Electric brush assembly, conduction device and inner-rotor electric motor

Abstract

An electric brush assembly, a conduction device and an inner-rotor electric motor. The electric brush assembly comprises: a support body and at least two electric brush members spaced apart from each other in an axial direction, wherein each electric brush member comprises an elastic piece and a carbon brush, each elastic piece comprising a fixed end fixedly connected to the support body and a free end opposite the fixed end, each carbon brush being fixed to the free end of the corresponding elastic piece and having a contact face configured to be in sliding contact with a sliding ring, and the outward orientations of the contact faces that face away from the carbon brushes providing clearance for and bypassing the support body and all elastic pieces. By means of pushing each carbon brush at the free end of one elastic piece, the sliding ring can continue to move in a predetermined mounting direction until the sliding ring reaches a predetermined position relative to the support body. Since the electric brush assembly of the present application cannot form a closed inner peripheral area, an operation of pushing each elastic piece to the periphery by means of a special tool is omitted, thereby facilitating the simplification of an assembly process for the inner-rotor electric motor, and also facilitating an improvement in the assembly efficiency of the inner-rotor electric motor.

Description

Brush assembly, conduction device and inner rotor motor Technical Field

[0001] The present application relates to the field of motor technology, and in particular to a brush assembly, a conduction device, and an inner rotor motor. Background Art

[0002] A motor generally consists of a stator and a rotor, which rotates relative to the stator. Depending on the internal and external position of the stator and rotor, motors can be divided into two categories: internal rotor motors and external rotor motors. In an internal rotor motor, the stator surrounds the rotor, while the rotor rotates within the stator.

[0003] During the rotation of the rotor, brushes are usually required to cooperate with the commutator or slip rings to achieve the conductivity of the rotor. When the slip ring on the rotor needs to contact multiple brushes, in order to ensure the insulation between the multiple brushes, the traditional technology generally allows the multiple brushes to be evenly staggered along the outer circumference of the rotor. However, during the assembly process of the motor, after the multiple brushes are installed first, each brush moves closer to the central axis under the action of the spring, resulting in the diameter of the inner circumference area enclosed by each brush in its natural form being smaller than the diameter of the slip ring. During the assembly process of the motor, the slip ring cannot be directly inserted axially into the inner circumference area defined by the multiple brushes. It is necessary to use a jig to push each brush in the outer circumference direction to expand the diameter of the inner circumference area defined by each brush before the slip ring can be pushed axially into the inner circumference area. Since the motor needs to use special tools to push the brushes during assembly, the assembly steps of the motor are relatively complicated, which is not conducive to improving the assembly efficiency of the motor.

[0004] Summary of the Invention

[0005] Based on this, the present invention provides a brush assembly, a conducting device and an inner rotor motor that can solve or at least alleviate the above technical problems.

[0006] The present invention provides a brush assembly, comprising:

[0007] a support; and

[0008] At least two brush members are arranged at intervals along the axial direction; each of the brush members includes a spring piece and a carbon brush; each spring piece includes a fixed end fixedly connected to the support body and a free end opposite to the fixed end; each carbon brush is fixed to the free end of its corresponding spring piece and has a contact surface for sliding contact with a slip ring; the contact surface is outward-facing away from the carbon brush and is avoided around the support body and all spring pieces.

[0009] In the brush assembly described above, the fixed end of the spring clip is connected to the support, maintaining a stable position. The spring clip can elastically deform within a certain range, causing the carbon brush fixed at the free end to change position relative to the fixed end. The centerline of the slip ring is parallel or nearly parallel to the axial direction. When the slip ring moves radially toward the brush assembly, the predetermined installation direction of the slip ring is perpendicular or nearly perpendicular to the axial direction. When the predetermined installation direction of the slip ring is parallel or nearly parallel to the outward orientation of the contact surface, the spring clip, in its free state, faces outward away from the support and all spring clips. Therefore, when the slip ring approaches the contact surface of the carbon brush along the predetermined installation direction, it is not obstructed by the support or spring clip. After the contact surface of the slip ring and the carbon brush contacts, the slip ring can continue to move in the predetermined installation direction by pushing against the carbon brush at the free end of the spring clip until it reaches the predetermined position relative to the support. At this point, the spring clip deforms slightly under the pressure of the slip ring, ensuring a stable fit of the carbon brush against the surface of the slip ring. Because at least two brush elements are axially spaced apart, and their contact surfaces face outwards away from the support and all springs, when installing the slip ring, the slip ring can be used to directly push against the contact surfaces of all carbon brushes, reaching a position that coincides with the predetermined position. Because the brush assembly of the present application does not form a closed inner circumference, the slip ring can be installed by directly pushing against the carbon brushes from the radial direction, eliminating the need to use specialized tools to push each spring toward the outer circumference. This simplifies the assembly process of inner-rotor motors and improves their assembly efficiency.

