A new brushless motor with integrated mandrel

Abstract

This utility model discloses a novel brushless motor with an integrated metal mandrel, comprising a stator assembly, a rotor assembly, a front cover, a rear cover, a front ball bearing, and a rear ball bearing. The rotor assembly includes a metal mandrel and a magnetic ring. A plastic shaft is encased around the center of the metal mandrel, and the plastic shaft and metal mandrel are injection molded into a single structure. The magnetic ring is fitted and riveted to the outer periphery of the plastic shaft. A front bearing mounting part is provided at the front end of the plastic shaft, and the inner ring of the front ball bearing is riveted to the outer periphery of the front bearing mounting part. A rear bearing mounting part is provided at the rear end of the plastic shaft, and the inner ring of the rear ball bearing is riveted to the outer periphery of the rear bearing mounting part. The front and rear covers are made of rigid plastic. The outer ring of the front ball bearing is riveted to the front bearing hole of the front cover, and the outer ring of the rear ball bearing is riveted to the front bearing hole of the rear cover. Through the above structural design, this utility model has the advantages of novel structural design and no axial movement of the rotor assembly.

Description

Technical Field

[0001] This utility model relates to the field of brushless motor technology, and in particular to a novel brushless motor with an integrated spindle. Background Technology

[0002] The Chinese utility model patent with patent number ZL202422004164.3 and patent name, entitled "A Novel Brushless DC Motor," discloses the following technical solution: A novel brushless DC motor includes a rotor assembly, a stator assembly sleeved on the outer periphery of the rotor assembly, a first end cover disposed at one end of the stator assembly, and a second end cover disposed at the other end of the stator assembly. The rotor assembly includes a rotor, a rotor bushing, and rotor magnets (also known as magnetic rings). The stator assembly includes windings, a first wire frame, a second wire frame, and a plurality of stator iron cores. One end of the rotor is rotatably mounted on the first end cover via a first bearing, and the other end is rotatably mounted on the second end cover via a second bearing. A washer sleeved on the rotor is provided between the first end cover and the first bearing. The washer is a wave washer.

[0003] For the aforementioned novel brushless DC motor, the first bearing and the second bearing support the rotation of the rotor assembly and bear radial and axial loads, while the wave washer located between the first end cover and the first bearing is used to adjust the axial movement of the motor.

[0004] It should be noted that the above-mentioned new type of brushless DC motor still has the following defects: the wave washer can only reduce the axial movement of the rotor assembly to a certain extent. When the wave washer undergoes elastic deformation, the rotor assembly will still experience axial movement. That is, the new type of brushless DC motor cannot completely eliminate the axial movement of the rotor assembly. Due to the axial movement of the rotor assembly, the new type of brushless DC motor will experience vibration and noise problems when it is working. Utility Model Content

[0005] The purpose of this invention is to provide a novel brushless motor with an integrated spindle to address the shortcomings of existing technologies. This novel brushless motor with an integrated spindle has a novel structural design and the rotor assembly has no axial movement.

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution.

[0007] A novel brushless motor with an integrated metal spindle includes a stator assembly, a rotor assembly, a front cover, a rear cover, a front ball bearing, and a rear ball bearing. The rotor assembly is rotatably mounted inside the stator assembly, and the rotor assembly includes a metal spindle and a magnetic ring fitted around the metal spindle. The front cover has a front bearing hole, in which a front ball bearing is fitted; the rear cover has a rear bearing hole, in which a rear ball bearing is fitted. The metal mandrel is surrounded by a plastic shaft, which is injection molded into a single structure with the metal mandrel. A magnetic ring is riveted to the outside of the plastic shaft. The front end of the plastic shaft is provided with a front bearing mounting part corresponding to the front ball bearing, and the inner ring of the front ball bearing is riveted to the outer periphery of the front bearing mounting part; the rear end of the plastic shaft is provided with a rear bearing mounting part corresponding to the rear ball bearing, and the inner ring of the rear ball bearing is riveted to the outer periphery of the rear bearing mounting part. The front and rear covers are made of hard rubber. The outer ring of the front ball bearing is riveted to the front bearing hole of the front cover, and the outer ring of the rear ball bearing is riveted to the front bearing hole of the rear cover.

[0008] The metal mandrel has a flat groove in the middle, and the plastic shaft has a shaft protrusion that fills the flat groove.

[0009] The inner circumferential surface of the magnetic ring is provided with a number of grooves arranged in a ring array and extending along the axis of the magnetic ring. The plastic shaft is provided with a boss corresponding to each groove of the magnetic ring, and each boss is embedded into the corresponding groove. The plastic shaft is also provided with several tight-fitting ribs arranged in a ring array. The tight-fitting ribs are located on the side of the boss, and each tight-fitting rib presses against the inner circumferential surface of the contact magnetic ring. There is a gap between the magnetic ring and the plastic shaft, and the gap is filled with colloid.

