Hollow cup type brushless sensorless motor

Abstract

The utility model discloses a hollow cup type brushless sensorless motor, and relates to the technical field of motors. The hollow cup type brushless sensorless motor comprises a casing structure and a driving plate, the casing structure comprises a casing main body and a rear end cover, the casing main body is integrally formed, and an accommodating cavity and an opening and a through hole communicated with the accommodating cavity are formed in the casing main body; the rear end cover is arranged at the opening, and a mounting area is arranged on one side, opposite to the accommodating cavity, of the rear end cover; and the driving plate is arranged in the mounting area. According to the technical scheme, the number of parts can be reduced, the requirement for the matching precision of all the parts is lowered, and then the efficiency of combined installation is improved.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a hollow cup type brushless sensorless motor. Background Technology

[0002] The coreless brushless motor is a micro-motor that integrates DC, permanent magnet, and servo characteristics. Based on traditional motors, it employs a cogging-free structure. This not only significantly reduces eddy current losses in the iron core and improves the motor's energy efficiency, but also greatly reduces the motor's weight and moment of inertia, thereby effectively reducing mechanical losses.

[0003] In the existing manufacturing process of hollow cup brushless motors, it is usually necessary to precisely install the stator assembly and rotor assembly into the housing. Subsequently, a drive plate support is installed inside the housing, the drive plate is installed on the drive plate support, and finally, a front cover and a rear cover that match the housing are installed, encapsulating the stator assembly, rotor assembly, and drive plate inside the housing.

[0004] However, since the front cover, rear cover, drive plate support and housing need to be processed separately, the number of parts to be processed is large, and the fitting accuracy between the components is high, which leads to low efficiency in assembly. Utility Model Content

[0005] The main purpose of this invention is to propose a hollow cup-type brushless sensorless motor, which aims to improve installation efficiency.

[0006] To achieve the above objectives, this utility model proposes a hollow cup-type brushless sensorless motor, which includes:

[0007] A housing structure, comprising a housing body and a rear end cover, wherein the housing body is integrally formed and has a receiving cavity and an opening and a passage communicating with the receiving cavity; the rear end cover is disposed at the opening, and a mounting area is provided on the side of the rear end cover facing away from the receiving cavity; and

[0008] A driver board is located in the mounting area.

[0009] In one embodiment, the rear end cover includes a main body and a protrusion on the side wall of the main body. The mounting area is located on the side of the main body facing away from the receiving cavity. A portion of the main body is inserted into the receiving cavity so that the side of the housing body near the opening abuts against the protrusion.

[0010] In one embodiment, the side wall of the main body is further provided with a plurality of mounting grooves. Along the circumferential direction of the main body, the mounting grooves and the protrusions are staggered. A plurality of limiting parts are formed on the side of the housing body near the opening. Each limiting part corresponds to a mounting groove. The limiting part extends into the mounting groove so that the housing body and the main body are connected.

[0011] In one embodiment, the rear end cover further includes a boss located on the side of the main body facing away from the receiving cavity, and the surface of the boss forms the mounting area.

[0012] In one embodiment, the boss is further provided with a plurality of limiting posts, and the drive plate is provided with a plurality of limiting holes. The limiting holes correspond one-to-one with the limiting posts, and the limiting posts pass through the limiting holes to limit the drive plate.

[0013] In one embodiment, the main body has a plurality of wire outlet holes, all of which are connected to the receiving cavity, and the plurality of wire outlet holes are used for the wiring of the stator assembly.

[0014] In one embodiment, the main body is provided with a plurality of guide holes, and the rear end cover is further provided with a plurality of guide posts, each guide post passing through a guide hole, and each guide post being provided with a wire outlet hole.

[0015] In one embodiment, the drive board is provided with clearance holes that correspond one-to-one with the outlet holes, and the clearance holes are used for the wiring of the stator assembly to pass through.

[0016] In one embodiment, the drive plate has a plurality of welding areas on the side facing away from the rear end cover, and each welding area is disposed adjacent to a clearance hole.

[0017] In one embodiment, the hollow cup type brushless sensorless motor further includes a stator assembly and a rotor assembly. The stator assembly is disposed on the inner wall of the main body of the housing, and the rotor assembly is disposed inside the stator assembly. One end of the rotor assembly is movably inserted through the opening, and the other end is movably inserted through the rear end cover.