[0010] In one embodiment, on a plane perpendicular to the axial direction, a first central angle corresponding to the projections of all free ends is not greater than a second central angle corresponding to the projections of all fixed ends, wherein the first central angle is the central angle of the span of the projections of all free ends in the circumferential direction with respect to the axis, and the second central angle is the central angle of the span of the projections of all fixed ends in the circumferential direction with respect to the axis, and the axis is the projection of the central axis of the slip ring on a plane perpendicular to the axial direction when the carbon brush and the slip ring are in an assembled state.

[0011] In one embodiment, the two axially adjacent carbon brushes are staggered in the axial direction.

[0012] In one embodiment, on a plane perpendicular to the axial direction, a central angle of the projections of two axially adjacent carbon brushes about the axis is equal to a central angle of the span of the projections of all the carbon brushes in the circumferential direction about the axis.

[0013] In one embodiment, the support body includes a mounting portion and a supporting portion, one end of the supporting portion is connected to the mounting portion, and the other end is connected to the fixed end of the spring sheet, and the distance between the free end and the mounting portion is smaller than the distance between the fixed end and the mounting portion.

[0014] In one embodiment, a first guide groove is provided on a side surface of the mounting portion for axial guidance and radial limitation when the brush assembly is mounted to a first recessed position of a stator housing.

[0015] In one embodiment, the mounting portion includes at least two seat body components arranged adjacent to each other along the axial direction, and each of the seat body components is snap-fitted with the adjacent seat body components; the supporting portion includes at least two conductive sheets, and one end of each of the conductive sheets is passed through one of the seat body components, and the other end is connected to the fixed end of one of the spring sheets.

[0016] In one embodiment, each of the base components is provided with a positioning groove, and each of the conductive sheets is at least partially inserted into the positioning groove of its corresponding base component.

[0017] The present invention provides a conducting device, comprising a slip ring and a brush assembly. The slip ring comprises at least two mutually insulated conductive rings, and the contact surface of each carbon brush abuts against one of the conductive rings.

[0018] The present invention provides an inner rotor motor, comprising a stator assembly and a rotor assembly rotatably disposed within the stator assembly, the stator assembly comprising a stator housing, a magnet disposed on the inner wall surface of the stator housing, and a brush assembly, the magnet forming a magnetic field stationary relative to the stator housing; the rotor assembly comprising an iron core, a rotating shaft inserted into the iron core, and a coil wound around the iron core; a slip ring electrically connected to the coil is sleeved on the rotating shaft, and a contact surface of the brush assembly abuts against the slip ring. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG1 is a perspective schematic diagram of an inner rotor motor according to an embodiment of the present application.

[0020] FIG. 2 is a perspective schematic diagram of the inner rotor motor shown in FIG. 1 at another angle.

[0021] FIG3 is an exploded schematic diagram of the inner rotor motor shown in FIG2 .

[0022] FIG. 4 is an exploded schematic diagram of the inner rotor motor shown in FIG. 2 at another angle.

[0023] FIG5 is a perspective schematic diagram of the brush assembly in the inner rotor motor shown in FIG4 in a free state.

[0024] FIG. 6 is a perspective schematic diagram of the brush assembly in the inner rotor motor shown in FIG. 4 at another angle.

[0025] FIG. 7 is an exploded schematic diagram of the brush assembly shown in FIG. 6 .

