Hall sensor mounting structure of brushless motor

Abstract

The utility model discloses a brushless motor Hall sensor installation structure, comprising a brushless motor body, a plurality of sensing assemblies and a clamping assembly, the brushless motor body comprises a stator and a rotor, the rotor is arranged at the periphery of the stator and can rotate around the stator, and in the stator, an accommodating groove is formed between each pair of adjacent windings; each sensing assembly comprises a Hall sensor and a fixing part, each fixing part is provided with a fixing end and a mounting end, the Hall sensors are mounted at the mounting ends, and the mounting ends are arranged in the containing grooves; the clamping and fixing assembly is fixedly arranged on one side of the stator and is clamped and matched with the fixing ends of the fixing pieces, so that the Hall sensor is fixed in the accommodating groove; according to the device, the accommodating groove naturally formed between the stator windings is used as an installation reference, so that the requirement of relying on an external mold for assembly is avoided, the installation error is reduced, the sensing assembly, the magnetic shielding shell and other components are integrated in the stator, the miniaturization of the structure is realized, and the space is saved.

Description

Technical Field

[0001] This utility model relates to the field of brushless motor technology, specifically to a Hall sensor mounting structure for a brushless motor. Background Technology

[0002] Brushless motors, due to their advantages such as high efficiency, low noise, and long lifespan, have been widely used in industrial automation, electric vehicles, and home appliances. As a core component of brushless motor commutation control, the installation location and fixing method of the Hall sensor directly affect the motor's operating performance and reliability.

[0003] In current technology, the installation of Hall sensors typically requires first fixing them to a circuit board, and then using a specially designed mold to assemble the circuit board with the Hall sensor onto the outside of the motor to ensure the stability of the Hall sensor's position. However, this method has several shortcomings:

[0004] 1. Large installation error: Since the machining and assembly accuracy of the mold directly affects the positional accuracy of the Hall sensor, this can easily lead to deviations in rotor position detection;

[0005] 2. Redundancy in size: The external mounting structure occupies extra space, which limits the development of motors towards miniaturization. Utility Model Content

[0006] The purpose of this invention is to overcome the above-mentioned technical deficiencies and propose a Hall sensor mounting structure for brushless motors, thereby solving the technical problems of large mounting errors and volume redundancy of Hall sensors in existing brushless motors.

[0007] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution:

[0008] This utility model provides a Hall sensor mounting structure for a brushless motor, comprising: a brushless motor body, several sensing components, and a locking assembly. The brushless motor body includes a stator and a rotor. The rotor is disposed around the stator and can rotate around the stator. In the stator, a receiving groove is formed between each pair of adjacent windings. Each of the several sensing components includes a Hall sensor and a fixing member. The fixing member has a fixing end and a mounting end. The Hall sensor is mounted on the mounting end, which is disposed in the receiving groove. The locking assembly is fixedly disposed on one side of the stator and engages with the fixing ends of the several fixing members to fix the Hall sensor in the receiving groove.

[0009] In some embodiments, the Hall sensor mounting structure of the brushless motor further includes a plurality of magnetic shielding shells, which are respectively disposed in a plurality of the receiving slots, and each magnetic shielding shell covers the outer periphery of the corresponding Hall sensor. The magnetic shielding shell has an opening on the side corresponding to the rotor, and the sensing end of the Hall sensor is disposed facing the opening to sense changes in the magnetic field of the rotor.

[0010] In some embodiments, the mounting end of the fastener includes a mounting inner shell, which is slidably disposed within the magnetic shielding outer shell. The mounting inner shell has a mounting groove, and the Hall sensor is disposed within the mounting groove.

[0011] In some embodiments, the two ends of the mounting groove extend through both sides of the mounting inner shell, and both ends of the mounting groove are provided with heat dissipation mesh.

[0012] In some embodiments, a gap is reserved between the heat dissipation mesh and the magnetic shielding shell, and support blocks are provided on both sides of the inner wall of the magnetic shielding shell, with the support blocks correspondingly abutting against the heat dissipation mesh.

[0013] In some embodiments, the sensing component further includes a heat sink, wherein the water inlet of the heat sink is disposed inside the magnetic shielding housing and between the magnetic shielding housing and the heat dissipation mesh, and its water outlet is disposed outside the magnetic shielding housing and communicates with the water inlet.

[0014] In some embodiments, the sensing component further includes a temperature sensor mounted on the mounting end of the fixture.

