An electric motor electric deflection angle adjusting mechanism

Abstract

The utility model relates to a motor electric deflection angle adjusting mechanism, solve the problem that the motor assembly is not qualified after the accumulation of part tolerance in prior art. The mechanism includes the bottom plate, the servo -ball screw flat -push module of fixed on the bottom plate, the rigid connection of screw nut of screw rod, the two sets of thrust bearing and bearing seat symmetrically installed on the both sides of push plate, the shell positioning jig of only being able to rotate around the own axis through the pin and bearing seat fixed connection, the rear cover positioning jig of coaxial setting in shell positioning jig and with its common clamping motor to be adjusted, the crossed roller bearing of being pressed into the outer circle of shell positioning jig and being pre -pressed to zero clearance with flange cover plate, and the bearing compression nut for the axial locking of crossed roller bearing. The mechanism compact structure, the degree of automation is high, can significantly reduce the repair rate and manufacturing cost, especially suitable for the production assembly of brushless motor.

Description

Technical Field

[0001] This utility model relates to the field of brushless motor manufacturing technology, and in particular to a motor deflection angle adjustment mechanism. Background Technology

[0002] Brushless DC motors, due to their high power density, long lifespan, and low maintenance requirements, have been widely used in automotive electric drives, power tools, home appliances, and industrial automation. These motors typically employ Hall effect sensors as rotor position sensors to achieve electronic commutation. The relative position between the Hall effect sensor's output signal and the rotor's magnetic field—the electrical deflection angle—directly affects the accuracy of the commutation timing. If the electrical deflection angle deviates from the design range, it will cause commutation to occur too early or too late, leading to current waveform distortion, increased torque fluctuations, decreased efficiency, and increased vibration and noise. In severe cases, it can even cause overcurrent or loss of synchronism, adversely affecting the overall safety, reliability, and user experience of the machine.

[0003] In existing technologies, to ensure that the electrical deflection angle is within the acceptable range, a "mechanical zeroing" scheme is often adopted: positioning bosses, keyways, pin holes, and other structures are set on the stator assembly, end cover, or dedicated Hall effect support to uniquely determine the circumferential relative position between the Hall element and the stator winding at the moment of assembly. Theoretically, as long as the dimensional tolerances, geometric tolerances, and magnetization directions of each component are consistent, the required electrical deflection angle can be obtained in batches. However, in actual manufacturing processes, the following unavoidable sources of deviation exist: cumulative errors in the stator core stacking thickness lead to uneven circumferential distribution of the slot openings; changes in the coaxiality of the bearing housing and the end cover stop clearance cause relative offset between the stator and rotor; the embedding position of the Hall element is dispersed during injection molding or pressing; wear of the permanent magnet magnetizing fixture and differences in magnetic field orientation cause offset of the magnetic pole centerline; when producing multiple varieties in mixed flow, different frame sizes and different winding schemes require different positioning structures, further increasing the variety of tooling and management difficulty.

[0004] The combined effect of these error factors means that even with high-level precision in parts, a certain percentage of parts with out-of-tolerance electrical deflection angles will still occur at the assembly stage. Traditional remedial methods include rework, disassembly and repositioning, individual pairing and marking, and increasing the proportion of 100% inspection of parts. However, all of these methods involve significant manual intervention, slow cycle time, and high costs. Furthermore, to avoid rework, some manufacturers choose to reserve higher precision margins during the design phase, leading to a significant increase in the difficulty of parts processing and material costs, yet still failing to completely eliminate individual non-conformities caused by the accumulation of random errors.

[0005] Therefore, there is an urgent need in this field for a compact, highly automated end-of-line adjustment solution that can be integrated with existing assembly lines, so that the electrical deflection angle can be finely adjusted in a closed loop after the motor is assembled, thereby being compatible with components in the conventional tolerance zone, eliminating expensive precision redundancy design, and significantly reducing rework rate and manufacturing cost. Utility Model Content

[0006] The present invention aims to solve the above-mentioned technical problem by providing a stator winding connection and positioning structure for a brushless motor.

[0007] The technical solution adopted by this application to solve its technical problem is: a motor deflection angle adjustment mechanism, including a base plate, a servo-ball screw push module fixed on the base plate, a push plate rigidly connected to the screw nut, two sets of thrust bearings and bearing seats symmetrically installed on both sides of the push plate, a housing positioning fixture fixed to the two bearing seats by pins and only able to rotate around its own axis, a rear cover positioning fixture coaxially arranged in the housing positioning fixture and together with it clamping the motor being adjusted, a crossed roller bearing pressed into the outer circle of the housing positioning fixture and pre-pressed to zero clearance by a flange cover plate, and a bearing clamping nut for axially locking the crossed roller bearing.