[0026] FIG8 is an exploded schematic diagram of the brush assembly shown in FIG6 at another angle.

[0027] FIG. 9 is a partially exploded schematic diagram of the brush assembly shown in FIG. 6 .

[0028] FIG. 10 a is a top view of the brush assembly shown in FIG. 5 .

[0029] FIG10 b is a top view of the brush assembly shown in FIG5 , in a state where the carbon brush is abutted by the slip ring.

[0030] FIG11 a is a three-dimensional schematic diagram of a brush assembly in a free state according to an embodiment of the present application.

[0031] FIG. 11 b is a top view of the brush assembly shown in FIG. 11 a .

[0032] FIG12 is a side view of an inner rotor motor according to another embodiment of the present application.

[0033] FIG13 is a schematic diagram of an inner rotor motor during assembly according to another embodiment of the present application.

[0034] FIG14 is a top view of the brush assembly in the inner rotor motor shown in FIG13 , wherein the spring piece is in a state of being supported by the slip ring.

[0035] Reference numerals: 100, inner rotor motor; 20, stator housing; 21, first recess; 22, open end; 23, side wall block; 30, rotor assembly; 31, rotating shaft; 32, iron core; 33, coil; 40, conducting device; 70, brush assembly; 71, support body; 72, mounting portion; 721, inner seat; 720, rib; 722, outer seat; 723, transition portion; 724, seat body component; 725, positioning groove; 726, clamping block; 727, clamping groove; 728, first guide groove; 729, second guide groove; 73 , conductive sheet; 730, bending transition; 731, extension section; 732, lateral extension section; 733, longitudinal extension section; 734, pin section; 735, end; 74, brush member; 75, spring piece; 751, fixed end; 752, free end; 753, folded section; 754, sheet section; 76, carbon brush; 761, contact surface; 90, slip ring; 91, conductive ring; 50, magnet; 80, end cover; 81, bearing member; 82, second recess; F1, axial direction; F2, predetermined installation direction; F3, outward direction; F4, relative direction. DETAILED DESCRIPTION

[0036] The following will clearly and completely describe the technical solution of this application in conjunction with the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0037] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, integrated connections, mechanical connections, electrical connections, direct connections, indirect connections through an intermediate medium, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0039] The technical solutions provided by the embodiments of the present application are described below with reference to the accompanying drawings.

[0040] 1 to 14 , the present application provides an inner rotor motor 100. The inner rotor motor 100 can be used in the automotive field or other industrial fields (such as household appliances, power tools, etc.) as a driving component for outputting driving torque.

[0041] In some embodiments, as shown in conjunction with FIG. 3 and FIG. 4 , the inner rotor motor 100 includes a stator assembly and a rotor assembly 30 rotatably disposed within the stator assembly.

[0042] In some embodiments, as shown in FIG3 , the stator assembly includes a stator housing 20, a magnet 50 disposed on the inner wall of the stator housing 20, and a brush assembly 70. The magnet 50 forms a magnetic field that is stationary relative to the stator housing 20. The rotor assembly 30 includes an iron core 32, a rotating shaft 31 inserted into the iron core 32, and a coil 33 wound around the iron core 32. A slip ring 90 is sleeved on the rotating shaft 31 and electrically connected to the coil 33. Specifically, the magnet 50 can be a magnet or other magnetic component.

[0043] In some embodiments, the coil 33 is a multi-phase coil or a single-phase coil, and accordingly, the external power source is an AC power source, such as a multi-phase or single-phase AC power source. When the coil 33 is a multi-phase coil, the number of conductive rings 91 is not less than the number of phases of the multi-phase coil. Each phase coil 33 is electrically connected to one of the conductive rings 91. Thus, each phase coil 33 can be electrically connected to the external power source via a conductive ring 91. The number of conductive rings 91 is preferably equal to the number of phases of the multi-phase coil. When the coil 33 is a single-phase coil, the number of conductive rings 91 is two, and the two conductive rings 91 are respectively connected to the head and tail of the single-phase coil. Thus, both the head and tail of the single-phase coil can be electrically connected to the external power source via a conductive ring 91.

