal arrangement 122 in that the terminals 124 are positioned at different relative positions around the end wall 126. Specifically, the three terminals 124 in the terminal arrangement 122d are positioned in a grouping generally on one side of the end wall 126 and are relatively closely spaced from each other. For example, the terminals 124 can be spaced approximately 20 degrees apart from each other relative to the axis 24. This arrangement provides relatively more space for the motor 14 to accommodate the PCBA 66 between the terminals 124, the insulator 36, and the stator mount 26. Specifically, in this arrangement, the present invention is combined with Figure 23 to Figure 25 The depicted PCBAs 66 ″, 66 ′″, and 66 ″″ may be positioned generally opposite the terminals 124 without interfering with the terminals 124 at all.

[0120] Figure 47 to Figure 49Another embodiment of a terminal arrangement 122e for connecting the coil 32 to one or more power sources is illustrated. The terminal arrangement 122e does not include distinct terminals attached to the end wall 126. Instead, the terminal arrangement 122e includes a PCBA 160e having a generally annular or ring-shaped circuit board 162e having three integrally formed terminal structures or horns 164e. The horns 164e protrude toward the radially inner circumference of the circuit board 162e, and the conductive pads 166e are located on the horns 164e. Fig.48 As shown, windings W1-W3 can be wrapped around the horn 164e to electrically connect the windings to pads 166e on the horn 164e. Fig.49 As shown, windings W1-W3 can be further soldered to pads 166e to form mechanical and electrical connections therewith. PCBA 160e further includes traces 168e extending between pads 166e and a power line connector 170e also located on circuit board 162e. In this way, PCBA 160e itself electrically connects coil 32 to a power source via pads 166e, traces 168e, and power line connector 170e. This eliminates the need for separately formed terminals, thereby reducing the overall length of electric motor 14.

[0121] Figure 50 to Figure 52 Another embodiment of a terminal arrangement 122f for connecting the coil 32 to one or more power sources is illustrated. The terminal arrangement 122f includes a commutator ring 148f, which includes a plurality of terminals 124f arranged in an annular structure and spaced apart from each other at equal intervals. Specifically, the commutator ring 148f includes three terminals 124f, which are connected to each other by three insulating segments 150f, so that the terminals 124f and the insulating segments 150f together form an annular structure. In other embodiments (not shown), the terminals 124f can be supported by a continuous molded ring. In the illustrated embodiment, the commutator ring 148f is attached to the reference numeral 150f of this document. Fig.22A Each terminal 124f includes a base portion 128f, two tangs 130f extending generally laterally from opposite sides of the base portion 128f, and a connecting portion 132f extending axially away from the base portion 128f. The connecting portion 132f of each terminal 124f is received in a corresponding through hole 172f formed in the PCBA 66 to mechanically and electrically connect the terminal 124f to the PCBA 66. In this way, the commutator ring 148f is directly attached to the PCBA 66 itself and is not directly supported by the insulator 36.

[0122] Each tang 130f defines a slot 174f that receives two corresponding wires of the windings W1-W3 to electrically connect the windings W1-W3 to the terminals 124f. This simplifies the winding process by requiring fewer wire connections per tang 130f compared to the terminal arrangement 122 described herein. In addition, the inner diameter of the commutator ring 148f is greater than the outer diameter of the stator core assembly 28, so that the commutator ring 148f is positioned around the first axial end 108 of the stator core assembly 28. That is, the commutator ring 148f surrounds the first axial end 108 of the stator core assembly 28 or around the outer circumference of the stator core assembly 28. This saves space because the commutator ring 148f does not need to be assembled between the stator core assembly 28 and the PCBA 66. In addition, the outer diameter of the commutator ring 148f is less than or equal to the outer diameter of the PCBA 66, so that the commutator ring 148f does not increase the overall outer diameter of the assembled motor 14.

[0123] Fig.53 A method 1000 of calibrating a motor 14 on a per-motor basis is illustrated. There is a risk that tolerance stack-up on the motor 14 may result in excessive angular misalignment between the position sensor 118 of the PCBA 66 and the permanent magnet 56 of the rotor 22. This may result in improper commutation, which affects power and efficiency. The calibration method 1000 can measure these angular misalignments due to manufacturing tolerances and compensate for them on a per-motor basis.