[0008] Furthermore, the bearing clamping nut is threaded into the housing positioning fixture to preload the crossed roller bearing to zero axial clearance.

[0009] Furthermore, the thrust bearing is a one-way thrust ball bearing, with its race fixed to the bearing housing and its shaft race fixed to the push plate, thus realizing the conversion of horizontal thrust into rotational torque.

[0010] Furthermore, it also includes a laser displacement sensor and a controller. The laser displacement sensor detects the tangential displacement of the edge of the housing positioning fixture in real time and feeds it back to the controller to form a closed-loop control of the rotation angle.

[0011] Furthermore, the controller includes a scanning mechanism, a recording mechanism, a calculation mechanism, a judgment mechanism, an execution mechanism, and a re-execution mechanism; the scanning mechanism is used to retrieve the current motor model parameters; the recording mechanism is used to record the servo motor drive screw being pushed lightly to the preload position and to record the measured arc length of the laser; the calculation mechanism is used to calculate the remaining stroke based on the built-in ΔL-Δθ line table; the judgment mechanism is used for servo secondary feed until the laser feedback value falls within the ±0.05° judgment window; the execution mechanism is used to output an "OK" signal and tighten the motor housing bolts; the re-execution mechanism is used to reverse slightly and replenish the stroke when it exceeds the window until it is qualified.

[0012] Furthermore, the rear cover positioning fixture and the outer shell positioning fixture are respectively equipped with a rear cover positioning pin and an outer shell positioning pin, which are used to cooperate with the positioning holes on the rear cover and outer shell of the motor being adjusted to achieve coaxial clamping.

[0013] Furthermore, the servo-ball screw flat-push module includes a target position judgment mechanism, a thrust adjustment and limiting mechanism, a speed curve adjustment mechanism, and an angle judgment window mechanism; the minimum resolution of the target position judgment mechanism is 0.01 mm; the range of the thrust adjustment and limiting mechanism is 0-300% of the rated torque; the speed curve adjustment mechanism is used to adjust the acceleration and deceleration time and the running speed; the angle judgment window mechanism is used to determine whether the difference between the laser feedback and the theoretical arc length is ≤ ±0.05°.

[0014] The beneficial effects of the technical solution in this application are as follows: This application uses a servo-ball screw push module to precisely convert linear displacement into micron-level rotation of the positioning fixture. Then, by utilizing a composite structure of zero-backlash preload of crossed roller bearings and bidirectional load-bearing of thrust bearings, only one miniaturized module is needed to output a large torque rotational adjustment force. This eliminates the need for high-precision positioning bosses, keyways, and multiple sets of special fixtures required in the traditional "mechanical zeroing" solution, significantly simplifying the motor assembly process and reducing the precision requirements and manufacturing costs of parts.

[0015] This application utilizes a laser displacement sensor to detect the tangential displacement of the edge of the housing positioning fixture in real time, and performs a closed-loop comparison with the built-in ΔL-Δθ broken line table to form an integrated control loop of "feed-measurement-compensation". It can complete the electrical deflection angle correction within ±0.05° in a single cycle, eliminate manual rework and matching marks, improve the first-pass yield, and avoid quality risks such as enameled wire scratches and bearing contamination caused by repeated disassembly and assembly.

[0016] This application integrates the rear cover positioning fixture and the outer shell positioning fixture coaxially, and uses positioning pins to directly cooperate with the original mounting holes of the motor, without requiring additional axial or radial space; the adjustment mechanism has a flat overall layout, which can be embedded into the existing assembly line to achieve fully automatic online adjustment, greatly improving the production cycle and automation level, and providing a structural basis for the lightweight and platform-based design of the motor.

[0017] This application uses a controller to adjust multiple parameters in real time, including target position, thrust limit, speed curve, and angle determination window. It is compatible with motor models of different frame sizes, stack thicknesses, and pole slot combinations. When changing models, only the corresponding variable table needs to be called, without the need to replace mechanical parts. This significantly enhances production flexibility and equipment utilization, and reduces equipment investment and maintenance costs for multi-variety mixed production. Attached Figure Description

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments: Figure 1 is a schematic diagram of the relevant structure of the motor deflection angle adjustment mechanism.

[0019] Figure 2 is a partial structural schematic diagram of the motor deflection angle adjustment mechanism.

[0020] Figure 3 is a cross-sectional view of the motor deflection angle adjustment mechanism along the AA direction.

[0021] Figure 4 is a schematic block diagram of the controller for the motor deflection angle adjustment mechanism.