[0044] In some embodiments, as shown in FIG3 , the magnets 50 are evenly spaced along the circumferential direction of the stator housing 20, and adjacent magnets 50 have opposite polarities. That is, if one of two adjacent magnets 50 has an N pole at its radial inner end and an S pole at its radial outer end, the other has an S pole at its radial inner end and an N pole at its radial outer end. This results in alternating N and S poles being formed circumferentially within the stator housing 20, forming a stator magnetic field that is stationary relative to the stator housing 20. In some embodiments, the magnets 50 are made of a weak magnetic material, such as ferrite. The magnets 50 can also be made of a strong magnetic material, such as neodymium iron boron. The magnets 50 can also be electromagnets.

[0045] In some embodiments, as shown in FIG3 , the stator housing 20 is provided with a first recess 21. In some embodiments, the first recess 21 is provided at the edge of the open end 22 of the stator housing 20. In some embodiments, the iron core 32 may be formed by stacking a plurality of silicon steel sheets, including a yoke portion that is sleeved on the rotating shaft 31 and a plurality of teeth that extend radially outward from the yoke portion. The rotating shaft 31 is fixedly plugged into the yoke portion of the iron core 32, and both ends of the rotating shaft 31 extend outside the iron core 32 to transmit power outward. The coil 33 is wound around each tooth portion, and adjacent teeth portions are spaced apart in the circumferential direction to form a winding slot for winding the coil 33.

[0046] In some embodiments, as shown in Figures 3 and 4, the inner rotor motor 100 further includes an end cover 80. The end cover 80 is used to cover the open end 22 of the stator case 20. In some embodiments, the end cover 80 is embedded in the inner side of the open end 22 of the stator case 20. In some embodiments, the inner rotor motor 100 further includes a bearing member 81. The bearing member 81 can be disposed between the stator case 20 and the rotating shaft 31. The bearing member 81 can also be disposed between the end cover 80 and the rotating shaft 31. In some embodiments, as shown in Figure 13, the end cover 80 is provided with a second recess 82. In some embodiments, the second recess 82 extends radially from the outer peripheral edge of the end cover 80 toward the center of the end cover 80.

[0047] As shown in conjunction with Figures 3 and 4 , the present application provides a conducting device 40. The conducting device 40 is used to conduct current to the coil 33. When current flows through the coil 33, it is subjected to electromagnetic force and rotates relative to the stator housing 20. In some embodiments, the conducting device 40 includes a slip ring 90 and a brush assembly 70. The slip ring 90 is fixedly mounted on the rotating shaft 31 and rotates with the rotating shaft 31. The slip ring 90 is electrically connected to the coil 33. The brush assembly 70 is in a fixed position relative to the stator housing 20. The brush assembly 70 and the slip ring 90 maintain electrical connection through sliding contact.

[0048] In some embodiments, as shown in FIG3 , the slip ring 90 includes at least two mutually insulated conductive rings 91. The at least two conductive rings 91 are spaced apart from each other along the axial direction F1. In some embodiments, the diameters of the at least two conductive rings 91 may be the same or different.

[0049] In conjunction with Figures 5 and 6 , the present application further provides a brush assembly 70, which can be applied to at least the above-mentioned conduction device 40 or the above-mentioned inner rotor motor 100. In some embodiments, the brush assembly 70 includes: a support body 71 and at least two brush members 74 spaced apart along the axial direction F1. Each brush member 74 includes a spring 75 and a carbon brush 76. Each spring 75 includes a fixed end 751 fixedly connected to the support body 71 and a free end 752 opposite to the fixed end 751. Each carbon brush 76 is fixed to the free end 752 of its corresponding spring 75 and has a contact surface 761 for sliding contact with a slip ring 90. The contact surface 761 is away from the outward direction F3 of the carbon brush 76 and is wrapped around the support body 71 and all springs 75.

