Electrical interface for a brushless electric machine and brushless electric machine comprising the same

Abstract

The utility model relates to an electrical interface for brushless motor and brushless motor including this electrical interface. Electrical interface (20) includes the first connector (21) for connecting stator winding and the second connector (22) for connecting hall power and signal output. The first connector (21) has three first pin (23), and the second connector (22) has five second pin (24). The size of first pin (23) is greater than the size of second pin (24). According to the utility model, the first connector for connecting stator winding adopts the first pin of larger size, and the second connector for connecting hall power and signal output adopts the second pin of smaller size, thereby giving consideration to current carrying capacity requirement and product compactness requirement.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and more specifically, to an electrical interface for a brushless motor and a brushless motor including the electrical interface. Background Technology

[0002] With the development of science and technology, in order to meet the needs of car users as much as possible and improve user comfort, more and more functions are being integrated into automobiles, such as power seats. To achieve these functions, small motors, especially brushless motors, are widely used in the automotive industry.

[0003] A brushless motor comprises a stator assembly and a rotor assembly. The stator assembly includes a stator and stator windings wound on the stator, while the rotor assembly includes a rotor shaft and permanent magnets and a rotor core mounted on the rotor shaft. To determine the rotor pole position and speed in real time to provide commutation and speed regulation data to the controller, brushless motors typically incorporate Hall effect sensors, such as three Hall effect elements mounted on a printed circuit board.

[0004] For brushless motors with built-in Hall effect sensors, the electrical interface typically requires eight pins. Three pins connect to the three-phase stator windings, requiring a relatively high current carrying capacity; the client needs to connect wires with a wire gauge of AWG18 or higher. The other five pins are used for powering the Hall effect sensor and for signal output, requiring a relatively low current carrying capacity; the client only needs to connect wires with a wire gauge of AWG20 or lower. Currently, global plug manufacturers do not differentiate between the three pins connecting the stator windings and the five pins connecting the Hall effect sensor in their 8-pin plugs; instead, they use a uniform eight pins, and correspondingly, the maximum wire gauge allowed for the plugs is also uniform. If the current carrying capacity of the stator windings needs to be met, the pin size needs to be large enough, and the size of the standard 8-pin plug also increases accordingly, failing to meet customer requirements for product compactness. On the other hand, if the customer's requirements for product compactness need to be met, a smaller 8-pin plug needs to be selected, and the internal pin size decreases accordingly, thus failing to meet the current carrying capacity requirements. Utility Model Content

[0005] This invention is proposed based on the above background, and its purpose is to provide an electrical interface for brushless motors that can take into account both current carrying capacity requirements and product compactness requirements.

[0006] To achieve the above objectives, a first aspect of this invention provides an electrical interface for a brushless motor, the brushless motor including a housing, an end cap connected to one end of the housing, a stator winding and a printed circuit board built into the housing, and a Hall element disposed on the printed circuit board. The electrical interface includes a first connector for connecting the stator winding and a second connector for connecting Hall power and signal output. The first connector has three first pins, and the second connector has five second pins, wherein the size of the first pins is larger than the size of the second pins.

[0007] According to one embodiment of the present invention, the first connector and the second connector are integrated on the same motor component.

[0008] According to one embodiment of the present invention, the second connector is embedded in the end cap.

[0009] According to one embodiment of the present invention, the first connector is a standardized 3-pin female connector, and the second connector is a standardized 5-pin female connector.

[0010] According to one embodiment of the present invention, the first pin and / or the second pin are soldered to the printed circuit board.

[0011] According to one embodiment of the present invention, the first pin and / or the second pin are connected to the printed circuit board by an interference fit.

[0012] According to one embodiment of the present invention, the first pin and / or the second pin are fisheye pins.

[0013] A second aspect of this invention provides a brushless motor comprising a housing, an end cap connected to one end of the housing, and a stator assembly, a rotor assembly, and a printed circuit board housed within the housing. The stator assembly includes a stator and stator windings wound on the stator, the rotor assembly includes a rotor shaft and permanent magnets and a rotor core disposed on the rotor shaft, and Hall effect sensors are disposed on the printed circuit board. This brushless motor particularly includes the electrical interface described above according to the first aspect of this invention.

[0014] According to one embodiment of the present invention, the outer diameter of the housing is 20-45 mm, and the axial length of the housing is 40-100 mm.

[0015] According to one embodiment of the present invention, the maximum width of the electrical interface is 10-35 mm, and the distance between the outermost radial side of the electrical interface and the rotation center of the rotor shaft is 15-40 mm.