[0018] The technical solution of this utility model forms an installation area on the rear end cover, allowing the drive plate to be directly mounted on the rear end cover. Simultaneously, the rear end cover is located at the opening, directly sealing the accommodating cavity, thus eliminating the need for separate processing and installation steps for the front end cover and the drive plate support. This reduces the number of parts, lowers the precision requirements for the fit between components, and thereby improves the efficiency of assembly. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 A schematic diagram of a hollow cup-type brushless sensorless motor according to an embodiment of the present invention;

[0021] Figure 2 for Figure 1 Cross-sectional view of a hollow cup-type brushless sensorless motor;

[0022] Figure 3 for Figure 2 A magnified view of a section at point A in the middle;

[0023] Figure 4 for Figure 1 Schematic diagram of the structure of the main body of the middle casing;

[0024] Figure 5 for Figure 1 Another structural schematic diagram of the inner casing body;

[0025] Figure 6 for Figure 1 Schematic diagram of the middle and rear end caps;

[0026] Figure 7 for Figure 1 A schematic diagram of the drive board.

[0027] Explanation of icon numbers:

[0028] 100. Hollow Cup Type Brushless Sensorless Motor; 1. Housing Structure; 11. Housing Body; 111. Receiving Cavity; 112. Opening; 113. Through Port; 114. Base Plate; 1141. Mounting Platform; 115. Enclosure; 1151. Limiting Part; 12. Rear End Cover; 121. Mounting Area; 122. Main Body; 1221. Cable Outlet Hole; 1222. Guide Hole; 123. Protrusion; 124. Mounting Slot; 125. Boss; 1251. Limiting Post; 126. Guide Post; 127. Clearance Space; 2. Drive Plate; 21. Limiting Hole; 22. Clearance Hole; 23. Welding Area; 3. Stator Assembly; 31. Stator Core; 32. Coil Cup; 4. Rotor Assembly; 41. Shaft; 42. Magnetic Ring; 43. Bearing; 44. Elastic Component.

[0029] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0031] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0032] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0033] The coreless brushless motor is a micro-motor that integrates DC, permanent magnet, and servo characteristics. Based on traditional motors, it employs a cogging-free structure. This not only significantly reduces eddy current losses in the iron core and improves the motor's energy efficiency, but also greatly reduces the motor's weight and moment of inertia, thereby effectively reducing mechanical losses.

[0034] In the existing manufacturing process of hollow cup brushless motors, it is usually necessary to precisely install the stator assembly and rotor assembly into the housing. Subsequently, a drive plate support is installed inside the housing, the drive plate is installed on the drive plate support, and finally, a front cover and a rear cover that match the housing are installed, encapsulating the stator assembly, rotor assembly, and drive plate inside the housing.

[0035] However, since the front cover, rear cover, drive plate support and housing need to be processed separately, the number of parts to be processed is large, and the fitting accuracy between the components is high, which leads to low efficiency in assembly.

[0036] The main purpose of this invention is to propose a hollow cup-type brushless sensorless motor 100, which aims to improve installation efficiency.

[0037] Please see Figures 1 to 7 In one embodiment of this utility model, the hollow cup-type brushless sensorless motor 100 includes a housing structure 1 and a drive plate 2. The housing structure 1 includes a housing body 11 and a rear end cover 12. The housing body 11 is integrally formed and has a receiving cavity 111 and an opening 112 and a through-hole 113 communicating with the receiving cavity 111. The rear end cover 12 is disposed at the opening 112, and a mounting area 121 is provided on the side of the rear end cover 12 facing away from the receiving cavity 111. The drive plate 2 is disposed in the mounting area 121.

[0038] The technical solution of this utility model forms an installation area 121 on the rear end cover 12, allowing the drive plate 2 to be directly installed on the rear end cover 12. Simultaneously, the rear end cover 12 is located at the opening 112, directly closing the accommodating cavity 111, thus eliminating the need for separate processing and installation steps for the front end cover and the drive plate 2 support. This reduces the number of parts, lowers the precision requirements for the fit between components, and thereby improves the efficiency of assembly.

[0039] In this embodiment, the main body 11 of the housing is manufactured by an integral stretch forming process, and the rear end cover 12 is manufactured by an injection molding process. Compared with traditional machining methods, this reduces processing complexity, shortens the production cycle, and improves production efficiency. The integral stretch forming process makes the structure of the main body 11 of the housing more compact and stable, and reduces material waste during processing. The rear end cover 12 uses plastic material to seal the opening 112, which not only ensures the sealing of the opening 112, but also facilitates the processing of the structure of the mounting area 121 for mounting the drive plate 2.