[0050] Specifically, because the fixed end 751 of the spring clip 75 is connected to the support body 71, the fixed end 751 of the spring clip 75 is in a stable position. The spring clip 75 can elastically deform within a certain range, causing the carbon brush 76 fixed to the free end 752 to change position relative to the fixed end 751. The centerline of the slip ring 90 is parallel or nearly parallel to the axial direction F1. When the slip ring 90 moves radially toward the brush assembly 70, the predetermined installation direction F2 of the slip ring 90 is perpendicular or nearly perpendicular to the axial direction F1. When the predetermined installation direction F2 of the slip ring 90 is parallel or nearly parallel to the outward direction F3 of the contact surface 761, since the outward direction F3 is avoided around the support body 71 and all spring clips 75 when the spring clip 75 is free, when the slip ring 90 approaches the contact surface 761 of the carbon brush 76 along the predetermined installation direction F2, the slip ring 90 is not blocked by the support body 71 or the spring clip 75. After the slip ring 90 and the contact surface 761 of the carbon brush 76 have just contacted, the slip ring 90 can continue to move in the predetermined installation direction F2 by pushing against the carbon brush 76 at the free end 752 of the spring plate 75, until the slip ring 90 reaches the predetermined position relative to the support body 71. At this point, the spring plate 75 deforms slightly under the pressure of the slip ring 90, allowing the carbon brush 76 to be stably attached to the surface of the slip ring 90. Because at least two brush members 74 are spaced apart axially F1 and the contact surface 761 faces outward F3, avoiding the support body 71 and all spring plates 75, when installing the slip ring 90, the slip ring 90 can directly push against the contact surfaces 761 of all carbon brushes 76, reaching a position that coincides with the predetermined position. Since the brush assembly 70 of the present application does not form a closed inner peripheral area, the slip ring 90 can be installed directly by pushing the carbon brush 76 from the radial direction, eliminating the need to use special tools to push each spring piece 75 toward the outer periphery, thereby simplifying the assembly process of the inner rotor motor 100 and improving the assembly efficiency of the inner rotor motor 100.

[0051] Specifically, as shown in Figures 5 and 10a , the front side of the spring clip 75 faces away from the support body 71, while the back side of the spring clip 75 faces the support body 71. The carbon brush 76 is disposed on the front side of the spring clip 75. Regarding the outward-facing direction F3 of the contact surface 761 avoiding the spring clip 75, it can be understood that the outward-facing direction F3 of the contact surface 761 avoids the front side of the spring clip 75 and avoids the space extending along the axial direction F1 of the front side of the spring clip 75. In some embodiments, the outward-facing direction F3 of the contact surface 761 can point to the space extending along the axial direction F1 of the back side of the spring clip 75.

[0052] In some embodiments, as shown in conjunction with FIG5 and FIG10a , the support body 71 includes a mounting portion 72 and a supporting portion. One end of the supporting portion is connected to the mounting portion 72, and the other end is connected to the fixed end 751 of the spring clip 75. The distance between the free end 752 and the mounting portion 72 is smaller than the distance between the fixed end 751 and the mounting portion 72. Specifically, the support body 71 is mounted on another device via the mounting portion 72. The supporting portion is used to provide support for the fixed end 751 of the spring clip 75, thereby maintaining a stable position. Specifically, in the free state, the distance between the free end 752 and the mounting portion 72 is smaller than the distance between the fixed end 751 and the mounting portion 72. The free end 752 of the spring piece 75 and the mounting portion 72 are spaced relative to each other along the predetermined mounting direction F2 of the slip ring 90. When the slip ring 90 pushes the carbon brush 76 along the predetermined mounting direction F2, the spring piece 75 can produce more significant elastic deformation. The carbon brush 76 is subjected to a more sufficient elastic force, thereby maintaining stable sliding contact with the slip ring 90. In some embodiments, the mounting portion 72 is insulating, thereby preventing short circuit contact between the conductive sheet 73 and other components.

[0053] In some embodiments, as shown in conjunction with Figures 3 and 6 , the support body 71 is mounted to the stator housing 20 via the mounting portion 72. In other embodiments, the support body 71 is mounted to the end cover 80 via the mounting portion 72. In some embodiments, the mounting portion 72 of the support body 71 is retained within the first recess 21, thereby maintaining a relatively stable position for the brush assembly 70 after the support body 71 is at least partially accommodated within the stator housing 20.

