A brushless motor assembly structure

Abstract

This utility model discloses a brushless motor assembly structure. It includes: a rotor assembly, comprising a shaft, from which a bearing, a balance ring, a magnetic ring, a flange bearing, and a moving impeller are sequentially fitted and fixed; and a stator housing, which has rotor assembly holes matching the rotor assembly. The rotor assembly is dynamically balanced before being inserted into the rotor assembly holes. The magnetic ring, balance ring, and bearing are all located inside the stator housing. After the rotor assembly is assembled with the stator housing, the magnetic ring is magnetized. The flange bearing is installed at the rotor assembly hole, and a positioning mechanism is provided between them. The moving impeller is located outside the stator housing. Both ends of the shaft are connected to the stator housing via bearings and flange bearings, respectively. The advantages of this utility model are: low noise, long service life, and convenient assembly.

Description

Technical Field

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

[0002] A brushless DC motor (BLDC) is a type of DC motor that uses electronic commutation technology to replace traditional mechanical brushes. Its core feature is that no physical contact parts are required during the conversion of electrical energy into mechanical energy, thereby significantly improving performance and reliability.

[0003] The following defects exist in the assembly and manufacturing of existing brushless motors: 1. In the assembly of traditional motors, the rotor is assembled first, then the impeller is pressed in and dynamic balancing is performed. After assembly, the accumulated parts result in a large dynamic imbalance of the motor, which leads to greater vibration and noise, resulting in a poor user experience. Furthermore, the vibration reduces the lifespan of the bearings, and assembly is cumbersome and repairs are inconvenient; 2. Current processes often use magnetization before assembly. After magnetization, the rotor attracts iron filings due to magnetic force or interferes with the stator, making assembly difficult, and the magnetic ring is easily scratched.

[0004] In summary, there is a current need for a brushless motor assembly structure that is low in noise, has a long service life, and is easy to assemble. Utility Model Content

[0005] The present invention aims to overcome the shortcomings of the prior art and provide a brushless motor assembly structure that features low noise, long service life, and convenient assembly.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A brushless motor assembly structure, comprising:

[0008] A rotor assembly, comprising a shaft, wherein a bearing, a balance ring, a magnetic ring, a flange bearing, and a moving impeller are sequentially sleeved and fixed from one end to the other on the shaft.

[0009] The stator housing has rotor assembly holes that match the rotor assembly. After the rotor assembly is dynamically balanced, it is inserted into the rotor assembly holes. The magnetic ring, balance ring, and bearing are all located inside the stator housing. The magnetic ring is magnetized after the rotor assembly is assembled with the stator housing. The flange bearing is installed at the rotor assembly hole and a positioning mechanism is provided between them. The moving impeller is located outside the stator housing. The two ends of the rotating shaft are connected to the stator housing through bearings and flange bearings, respectively.

[0010] During assembly, the bearings, balance rings, magnetic rings, flange bearings, and moving impeller are sequentially installed onto the shaft, fixing them into a single rotor assembly. The assembled rotor assembly is then dynamically balanced before being inserted into the stator housing through the rotor mounting holes. Dynamic balancing eliminates imbalances in all moving parts, extending bearing life and reducing motor vibration and noise. The design of mounting the moving impeller onto the rotor first allows for dynamic balancing of all rotating parts within the motor that could affect dynamic balance. Magnetizing the magnetic ring after assembling the rotor assembly with the stator housing ensures stable, vertical insertion of the rotor assembly. This effectively prevents the magnetic ring from attracting iron filings that could interfere with the stator, and avoids assembly difficulties caused by magnetism. This significantly reduces assembly difficulty and damage to the magnetic ring, making assembly more convenient.

[0011] Preferably, the bearing and balance ring are fitted onto one end of the rotating shaft and both are interference-fitted with the shaft; the magnetic ring is fitted onto the middle of the rotating shaft and is bonded and fixed to the shaft; the flange bearing and impeller are fitted onto the other end of the rotating shaft and both are interference-fitted with the shaft. This provides good fixing effect and high connection strength.

[0012] Preferably, the positioning mechanism includes a limiting step fixed to the outside of the flange bearing, and a limiting groove matching the limiting step is provided on the outer surface of the end cover. The rotor assembly hole is located on the bottom surface of the limiting groove, and the limiting step is placed in the limiting groove and the two are bonded to each other. During the insertion of the rotor assembly into the rotor assembly hole, the rotor assembly is positioned by the limiting step on the flange bearing and the limiting groove on the stator housing, and is bonded with adhesive. This results in higher assembly efficiency, longer motor stability and lifespan, and a lower scrap rate for parts.