[0015] In some embodiments, the locking assembly includes a rotary positioning member and a rotation limiting member. The rotary positioning member is rotatably disposed on one side of the stator, and its rotational stroke has a first position and a second position. When the rotary positioning member is in the first position, it engages with the fixed ends of a plurality of the fixing members to fix the Hall sensor and the fixing members in the receiving groove. When the rotary positioning member rotates to the second position, it separates from the fixed ends of the plurality of fixing members. The rotation limiting member is disposed on one side of the rotary positioning member to restrict the rotation of the rotary positioning member.

[0016] In some embodiments, the rotary positioning component includes a turntable and a plurality of fixing blocks. The turntable has fixing slots at positions corresponding to the plurality of sensing components. The fixing blocks are fixedly disposed in the fixing slots. The fixing component has grooves at positions corresponding to the fixing blocks. When the rotary positioning component rotates to the first position, the fixing blocks are engaged in the grooves. When the rotary positioning component rotates to the second position, the fixing blocks are separated from the grooves.

[0017] In some embodiments, the rotation limiting member includes a fixed plate, a sliding groove, a slider, and a spring. The fixed plate is disposed on the inner side of the turntable and has a sliding groove thereon. The slider is slidably disposed in the sliding groove. One end of the spring is connected to the slider and the other end is connected to the inner wall of the sliding groove. A slot is provided on the turntable on the side corresponding to the slider. When the rotation positioning member is in the first working position, the sliding groove can be correspondingly locked in the slot to limit the rotation of the rotation positioning member.

[0018] Compared with existing technologies, the Hall sensor mounting structure for brushless motors provided by this utility model, by setting up the brushless motor body, sensing components, and locking components, and utilizing the naturally formed receiving grooves between the stator windings as the mounting reference, ensures the relative position of the Hall sensor and the stator magnetic field, thereby avoiding the need for assembly based on external molds and reducing installation errors. Simultaneously, components such as the sensing components and magnetic shielding shell are integrated inside the stator, achieving structural miniaturization and saving space. Furthermore, the snap-fit ​​design between the locking components and the fixed end ensures the stability and accuracy of multiple sensor installations. The sensing components adopt a detachable modular design, supporting independent installation and removal of individual sensors without the need for overall motor disassembly. The snap-fit ​​fixing achieves non-destructive installation and removal, reducing maintenance costs. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall front view cross-sectional structure of the Hall sensor mounting structure for the brushless motor provided in this embodiment of the utility model;

[0020] Figure 2 This is a side cross-sectional view of the Hall sensor mounting structure for a brushless motor provided in this embodiment of the utility model.

[0021] Figure 3 yes Figure 1 Enlarged view of point A in the middle;

[0022] Figure 4 This is a schematic diagram of the rotating positioning component of the Hall sensor mounting structure of the brushless motor provided in this embodiment of the present invention when it is in the first working position;

[0023] Figure 5This is a schematic diagram of the rotating positioning component of the Hall sensor mounting structure of the brushless motor provided in this embodiment of the present invention when it is in the second position;

[0024] Figure 6 yes Figure 4 Enlarged view of section B in the middle.

[0025] Explanation of reference numerals in the attached figures:

[0026] 1. Brushless motor body; 11. Stator; 12. Rotor; 13. Receiving slot; 14. Motor rear housing;

[0027] 2. Sensing components; 21. Hall sensor; 22. Fixing component; 221. Mounting housing; 2211. Mounting slot; 222. Heat dissipation mesh; 223. Groove; 224. Positioning block; 225. Support block;

[0028] 3. Locking assembly; 31. Rotary positioning component; 311. Turntable; 3111. Fixing groove; 3112. Locking groove; 312. Fixing block; 32. Rotation limit component; 321. Fixing disc; 322. Slide groove; 323. Slider; 324. Spring;

[0029] 4. Magnetic shielding shell; 5. Temperature sensor; 6. Heat sink. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0031] To address the technical issues of large installation errors and bulk redundancy of Hall sensors in brushless motors, this invention provides a Hall sensor installation structure for brushless motors. By utilizing the naturally formed receiving slots between the stator windings as the installation reference, the need for assembly using external molds is avoided, reducing installation errors. The sensing components and magnetic shielding shell are integrated inside the stator, achieving miniaturization and saving space.

[0032] Please see Figures 1 to 3The Hall sensor mounting structure for a brushless motor includes: a brushless motor body 1, several sensing components 2, and a locking component 3. The brushless motor body 1 includes a stator 11 and a rotor 12. The rotor 12 is disposed around the stator 11 and can rotate around the stator 11. In the stator 11, a receiving groove 13 is formed between each pair of adjacent windings. Each of the several sensing components 2 includes a Hall sensor 21 and a fixing member 22. The fixing member 22 has a fixing end and a mounting end. The Hall sensor 21 is mounted on the mounting end, which is disposed in the receiving groove 13. The locking component 3 is fixedly disposed on one side of the stator 11 and engages with the fixing ends of the several fixing members 22 to fix the Hall sensor 21 in the receiving groove 13.