[0040] Please see 2 and Figure 4As can be understood, the main body 11 of the casing includes a base plate 114 and a surrounding plate 115 arranged around the periphery of the base plate 114. The base plate 114 and the surrounding plate 115 form a receiving cavity 111. An opening 112 communicating with the receiving cavity 111 is formed on the side of the surrounding plate 115 away from the base plate 114, and a rear end cover 12 is provided at the opening 112. The base plate 114 is equivalent to the front end cover in a traditional production process, and the surrounding plate 115 is equivalent to the casing. In this embodiment, the base plate 114 and the surrounding plate 115 are directly formed by an integral stretching forming process, without the need for an additional installation process. The base plate 114 has a through-hole 113 for the rotor assembly 4 to pass through, so as to realize the normal rotation of the rotor assembly 4. The through-hole 113 of the base plate 114 extends away from the receiving cavity 111, forming a mounting platform 1141. The inner wall of the mounting platform 1141 is provided with a bearing 43, and the mounting platform 1141 is mounted on the rotor assembly 4 through the bearing 43. Along the extension direction of the rotor assembly 4, one side of the bearing 43 abuts against the mounting platform 1141, and the opposite side abuts against the rotor assembly 4 through an elastic element, thereby preventing the bearing 43 from moving along the extension direction of the rotor assembly 4 during rotation and ensuring the stability of the rotation process.

[0041] Please see Figure 1 , Figure 5 and Figure 6 In one embodiment, the rear cover 12 includes a main body 122 and a protrusion 123 provided on the side wall of the main body 122. The mounting area 121 is provided on the side of the main body 122 facing away from the receiving cavity 111. A portion of the main body 122 is inserted into the receiving cavity 111 so that the side of the housing body 11 near the opening 112 abuts against the protrusion 123.

[0042] In this embodiment, the inner diameter of the housing body 11 is equal to the outer diameter of the main body 122, facilitating the insertion of the main body 122 into the receiving cavity 111 from the opening 112. Simultaneously, the outer diameter of the protrusion 123 is equal to the outer diameter of the housing body 11. As the rear end cover 12 extends into the receiving cavity 111, the side of the housing body 11 near the opening 112 abuts against the protrusion 123, thus determining the installation position of the rear end cover 12. Furthermore, when the rear end cover 12 is in place, the protrusion 123 is precisely aligned with the outer wall of the housing body 11, enhancing aesthetics. It should be noted that this equality is within the assembly error range, not absolute equality.

[0043] Please see Figure 3 , Figure 5 and Figure 6In one embodiment, the side wall of the main body 122 is also provided with a plurality of mounting grooves 124. Along the circumferential direction of the main body 122, the mounting grooves 124 and the protrusions 123 are arranged alternately. The side of the housing body 11 near the opening 112 is provided with a plurality of limiting parts 1151. Each limiting part 1151 corresponds to a mounting groove 124. The limiting part 1151 extends into the mounting groove 124 so that the housing body 11 and the main body 122 are connected.

[0044] In this embodiment, the side wall of the main body 122 is provided with a plurality of mounting grooves 124. When the main body 122 is inserted into the receiving cavity 111 through the opening 112, part of the mounting groove 124 will be blocked by the housing body 11. At this time, the part of the housing body 11 corresponding to the mounting groove 124 is pressed into the mounting groove 124 to form a limiting part 1151. The limiting part 1151 extends into the mounting groove 124, so that the main body 122 and the housing body 11 fit tightly together, thereby preventing the main body 122 from separating from the housing body 11 and ensuring the stability of the connection.

[0045] Alternatively, the limiting part 1151 may be rotatably disposed on the main body 11 of the housing before being inserted into the receiving cavity 111. After the rear cover 12 is installed in place, the limiting part 1151 rotates and extends into the mounting groove 124 to abut against the main body 122, so that the main body 122 is tightly connected to the main body 11 of the housing.

[0046] Optionally, the mounting grooves 124 are evenly arranged along the circumferential direction of the main body 122 to ensure the force balance when the main body 11 and the rear cover 12 are connected, thereby increasing the stability of the structure.