[0022] Figure 5 is a schematic diagram of the servo-ball screw flat push module of the motor deflection angle adjustment mechanism. Detailed Implementation

[0023] Explanation of reference numerals in the attached drawings: 1. Base plate; 2. Flat push module; 3. Push plate; 4. Thrust bearing; 5. Bearing housing; 6. Adapter module; 7. Rear cover positioning fixture; 8. Outer shell positioning fixture; 9. Rear cover positioning pin; 10. Outer shell positioning pin; 11. Cross roller bearing; 12. Bearing clamping nut.

[0024] according to Figures 1 to 5 The technical solution shown provides a motor deflection angle adjustment mechanism, including a base plate (1), a servo-ball screw push module (2) fixed on the base plate (1), a push plate (3) rigidly connected to the screw nut, two sets of thrust bearings (4) and bearing seats (5) symmetrically installed on both sides of the push plate (3), a housing positioning fixture (8) fixed to the two bearing seats (5) by pins and only able to rotate around its own axis, a rear cover positioning fixture (7) coaxially arranged in the housing positioning fixture (8) and together with it clamping the motor being adjusted, a crossed roller bearing (11) pressed into the outer circle of the housing positioning fixture (8) and pre-pressed to zero clearance by a flange cover plate (13), and a bearing clamping nut (12) for axially locking the crossed roller bearing (11). The above technical solution enables the entire adjustment mechanism to achieve high-precision deflection angle adjustment in a compact space, solves the problem of unqualified deflection angle caused by the accumulation of part tolerances in traditional methods, and improves the accuracy and efficiency of motor assembly.

[0025] Furthermore, the bearing clamping nut (12) engages with the housing positioning fixture (8) via a thread, pre-compressing the crossed roller bearing (11) to zero axial clearance. This technical solution enables the crossed roller bearing (11) to be stably fixed on the housing positioning fixture (8), ensuring the accuracy and stability of the rotational motion.

[0026] Furthermore, the thrust bearing (4) is a one-way thrust ball bearing, with its race fixed to the bearing housing (5) and its shaft ring fixed to the push plate (3), thus realizing the conversion of horizontal thrust into rotational torque. The above technical solution enables the horizontal thrust motion of the push plate (3) to be efficiently converted into the rotational motion of the housing positioning fixture (8), thereby improving the transmission efficiency of the adjustment mechanism.

[0027] Furthermore, it also includes a laser displacement sensor and a controller. The laser displacement sensor detects the tangential displacement of the edge of the housing positioning fixture (8) in real time and feeds it back to the controller to form a closed-loop control of the rotation angle. The above technical solution enables the adjustment of the electrical deflection angle to achieve high-precision closed-loop control, improving the accuracy and reliability of the adjustment.

[0028] Furthermore, the controller includes a scanning mechanism, a recording mechanism, a calculation mechanism, a judgment mechanism, an execution mechanism, and a re-execution mechanism. The scanning mechanism is used to retrieve the current motor model parameters; the recording mechanism is used to record the servo motor drive screw being pushed lightly to the pre-load position and to record the measured arc length of the laser; the calculation mechanism is used to calculate the remaining stroke based on the built-in ΔL-Δθ line graph; the judgment mechanism is used for servo secondary feed until the laser feedback value falls within the ±0.05° judgment window; the execution mechanism is used to output a confirmation signal and tighten the motor housing bolts; the re-execution mechanism is used to reverse slightly and replenish the stroke if it exceeds the window until it is qualified. The above technical solution enables the entire adjustment process to be automated, improving adjustment efficiency and quality.

[0029] Furthermore, the rear cover positioning fixture (7) and the outer shell positioning fixture (8) are respectively provided with a rear cover positioning pin (9) and an outer shell positioning pin (10), which are used to cooperate with the positioning holes on the rear cover and outer shell of the motor being adjusted to achieve coaxial clamping. The above technical solution enables the motor being adjusted to be stably fixed on the adjustment mechanism, ensuring the stability of the adjustment process.

[0030] Furthermore, the servo-ball screw flat-push module (2) includes a target position judgment mechanism, a thrust adjustment and limiting mechanism, a speed curve adjustment mechanism, and an angle judgment window mechanism; the minimum resolution of the target position judgment mechanism is 0.01 mm; the range of the thrust adjustment and limiting mechanism is 0-300% of the rated torque; the speed curve adjustment mechanism is used to adjust the acceleration and deceleration time and the running speed; the angle judgment window mechanism is used to determine that the difference between the laser feedback and the theoretical arc length is ≤ ±0.05°. The above technical solution enables the servo-ball screw flat-push module (2) to accurately control the movement of the push plate (3), improving the accuracy and efficiency of the adjustment.