[0033] In this device, the brushless motor body 1 rotates through the cooperation of the stator 11 and the rotor 12. Simultaneously, several Hall effect sensors 2 are installed in receiving slots 13 formed between the windings of the stator 11. The stability and accuracy of the Hall sensors 21 are ensured by the snap-fit ​​engagement of the fixing component 22 and the locking component 3. By directly installing the Hall sensors 21 into the receiving slots 13 inside the stator 11 of the brushless motor and fixing them with the locking component 3, the use of external molds for assembling the Hall sensors is avoided, reducing installation errors and improving positional accuracy. Furthermore, by integrating the sensing components 2 and the magnetic shielding housing 4 inside the stator 11, the structure is miniaturized, saving space.

[0034] To avoid interference from high-frequency magnetic fields, please refer to [link / reference]. Figure 3 In some possible embodiments, a magnetic shielding shell 4 is provided in the receiving slot 13 where the Hall sensor 21 needs to be installed, for magnetically shielding the Hall sensor 21. The magnetic shielding shell 4 is fixed to the stator 11, and each magnetic shielding shell 4 covers the outer periphery of the corresponding Hall sensor 21 and the fixing member 22. The magnetic shielding shell 4 is designed with an opening on the side corresponding to the rotor 12 so that the magnetic field can pass through without obstruction. The sensing end of the Hall sensor 21 is positioned opposite the opening so that it can capture the changes in the magnetic field generated by the rotor 12 when it rotates. This ensures that the sensor can sensitively detect small changes in the magnetic field, thereby accurately monitoring and controlling the position and speed of the rotor 12.

[0035] It should be noted that you should refer to [link / reference]. Figure 2The brushless motor body 1 also has a motor rear housing 14, which is fixedly connected to the stator 11. The motor rear housing 14 is also provided with heat dissipation holes or heat sinks to effectively dissipate the heat generated by the generator during operation. This helps prevent the motor from overheating and ensures that it is always in optimal operating condition. In addition, the motor rear housing 14 is also equipped with terminals or connectors for easy connection to an external power supply or control system.

[0036] Specifically, please refer to Figure 2 and Figure 3 In one embodiment, the mounting end of the fixing member 22 includes a mounting inner shell 221, and its fixing end is a positioning block 224. The mounting inner shell 221 extends into the magnetic shielding outer shell 4 through the opening of the motor rear shell 14 and is slidably connected to the magnetic shielding outer shell 4. The mounting inner shell 221 is provided with a mounting groove 2211, and the Hall sensor 21 is installed in the mounting groove 2211.

[0037] To further improve the performance of the brushless motor, please refer to [link / reference]. Figure 2 and Figure 3 In some possible embodiments, a temperature sensor 5 is added within the mounting slot 2211 for mounting the Hall sensor 21 to monitor temperature changes inside the stator 11 in real time. Simultaneously, a heat dissipation structure is added. Specifically, both ends of the mounting slot 2211 extend through both sides of the inner mounting shell 221, and each end is equipped with a heat dissipation mesh 222. A certain space is reserved between the heat dissipation mesh 222 and the magnetic shielding shell 4 to ensure a gap between them, effectively preventing unnecessary friction or heat transfer caused by direct contact. Furthermore, support blocks 225 are fixedly installed on both sides of the inner wall of the magnetic shielding shell 4. The support blocks 225 correspond to and abut against the heat dissipation mesh 222, providing additional support and stability, thereby further enhancing the structural strength and heat dissipation efficiency of the entire device.

[0038] Furthermore, heat dissipation pipes 6 are installed on both the inner and outer sides of the magnetic shielding shell 4. The water inlet of the heat dissipation pipe 6 is located inside the magnetic shielding shell 4, between the magnetic shielding shell 4 and the heat dissipation mesh 222, while its water outlet is located outside the magnetic shielding shell 4 and connected to the water inlet. The water inlet of the heat dissipation pipe 6 is connected to an external cooling system. Coolant in the cooling system enters the heat dissipation pipe 6 through the water inlet, flows inside the heat dissipation pipe 6 and absorbs heat from the magnetic shielding shell 4 and the heat dissipation mesh 222, and then flows out from the water outlet, carrying away the heat. This achieves effective heat dissipation for the stator 11 and the Hall sensor 21.

