Brushless direct current motor integrated with wind wheel

Abstract

The utility model belongs to the field of motors, and particularly relates to a brushless direct current motor integrated with a wind wheel, the brushless direct current motor takes the wind wheel as a part of an outer rotor assembly, and the wind wheel and a rotor iron shell are subjected to integral injection molding, so that the wind wheel and the motor which originally belong to two parts are integrated into a whole; a customer can directly install and fix outwards through the installation holes in the installation frame during use, so that the use is simple, and the efficiency is higher; in addition, the outer rotor assembly comprises a rotor iron shell which is matched with the magnetic ring without magnetic leakage, the magnetic performance of the rotor is free of loss, and the motor efficiency is higher.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a brushless DC motor with an integrated impeller. Background Technology

[0002] In electrical appliances such as range hoods, humidifiers, and air purifiers, a motor is used to drive a fan (impeller) to rotate and provide a strong airflow. Traditionally, the motor and the fan are two separate components, requiring separate purchase of the motor and the fan. During use, the fan is installed on the motor's shaft. After the motor and the fan are assembled together, the dynamic balance and vibration and noise levels must be checked to ensure they are up to standard before the motor can be installed inside the casing of the range hood, humidifier, or air purifier. The entire assembly process is cumbersome and inefficient. Utility Model Content

[0003] This application provides a brushless DC motor with an integrated impeller, which eliminates the need for customers to assemble the motor and impeller separately, making it more convenient and efficient to use.

[0004] To achieve the above objectives, this application provides a brushless DC motor with an integrated impeller, comprising an outer rotor assembly and a stator assembly. The outer rotor assembly includes an impeller with a central receiving slot, a rotor housing adapted to the central receiving slot, a main shaft coaxially arranged with the rotor housing, and a magnetic ring fixed to the inner wall of the rotor housing. The rotor housing is embedded in the central receiving slot and integrally injection molded with the impeller. The stator assembly includes a mounting bracket, bearings, and stator windings. The mounting bracket is rotatably mounted on the main shaft via the bearings. The stator windings are fixed to the mounting bracket and spaced apart from the magnetic ring. The mounting bracket has mounting holes for external mounting.

[0005] Optionally, the wind turbine includes a top plate, an annular rim, and multiple blades. The annular rim is located below the top plate and is arranged parallel to the top plate. The multiple blades are evenly arranged along the circumference of the top plate and connected between the top plate and the rim. The center of the top plate is recessed downward to form the central receiving groove.

[0006] Optionally, the wind turbine is made of glass fiber reinforced ABS plastic.

[0007] Optionally, the magnetic ring is made of neodymium iron boron.

[0008] Optionally, the mounting bracket includes a first cylinder and a second cylinder that are coaxial and connected to each other. The end of the main shaft away from the central receiving groove extends outward from the central receiving groove. The first cylinder is located inside the central receiving groove, and the second cylinder is located outside the central receiving groove. The stator winding is fixed to the outside of the first cylinder, and the mounting hole is provided at the end of the second cylinder away from the first cylinder.

[0009] Optionally, the bearing includes a first bearing and a second bearing, wherein the outer diameter of the second bearing is larger than the outer diameter of the first bearing, the inner diameter of the second cylinder is larger than the inner diameter of the first cylinder, the first bearing is disposed between the first cylinder and the main shaft, and the second bearing is disposed between the second cylinder and the main shaft.

[0010] Optionally, it also includes a motor control board, which is a circular plate with an outer diameter larger than the inner diameter of the magnetic ring. The motor control board has a through hole in the middle that matches the outer diameter of the first cylinder. The motor control board is sleeved on the first cylinder and is axially limited between the stator winding and the second cylinder. In the axial direction of the main shaft, there is a gap between the motor control board and the rotor shell.

[0011] The beneficial effects of the integrated wind turbine brushless DC motor provided in this application are as follows: Compared with the prior art, the integrated wind turbine brushless DC motor of this application integrates the wind turbine as part of the outer rotor assembly and integrally injection molded with the rotor iron housing, so that the wind turbine and motor, which were originally two parts, are integrated into one. When using it, customers can directly install and fix it through the mounting holes on the mounting bracket, which is simple to use and more efficient; in addition, the outer rotor assembly includes the rotor iron housing, which cooperates with the magnetic ring to prevent magnetic leakage, and the rotor magnetic performance is lossless, resulting in higher motor efficiency. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] in:

[0014] Figure 1 This is a schematic diagram of the overall structure of a brushless DC motor with an integrated wind turbine, as shown in one embodiment of this application.

[0015] Figure 2 This is a cross-sectional view of a brushless DC motor with an integrated impeller, as shown in one embodiment of this application.