[0010] The plastic shaft has a front shoulder at its front end, the front cover has a front cover shoulder, the rear end face of the inner ring of the front ball bearing is abutted against the front shoulder, and the front end face of the outer ring of the front ball bearing is abutted against the front cover shoulder. The rear end of the plastic shaft is provided with a shaft rear shoulder, the rear end cover is provided with a cover shoulder, the front end face of the inner ring of the rear ball bearing abuts against and is limited to the shaft rear shoulder, and the rear end face of the outer ring of the rear ball bearing abuts against and is limited to the cover shoulder.

[0011] The novel brushless motor with an integrated metal spindle also includes a metal housing, which is located between the front cover and the rear cover. The front end of the metal housing is riveted to the front cover, and the rear end of the metal housing is riveted to the rear cover. The positioning component is located inside the metal housing, and the stator component is secured between the front cover and the rear cover.

[0012] The metal housing has three housing front rivet points arranged in a circular array at its front edge. The edge of the front cover has a front cover rivet groove corresponding to each housing front rivet point. Each housing front rivet point is riveted to the corresponding front cover rivet groove. The rear edge of the metal casing has three casing rear riveting points arranged in a circular array. The edge of the rear cover has a rear cover riveting groove corresponding to each casing rear riveting point, and each casing rear riveting point is riveted to the corresponding rear cover riveting groove.

[0013] The front end cover is provided with a rearward protruding front positioning flange, the rear end cover is provided with a forward protruding rear positioning flange, and the stator assembly is secured between the front positioning flange and the rear positioning flange.

[0014] The metal casing is made of aluminum.

[0015] Compared with existing technologies, this invention has the following advantages: Specifically, in the novel brushless motor with an integrated spindle, the inner and outer rings of each ball bearing are riveted to corresponding connecting parts. This structural design effectively avoids rotor assembly misalignment and completely eliminates axial movement of the rotor assembly, thereby reducing vibration and noise during motor operation. Therefore, the novel brushless motor with an integrated spindle of this invention has the advantages of novel structural design, no axial movement of the rotor assembly, higher motor precision, less wobbling and vibration, lower noise, less vibration, and higher stability. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present invention.

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

[0018] Figure 2 This is an exploded view of the present invention.

[0019] Figure 3 This is a cross-sectional schematic diagram of the present invention.

[0020] Figure 4 This is a schematic diagram of the rotor assembly of this utility model.

[0021] Figure 5 This is a cross-sectional schematic diagram of the rotor assembly of this utility model.

[0022] exist Figures 1 to 5 This includes: 1-Stator assembly; 2-Rotor assembly; 21-Metal mandrel; 211-Flat slot; 22-Magnetic ring; 221-Groove; 23-Plastic shaft; 231-Front bearing mounting part; 232-Rear bearing mounting part; 233-Shaft protrusion; 234-Boss; 235-Fitting rib; 236-Shaft front shoulder; 237-Shaft rear shoulder; 24-Glue concealment gap; 31-Front end cover; 311-Front bearing hole; 312-Front cover shoulder; 313-Front cover riveting groove; 314-Front positioning flange; 32-Rear end cover; 321-Rear bearing hole; 322-Rear cover shoulder; 323-Rear cover riveting groove; 324-Rear positioning flange; 41-Front ball bearing; 42-Rear ball bearing; 5-Metal housing; 51-Front riveting point of housing; 52-Rear riveting point of housing. Detailed Implementation

[0023] The present invention will now be described in conjunction with specific embodiments.

[0024] Example 1, as Figures 1 to 5 As shown, a novel brushless motor with an integrated mandrel includes a stator assembly 1, a rotor assembly 2, a front cover 31, a rear cover 32, a front ball bearing 41, and a rear ball bearing 42. The rotor assembly 2 is rotatably mounted inside the stator assembly 1, and the rotor assembly 2 includes a metal mandrel 21 and a magnetic ring 22 fitted around the metal mandrel 21. The stator assembly 1 in this embodiment is already prior art and will not be described in detail here; the magnetic ring 22 in this embodiment can be a neodymium iron boron sintered part.

[0025] Among them, such as Figure 2 and Figure 3 As shown, the front cover 31 has a front bearing hole 311, and the front ball bearing 41 is fitted into the front bearing hole 311; the rear cover 32 has a rear bearing hole 321, and the rear ball bearing 42 is fitted into the rear bearing hole 321.