[0039] To fix sensor component 2, please refer to... Figure 1 , Figure 4 and Figure 5In this embodiment, the locking assembly 3 includes a rotary positioning member 31 and a rotation limiting member 32. The rotary positioning member 31 is rotatably disposed on one side of the stator 11, and its rotation stroke has a first position and a second position. When the rotary positioning member 31 is in the first position, it engages with the fixed ends of several fixing members 22 to fix the Hall sensor 21 and the fixing members 22 in the receiving groove 13. At this time, the Hall sensor 21 can accurately capture the magnetic field changes generated when the rotor 12 rotates. When the rotary positioning member 31 rotates to the second position, it separates from the fixed ends of several fixing members 22. At this time, the Hall sensor 21 and the fixing members 22 can be easily disassembled or installed to facilitate maintenance of the brushless motor or replacement of the sensing assembly 2. The rotation limiting member 32 is disposed on one side of the rotary positioning member 31 to limit the rotation of the rotary positioning member 31.

[0040] In one embodiment, please refer to Figure 1 , Figure 4 and Figure 5 The rotary positioning component 31 includes a turntable 311 and several fixing blocks 312. The turntable 311 is rotatably mounted on the outside of the motor rear housing 14, and fixing grooves 3111 are provided at positions corresponding to several mounting inner housings 221. The fixing blocks 312 are fixedly mounted on one inner wall of the fixing grooves 3111. The fixing component 22 has grooves 223 at positions corresponding to the fixing blocks 312 for engaging with the fixing blocks 312 to achieve snap-fit ​​fixation. When the turntable 311 rotates to the first position, the fixing blocks 312 snap into the grooves 223 of the fixing components 22, thereby firmly fixing the Hall sensor 21 and the fixing components 22 in the receiving groove 13. When the rotary positioning component 31 rotates to the second position, the fixing blocks 312 separate from the grooves 223 of the fixing components 22, at which point the Hall sensor 21 and the fixing components 22 can be easily disassembled or installed.

[0041] To ensure that the turntable 311 can be fixed in place when it rotates to the first position, please refer to [link / reference needed]. Figure 1 , Figures 4 to 6This ensures that the Hall sensor 21 and the fixing member 22 will not loosen or shift due to vibration or external force when the turntable 311 is in operation. In some possible embodiments, the rotation limiting member 32 includes a fixed plate 321, a slide groove 322, a slider 323, and a spring 324. The fixed plate 321 is located on the inner side of the turntable 311 and is fixedly connected to the motor rear housing 14 so that the turntable 311 can rotate on the outer side of the fixed plate 321. A slide groove 322 is formed on the top surface of the fixed plate 321. The slider 323 is slidably disposed in the slide groove 322. One end of the spring 324 is connected to the slider 323, and the other end is connected to the inner wall of the slide groove 322. The elastic force of the spring 324 allows the slider 323 to slide in the slide groove 322. The inner edge of the turntable 311 is provided with a slot 3112. When the turntable 311 rotates to the first position, the slot 3112 corresponds to the position of the slider 323. Under the action of the spring 324, the slider 323 is engaged in the slot 3112, thereby fixing the turntable 311. When it is necessary to rotate the turntable 311 to the second position, the slider 323 can be manually pushed to compress the spring 324 and drive the slider 323 to slide out of the slot 3112, at which point the turntable 311 can be rotated.

[0042] It should be noted that in this design, multiple sets of sensing components 2 are used, each set corresponding to a receiving slot 13 and a fixing slot 3111, and are evenly distributed around the stator 11 of the brushless motor. This not only improves the comprehensiveness and accuracy of magnetic field detection but also ensures the stability and reliability of the brushless motor during rotation. The arrangement of multiple sets of sensing components 2 enables the brushless motor to better sense changes in the position and speed of the rotor 12, thereby achieving precise control of the motor's operating state.

[0043] Working Principle: After the brushless motor starts, the rotor 12 begins to rotate under the influence of the magnetic field generated by the windings of the stator 11. As the rotor 12 rotates, the changes in its magnetic field are captured by the Hall sensor 21. The Hall sensor 21 converts the captured magnetic field changes into electrical signals, which, after processing, can be used to control the speed and position of the brushless motor. When disassembling or maintaining the Hall sensor 21, the slider 323 can be manually pushed, causing the compression spring 324 to drive the slider 323 out of the slot 3112. Then, the turntable 311 is rotated to the second position. At this time, the fixing block 312 separates from the groove 223 of the fixing member 22, allowing for easy disassembly or replacement. After the work is completed, the turntable 311 is rotated back to the first position, and the slider 323 is re-engaged into the slot 3112 by the action of the spring 324, thus fixing the turntable 311. In this way, the Hall sensor 21 and the fixing member 22 can be firmly fixed in the receiving groove 13 again, ensuring that the brushless motor can continue to work normally.