[0013] Preferably, the stator housing includes an end cover, a stator assembly, and a bracket. The rotor assembly hole is provided on the end cover, the limiting groove is located on the lower end face of the end cover, the upper end face of the end cover is provided with a stator limiting lower groove that matches the lower end of the stator assembly, and the lower end of the stator assembly is inserted into the stator limiting lower groove. The lower end face of the bracket is provided with a stator limiting upper groove that matches the upper end of the stator assembly, and the upper end of the stator assembly is inserted into the stator limiting upper groove. The rotor assembly is inserted into the inner side of the stator assembly. The bracket is also provided with a bearing mounting groove that matches the bearing, and the bearing is placed in the bearing mounting groove. During installation, first insert the lower end of the stator assembly into the lower stator limiting groove of the end cover, then place the bracket on the end cover for matching installation, ensuring the upper end of the stator assembly is positioned within the upper stator limiting groove of the bracket. The structure is simple and easy to install. The design of the lower and upper stator limiting grooves effectively positions the stator assembly, improving its fixation on the end cover and bracket. The bearing mounting groove serves to limit the bearing installation.

[0014] Preferably, a corrugated shim is provided at the bottom of the bearing mounting groove, and the corrugated shim is bonded to the inner bottom surface of the bearing mounting groove. The corrugated shim can adjust the axial clearance of the bearing through elastic deformation, ensuring that the bearing reaches the optimal working condition after installation and avoiding unstable operation or overheating due to excessive clearance.

[0015] Preferably, the stator assembly has an axial positioning groove on its side wall, and the lower stator limiting groove has a lower positioning post on its side wall that matches the lower opening of the axial positioning groove. The lower positioning post and the lower opening of the axial positioning groove are interlocked. The upper stator limiting groove has an upper positioning post on its side wall that matches the upper opening of the axial positioning groove. The upper positioning post and the upper opening of the axial positioning groove are interlocked. The interlocking of the lower positioning post and the lower opening of the axial positioning groove guides and limits the installation of the lower end of the stator assembly within the lower stator limiting groove. Similarly, the interlocking of the upper positioning post and the upper opening of the axial positioning groove guides and limits the installation of the upper end of the stator assembly within the upper stator limiting groove, further improving the installation stability of the stator assembly.

[0016] Preferably, the lower positioning post is located below the upper positioning post. The lower positioning post has a lower threaded hole, and the upper positioning post has an upper threaded hole that matches the lower threaded hole. The lower and upper positioning posts are fixedly connected by screws. By tightening the screws into the upper and lower threaded holes, the end cap and the bracket are fixed together. The connection method is simple and easy to operate, facilitating installation and disassembly, and reducing the difficulty of later maintenance and repair.

[0017] Preferably, a fan shroud is provided on the lower end face of the end cover, the fan shroud and the end cover are interlocked, and the moving impeller is placed inside the fan shroud. The fan shroud serves to protect the moving impeller.

[0018] Preferably, the upper surface of the bracket is provided with a PCB circuit board and a tail cover. The bracket has guide posts, and the PCB circuit board has guide grooves that match the guide posts. The PCB circuit board is directly mounted on the upper surface of the bracket through the cooperation of the guide grooves and guide posts. The tail cover and bracket are interlocked, with the PCB circuit board positioned inside the tail cover. The PCB circuit board is electrically connected to the stator assembly. The design of the guide grooves and guide posts guides and limits the installation of the PCB circuit board on the bracket. The PCB circuit board is connected to the stator assembly via wires, forming a complete electromagnetic drive system. When the stator assembly is energized, it generates a rotating magnetic field, which interacts with the magnetic ring on the rotor assembly to generate driving force, causing the shaft to rotate. The tail cover protects the PCB circuit board.

