Motor rotor and brushless motor

Abstract

The utility model discloses a motor rotor and a brushless motor, which are movably embedded in a stator assembly and located between the stator assembly and a rear end cover assembly. The motor rotor comprises a rotor end cover which is far away from one side of the rear end cover assembly, a magnetic shoe assembly, a magnetic ring seat and a magnetic ring piece which are sequentially arranged on one side, close to the rear end cover assembly, of the rotor end cover, a rotor iron core embedded in an inner groove of the magnetic shoe assembly, and a rotating shaft embedded in the inner side of the rotor iron core, and the magnetic ring piece is formed by enclosing at least four split magnetic rings; the sensor is embedded in the side, close to the rotor assembly, of the rear end cover assembly, the split magnetic rings are arranged close to the sensor, the machining mode that the split magnetic rings are formed one by one in a breaking mode is adopted, then the four machined and formed split magnetic rings are annularly arranged in a staggered mode, and in the process, the operation of machining protruding points on the surfaces of traditional integrated magnetic rings is not needed any more. And the processing technology of the magnetic ring is simplified under the condition that the original effect of the magnetic ring is ensured.

Description

Technical Field

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

[0002] A brushless motor (BLDC motor) is a drive device that converts electrical energy into mechanical energy. Also known as a brushless DC motor, its working principle primarily relies on an electronic commutator for commutation, eliminating the need for carbon brushes and a commutator, thus avoiding frictional losses, spark interference, and maintenance costs. Specifically, when the stator windings are energized, a rotating magnetic field is generated. This magnetic field attracts the rotor's permanent magnets, causing them to rotate and thus initiating motor operation. When a position sensor detects a change in rotor position, it triggers the electronic commutator to change the current direction, ensuring the magnetic field follows the rotor and guarantees continuous and stable motor operation.

[0003] Brushless motors are divided into sensorless and sensored types. Sensorless brushless motors require the rotor to rotate to determine its position, which can cause vibration during startup and make them difficult to control at low speeds. Sensored brushless motors, on the other hand, use sensors to detect the rotor's state and position. Upon startup, they can clearly determine the rotor's magnetic pole orientation and directly supply the corresponding current to the corresponding coils to drive the rotor, resulting in strong speed stability. Sensored brushless motors use a magnetic ring (a ring magnet with N and S poles) and a sensor to monitor the rotor's position. The magnetic ring is mounted on the rotor and rotates synchronously with it, while the sensor is parallel to the magnetic ring and mounted on a fixed part.

[0004] Currently, the magnetic ring design on brushless motor rotors is usually a one-piece molding design. In the one-piece molding magnetic ring design, positioning protrusions need to be added to the magnetic ring for auxiliary positioning of the rotor. However, due to the fragile structural characteristics of the magnetic ring itself, and the need to ensure its magnetic field balance when adding protrusions, it is quite troublesome to add protrusions to its surface and the magnetic ring is prone to breakage during the addition process, making the process quite difficult. Utility Model Content

[0005] Based on this, the purpose of this utility model is to provide a motor rotor and a brushless motor, which aims to solve the problem that the process of adding protrusions to the magnetic ring is currently quite difficult.

[0006] The present invention discloses a motor rotor, which is movably embedded in a stator assembly and located between the stator assembly and the rear end cover assembly. The motor rotor includes a rotor end cover on the side away from the rear end cover assembly, a magnetic tile assembly, a magnetic ring seat and a magnetic ring component arranged sequentially on the side of the rotor end cover near the rear end cover assembly, a rotor core embedded in the inner slot of the magnetic tile assembly, and a rotating shaft embedded in the inner side of the rotor core.

[0007] The magnetic ring component is composed of at least four separate magnetic rings. The rear end cover assembly has a sensor embedded on the side closer to the rotor assembly, and the separate magnetic rings are positioned close to the sensor.

[0008] The above describes a process using a modular magnetic ring, where four modular magnetic rings are formed piece by piece. These four rings are then arranged in an alternating ring pattern. This eliminates the need for machining protrusions on the surface of traditional one-piece magnetic rings, preventing damage or breakage of the one-piece ring during manufacturing. This significantly reduces the difficulty of the manufacturing process. Understandably, this simplifies the manufacturing process while maintaining the original function of the magnetic ring. Furthermore, the magnetic poles of the modular magnetic rings correspond to the magnetic poles of the magnetic tile assembly, improving the sensor's sensing accuracy of the magnetic tile assembly. This solves the problem of the significant difficulty in adding protrusions to the magnetic ring.