[0047] Please see Figure 2 and Figure 6 In one embodiment, the rear cover 12 further includes a boss 125, which is provided on the side of the main body 122 facing away from the receiving cavity 111, and the surface of the boss 125 forms a mounting area 121.

[0048] In this embodiment, a boss 125 is provided on the side of the main body 122 facing away from the receiving cavity 111, and the drive plate 2 is mounted on the surface of the boss 125. On the one hand, the boss 125 forms a mounting area 121 for mounting the drive plate 2. On the other hand, the boss 125 surrounds a clearance space 127, allowing the edge areas of the drive plate 2 without electronic components to be directly mounted to the mounting area 121, while the central area of ​​the drive plate 2 (where electronic components are located) corresponds to the clearance space 127. This avoids interference during installation of the drive plate 2 and ensures the stability of the connection. Furthermore, by providing the clearance space 127, the heat dissipation efficiency of the drive plate 2 can be improved, reducing the risk of performance degradation or failure due to overheating.

[0049] Please see Figure 1, Figure 6 and Figure 7 In one embodiment, the boss 125 is also provided with a plurality of limiting posts 1251, and the drive plate 2 is provided with a plurality of limiting holes 21. The limiting holes 21 correspond one-to-one with the limiting posts 1251, and the limiting posts 1251 pass through the limiting holes 21 to limit the drive plate 2.

[0050] In this embodiment, the boss 125 is also provided with a plurality of limiting posts 1251. The limiting posts 1251 can cooperate with the limiting holes 21 of the drive plate 2, so that when the drive plate 2 is placed on the boss 125, the limiting posts 1251 can pass through the limiting holes 21, thereby restricting the drive plate 2 from moving on the boss 125, so as to improve the stability of the assembly.

[0051] Optionally, two limiting posts 1251 are provided, and the two limiting posts 1251 are arranged opposite each other on both sides of the boss 125. This allows the drive plate 2 to be limited from both sides simultaneously, preventing the drive plate 2 from moving. It can be understood that three, four or more limiting posts 1251 can also be provided. In this case, multiple limiting posts 1251 are evenly distributed along the circumferential direction of the main body 122 to ensure the drive plate 2 is subjected to balanced forces and improve the stability during limiting.

[0052] Please see Figure 2 and Figure 6 In one embodiment, the main body 122 has a plurality of wire outlet holes 1221, all of which are connected to the receiving cavity 111 and are used for wiring of the stator assembly 3.

[0053] In this embodiment, the main body 122 also has a plurality of wire outlet holes 1221 for the stator assembly 3 to pass through. The number of wire outlet holes 1221 can be adaptively adjusted according to the number of wires in the stator assembly 3.

[0054] Please see Figure 2 and Figure 6 In one embodiment, the main body 122 is provided with a plurality of guide holes 1222, and the rear end cover 12 is further provided with a plurality of guide posts 126, each guide post 126 passing through a guide hole 1222, and each guide post 126 is provided with a wire outlet hole 1221.

[0055] In this embodiment, the main body 122 is provided with a plurality of guide posts 126, and the wire outlet hole 1221 is formed in the guide posts 126. At this time, the guide posts 126 can not only protect the wiring of the stator assembly 3 from interference from the external environment, but also gather the wiring together to avoid the wiring being randomly distributed in the receiving cavity 111, which would cause safety hazards.

[0056] Please see Figure 1 and Figure 7In one embodiment, the drive plate 2 is provided with clearance holes 22 corresponding to the wire outlet holes 1221, and the clearance holes 22 are used for the wiring of the stator assembly 3 to pass through.

[0057] In this embodiment, after the stator assembly 3 wire passes through the outlet hole 1221, it is connected to the drive board 2. Since the side of the drive board 2 facing the housing body is set on the boss 125, which is inconvenient for welding, a clearance hole 22 is also provided on the drive board 2. The clearance hole 22 is used for the stator assembly 3 wire to pass through, so that the stator assembly 3 wire is welded to the side of the drive board 2 facing away from the housing body.

[0058] Please see Figure 1 and Figure 7 In one embodiment, a plurality of welding areas 23 are formed on the side of the drive plate 2 facing away from the rear end cover 12, and each welding area 23 is disposed adjacent to an avoidance hole 22.

[0059] In this embodiment, each clearance hole 22 is arranged adjacent to a welding area 23 so that the wiring of the stator assembly 3 can be connected to the drive board 2 immediately after passing through the clearance hole 22, avoiding complex winding or additional wiring steps, reducing the complexity of wiring, and improving the neatness and aesthetics of the drive board 2.