[0019] The beneficial effects of this utility model are as follows: By first mounting the moving impeller on the rotor, all rotating parts inside the motor that affect dynamic balance can be dynamically balanced; by first performing dynamic balancing on the assembled rotor assembly and then inserting it into the stator housing through the rotor assembly hole, the unbalanced position of the entire moving part can be eliminated, extending the service life of the bearings and reducing motor vibration and noise; by assembling the rotor assembly with the stator housing and then magnetizing the magnetic ring, the rotor assembly can be stably and vertically installed during assembly, effectively preventing the magnetic ring from attracting iron filings and interfering with the stator due to magnetic force, and avoiding assembly inconvenience caused by magnetism, thus effectively reducing assembly difficulty and damage to the magnetic ring, making assembly more convenient. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of this utility model;

[0021] Figure 2 This is a diagram of the internal structure of this utility model;

[0022] Figure 3 This is an exploded view of this utility model;

[0023] Figure 4 This is a structural schematic diagram of the stator housing;

[0024] Figure 5 This is a schematic diagram of the rotor assembly.

[0025] In the diagram: 1. Rotor assembly, 2. Stator housing, 3. Shaft, 4. Bearing, 5. Balance ring, 6. Magnetic ring, 7. Flange bearing, 8. Moving impeller, 9. Rotor mounting hole, 10. Limiting step, 11. Limiting groove, 12. End cover, 13. Stator assembly, 14. Bracket, 15. Lower stator limiting groove, 16. Upper stator limiting groove, 17. Bearing mounting groove, 18. Waveform gasket, 19. Axial positioning groove, 20. Lower positioning post, 21. Upper positioning post, 22. Lower threaded hole, 23. Upper threaded hole, 24. Screw, 25. Fan cover, 26. PCB circuit board, 27. Tail cover, 28. Guide post, 29. Guide groove. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0027] like Figures 1-5 In the embodiments described above, a brushless motor assembly structure includes:

[0028] Rotor assembly 1 includes a rotating shaft 3, from one end of the rotating shaft 3 to the other end of which a bearing 4, a balance ring 5, a magnetic ring 6, a flange bearing 7 and a moving impeller 8 are sequentially sleeved and fixed.

[0029] The stator housing 2 has a rotor assembly hole 9 that matches the rotor assembly 1. After the rotor assembly 1 is dynamically balanced, it is inserted into the rotor assembly hole 9. The magnetic ring 6, balance ring 5 and bearing 4 are all located inside the stator housing 2. After the rotor assembly 1 is assembled with the stator housing 2, the magnetic ring 6 is magnetized. The flange bearing 7 is installed at the rotor assembly hole 9 and a positioning mechanism is provided between the two. The impeller 8 is located outside the stator housing 2. The two ends of the shaft 3 are connected to the stator housing 2 through the bearing 4 and the flange bearing 7, respectively.

[0030] Bearing 4 and balance ring 5 are sleeved on one end of rotating shaft 3 and are both interference fit with rotating shaft 3. Magnetic ring 6 is sleeved on the middle position of rotating shaft 3 and is bonded and fixed to rotating shaft 3. Flange bearing 7 and moving impeller 8 are sleeved on the other end of rotating shaft 3 and are both interference fit with rotating shaft 3.

[0031] The positioning mechanism includes a limiting step 10 fixed to the outside of the flange bearing 7, and a limiting groove 11 matching the limiting step 10 is provided on the outer surface of the end cover 12. The rotor assembly hole 9 is located on the bottom surface of the limiting groove 11, and the limiting step 10 is placed in the limiting groove 11 and the two are bonded to each other.

[0032] The stator housing 2 includes an end cover 12, a stator assembly 13, and a bracket 14. The rotor assembly hole 9 is provided on the end cover 12. The limiting groove 11 is located on the lower end face of the end cover 12. The upper end face of the end cover 12 is provided with a stator limiting lower groove 15 that matches the lower end of the stator assembly 13. The lower end of the stator assembly 13 is inserted into the stator limiting lower groove 15. The lower end face of the bracket 14 is provided with a stator limiting upper groove 16 that matches the upper end of the stator assembly 13. The upper end of the stator assembly 13 is inserted into the stator limiting upper groove 16. The rotor assembly 1 is inserted into the inner side of the stator assembly 13. The bracket 14 is also provided with a bearing mounting groove 17 that matches the bearing 4. The bearing 4 is placed in the bearing mounting groove 17.

[0033] A corrugated gasket 18 is provided at the bottom of the bearing mounting groove 17, and the corrugated gasket 18 is bonded to the inner bottom surface of the bearing mounting groove 17.