[0124] In step 1001 of method 1000, the motor 14 is fully assembled. In step 1002, a specific QR code is assigned to the motor 14. In step 1003, the motor 14 is placed on a fixture (not shown), which includes a separate motor, an oscilloscope, a power supply, a Delta to Wye resistor bridge, connectors for each winding phase and position sensor signal of the motor 14, a QR code scanner, and a computer. In step 1003, the QR code of the specific motor 14 is scanned. Next, the fixture rotates the motor 14, and a set of calibration values ​​is generated and stored (step 1004). Then a pre-programmed PCBA (not shown) is installed on the motor 14 (step 1005). In step 1006, the operator connects to the pre-programmed PCBA (e.g., via a computer and an adapter) and scans the QR code. Finally, in step 1007, the computer loads the corresponding calibration values ​​from step 1004 into the PCBA based on the QR code.

[0125] Fig.54 An alternative embodiment of a stator core assembly 28' is shown which may be used in a motor 14 ( Figure 2 ) replaces the stator core assembly 28 and the stator mounting member 26 ( Figure 8 and Fig. 9). The stator core assembly 28' includes the same stator core 34 as the stator core assembly 28, but includes a molded insulator mount 176' that is different from the insulator 36 and replaces the stator mount 26 described above. The molded insulator mount 176' includes an insulator portion 178', a stator support portion 44', and a motor support portion 46', all of which are integrally formed together via, for example, a molding process. In other words, the molded insulator mount 176' is an integral molded part that includes the structure of both the insulator 36 and the stator mount 26 described above. As such, the insulator portion 178' is substantially similar to Figure 8 and Fig. 9 36, the stator support portion 44' is substantially similar to the stator support portion 44, and the motor support portion 46' is substantially similar to the motor support portion 46. The molded insulator mount 176' can be formed by a molding process (e.g., injection molding) and can be molded before or after winding. In addition, the molded insulator mount 176' can be formed by a two-part molding process. The insulator portion 178' and the stator support portion 44' can be formed by a first molding step, and then the motor support portion 46' can be molded to the stator support portion 44' during a subsequent second molding step. This allows the stator core assembly 28' to be wound after the first molding step and before the second molding step.

[0126] Fig.55 Another embodiment of a stator core assembly 28" is shown, which may be used in a motor 14 ( Figure 2 ) replaces the stator core assembly 28 and the stator mounting member 26 ( Figure 8 and Fig. 9 ). The stator core assembly 28" is similar to the stator core assembly 28' ( Fig.54 ), except that the stator core assembly 28" includes a motor support portion 46" that is different from the motor support portion 46'. The motor support portion 46" does not include a tab with a screw hole. Instead, the motor support portion 46" includes a generally cylindrical body 180", which defines a first bearing socket 74" and includes a threaded outer surface 182". The threaded outer surface 182" can be threadedly connected to an internally threaded support structure (not shown), such as a gear box, to support the motor 14.

[0127] Fig.56 and Fig.57 Another embodiment of a stator core assembly 28"' is shown, which may be used in a motor 14 ( Figure 2 ) replaces the stator core assembly 28 and the stator mounting member 26 ( Figure 8 and Fig. 9 ). The stator core assembly 28"' is similar to the stator core assembly 28' ( Fig.54), except that the stator core assembly 28"' includes a motor support portion 46"' that is different from the motor support portion 46'. Specifically, the motor support portion 46"' includes a first portion 184"' formed integrally with the stator support portion 44"' and the insulator portion 178"', and a second portion 186"' formed separately from the first portion 184"'. The first portion 184"' defines a first bearing socket 74"'. The second portion 186"' includes a tab 80"' and a screw hole 82"' for fixing the motor support portion 46"' to an external mounting structure. The first portion 184"' can be formed during a first molding step, and then the second portion 186"' can be formed during a subsequent second molding step and connected to the first portion 184"'.

[0128] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure described.

Claims

1. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mount including a stator support portion and a motor support portion, and a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a central bore receiving the rotor shaft and the stator support portion; as well as a bearing having an outer race and an inner race, the outer race being supported by the stator core assembly and the inner race supporting the rotor shaft for rotation relative to the stator assembly; wherein the stator core assembly further defines a bearing socket adjacent to the central bore and configured to receive an outer race of the bearing; and A step is formed at a position where the bearing socket transitions to the center hole.