[0060] Please see Figure 1 In one embodiment, the hollow cup type brushless sensorless motor 100 further includes a stator assembly 3 and a rotor assembly 4. The stator assembly 3 is disposed on the inner wall of the main body 11 of the housing, and the rotor assembly 4 is disposed inside the stator assembly 3. One end of the rotor assembly 4 is movably inserted through the opening 113, and the other end is movably inserted through the rear end cover 12.

[0061] In this embodiment, the stator assembly 3 includes a stator core 31 disposed on the inner wall of the housing body and a coil cup 32 disposed on the inner wall of the stator core 31. The coil cup 32 is electrically connected to the drive plate 2. The rotor assembly 4 includes a rotating shaft 41 and a magnetic ring 42. One end of the rotating shaft 41 is rotatably disposed at the through-hole 113, and the other end is rotatably disposed at the rear end cover 12. The magnetic ring 42 is sleeved on the rotating shaft 41 and corresponds to the coil cup 32. The drive plate 2 controls the change of current through the coil cup 32 to control the rotation of the rotor assembly 4. The structure of the stator assembly 3 and the rotor assembly 4 is quite common and will not be described in detail here.

[0062] The above description is merely an exemplary embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural transformations made based on the technical concept of the present utility model and the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A hollow cup brushless sensorless motor characterized by, The hollow cup type brushless sensorless motor comprises: A shell structure comprising a shell main body and a rear end cover, the shell main body is integrally formed and is formed with a receiving cavity, an opening and a through hole communicating with the receiving cavity; the rear end cover is arranged at the opening, and the side of the rear end cover away from the receiving cavity is provided with a mounting area; and A drive plate arranged in the mounting area.

2. The hollow cup brushless sensorless motor of claim 1, wherein, The rear end cover comprises a main body part and a protrusion arranged on the side wall of the main body part, the mounting area is arranged on the side of the main body part away from the receiving cavity, and part of the main body part is inserted into the receiving cavity, so that the side of the shell main body close to the opening abuts against the protrusion.

3. The hollow cup brushless sensorless motor of claim 2, wherein, The side wall of the main body part is further provided with a plurality of mounting grooves, the mounting grooves and the protrusions are arranged alternately along the circumferential direction of the main body part, the side of the shell main body close to the opening is formed with a plurality of limiting parts, each limiting part corresponds to a mounting groove, and the limiting part extends into the mounting groove to connect the shell main body and the main body part.

4. The hollow cup brushless sensorless motor of claim 2, wherein, The rear end cover further comprises a boss, the boss is arranged on the side of the main body part away from the receiving cavity, and the surface of the boss forms the mounting area.

5. The hollow cup brushless sensorless motor of claim 4, wherein, The boss is further provided with a plurality of limiting columns, the drive plate is provided with a plurality of limiting holes, the limiting holes correspond to the limiting columns one by one, the limiting columns are arranged in the limiting holes to limit the drive plate.

6. The hollow cup brushless sensorless motor of claim 2, wherein, The main body part is formed with a plurality of wire outlet holes, the plurality of wire outlet holes are in communication with the receiving cavity, and the plurality of wire outlet holes are used for the wiring of the stator assembly.

7. The hollow cup brushless sensorless motor of claim 6, wherein, The main body part is provided with a plurality of guide holes, and the rear end cover further comprises a plurality of guide columns, each guide column is arranged in a guide hole, and each guide column is provided with a wire outlet hole.

8. The hollow cup brushless sensorless motor of claim 7, wherein, The drive plate is provided with a plurality of avoiding holes corresponding to the wire outlet holes, and the avoiding holes are used for the wiring of the stator assembly.

9. The hollow cup brushless sensorless motor of claim 8, wherein, The side of the drive plate away from the rear end cover is formed with a plurality of welding areas, and each welding area is arranged adjacent to an avoiding hole.

10. The hollow cup brushless sensorless motor of any one of claims 1 to 9, wherein, The hollow cup type brushless sensorless motor further comprises a stator assembly and a rotor assembly, the stator assembly is arranged on the inner wall of the shell main body, the rotor assembly is arranged in the stator assembly, one end of the rotor assembly is movably arranged in the through hole, and the other end of the rotor assembly is movably arranged in the rear end cover.

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