[0009] In addition, the motor rotor proposed according to the embodiments of this utility model may also have the following additional technical features:

[0010] Furthermore, the rotor core includes an outer cylindrical surface that contacts the inner side of the magnetic tile assembly, at least four first protrusions extending along the outer cylindrical surface toward the magnetic tile assembly, a through hole penetrating the center of the outer cylindrical surface, and an unloading groove disposed in the through hole for connecting the rotating shaft.

[0011] Furthermore, the magnetic tile assembly includes at least four magnetic tiles arranged in a ring, and an inner wall surface disposed inside the magnetic tiles and in contact with the outer cylindrical surface.

[0012] Furthermore, the magnetic ring seat includes a second rotor end cover disposed on the side of the magnetic tile assembly away from the rotor end cover, and a magnetic ring receiving cover disposed on the side near the rear end cover assembly.

[0013] Furthermore, the second rotor end cover includes a second groove for accommodating the axial end face of the rotor core, and at least four second protrusions extending outward along the periphery of the second groove, the second protrusions being embedded in the outer periphery of at least four of the magnetic tiles.

[0014] Furthermore, the magnetic ring receiving cover and the rear end cover assembly are axially abutted together. The magnetic ring receiving cover has a first intermediate through hole for receiving the rotating shaft at its center, a first groove embedded in the magnetic ring receiving cover and located around the first intermediate through hole, and an arc-shaped groove embedded in the magnetic ring receiving cover and located around the first groove for receiving at least four of the separate magnetic rings.

[0015] Furthermore, the rotor end cover includes a fourth groove for accommodating the rotor core, a second intermediate through hole penetrating the center of the rotor end cover for accommodating the rotating shaft, and a third groove formed on the side of the rotor end cover away from the fourth groove.

[0016] In addition, this utility model also provides a brushless motor, including a motor rotor disposed on the brushless motor. Attached Figure Description

[0017] Figure 1 This is an exploded structural diagram of a brushless motor proposed in an embodiment of this utility model;

[0018] Figure 2 This is a partial structural diagram of a motor rotor proposed in an embodiment of the present utility model;

[0019] Figure 3 This is a partial exploded structural diagram of a motor rotor proposed in an embodiment of this utility model;

[0020] Figure 4 This is a partial structural diagram of the rotor core in a motor rotor according to an embodiment of the present invention;

[0021] Figure 5 This is a partial structural schematic diagram of a magnetic tile assembly in a motor rotor according to an embodiment of the present utility model;

[0022] Figure 6 This is a schematic diagram of one side of the magnetic ring seat in a motor rotor according to an embodiment of the present utility model.

[0023] Figure 7 This is a schematic diagram of the other side of the magnetic ring seat in a motor rotor according to an embodiment of the present invention;

[0024] Figure 8 This is a schematic diagram of one side of the rotor end cover in an embodiment of the present invention.

[0025] Figure 9 This is a schematic diagram of the other side of the rotor end cover in an embodiment of the present utility model.

[0026] Figure 10 This is a partial structural diagram of a split magnetic ring in a motor rotor proposed in an embodiment of this utility model.

[0027] Explanation of key component symbols:

[0028]

[0029] The following detailed description, in conjunction with the accompanying drawings, will further illustrate this utility model. Detailed Implementation

[0030] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Several embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this utility model will be more thorough and complete.

[0031] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0032] 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 invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0033] Please see Figures 1 to 10 The image shows a motor rotor in an embodiment of this utility model. It is movably embedded in the stator assembly 1000 and located between the stator assembly 1000 and the rear end cover assembly 3000. The motor rotor includes a rotor end cover 2400 on the side away from the rear end cover assembly 3000, a magnetic tile assembly 2200, a magnetic ring seat 2300 and a magnetic ring component 2600 arranged sequentially on the side of the rotor end cover 2400 near the rear end cover assembly 3000, a rotor core 2100 embedded in the inner groove of the magnetic tile assembly 2200, and a rotating shaft 2500 embedded inside the rotor core 2100. The magnetic ring component 2600 is composed of at least four separate magnetic rings 2610. A sensor 3100 is embedded on the side of the rear end cover assembly 3000 near the rotor assembly 2000 to detect abnormal magnetic fields generated by the separate magnetic rings 2610 during rotation, thereby achieving the positioning of the rotor assembly 2000. The separate magnetic rings 2610 are positioned close to the sensor 3100.