[0034] The stator assembly 13 has an axial positioning groove 19 on its side wall. The stator limiting lower groove 15 has a lower positioning post 20 that matches the lower groove opening of the axial positioning groove 19 on its side wall. The lower positioning post 20 and the lower groove opening of the axial positioning groove 19 are inserted into each other. The stator limiting upper groove 16 has an upper positioning post 21 that matches the upper groove opening of the axial positioning groove 19 on its side wall. The upper positioning post 21 and the upper groove opening of the axial positioning groove 19 are inserted into each other.

[0035] The lower positioning post 20 is located below the upper positioning post 21. The lower positioning post 20 is provided with a lower threaded hole 22, and the upper positioning post 21 is provided with an upper threaded hole 23 that matches the lower threaded hole 22. The lower positioning post 20 and the upper positioning post 21 are fixedly connected by screws 24.

[0036] A fan cover 25 is provided on the lower end face of the end cover 12. The fan cover 25 and the end cover 12 are interlocked. The moving impeller 8 is placed inside the fan cover 25.

[0037] The upper end face of the bracket 14 is provided with a PCB circuit board 26 and a tail cover 27. The bracket 14 is provided with a guide post. The PCB circuit board 26 is provided with a guide groove 29 that matches the guide post 28. The PCB circuit board 26 is directly on the upper end face of the bracket 14 through the cooperation of the guide groove 29 and the guide post 28. The tail cover 27 and the bracket 14 are interlocked. The PCB circuit board 26 is placed inside the tail cover 27. The PCB circuit board 26 is electrically connected to the stator assembly 13.

[0038] Specific assembly process:

[0039] 1. Install bearing 4, balance ring 5, magnetic ring 6, flange bearing 7 and moving impeller 8 onto the rotating shaft 3 in sequence, so that they are fixed into a whole rotor assembly 1. Bearing 4 and balance ring 5 are located at one end of rotating shaft 3, magnetic ring 6 is located in the middle of rotating shaft 3, and flange bearing 7 and moving impeller 8 are located at the other end of rotating shaft 3. Then perform dynamic balancing on the assembled rotor assembly 1.

[0040] 2. First, attach the wave-shaped gasket 18 to the bottom of the bearing mounting groove 17. Then, through the mutual cooperation of the lower positioning pin 20 and the lower groove opening of the axial positioning groove 19, insert the lower end of the stator assembly 13 into the stator limiting lower groove 15 of the end cover 12. Through the mutual cooperation of the upper positioning pin 21 and the upper groove opening of the axial positioning groove 19, insert the upper end of the stator assembly 13 into the stator limiting upper groove 16 of the bracket 14. Tighten the screw 24 in the upper threaded hole 23 and the lower threaded hole 22 to achieve mutual fixation between the end cover 12, the stator assembly 13 and the bracket 14, forming the stator housing 2.

[0041] 3. Insert one end of the rotor assembly 1 into the stator housing 2 through the rotor assembly hole 9 on the end cover 12. The balance ring 5 and the bearing 4 are located inside the stator housing 2, and the bearing 4 is installed in the bearing mounting groove 17. The magnetic ring 6 is located inside the stator housing 2 and is placed inside the stator assembly 13. The flange bearing 7 is installed at the rotor assembly hole 9, and the limiting step 10 on it is attached to and bonded to the limiting groove 11 on the outer surface of the end cover 12. The moving impeller 8 is located outside the stator housing 2. The rotor assembly 1 and the stator housing rotate relative to each other through the bearing 4 and the flange bearing 7. After the assembly is completed, the magnetic ring 6 is magnetized.

[0042] Fourth, fix the fan cover 25 to the end cover 12 and place the moving impeller 8 inside the fan cover 25;

[0043] 5. Fix the PCB circuit board 26 and the tail cover 27 on the bracket 14 and place the PCB circuit board 26 inside the tail cover 27. Finally, connect the PCB circuit board 26 and the stator assembly 13 to each other through wires to conduct the circuit.