[0054] In some embodiments, as shown in Figures 3 and 6 , a first guide groove 728 is provided on the side of the mounting portion 72 to provide axial guidance ( F1 ) and radial positioning when the brush assembly 70 is installed in the first recess 21 of the stator case 20. Specifically, the first guide groove 728 is provided on the outer side of the mounting portion 72. When the brush assembly 70 is installed in the stator case 20, the edge portion of the stator case 20 defining the first recess 21 is inserted into the first guide groove 728 along the axial direction ( F1 ). The edge of the first recess 21 provides axial guidance ( F1 ) for the mounting portion 72. Furthermore, the width of the first guide groove 728 corresponds to the thickness of the stator case 20, thereby limiting the relative radial position of the mounting portion 72 and the stator case 20. In some embodiments, the two edge portions of the stator case 20 defining the first recess 21 can form an interference fit with the inner wall of the first guide groove 728.

[0055] In some embodiments, as shown in FIG6 , the mounting portion 72 includes an inner seat 721, an outer seat 722, and a transition portion 723. The inner seat 721 is configured to be accommodated within the stator housing 20. The outer seat 722 is disposed outside the stator housing 20. The transition portion 723 connects between the inner seat 721 and the outer seat 722. The circumferential width of the inner seat 721 along the stator housing 20 is greater than the circumferential width of the first recess 21 along the stator housing 20. The circumferential width of the outer seat 722 along the stator housing 20 is greater than the circumferential width of the first recess 21 along the stator housing 20. The circumferential width of the transition portion 723 along the stator housing 20 is less than or equal to the circumferential width of the first recess 21 along the stator housing 20. A first guide groove 728 is radially formed between the inner seat 721 and the outer seat 722. When the transition portion 723 is accommodated in the first recess 21, the inner seat 721 is accommodated within the stator case 20, while the outer seat 722 is located outside the stator case 20. In some embodiments, a portion of the surface of the inner seat 721 is disposed opposite the inner wall of the stator case 20, and a rib 720 is provided on this portion of the surface of the inner seat 721. The rib 720 is used to abut against the inner wall of the stator case 20, increasing the friction between the inner seat 721 and the inner wall of the stator case 20, thereby improving the installation stability between the mounting portion 72 and the stator case 20.

[0056] In some embodiments, as shown in FIG13 , the mounting portion 72 is provided with a second guide groove 729 to provide radial guidance and axial position limiting (F1) when the brush assembly 70 is docked with the second recess 82 of the end cover 80. Specifically, one side of the mounting portion 72 faces away from the interior of the stator housing 20, and the second guide groove 729 is provided on this side of the mounting portion 72. When the brush assembly 70 and the end cover 80 are docked and installed, the edge portion of the end cover 80 near the second recess 82 is radially inserted into the second guide groove 729. The second guide groove 729 limits the relative movement direction of the edge portion of the end cover 80 near the second recess 82. In addition, the width of the second guide groove 729 corresponds to the thickness of the end cover 80, thereby limiting the relative position of the mounting portion 72 and the end cover 80 in the axial direction (F1).

[0057] In some embodiments, as shown in FIG12 , the inner rotor motor 100 further includes a sidewall block 23. The support body 71 is mounted to the sidewall block 23 via a mounting portion 72. The sidewall block 23 and the support body 71 cooperate to form a structure capable of surrounding the brush assembly 74. The sidewall block 23 and the support body 71 are connected to the open end 22 of the stator housing 20. After the slip ring 90 deforms the free end 752 of the spring 75 by abutting against it, the sidewall block 23 moves from the side of the slip ring 90 facing away from the support body 71 toward the support body 71 and connects to the support body 71, forming a structure surrounding the slip ring 90. In some embodiments, the edge of the sidewall block 23 is curved. The sidewall block 23 and the support body 71 form a mutually circumferential relationship at an angle, thereby forming a structure that circumferentially surrounds the slip ring 90. In some embodiments, the support body 71 and the sidewall block 23 are confined between the end cover 80 and the open end 22 of the stator housing 20. In some embodiments, the end cover 80 may be fixedly connected to the stator housing 20 , and then the end cover 80 and the open end 22 of the stator housing 20 clamp and fix the side wall block 23 and the support body 71 from both sides.