[0034] Further, the rotor core 2100 includes an outer cylindrical surface 2140 that contacts the inner side of the magnetic tile assembly 2200, at least four first protrusions 2110 extending along the outer cylindrical surface 2140 toward the magnetic tile assembly 2200, a through hole 2120 penetrating the center of the outer cylindrical surface 2140, and an unloading groove 2130 disposed in the through hole 2120 for connecting the rotating shaft 2500. The magnetic tile assembly 2200 includes at least four magnetic tiles 2210 arranged in a ring, and an inner wall surface 2211 disposed inside the magnetic tiles 2210 and in contact with the outer cylindrical surface 2140. The magnetic ring seat 2300 includes a second rotor end cover disposed on the side of the magnetic tile assembly 2200 away from the rotor end cover 2400, and a magnetic ring receiving cover disposed on the side near the rear end cover assembly 3000. The second rotor end cover includes a second groove 2350 for receiving the axial end face of the rotor core 2100, and a groove 2350 extending along the outer cylindrical surface 2140. At least four second protrusions 2330 extend outward from the edge of the second groove 2350. The second protrusions 2330 are embedded in the outer edge of at least four magnetic tiles 2210. The magnetic ring receiving cover and the rear cover assembly are axially abutted. The magnetic ring receiving cover has a first intermediate through hole 2310 for receiving the rotating shaft 2500, a first groove 2340 embedded in the magnetic ring receiving cover and located around the first intermediate through hole 2310, and an arc-shaped groove 2320 embedded in the magnetic ring receiving cover and located around the first groove 2340 for receiving at least four separate magnetic rings 2610. The rotor end cover 2400 includes a fourth groove 2430 for receiving the rotor core 2100, a second intermediate through hole 2410 penetrating the center of the rotor end cover 2400 for receiving the rotating shaft 2500, and a third groove 2420 opened on the side of the rotor end cover 2400 away from the fourth groove 2430.

[0035] In practical implementation, this application mainly divides the sensor-driven brushless motor into three parts: stator assembly 1000, rotor assembly 2000, and rear end cover assembly 3000. The stator core is installed inside the stator assembly 1000; the sensor 3100 is fixed to the rear end cover assembly 3000 and faces the rotor assembly 2000, parallel to the magnetic ring component 2600. The rotor assembly 2000 mainly consists of a rotor core 2100, a magnetic tile assembly 2200, a magnetic ring seat 2300, a rotor end cover 2400, a shaft 2500, and a separate magnetic ring 2600. The rotor core 2100 has four first protrusions 2110 on its outer cylindrical surface 2140, which are at the same height as the rotor core 2100. These first protrusions 2110 are evenly distributed along the generatrix of the outer cylindrical surface 2140. The rotor core 2100 has a through hole 2120 at its center, which can be press-fitted to the shaft 2500. Several unloading grooves 2130 are formed on the side of the through hole 2120 to prevent the rotor core 2100 from being damaged when the shaft 2500 is pressed into it, thus providing adequate deformation space. The magnetic tile assembly 2200 consists of four magnetic tiles 2210, the number of which is equal to the number of the first protrusions 2110. The length of each magnetic tile 2210 is equal to the height of the first protrusions 2110. The magnetic tiles 2210 have N / S pole magnetism. The magnetic poles alternate, with the magnetic poles pointing radially. The inner wall 2211 of the magnetic tile 2210 is in close contact with the outer cylindrical surface 2140 of the rotor core 2100 and is connected by adhesive. The magnetic ring seat 2300 has a central through hole 2310, which is in an interference fit with the rotating shaft 2500. One end of the magnetic ring seat 2300 has several circumferentially distributed arc-shaped grooves 2320 for installing the split magnetic ring 2600 and fixing it by adhesive. There is a first groove 2340 for weight-adding dynamic balance. The other end of the magnetic ring seat 2300 has four circumferentially distributed second protrusions 2330, which correspond one-to-one with the first protrusions 2110. The second groove 2350 is used to store the adhesive used to fix the magnetic ring seat 2300 and the rotor core 2100.

[0036] Furthermore, the rotor end cover 2400 has a central through hole 2410, which is interference-fitted with the rotating shaft 2500; one end of the rotor end cover 2400 has a third groove 2420 for weight-adding dynamic balancing. During operation, the operator can add a counterweight block that matches the third groove 2420 to increase the weight and ensure the stable output of the rotor assembly 2000; the other end of the rotor end cover 2400 has a fourth groove 2430 for storing the adhesive used to fix the rotor end cover 2400 and the rotor core 2100.