[0016] Figure 3 This is an exploded structural diagram of a brushless DC motor with an integrated wind turbine, as shown in one embodiment of this application.

[0017] Figure 4 This is a top view of a brushless DC motor with an integrated impeller shown in one embodiment of this application.

[0018] Explanation of key component symbols:

[0019] 100. External rotor assembly;

[0020] 110. Wind turbine; 1101. Central receiving slot; 111. Top plate; 112. Annular rim; 113. Blade;

[0021] 120. Rotor iron casing;

[0022] 130. Spindle;

[0023] 140. Magnetic ring;

[0024] 200. Stator assembly;

[0025] 210. Mounting bracket; 2101. Mounting hole; 211. First cylinder; 212. Second cylinder;

[0026] 221. First bearing; 222. Second bearing;

[0027] 230. Stator winding;

[0028] 300. Motor control board. Detailed Implementation

[0029] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings. Preferred embodiments of this application are shown in the drawings. However, this application can be implemented in many other different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of this application.

[0030] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0031] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0034] Embodiments of this application provide a brushless DC motor with an integrated wind turbine, such as... Figures 1-3 As shown, the brushless DC motor includes an outer rotor assembly 100 and a stator assembly 200. The outer rotor assembly 100 includes a fan 110 with a central receiving groove 1101, a rotor housing 120 adapted to the central receiving groove 1101, a main shaft 130 coaxially arranged with the rotor housing 120, and a magnetic ring 140 fixed to the inner wall of the rotor housing 120. The rotor housing 120 is embedded in the central receiving groove 1101 and integrally injection molded with the fan 110. The stator assembly 200 includes a mounting bracket 210, bearings, and stator windings 230. The mounting bracket 210 is rotatably sleeved on the main shaft 130 through the bearings. The stator windings 230 are fixed on the mounting bracket 210 and spaced apart from the magnetic ring 140. The mounting bracket 210 has mounting holes 2101 for external installation.

[0035] It should be noted that the rotor shell 120 and the impeller 110 are integrally injection molded, reducing subsequent processing and assembly steps and improving production efficiency. In addition, the strong integrity of the parts avoids defects that may occur during assembly.

[0036] In this embodiment, the brushless DC motor with integrated impeller incorporates the impeller 110 as part of the outer rotor assembly 100, integrally injection molded with the rotor housing 120. This integrates the impeller and motor, which were originally two separate parts, into one unit, and allows for pre-balancing of the entire machine, resulting in better control of noise and vibration. Customers can simply mount and fix the motor externally through the mounting holes 2101 on the mounting bracket 210, making it simple to use and more efficient. Furthermore, the outer rotor assembly 100, including the rotor housing 120, cooperates with the magnetic ring 140 to prevent magnetic leakage, ensuring no loss of rotor magnetic performance and further increasing motor efficiency.

[0037] In one embodiment, such as Figures 1-3As shown, the wind turbine 110 includes a top plate 111, an annular rim 112, and multiple blades 113. The annular rim 112 is located below the top plate 111 and is arranged parallel to the top plate 111. The multiple blades 113 are evenly arranged along the circumference of the top plate 111 and are connected between the top plate 111 and the rim. The middle part of the top plate 111 is recessed downward to form a central receiving groove 1101.

[0038] By recessing the center of the top plate 111 downwards to form a central receiving groove 1101, the iron shell of the outer rotor assembly 100, the magnetic ring 140, the main shaft 130, and the stator assembly 200 are all housed in the central receiving groove 1101, which shortens the axial dimension of the entire brushless DC motor and makes the overall structure more compact.

[0039] Specifically, the wind turbine 110 can be injection molded from glass fiber reinforced ABS plastic. The addition of glass fiber significantly improves the strength and rigidity of ABS, making it perform better under load; the presence of glass fiber improves the heat resistance of ABS, allowing it to be used in higher temperature environments without loss of performance; glass fiber reinforced materials generally have a lower shrinkage rate, improving the dimensional stability of the processed product. In summary, glass fiber reinforced ABS plastic, with its superior mechanical properties, heat resistance, and excellent processability, has been widely used in various industries. This composite material combines the good properties of ABS with the reinforcing properties of glass fiber, providing an excellent solution for high-strength, lightweight products.

[0040] In one embodiment, such as Figures 1-3 As shown, the magnetic ring 140 is made of neodymium iron boron. Neodymium iron boron has a high magnetic energy product and provides a strong magnetic field, making it very suitable for high-performance brushless motors.

[0041] In one embodiment, such as Figure 2 As shown, the mounting bracket 210 includes a first cylindrical body 211 and a second cylindrical body 212 that are coaxial and connected to each other. The end of the main shaft 130 away from the central receiving groove 1101 extends outward from the central receiving groove 1101. The first cylindrical body 211 is located inside the central receiving groove 1101, and the second cylindrical body 212 is located outside the central receiving groove 1101. The stator winding 230 is fixed to the outside of the first cylindrical body 211, and the mounting hole 2101 is provided at the end of the second cylindrical body 212 away from the first cylindrical body 211.