[0026] Furthermore, such as Figures 2 to 5 As shown, a plastic shaft 23 is wrapped around the middle of the metal spindle 21. The plastic shaft 23 and the metal spindle 21 are injection molded into an integral structure. The magnetic ring 22 is fitted and riveted to the outside of the plastic shaft 23.

[0027] Furthermore, such as Figures 2 to 4 As shown, the front end of the plastic shaft 23 is provided with a front bearing mounting part 231 corresponding to the front ball bearing 41, and the inner ring of the front ball bearing 41 is riveted to the periphery of the front bearing mounting part 231; the rear end of the plastic shaft 23 is provided with a rear bearing mounting part 232 corresponding to the rear ball bearing 42, and the inner ring of the rear ball bearing 42 is riveted to the periphery of the rear bearing mounting part 232.

[0028] In addition, such as Figure 3As shown, the front cover 31 and the rear cover 32 are both made of rigid plastic. The outer ring of the front ball bearing 41 is riveted to the front bearing hole 311 of the front cover 31, and the outer ring of the rear ball bearing 42 is riveted to the front bearing hole 311 of the rear cover 32. It should be noted that the front cover 31 and the rear cover 32 in this embodiment can be injection molded from high-strength, high-temperature resistant nylon or other engineering plastics.

[0029] It should be emphasized that the plastic shaft 23 and the metal mandrel 21 are injection molded into an integral structure, that is, the plastic shaft 23 and the metal mandrel 21 are combined into an integral mandrel; the front bearing mounting part 231 and the rear bearing mounting part 232 of the plastic shaft 23 are respectively riveted to the inner rings of the corresponding front ball bearings 41 and the rear ball bearings 42. The plastic shaft 23, made of plastic material, will undergo plastic deformation during the riveting and mounting of the front ball bearings 41 and the rear ball bearings 42, so that the inner rings of the front ball bearings 41 and the rear ball bearings 42 are respectively fixedly mounted on the corresponding front bearing mounting parts 231 and the rear bearing mounting parts 232, and can effectively ensure the axial position of the front ball bearings 41 and the rear ball bearings 42 and the plastic shaft 23.

[0030] It should be further emphasized that, since the front cover 31 and the rear cover 32 are both plastic components, when the front ball bearing 41 and the rear ball bearing 42 are riveted and installed in the corresponding front bearing hole 311 and rear bearing hole 321, the front cover 31 and the rear cover 32 will undergo plastic deformation, so that the outer rings of the front ball bearing 41 and the rear ball bearing 42 are fixedly installed in the corresponding front bearing hole 311 and rear bearing hole 321, respectively, and can effectively ensure the axial position of the front ball bearing 41 and the front cover 31 and the axial position of the rear ball bearing 42 and the rear cover 32.

[0031] In summary, through the above structural design, the inner and outer rings of each ball bearing in the novel brushless motor with an integrated spindle of this embodiment are riveted to the corresponding connecting parts. This structural design effectively avoids axial movement and misalignment of the rotor assembly 2, and completely eliminates axial movement of the rotor assembly 2, thereby reducing vibration and noise during motor operation. Therefore, the novel brushless motor with an integrated spindle of this embodiment has the advantages of novel structural design and no axial movement of the rotor assembly 2. Example 2, as Figure 3 and Figure 5 As shown, the difference between this embodiment 2 and embodiment 1 is that: the metal mandrel 21 has a flat groove 211 in the middle, and the plastic shaft 23 has a shaft protrusion 233 that fills the flat groove 211.

[0032] It should be explained that the flat groove 211 of the metal mandrel 21 can be a "D" shaped flat groove structure, and correspondingly, the rotating shaft protrusion 233 of the plastic shaft 23 is "D". By cooperating with the flat groove 211 of the metal mandrel 21, this embodiment can effectively prevent relative rotation between the plastic shaft 23 and the metal mandrel 21, and can also effectively prevent relative axial sliding between the plastic shaft 23 and the metal mandrel 21, thereby effectively increasing the pull-out strength between the plastic shaft 23 and the metal mandrel 21. Example 3, as Figure 5 As shown, the difference between this embodiment 3 and embodiment 1 is that: the inner circumferential surface of the magnetic ring 22 is provided with a plurality of grooves 221 arranged in a ring array and extending along the axis of the magnetic ring 22 respectively; the plastic rotating shaft 23 is provided with a boss 234 corresponding to each groove 221 of the magnetic ring 22, and each boss 234 is embedded into the corresponding groove 221.