[0016] According to the electrical interface for brushless motors of this invention, the traditional single-specification 8-pin interface is decoupled into two independent interfaces: one is a high-current 3-pin power interface, and the other is a low-current 5-pin signal interface. This allows customers to choose standardized 3-pin and 5-pin plugs respectively, ensuring the high current carrying capacity required by the power interface while achieving miniaturization of the signal interface. Attached Figure Description

[0017] The above and other features and advantages of this utility model will become more readily understood from the following description with reference to the accompanying drawings, in which:

[0018] Figure 1 A side view schematic diagram of a brushless motor according to an embodiment of the present invention is shown;

[0019] Figure 2 A partial 3D view of the brushless motor is shown;

[0020] Figure 3 Show Figure 2 A 3D view of the electrical interfaces in the diagram;

[0021] Figure 4 Showing from Figure 1 The end view observed from the right side of the image;

[0022] Figure 5 This diagram illustrates the connection status of the electrical interface pins to the printed circuit board.

[0023] All accompanying drawings are schematic only and are not necessarily drawn to scale. Furthermore, they only show those parts necessary to illustrate the invention; other parts are omitted or merely mentioned. That is, the invention may include other components besides those shown in the drawings. Detailed Implementation

[0024] In the following description, numerous specific details are set forth to enable those skilled in the art to gain a more complete understanding of the present invention. However, it will be apparent to those skilled in the art that implementations of the present invention may not include some of these specific details. The various aspects, features, embodiments, and advantages described below are for illustrative purposes only and should not be construed as elements or limitations of the claims, unless expressly set forth in the claims. Terms such as "first," "second," etc., are used hereinafter to describe elements of this application; these terms are used only to distinguish individual elements and are not intended to limit the nature, sequence, order, or number of these elements. Furthermore, it should be noted that in this specification, identical and / or functionally identical technical features are represented by the same or similar reference numerals.

[0025] As mentioned in the background section, in existing brushless motors with built-in Hall sensors, the electrical interface typically uses a standardized 8-pin connector, without distinguishing between the three pins connecting the stator windings and the five pins connecting the Hall element. To meet the current carrying capacity of the stator windings, the pin size needs to be large enough, thus increasing the size of the standard 8-pin connector, which cannot meet customer requirements for product compactness. On the other hand, to meet customer requirements for product compactness, a smaller 8-pin connector needs to be selected, resulting in a reduction in the internal pin size, which also cannot meet the current carrying capacity requirements.

[0026] Therefore, this utility model proposes an improved electrical interface for brushless motors, which replaces the traditional 8-pin connector with two independent 3-pin and 5-pin connectors, thus simultaneously meeting the requirements for current carrying capacity and product compactness.

[0027] Specifically, Figures 1 to 5 A schematic diagram of a brushless motor 1 and its electrical interface 20 according to an embodiment of the present invention is shown. The present invention particularly relates to small-sized brushless motors. The outer diameter of the motor (i.e., the outer diameter of the motor housing) A can be 20-45 mm, for example, about 36 mm. The axial length B of the motor can be between 40 mm and 100 mm. Brushless motors of this size are well-suited for controlling the movement of electric seats in automobiles. Of course, this is not intended to limit the application of the present invention to other sizes and types of motors and application scenarios.

[0028] The brushless motor 1 includes a housing 10, an end cap 11 connected to one end of the housing 10, a stator assembly and a rotor assembly located within the housing 10, and an electrical interface 20 located outside the housing 10. The stator assembly includes a stator and stator windings wound on the stator. The rotor assembly includes a rotor shaft and permanent magnets and a rotor core disposed on the rotor shaft. The stator and rotor assemblies, not shown in the figures, employ conventional designs in the art. Figure 5 As shown, the brushless motor 10 also includes a printed circuit board 12 located within the housing 10, on which three Hall elements 13 are disposed. The three Hall elements 13, together with three signal lines and two power lines (not shown in the figure) arranged on the printed circuit board 12, constitute a Hall sensor. Preferably, the U, V, and W three-phase power lines of the stator winding are also connected to the printed circuit board 12.

[0029] like Figure 2 and Figure 3 As shown, the electrical interface 20 includes a first connector 21 and a second connector 22. The first connector 21 has three first pins 23, which are used to connect the U, V, and W three-phase power lines of the stator winding, respectively. The second connector 22 has five second pins 24, which are used to connect the two power lines and three signal lines of the Hall sensor, respectively.

[0030] The power supply lines of the stator windings require a relatively large current carrying capacity, with peak currents reaching several amperes or even tens of amperes. The power supply lines of the Hall sensor, on the other hand, require a relatively small current carrying capacity, typically only a few milliamperes. Therefore, the size of each first pin 23 can be significantly larger than the size of each second pin 24.