[0058] In some embodiments, as shown in Figures 6 to 9 , the mounting portion 72 includes at least two adjacent seat segments 724 arranged along the axial direction F1, with each seat segment 724 snap-fitting with the adjacent seat segment 724. The support portion includes at least two conductive plates 73, each of which has one end extending through a seat segment 724 and the other end connected to a fixed end 751 of a spring clip 75. Specifically, the fixed end 751 of the spring clip 75 is connected to the conductive plate 73. The snap-fitting between the seat segments 724 allows the different conductive plates 73 to maintain a stable positional relationship. If defects are discovered in some of the seat segments 724 or conductive plates 73, the defective seat segments 724 or conductive plates 73 can be easily replaced from the support body 71 by releasing the snap-fit ​​between the seat segments 724, thereby avoiding the need to scrap the entire brush assembly 70. Because the conductive sheet 73 and the spring sheet 75 are both conductive, once the position of the conductive sheet 73 is defined by the mounting portion 72, the conductive sheet 73 not only supports the spring sheet 75 but also allows the spring sheet 75 to conduct electricity to an external power source through the conductive sheet 73, thereby simplifying the structure of the brush assembly 70. In some embodiments, both ends of the conductive sheet 73 are exposed outside the mounting portion 72.

[0059] In some embodiments, as shown in Figures 7 and 8 , one of two adjacent seat segments 724 along the axial direction F1 is connected to a latch block 726. This latch block 726 protrudes from the connected seat segment 724 toward the other seat segment 724. The other seat segment 724 is provided with a latching slot 727. The latch block 726 is configured to be embedded within the latching slot 727, thereby securing each seat segment 724 to the adjacent seat segment 724. In some embodiments, the latch block 726 forms an interference fit with the inner wall of the latching slot 727, thereby enhancing the bonding strength between the two adjacent seat segments 724 and providing a more stable structure for the mounting portion 72.

[0060] In some embodiments, as shown in FIG7 , the block 726 and the slot 727 are disposed on the inner seat portion 721 of the mounting portion 72, that is, on the side of the mounting portion 72 facing the slip ring 90. In some embodiments, as shown in FIG8 , the block 726 and the slot 727 are disposed on the outer seat portion 722 of the mounting portion 72, that is, on the side of the mounting portion 72 facing away from the slip ring 90. In some embodiments, the upper seat segment 724 along the axial direction F1 is provided with a block 726, which protrudes toward the lower seat segment 724 along the axial direction F1. The lower seat segment 724 is provided with a slot 727, which opens toward the upper seat segment 724 to accommodate the block 726 of the upper seat segment 724. Since the distribution of the block 726 and the slot 727 is directional, when the direction of the seat body component 724 is flipped incorrectly, the block 726 of the seat body component 724 will abut against the block 726 of another seat body component 724, so that the two seat body components 724 cannot be assembled in the wrong direction, which is conducive to ensuring the misaligned distribution of adjacent conductive sheets 73 or brush components 74.

[0061] In some embodiments, as shown in Figures 7 and 9 , each seat segment 724 is provided with a positioning slot 725. Each conductive sheet 73 is at least partially inserted into the positioning slot 725 of its corresponding seat segment 724, thereby maintaining a stable positional relationship between the conductive sheet 73 and the corresponding seat segment 724. In some embodiments, the conductive sheet 73 and the inner wall surface of the positioning slot 725 are provided with an interference fit. In some embodiments, the opening of the positioning slot 725 of one seat segment 724 faces the other seat segment 724. Specifically, when the seat segment 724 is disassembled, the opening of the positioning slot 725 is exposed, allowing the conductive sheet 73 to be removed from the seat segment 724.