[0031] When using this utility model, the motor to be adjusted is first fixed on the rear cover positioning fixture (7) and the outer shell positioning fixture (8). Then, the servo-ball screw flat push module (2) is started by the controller, so that the push plate (3) performs a flat push movement according to the preset target position. The thrust bearing (4) converts the flat push force into rotational torque, driving the outer shell positioning fixture (8) to rotate. The laser displacement sensor detects the rotation angle of the outer shell positioning fixture (8) in real time and feeds the data back to the controller. The controller calculates the remaining stroke according to the built-in ΔL-Δθ line table and controls the servo-ball screw flat push module (2) to perform secondary feed until the laser feedback value falls into the ±0.05° judgment window. If it exceeds the window, the controller controls the push plate (3) to reverse slightly and replenish until it is qualified. Finally, the controller outputs a confirmation signal, locks the motor shell bolts, and completes the adjustment of the electrical deflection angle.

[0032] The overall operation of this utility model is as follows: Through the precise control of the servo-ball screw flat push module (2), combined with the efficient transmission of the thrust bearing (4) and the crossed roller bearing (11), and the closed-loop control of the laser displacement sensor and controller, high-precision adjustment of the motor's electrical deflection angle is achieved. The entire process is automated, improving adjustment efficiency and quality, and reducing manual intervention and costs.

[0033] It should be noted that the above-described embodiments only illustrate several preferred implementations of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be pointed out that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application.

Claims

1. A motor deflection angle adjustment mechanism, characterized in that, include: The base plate (1); the servo-ball screw push module (2) fixed on the base plate (1); the push plate (3) rigidly connected to the screw nut; two sets of thrust bearings (4) and bearing seats (5) symmetrically installed on both sides of the push plate (3); the housing positioning fixture (8) fixed to the two bearing seats (5) by pins and only able to rotate around its own axis; the rear cover positioning fixture (7) coaxially arranged in the housing positioning fixture (8) and together with it clamps the motor being adjusted; the cross roller bearing (11) pressed into the outer circle of the housing positioning fixture (8) and pre-pressed to zero clearance by the flange cover plate; and the bearing clamping nut (12) for axially locking the cross roller bearing (11).

2. The motor deflection angle adjustment mechanism according to claim 1, characterized in that: The bearing clamping nut (12) is threadedly engaged with the housing positioning fixture (8) to pre-compress the crossed roller bearing (11) to zero axial clearance.

3. The motor deflection angle adjustment mechanism according to claim 1, characterized in that: The thrust bearing (4) is a one-way thrust ball bearing, with its seat ring fixed to the bearing housing (5) and its shaft ring fixed to the push plate (3), thereby realizing the conversion of horizontal thrust to rotational torque.

4. The motor deflection angle adjustment mechanism according to claim 1, characterized in that: It also includes a laser displacement sensor and a controller. The laser displacement sensor detects the tangential displacement of the edge of the housing positioning fixture (8) in real time and feeds it back to the controller to form a closed-loop control of the rotation angle.

5. The motor deflection angle adjustment mechanism according to claim 4, characterized in that: The controller includes the following mechanisms: a scanning mechanism: calling up the current motor model parameters; a recording mechanism: recording the servo motor drive screw being pushed to the pre-press position and recording the measured arc length of the laser; a calculation mechanism: calculating the remaining stroke based on the built-in ΔL-Δθ line table; a judgment mechanism: the servo feeds twice until the laser feedback value falls within the ±0.05° judgment window; an execution mechanism: outputting a confirmation signal and tightening the motor housing bolts; and a re-execution mechanism: if it exceeds the window, it reverses slightly and re-computes until it passes the test.

6. The motor deflection angle adjustment mechanism according to claim 1, characterized in that: The rear cover positioning fixture (7) and the outer shell positioning fixture (8) are respectively provided with a rear cover positioning pin (9) and an outer shell positioning pin (10), which are used to cooperate with the positioning holes on the rear cover and outer shell of the motor being adjusted to achieve coaxial clamping.

7. The motor deflection angle adjustment mechanism according to claim 1, characterized in that: The servo-ball screw flat push module (2) includes: a target position judgment mechanism with a minimum resolution of 0.01 mm; a thrust adjustment and limiting mechanism to adjust the rated torque; a speed curve adjustment mechanism to adjust the acceleration and deceleration time and running speed; and an angle judgment window mechanism to adjust the difference between the laser feedback and the theoretical arc length to ≤ ±0.05°.

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