[0033] The plastic shaft 23 is also provided with several tight-fitting ribs 235 arranged in a ring array. The tight-fitting ribs 235 are located on the side of the boss 234, and each tight-fitting rib 235 presses against the inner circumferential surface of the contact magnetic ring 22.

[0034] In addition, there is a glue-filled gap 24 between the magnetic ring 22 and the plastic shaft 23, and the glue-filled gap 24 is filled with glue (not shown in the figure).

[0035] It should be explained that, by cooperating with the groove 221 of the magnetic ring 22 and the boss 234 of the plastic shaft 23, this embodiment can effectively prevent relative rotation between the magnetic ring 22 and the plastic shaft 23.

[0036] Furthermore, by using the adhesive within the adhesive gap 24 to achieve an adhesive connection between the magnetic ring 22 and the plastic shaft 23, this third embodiment can further improve the stability and reliability of the magnetic ring 22 installation. Example 4, as Figure 2 and Figure 3 As shown, the difference between this embodiment four and embodiment one is that: the front end of the plastic shaft 23 is provided with a shaft front shoulder 236, the front end cover 31 is provided with a front cover shoulder 312, the rear end face of the inner ring of the front ball bearing 41 is abutted and limited to the shaft front shoulder 236, and the front end face of the outer ring of the front ball bearing 41 is abutted and limited to the front cover shoulder 312.

[0037] The plastic shaft 23 has a rear shoulder 237 at its rear end, and the rear cover 32 has a rear cover shoulder 322. The front end face of the inner ring of the rear ball bearing 42 is located at the rear shoulder 237, and the rear end face of the outer ring of the rear ball bearing 42 is located at the rear cover shoulder 322.

[0038] It should be explained that, through the front cover shoulder 312 and the front shaft shoulder 236, this embodiment four can further limit the axial movement of the front ball bearing 41, thereby further preventing axial movement. Similarly, through the rear cover shoulder 322 and the rear shaft shoulder 237, this embodiment four can further limit the axial movement of the rear ball bearing 42, thereby further preventing axial movement. Example 5, as Figures 1 to 3 As shown, the difference between this fifth embodiment and the first embodiment is that the new brushless motor with an integrated spindle also includes a metal housing 5. The metal housing 5 is located between the front cover 31 and the rear cover 32, and the front end of the metal housing 5 is riveted to the front cover 31, and the rear end of the metal housing 5 is riveted to the rear cover 32.

[0039] The positioning component is located inside the metal housing 5, and the stator component 1 is secured between the front cover 31 and the rear cover 32.

[0040] Specifically, in this embodiment five, the metal housing 5 can be riveted to the front cover 31 and the rear cover 32 respectively using the following structural forms: the front edge of the metal housing 5 is provided with three housing front rivet points 51 arranged in a circular array, and the edge of the front cover 31 is provided with a front cover rivet groove 313 corresponding to each housing front rivet point 51, and each housing front rivet point 51 is riveted to the corresponding front cover rivet groove 313; the rear edge of the metal housing 5 is provided with three housing rear rivet points 52 arranged in a circular array, and the edge of the rear cover 32 is provided with a rear cover rivet groove 323 corresponding to each housing rear rivet point 52, and each housing rear rivet point 52 is riveted to the corresponding rear cover rivet groove 323.

[0041] In addition, such as Figure 2 and Figure 3 As shown, the front cover 31 is provided with a rearward protruding front positioning flange 314, and the rear cover 32 is provided with a forward protruding rear positioning flange 324. The stator assembly 1 is fixed between the front positioning flange 314 and the rear positioning flange 324.

[0042] It should be explained that the metal casing 5 is made of aluminum; specifically, the metal casing 5 can be manufactured by extrusion molding or by turning and cutting aluminum tubes.

[0043] In this fifth embodiment, the motor housing adopts a segmented assembly design, and the housing consists of a front cover 31, a metal housing 5, and a rear cover 32 connected sequentially from front to back. The front cover 31 and rear cover 32, which are made of hard plastic parts, can effectively reduce the weight of the motor housing, thereby achieving an overall weight reduction of the motor product.

[0044] The above description is only a preferred embodiment of this utility model. For those skilled in the art, there will be changes in the specific implementation method and application scope based on the idea of ​​this utility model. The content of this specification should not be construed as a limitation of this utility model.