2. The electric motor according to claim 1, wherein: The central bore has a first diameter, and wherein the bearing socket has a second diameter greater than the first diameter.

3. The electric motor according to claim 1, wherein: The step fixes the position of the bearing in the axial direction.

4. The electric motor according to claim 1, wherein: The bearing socket is a second bearing socket and the bearing is a second bearing, and wherein the motor support portion defines a first bearing socket configured to receive a first bearing such that an inner race of the first bearing supports the rotor shaft for rotation relative to the stator assembly.

5. The electric motor according to claim 1, wherein: The stator core assembly includes a stator core and an insulator coupled to the stator core, and wherein the electric motor further includes a printed circuit board assembly attached to the insulator.

6. The electric motor according to claim 5, wherein: The printed circuit board assembly is located between the rotor body and the motor support portion in the axial direction.

7. The electric motor according to claim 5, wherein: The insulator defines a plurality of standoffs projecting axially away from the stator core, and wherein the printed circuit board assembly includes a circuit board defining a plurality of through holes configured to receive the plurality of standoffs to secure the printed circuit board assembly to the insulator.

8. The electric motor according to claim 7, wherein: A distal end of each of the plurality of standoffs defines a flange having a diameter greater than a diameter of each of the plurality of through holes.

9. The electric motor according to claim 8, wherein: The insulator further defines a plurality of posts protruding axially away from the stator core, and wherein each of the plurality of standoffs protrudes from each respective one of the plurality of posts.

10. The electric motor according to claim 9, wherein: A shoulder is defined between each standoff of the plurality of standoffs and each corresponding post of the plurality of posts, and wherein the shoulder abuts a surface of the circuit board.

11. The electric motor according to claim 10, wherein: The circuit board is clamped between each shoulder and each flange.

12. The electric motor of claim 1, wherein: The motor support portion defines an aperture configured to receive a pin that secures the motor support portion to the gearbox.

13. An electric tool comprising: case; An electric motor comprising a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body, and a stator assembly at least partially received within the rotor assembly, the stator assembly comprising a stator mount having a stator support portion and a motor support portion, and a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a central bore receiving the rotor shaft and the stator support portion; an adapter configured to be fixedly coupled to the motor support portion, the adapter comprising a first coupling member; as well as A gearbox includes a second coupling member configured to be received by the first coupling member to removably couple the adapter to the gearbox.

14. The electric power tool according to claim 13, wherein: The adapter further includes a base plate, and the first coupling includes a bayonet coupling protruding from the base plate and defining a slot, and wherein the second coupling includes a tab configured to be received in the slot.

15. The electric power tool according to claim 14, wherein: The motor supporting portion includes a tab, and wherein one of the tab and the base plate includes a screw hole, and wherein the electric power tool further includes a screw inserted into the other of the tab and the base plate and fastened into the screw hole.

16. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mounting member, the stator mounting member comprising a stator supporting portion and a motor supporting portion, a stator core assembly fixedly supported by the stator mount, the stator core assembly comprising a stator core and an insulator coupled to the stator core, the stator core defining a central bore that receives the rotor shaft and the stator support portion, and a plurality of windings defining a plurality of coils supported on the stator core assembly; as well as a printed circuit board assembly attached to the insulator; wherein the insulator defines a plurality of standoffs projecting axially away from the stator core; and The printed circuit board assembly includes a circuit board defining a plurality of through holes configured to receive the plurality of support members to secure the printed circuit board assembly to the insulator.

17. The electric motor of claim 16, wherein: A distal end of each of the plurality of standoffs defines a flange having a diameter greater than a diameter of each of the plurality of through holes.

18. The electric motor of claim 17, wherein: The insulator further defines a plurality of posts protruding axially away from the stator core, and wherein each of the plurality of standoffs protrudes from each respective one of the plurality of posts.

19. The electric motor of claim 18, wherein: A shoulder is defined between each standoff of the plurality of standoffs and each corresponding post of the plurality of posts, and wherein the shoulder abuts a surface of the circuit board.

20. The electric motor of claim 19, wherein: The circuit board is clamped between each shoulder and each flange.

21. The electric motor of claim 16, wherein: The plurality of through holes are further configured to receive the plurality of standoffs in a unique orientation of the printed circuit board assembly relative to the insulator.