[0031] The first connector 21 can be configured as a standardized 3-pin female connector. The second connector 22 can be configured as a standardized 5-pin female connector. This allows customers to easily select standardized 3-pin male connectors and standardized 5-pin male connectors to mate with the first connector 21 and the second connector 22, respectively. The 3-pin male connector requires wire with a wire gauge of AWG18 or higher to meet the higher current carrying requirements of the stator winding. The 5-pin male connector only requires wire with a wire gauge of AWG20 or lower.

[0032] The first connector 21 and the second connector 22 are preferably integrated on the same motor component. In this embodiment, the first connector 21 and the second connector 22 are integrated on the end cover 11 of the brushless motor 1. More specifically, the housings of the first connector 21 and the second connector 22 are connected together (e.g., they can be integrally formed by injection molding), and the second connector 22 is embedded in the end cover 11, such as... Figure 2 As shown. This embedded design can further improve product compactness and meet customer requirements for product compactness.

[0033] As an example, such as Figure 4 As shown, the maximum width C of the electrical interface 20 (i.e., the width of the first connector 21 in the direction perpendicular to the motor axial and radial directions) can be between 10 mm and 35 mm, and the distance D between the outermost radial part of the electrical interface 20 (i.e., the outermost radial part of the first connector 21) and the rotation center O of the rotor shaft can be between 15 mm and 40 mm.

[0034] like Figure 5 As shown, the first pin 23 of the first connector 21 and / or the second pin 24 of the second connector 22 can be connected to the printed circuit board 12 by soldering (e.g., tin soldering) or interference fit. Preferably, the first pin 23 and / or the second pin 24 can be constructed as fisheye pins commonly used in this field.

[0035] As described above, the electrical interface 20 used in the brushless motor 1 of this invention replaces the traditional single-specification 8-pin interface with two independent interfaces, one of which is a high-current 3-pin power interface and the other is a low-current 5-pin signal interface. This allows customers to choose standardized 3-pin plugs and 5-pin plugs respectively, thereby balancing current carrying capacity requirements and product compactness requirements.

[0036] Various modifications and variations can be made to the embodiments disclosed above without departing from the scope or spirit of this invention. Other embodiments of this invention will be apparent to those skilled in the art based on the practice of this invention disclosed in this specification. This specification and the examples disclosed herein should be considered illustrative only, and the true scope of this invention is defined by the appended claims and their equivalents.

Claims

1. An electrical interface (20) for a brushless motor (1), the brushless motor (1) comprising a housing (10), an end cap (11) connected to one end of the housing (10), a stator winding and a printed circuit board (12) built into the housing (10), and a Hall element (13) disposed on the printed circuit board (12), characterized in that, The electrical interface (20) includes a first connector (21) for connecting the stator winding and a second connector (22) for connecting the Hall power supply and signal output. The first connector (21) has three first pins (23) and the second connector (22) has five second pins (24). The size of the first pins (23) is larger than the size of the second pins (24).

2. The electrical interface (20) of the brushless motor according to claim 1, characterized in that, The first connector (21) and the second connector (22) are integrated on the same motor component.

3. The electrical interface (20) of the brushless motor according to claim 2, characterized in that, The second connector (22) is embedded in the end cap (11).

4. The electrical interface (20) of the brushless motor according to any one of claims 1 to 3, characterized in that, The first connector (21) is a standardized 3-pin female connector, and the second connector (22) is a standardized 5-pin female connector.

5. The electrical interface (20) of the brushless motor according to any one of claims 1 to 3, characterized in that, The first pin (23) and / or the second pin (24) are connected to the printed circuit board (12) by an interference fit.

6. The electrical interface (20) of the brushless motor according to claim 5, characterized in that, The first pin (23) and / or the second pin (24) are fisheye pins.

7. The electrical interface (20) of the brushless motor according to any one of claims 1 to 3, characterized in that, The first pin (23) and / or the second pin (24) are soldered to the printed circuit board (12).

8. A brushless motor (1), comprising a housing (10), an end cap (11) connected to one end of the housing (10), and a stator assembly, a rotor assembly, and a printed circuit board (12) built into the housing (10), wherein the stator assembly comprises a stator and a stator winding wound on the stator, the rotor assembly comprises a rotor shaft and a permanent magnet and a rotor core disposed on the rotor shaft, and a Hall element (13) is disposed on the printed circuit board (12), characterized in that, The brushless motor (1) further includes an electrical interface (20) according to any one of claims 1 to 7.

9. The brushless motor (1) according to claim 8, characterized in that, The outer diameter (A) of the housing (10) is 20-45 mm, and the axial length (B) of the housing (10) is 40-100 mm.

10. The brushless motor (1) according to claim 8 or 9, characterized in that, The maximum width (C) of the electrical interface (20) is 10-35 mm, and the distance (D) between the outermost radial side of the electrical interface (20) and the rotation center (O) of the rotor shaft is 15-40 mm.

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