Claims

1. A novel brushless motor with an integrated spindle, comprising a stator assembly (1), a rotor assembly (2), a front end cover (31), a rear end cover (32), a front ball bearing (41), and a rear ball bearing (42), wherein the rotor assembly (2) is rotatably mounted on the inner side of the stator assembly (1), and the rotor assembly (2) includes a metal spindle (21) and a magnetic ring (22) fitted around the metal spindle (21). The front cover (31) has a front bearing hole (311) and a front ball bearing (41) is fitted into the front bearing hole (311); the rear cover (32) has a rear bearing hole (321) and a rear ball bearing (42) is fitted into the rear bearing hole (321). characterized in that The outer periphery of the metal spindle (21) is encased in a plastic shaft (23). The plastic shaft (23) and the metal spindle (21) are injection molded into a single structure. The magnetic ring (22) is fitted and riveted to the outer periphery of the plastic shaft (23). The front end of the plastic shaft (23) is provided with a front bearing mounting part (231) corresponding to the front ball bearing (41), and the inner ring of the front ball bearing (41) is riveted to the periphery of the front bearing mounting part (231); the rear end of the plastic shaft (23) is provided with a rear bearing mounting part (232) corresponding to the rear ball bearing (42), and the inner ring of the rear ball bearing (42) is riveted to the periphery of the rear bearing mounting part (232); The front cover (31) and the rear cover (32) are both made of hard rubber. The outer ring of the front ball bearing (41) is riveted to the front bearing hole (311) of the front cover (31), and the outer ring of the rear ball bearing (42) is riveted to the front bearing hole (311) of the rear cover (32).

2. The novel brushless motor with an integrated spindle according to claim 1, characterized in that: The metal mandrel (21) has a flat groove (211) in the middle, and the plastic shaft (23) has a shaft protrusion (233) that fills the flat groove (211).

3. A novel brushless motor with an integrated mandrel as claimed in claim 1 characterized in that: The inner circumferential surface of the magnetic ring (22) is provided with a plurality of grooves (221) arranged in a ring array and extending along the axis of the magnetic ring (22). The plastic shaft (23) is provided with a boss (234) corresponding to each groove (221) of the magnetic ring (22), and each boss (234) is embedded into the corresponding groove (221). The plastic shaft (23) is also provided with a number of tight-fitting ribs (235) arranged in a ring array. The tight-fitting ribs (235) are located on the side of the boss (234), and each tight-fitting rib (235) presses against the inner circumferential surface of the contact magnetic ring (22). There is a glue-filled gap (24) between the magnetic ring (22) and the plastic shaft (23), and the glue-filled gap (24) is filled with glue.

4. A novel brushless motor with an integrated mandrel as claimed in claim 1, characterized in that: The front end of the plastic shaft (23) is provided with a shaft front shoulder (236), the front end cover (31) is provided with a front cover shoulder (312), the rear end face of the inner ring of the front ball bearing (41) is abutted and limited to the shaft front shoulder (236), and the front end face of the outer ring of the front ball bearing (41) is abutted and limited to the front cover shoulder (312). The rear end of the plastic shaft (23) is provided with a shaft rear shoulder (237), the rear end cover (32) is provided with a rear cover shoulder (322), the front end face of the inner ring of the rear ball bearing (42) abuts against the shaft rear shoulder (237), and the rear end face of the outer ring of the rear ball bearing (42) abuts against the rear cover shoulder (322).

5. A novel brushless motor with an integrated mandrel as claimed in claim 1, characterized in that: The novel brushless motor with an integrated spindle also includes a metal housing (5), which is located between the front end cover (31) and the rear end cover (32), and the front end of the metal housing (5) is riveted to the front end cover (31), and the rear end of the metal housing (5) is riveted to the rear end cover (32). The stator assembly is located inside the metal housing (5), and the stator assembly (1) is secured between the front cover (31) and the rear cover (32).

6. A novel brushless motor with an integrated mandrel as claimed in claim 5, characterized in that: The front edge of the metal housing (5) is provided with three housing front rivet points (51) arranged in a ring array. The edge of the front cover (31) is provided with a front cover rivet groove (313) corresponding to each housing front rivet point (51). Each housing front rivet point (51) is riveted to the corresponding front cover rivet groove (313). The rear edge of the metal housing (5) is provided with three housing rear rivet points (52) arranged in a ring array. The edge of the rear cover (32) is provided with a rear cover rivet groove (323) corresponding to each housing rear rivet point (52). Each housing rear rivet point (52) is riveted to the corresponding rear cover rivet groove (323).

7. A novel brushless motor with an integrated mandrel as claimed in claim 5, characterized in that: The front end cover (31) is provided with a rearward protruding front positioning flange (314), the rear end cover (32) is provided with a forward protruding rear positioning flange (324), and the stator assembly (1) is secured between the front positioning flange (314) and the rear positioning flange (324).

8. A novel brushless motor with an integrated mandrel as claimed in claim 5, characterized in that: The metal casing (5) is made of aluminum.

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