Claims

1. A brushless motor assembly structure, characterized in that, include: The rotor assembly (1) includes a shaft (3), and the shaft (3) is fitted with a bearing (4), a balance ring (5), a magnetic ring (6), a flange bearing (7) and a moving impeller (8) in sequence from one end to the other. The stator housing (2) is provided with a rotor assembly hole (9) that matches the rotor assembly (1). After the rotor assembly (1) is dynamically balanced, it is then inserted into the rotor assembly hole (9). The magnetic ring (6), balance ring (5) and bearing (4) are all located inside the stator housing (2). After the rotor assembly (1) is assembled with the stator housing (2), the magnetic ring (6) is magnetized. The flange bearing (7) is installed at the rotor assembly hole (9) and a positioning mechanism is provided between them. The moving impeller (8) is located outside the stator housing (2). The two ends of the rotating shaft (3) are connected to the stator housing (2) through the bearing (4) and the flange bearing (7) respectively.

2. A brushless motor assembly according to claim 1, wherein The bearing (4) and the balance ring (5) are fitted onto one end of the rotating shaft (3) and are both interference fit with the rotating shaft (3). The magnetic ring (6) is fitted onto the middle position of the rotating shaft (3) and is bonded and fixed to the rotating shaft (3). The flange bearing (7) and the moving impeller (8) are fitted onto the other end of the rotating shaft (3) and are both interference fit with the rotating shaft (3).

3. A brushless motor assembly structure according to claim 1 or 2, characterized in that, The positioning mechanism includes a limiting step (10) fixed to the outside of the flange bearing (7). The stator housing (2) includes an end cover (12), a stator assembly (13), and a bracket (14). The outer surface of the end cover (12) is provided with a limiting groove (11) that matches the limiting step (10). The rotor assembly hole (9) is located on the bottom surface of the limiting groove (11). The limiting step (10) is placed in the limiting groove (11) and the two are bonded to each other. The rotor assembly hole (9) is set on the end cover (12). The limiting groove (11) is located on the lower end face of the end cover (12). The upper end face of the bracket (14) is provided with a stator limiting lower groove (15) that matches the lower end of the stator assembly (13). The lower end of the stator assembly (13) is inserted into the stator limiting lower groove (15). The lower end face of the bracket (14) is provided with a stator limiting upper groove (16) that matches the upper end of the stator assembly (13). The upper end of the stator assembly (13) is inserted into the stator limiting upper groove (16). The rotor assembly (1) is inserted into the inner side of the stator assembly (13). The bracket (14) is also provided with a bearing mounting groove (17) that matches the bearing (4). The bearing (4) is placed in the bearing mounting groove (17).

4. A brushless motor assembly according to claim 3, wherein A corrugated gasket (18) is provided at the bottom of the bearing mounting groove (17), and the corrugated gasket (18) is bonded to the inner bottom surface of the bearing mounting groove (17).

5. A brushless motor assembly according to claim 3, wherein The stator assembly (13) has an axial positioning groove (19) on its side wall. The stator limiting lower groove (15) has a lower positioning post (20) that matches the lower groove opening of the axial positioning groove (19) on its side wall. The lower positioning post (20) and the lower groove opening of the axial positioning groove (19) are inserted into each other. The stator limiting upper groove (16) has an upper positioning post (21) that matches the upper groove opening of the axial positioning groove (19) on its side wall. The upper positioning post (21) and the upper groove opening of the axial positioning groove (19) are inserted into each other.

6. A brushless motor assembly according to claim 5, wherein The lower positioning post (20) is located below the upper positioning post (21). The lower positioning post (20) is provided with a lower threaded hole (22), and the upper positioning post (21) is provided with an upper threaded hole (23) that matches the lower threaded hole (22). The lower positioning post (20) and the upper positioning post (21) are fixedly connected by screws (24).

7. The brushless motor assembly of claim 3, wherein the rotor assembly further comprises a rotor core having a plurality of slots formed therein, and a plurality of permanent magnets embedded in the plurality of slots. The lower end face of the end cover (12) is provided with a wind hood (25), the wind hood (25) and the end cover (12) are interlocked, and the moving impeller (8) is placed inside the wind hood (25).

8. The brushless motor assembly of claim 3, wherein: The upper end face of the bracket (14) is provided with a PCB circuit board (26) and a tail cover (27). The bracket (14) is provided with a guide post (28). The PCB circuit board (26) is provided with a guide groove (29) that matches the guide post (28). The PCB circuit board (26) is directly on the upper end face of the bracket (14) through the cooperation of the guide groove (29) and the guide post (28). The tail cover (27) and the bracket (14) are interlocked. The PCB circuit board (26) is placed inside the tail cover (27). The PCB circuit board (26) is electrically connected to the stator assembly (13).

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