22. The electric motor of claim 16, wherein: The printed circuit board assembly further includes a plurality of position sensors.

23. The electric motor of claim 22, wherein: The circuit board has an arc shape.

24. The electric motor of claim 22, wherein: The rotor assembly is configured to rotate about an axis, and wherein the circuit board extends less than 180 degrees about the axis.

25. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; as well as a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mounting member, the stator mounting member comprising a stator supporting portion and a motor supporting portion, a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly comprising a stator core and an insulator coupled to the stator core, the stator core defining a central bore receiving the rotor shaft and the stator support portion, a plurality of windings defining a plurality of coils supported on the plurality of teeth, and A terminal arrangement includes a plurality of terminals configured to be mechanically and electrically connected to the plurality of windings, the plurality of terminals being supported on a cylindrical end wall that protrudes axially from the insulator on an inner periphery of the insulator.

26. The electric motor of claim 25, wherein: The cylindrical end wall is located radially inward from the plurality of teeth.

27. The electric motor of claim 25, wherein: Each terminal is attached to a ring mount which is attached to the cylindrical end wall.

28. The electric motor of claim 25, wherein: Each terminal includes a tang configured to be mechanically and electrically connected to at least one winding of the plurality of windings and a connecting portion configured to be mechanically and electrically connected to a power line to supply power to the at least one winding.

29. The electric motor of claim 28, wherein: Each connecting portion projects axially toward the motor supporting portion.

30. The electric motor of claim 29, wherein: The motor support portion defines a plurality of recesses, and wherein each recess receives at least a portion of each connecting portion, respectively.

31. The electric motor of claim 28, wherein: Each connecting portion protrudes in a lateral direction transverse to an axial direction of the electric motor.

32. The electric motor of claim 28, wherein: The tang is a first tang, and wherein each terminal further comprises a second tang.

33. The electric motor of claim 25, further comprising a printed circuit board assembly attached to the insulator, the printed circuit board assembly comprising a circuit board having an arcuate shape and located radially outward from the plurality of terminals.

34. An electric motor as claimed in claim 33, wherein: The circuit board extends around two terminals of the plurality of terminals.

35. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; as well as a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mounting member, the stator mounting member comprising a stator supporting portion and a motor supporting portion, a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly comprising a stator core and an insulator coupled to the stator core, the stator core defining a central bore for receiving the rotor shaft and the stator support portion, the insulator defining a cylindrical end wall that protrudes axially from the stator core on an inner periphery of the insulator, a plurality of windings defining a plurality of coils supported on the plurality of teeth, and A terminal arrangement includes a commutator ring having a plurality of terminals angularly spaced apart from one another by a plurality of insulating portions, the commutator ring being supported about the cylindrical end wall, the plurality of terminals being configured to be mechanically and electrically connected to the plurality of windings.

36. An electric motor as claimed in claim 35, wherein: The cylindrical end wall is located radially inward from the plurality of teeth.

37. The electric motor of claim 35, wherein: Each terminal includes a tang configured to be mechanically and electrically connected to at least one winding of the plurality of windings and a connecting portion configured to be mechanically and electrically connected to a bus bar to supply power to the at least one winding.

38. An electric motor as claimed in claim 37, wherein: Each connecting portion projects axially toward the motor supporting portion.

39. The electric motor of claim 35, further comprising a bus bar having an arc shape and electrically connecting a first terminal of the plurality of terminals with a second terminal of the plurality of terminals.

40. The electric motor of claim 39, wherein: The bus bar includes a power connector configured to mechanically and electrically connect to a power line.

41. The electric motor of claim 39, wherein: The bus bar includes a terminal connector defining a through-hole, and wherein at least one terminal of the plurality of terminals includes a connecting portion received in the through-hole.

42. The electric motor of claim 39, wherein: The bus bar includes a terminal connector that protrudes axially and contacts at least one terminal of the plurality of terminals.

43. The electric motor of claim 35, further comprising a printed circuit board assembly attached to the insulator, the printed circuit board assembly comprising a circuit board having an annular shape and positioned radially outward from the commutator ring.

44. An electric motor as claimed in claim 43, wherein: The circuit board extends around two terminals of the plurality of terminals.

45. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mounting member, the stator mounting member comprising a stator supporting portion and a motor supporting portion, a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly comprising a stator core and an insulator coupled to the stator core, the stator core defining a central bore receiving the rotor shaft and the stator support portion, a plurality of windings defining a plurality of coils supported on the plurality of teeth, and a terminal arrangement including a commutator ring having a plurality of terminals angularly spaced apart from one another by a plurality of insulating portions, the plurality of terminals being configured to be mechanically and electrically connected to the plurality of windings; as well as a printed circuit board assembly attached to the insulator; and The commutator ring is supported around the stator core assembly by the printed circuit board assembly.

46. ​​An electric motor as claimed in claim 45, wherein: Each terminal includes a connection portion extending in an axial direction of the electric motor, and wherein the printed circuit board assembly includes a circuit board having an arc shape and defining a plurality of through holes, and wherein each connection portion is received in a corresponding through hole of the plurality of through holes.

47. An electric motor as claimed in claim 46, wherein: Each connecting portion is mechanically and electrically connected to the printed circuit board assembly.

48. The electric motor of claim 46, wherein: Each terminal includes a tang configured to mechanically and electrically connect to at least one winding of the plurality of windings.

49. An electric motor as claimed in claim 48, wherein: The tang is a first tang, and wherein each terminal further comprises a second tang.

50. The electric motor of claim 48, wherein: The tang defines a slot that receives a wire portion of the at least one winding.

51. The electric motor of claim 45, wherein: The commutator ring surrounds the outer circumference of the stator core assembly.

52. An electric motor as claimed in claim 51, wherein: The outer diameter of the stator core assembly is smaller than the inner diameter of the commutator ring.

53. The electric motor of claim 45, wherein: The printed circuit board assembly includes a circuit board having an arc shape, and wherein an outer diameter of the commutator ring is less than or equal to an outer diameter of the circuit board.

54. The electric motor of claim 45, wherein: The commutator ring is attached to the printed circuit board assembly.

55. An electric motor comprising: a rotor assembly comprising a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body; a stator assembly at least partially received within the rotor body, the stator assembly comprising a stator mounting member, the stator mounting member comprising a stator supporting portion and a motor supporting portion, a stator core assembly fixedly supported by the stator mount and defining a plurality of teeth, the stator core assembly comprising a stator core and an insulator coupled to the stator core, the stator core defining a central bore receiving the rotor shaft and the stator support portion, and a plurality of windings defining a plurality of coils supported on the plurality of teeth; as well as a printed circuit board assembly attached to the insulator, the printed circuit board assembly comprising a circuit board having an annular shape and including an inner periphery and an outer periphery in a radial direction, the circuit board further comprising a plurality of horn-shaped members located on the inner periphery and protruding radially inward, each horn-shaped member supporting a conductive pad; The plurality of horn-shaped members are configured to be mechanically and electrically connected to the plurality of windings.

56. An electric motor as claimed in claim 55, wherein: The plurality of windings are welded to each conductive pad of the plurality of horns.

57. The electric motor of claim 55, wherein: The printed circuit board assembly includes a plurality of power line connectors and a plurality of conductive traces extending between the conductive pads of each horn and the plurality of power line connectors.

58. The electric motor of claim 55, wherein: The printed circuit board assembly is located between the rotor body and the motor support portion in the axial direction.

59. An electric motor as claimed in claim 58, wherein: The insulator defines a plurality of standoffs projecting axially away from the stator core, and wherein the circuit board defines a plurality of through holes configured to receive the plurality of standoffs to secure the printed circuit board assembly to the insulator.

60. The electric motor of claim 59, wherein: A distal end of each of the plurality of standoffs defines a flange having a diameter greater than a diameter of each of the plurality of through holes.

61. An electric motor as claimed in claim 60, wherein: The insulator further defines a plurality of posts protruding axially away from the stator core, and wherein each of the plurality of standoffs protrudes from each respective one of the plurality of posts.

62. An electric motor as claimed in claim 61, wherein A shoulder is defined between each standoff of the plurality of standoffs and each corresponding post of the plurality of posts, and wherein the shoulder abuts a surface of the circuit board.

63. An electric motor as claimed in claim 62, wherein: The circuit board is clamped between each shoulder and each flange.

64. The electric motor of claim 59, wherein: The plurality of through holes are further configured to receive the plurality of standoffs in a unique orientation of the printed circuit board assembly relative to the insulator.

Images