[0044] This invention, by setting up a brushless motor body 1, a sensing component 2, and a locking component 3, and utilizing the naturally formed receiving groove 13 between the stator windings 11 as an installation reference, ensures the precise relative position of the Hall sensor 21 and the magnetic field of the stator 11, thereby avoiding the need for assembly using external molds and reducing installation errors. Simultaneously, components such as the sensing component 2 and the magnetic shielding shell 4 are integrated inside the stator 11, achieving structural miniaturization and saving space. Furthermore, the snap-fit ​​design of the locking component 3 with the fixed end ensures the stability and accuracy of installing multiple sensors. The sensing component 2 adopts a detachable modular design, supporting independent installation and removal of individual sensors without the need for complete motor disassembly. The snap-fit ​​fixing achieves non-destructive installation and removal, reducing maintenance costs.

[0045] In the description of this application, it should be noted that the terms "upper" and "lower," etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, 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, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0046] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0047] The specific embodiments of this utility model described above do not constitute a limitation on the scope of protection of this utility model. Any other corresponding changes and modifications made based on the technical concept of this utility model should be included within the scope of protection of the claims of this utility model.

Claims

1. A Hall sensor mounting structure of a brushless motor, characterized by comprising: The application relates to a Hall sensor mounting structure of a brushless motor. The brushless motor body comprises a stator and a rotor, the rotor is arranged on the side of the stator and can rotate around the stator, and a containing groove is formed between each pair of adjacent windings in the stator. The Hall sensor mounting structure further comprises a plurality of magnetic shielding shells, each of which is arranged in the containing groove, and each of the magnetic shielding shells covers the outer periphery of the corresponding Hall sensor. The mounting end of the fixing member comprises a mounting inner shell which is slidingly arranged in the magnetic shielding shell.

2. The Hall sensor mounting structure for a brushless motor according to claim 1, characterized by, The two ends of the mounting groove penetrate through the two sides of the mounting inner shell, and the two ends of the mounting groove are provided with heat dissipation nets.

3. The Hall sensor mounting structure for a brushless motor according to claim 2, characterized by The heat dissipation nets and the magnetic shielding shells are provided with gaps, and the inner walls of the magnetic shielding shells are provided with supporting blocks which are in abutting engagement with the heat dissipation nets.

4. The Hall sensor mounting structure for a brushless motor according to claim 3, characterized by The sensing assembly further comprises a temperature sensor which is mounted on the mounting end of the fixing member.

5. The Hall sensor mounting structure for a brushless motor according to claim 4, characterized by The clamping assembly comprises a rotating positioning member and a rotating limiting member, the rotating positioning member is rotatably arranged on one side of the stator, the rotating stroke of the rotating positioning member has a first station and a second station, when the rotating positioning member is in the first station, the rotating positioning member is in clamping engagement with the fixing end of the fixing member, so that the Hall sensor and the fixing member are fixed in the containing groove, when the rotating positioning member rotates to the second station, the rotating positioning member is separated from the fixing end of the fixing member.

6. The Hall sensor mounting structure for a brushless motor according to claim 5, characterized by The rotating limiting member is arranged on one side of the rotating positioning member and is used for limiting the rotation of the rotating positioning member.

7. The Hall sensor mounting structure for a brushless motor according to claim 1, characterized by The rotating positioning member comprises a rotating disc and a plurality of fixing blocks, the rotating disc is provided with a fixing groove at a position corresponding to the sensing assembly, the fixing block is fixedly arranged in the fixing groove, the fixing member is provided with a recess at a position corresponding to the fixing block, when the rotating positioning member rotates to the first station, the fixing block is clamped in the recess, and when the rotating positioning member rotates to the second station, the fixing block is separated from the recess.

8. The Hall sensor mounting structure for a brushless motor according to claim 1, characterized by ​ ​ 9. The Hall sensor mounting structure for a brushless motor according to claim 8, characterized by ​ 10. The Hall sensor mounting structure for a brushless motor according to claim 9, characterized by The rotation limiting piece comprises a fixed disc, a sliding slot, a sliding block and a spring, the fixed disc is arranged on the inner side of the rotating disc, the sliding slot is arranged on the fixed disc, the sliding block is slidingly arranged in the sliding slot, one end of the spring is connected with the sliding block, and the other end of the spring is connected with the inner wall of the sliding slot, a clamping slot is arranged on the rotating disc corresponding to one side of the sliding block, when the rotation limiting piece is in the first station, the sliding slot can be clamped in the clamping slot, so as to limit the rotation of the rotation limiting piece.

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