[0042] Specifically, the bearing includes a first bearing 221 and a second bearing 222. The outer diameter of the second bearing 222 is larger than the outer diameter of the first bearing 221, and the inner diameter of the second cylinder 212 is larger than the inner diameter of the first cylinder 211. The first bearing 221 is disposed between the first cylinder 211 and the main shaft 130, and the second bearing 222 is disposed between the second cylinder 212 and the main shaft 130.

[0043] By setting two bearings, the coaxiality between the mounting bracket and the stator winding 230 is improved, thereby improving the coaxiality between the stator assembly 200 and the outer rotor assembly 100.

[0044] It is understandable that the first bearing 221 and the second bearing 222 can be axially limited on the spindle 130 by setting an annular groove on the spindle 130, in conjunction with a snap ring (E-type retaining ring) and a washer.

[0045] In some embodiments, such as Figures 1-4 As shown, the brushless DC motor with integrated impeller also includes a motor control board 300. The motor control board 300 is a circular plate with an outer diameter larger than the inner diameter of the magnetic ring 140. The motor control board 300 has a through hole in the middle that matches the outer diameter of the first cylinder 211. The motor control board 300 is sleeved on the first cylinder 211 and is axially limited between the stator winding 230 and the second cylinder 212. In the axial direction of the main shaft 130, there is a gap between the motor control board 300 and the rotor iron shell 120.

[0046] Specifically, the motor control board 300 includes a PCBA board and electronic components mounted on the PCBA board. The electronic components are located on the side of the PCBA board away from the rotor housing 120. This arrangement allows for a smaller gap between the PCBA board and the rotor housing 120, thus providing better dust prevention and protection.

[0047] With the above settings, the motor control board 300 can be installed and fixed, and the motor control board 300 can cover the opening of the rotor housing 120, thus protecting the components located inside the rotor housing 120.

[0048] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0049] The above embodiments are merely illustrative of several implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A brushless DC motor with an integrated impeller, characterized in that, The device includes an outer rotor assembly and a stator assembly. The outer rotor assembly includes a wind turbine with a central receiving slot, a rotor housing adapted to the central receiving slot, a main shaft coaxially arranged with the rotor housing, and a magnetic ring fixed to the inner wall of the rotor housing. The rotor housing is embedded in the central receiving slot and integrally injection molded with the wind turbine. The stator assembly includes a mounting bracket, bearings, and stator windings. The mounting bracket is rotatably sleeved on the main shaft through the bearings. The stator windings are fixed on the mounting bracket and spaced apart from the magnetic ring. The mounting bracket has mounting holes for external installation.

2. The brushless DC motor with integrated impeller according to claim 1, characterized in that, The wind turbine includes a top plate, an annular rim, and multiple blades. The annular rim is located below the top plate and is arranged parallel to the top plate. The multiple blades are evenly arranged along the circumference of the top plate and are connected between the top plate and the rim. The center of the top plate is recessed downward to form the central receiving groove.

3. The brushless DC motor with integrated impeller according to claim 1, characterized in that, The wind turbine is made of glass fiber reinforced ABS plastic.

4. The brushless DC motor with integrated impeller according to claim 1, characterized in that, The magnetic ring is made of neodymium iron boron.

5. The brushless DC motor with integrated impeller according to claim 1, characterized in that, The mounting bracket includes a first cylinder and a second cylinder that are coaxial and connected to each other. The end of the main shaft away from the central receiving groove extends outward from the central receiving groove. The first cylinder is located inside the central receiving groove, and the second cylinder is located outside the central receiving groove. The stator winding is fixed to the outside of the first cylinder, and the mounting hole is provided at the end of the second cylinder away from the first cylinder.

6. The brushless DC motor with integrated impeller according to claim 5, characterized in that, The bearing includes a first bearing and a second bearing. The outer diameter of the second bearing is larger than the outer diameter of the first bearing, and the inner diameter of the second cylinder is larger than the inner diameter of the first cylinder. The first bearing is disposed between the first cylinder and the main shaft, and the second bearing is disposed between the second cylinder and the main shaft.

7. The brushless DC motor with integrated impeller according to claim 5, characterized in that, It also includes a motor control board, which is a circular plate with an outer diameter larger than the inner diameter of the magnetic ring. The motor control board has a through hole in the middle that matches the outer diameter of the first cylinder. The motor control board is sleeved on the first cylinder and is axially limited between the stator winding and the second cylinder. In the axial direction of the main shaft, there is a gap between the motor control board and the rotor shell.

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