[0037] Furthermore, the surface of the rotating shaft 2500 has four third protrusions 2510. It should be noted that the third protrusions 2510 are made using a rib-making process, which is understandable to those skilled in the art. These third protrusions 2510 make the connection between the rotating shaft 2500 and the rotor core 2100, the magnetic ring seat 2300, and the rotor end cover 2400 more reliable. It is understood that they are used to fill the connection gaps and improve the stability of the connection between the structures. The magnetic ring component 2600 consists of four separate magnetic rings 2610, which are arranged in a ring with alternating N and S poles. The magnetization direction is the axial direction of the rotor assembly 2000. It should be noted that the purpose of using four separate magnetic rings 2610 in this application is that, compared to traditional integrated magnetic rings, the processing technology of the separate magnetic rings 2610 is simpler. Only one separate magnetic ring 2610 needs to be processed, and then the four processed separate magnetic rings 2610 are arranged in an alternating ring. This eliminates the need for machining protrusions on the surface of traditional integrated magnetic rings, avoiding the need for such processing. The damage or breakage of the integrated magnetic ring during processing greatly reduces the difficulty of the production process. Understandably, the processing of the magnetic ring is simplified while ensuring its original function. Moreover, the magnetic poles of the split magnetic ring 2610 correspond to the magnetic poles of the magnetic tile 2210, which can improve the sensing accuracy of the sensor 3100 for the magnetic tile 2210. In some optional embodiments, a layer of Kevlar aramid sewing thread can be wrapped around the outer surface of the magnetic tile assembly 2200 of the rotor assembly 2000 and fixed by adhesive. This can ensure that the magnetic tile 2210 will not be thrown out by centrifugal force when the motor is running at high speed.

[0038] In summary, by using the split magnetic ring 2610, which is manufactured piecemeal, the four split magnetic rings 2610 are then arranged in an alternating ring pattern. This eliminates the need for machining protrusions on the surface of the traditional one-piece magnetic ring, avoiding damage or breakage of the one-piece magnetic ring during manufacturing. This significantly reduces the difficulty of the manufacturing process. Understandably, the manufacturing process of the magnetic ring is simplified while maintaining its original function. Furthermore, the magnetic poles of the split magnetic ring 2610 correspond to the magnetic poles of the magnetic tile assembly 2200, which can improve the sensing accuracy of the sensor 3100 for the magnetic tile assembly 2200. This solves the problem of the high difficulty of adding protrusions to the magnetic ring.

[0039] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0040] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A motor rotor, movably embedded within a stator assembly and located between the stator assembly and a rear end cover assembly, characterized in that, The motor rotor includes a rotor end cover on the side away from the rear end cover assembly, a magnetic tile assembly, a magnetic ring seat and a magnetic ring piece arranged sequentially on the side of the rotor end cover near the rear end cover assembly, a rotor core embedded in the inner slot of the magnetic tile assembly, and a rotating shaft embedded in the inner side of the rotor core. The magnetic ring component is composed of at least four separate magnetic rings. The rear end cover assembly has a sensor embedded on the side closer to the rotor assembly, and the separate magnetic rings are positioned close to the sensor.

2. The motor rotor according to claim 1, characterized in that, The rotor core includes an outer cylindrical surface that contacts the inner side of the magnetic tile assembly, at least four first protrusions extending along the outer cylindrical surface toward the magnetic tile assembly, a through hole penetrating the center of the outer cylindrical surface, and an unloading groove disposed in the through hole for connecting the rotating shaft.

3. The motor rotor according to claim 2, characterized in that, The magnetic tile assembly includes at least four magnetic tiles arranged in a ring, and an inner wall surface disposed inside the magnetic tiles and in contact with the outer cylindrical surface.

4. The motor rotor according to claim 3, characterized in that, The magnetic ring seat includes a second rotor end cover disposed on the side of the magnetic tile assembly away from the rotor end cover, and a magnetic ring receiving cover disposed on the side of the rear end cover assembly.

5. The motor rotor according to claim 4, characterized in that, The second rotor end cover includes a second groove for accommodating the axial end face of the rotor core, and at least four second protrusions extending outward along the periphery of the second groove, the second protrusions being embedded in the outer periphery of at least four of the magnetic tiles.

6. The motor rotor according to claim 5, characterized in that, The magnetic ring receiving cover abuts axially with the rear end cover assembly. The magnetic ring receiving cover has a first intermediate through hole for receiving the rotating shaft at its center, a first groove embedded in the magnetic ring receiving cover and located around the first intermediate through hole, and an arc-shaped groove embedded in the magnetic ring receiving cover and located around the first groove for receiving at least four of the split magnetic rings.

7. The motor rotor according to claim 6, characterized in that, The rotor end cover includes a fourth groove for accommodating the rotor core, a second intermediate through hole penetrating the center of the rotor end cover for accommodating the rotating shaft, and a third groove formed on the side of the rotor end cover away from the fourth groove.

8. A brushless motor, characterized in that: The motor rotor, as claimed in any one of claims 1 to 7, is disposed on the brushless motor.

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