[0062] In some embodiments, for two adjacent seat segments 724 along the axial direction F1, a portion of the conductive sheet 73 is inserted into the positioning slot 725 of one seat segment 724, while the remaining portion is inserted into the positioning slot 725 of the other seat segment 724. Because the conductive sheet 73 is inserted into both adjacent seat segments 724, it can be used to position the two adjacent seat segments 724, allowing for more accurate docking between the two adjacent seat segments 724. When the conductive sheet 73 forms an interference fit with the inner wall of the positioning slot 725, the friction between the conductive sheet 73 and the seat segment 724 can enhance the coupling strength between the two adjacent seat segments 724, thereby maintaining a more stable relative position between the two adjacent seat segments 724.

[0063] In some embodiments, as shown in FIG. 10 a and FIG. 10 b , a bent end of the conductive sheet 73 is welded and fixed to one end of the elastic sheet 75 .

[0064] In some embodiments, as shown in conjunction with FIG7 and FIG9 , the conductive sheet 73 includes an outer extension 731, a lateral extension 732, and a longitudinal extension 733. The lateral extension 732 is connected between the outer extension 731 and the longitudinal extension 733. The outer extension 731 and the longitudinal extension 733 are bent relative to the lateral extension 732 in different directions. The fixed end 751 of the spring 75 is connected to the longitudinal extension 733. Because the lateral extension 732 is bent relative to the outer extension 731, when the outer extensions 731 of each conductive sheet 73 are substantially parallel to each other, the lateral extensions 732 of adjacent conductive sheets 73 extend in opposite directions relative to the outer extension 731. This allows the longitudinal extensions 733 of adjacent conductive sheets 73 along the axial direction F1 to be staggered, creating a larger insulation space between two longitudinal extensions 733 that face each other along the axial direction F1. This ensures insulation between adjacent conductive sheets 73 even when the longitudinal extensions 733 are exposed outside the mounting portion 72.

[0065] In some embodiments, as shown in Figures 7 and 9 , the extension direction of the lateral extension section 732 relative to the outer extension section 731 is parallel or nearly parallel to the relative direction F4 between the two fixed ends 751. The extension direction of the longitudinal extension section 733 relative to the lateral extension section 732 is substantially parallel to the predetermined installation direction F2. In some embodiments, as shown in Figures 13 and 14 , the longitudinal extension section 733 is bent away from the end 735 of the lateral extension section 732, and the fixed end 751 of the spring clip 75 is connected to the end 735 of the longitudinal extension section 733 and has a corresponding bending structure, thereby increasing the contact area between the end 735 of the lateral extension section 732 and the fixed end 751 of the spring clip 75 within a limited space, thereby ensuring the stability of current conduction.

[0066] In some embodiments, as shown in Figures 7 and 9 , the conductive sheet 73 further includes a pin segment 734 connected to the extension segment 731. The pin segment 734 is exposed outside the mounting portion 72. The pin segment 734 is used to connect to an external power source. In some embodiments, for two adjacent conductive sheets 73 along the axial direction F1, the pin segments 734 of the two conductive sheets 73 are staggered, thereby increasing the relative distance between the two pin segments 734 and improving insulation.

[0067] In some embodiments, as shown in FIG. 7 and FIG. 9 , the extension direction of the extension section 731 is parallel to the radial direction of the stator case 20 , so that the extension section 731 can extend inside and outside the stator case 20 with a shorter length.

[0068] In some embodiments, as shown in FIG14 , when the carbon brush 76 and the slip ring 90 are assembled, the projection of the central axis of the slip ring 90 on a plane perpendicular to the axial direction F1 is the axis center, the central angle of the circumferential span of the projections of all free ends 752 with respect to the axis center is a first central angle β1, and the central angle of the circumferential span of the projections of all fixed ends 751 with respect to the axis center is a second central angle β2. Specifically, when the inner rotor motor 100 is in operation, the rotor assembly 30 rotates about the axis center.

[0069] In some embodiments, as shown in FIG14 , on a plane perpendicular to the axial direction F1, the first central angle β1 corresponding to the projections of all free ends 752 is no greater than the second central angle β2 corresponding to the projections of all fixed ends 751, thereby placing all free ends 752 within the circumferential distribution of all fixed ends 751. Because the carbon brushes 76 are connected to the free ends 752, when the slip ring 90 approaches the movable carbon brushes 76 along the predetermined installation direction F2, even when the outer diameter of the slip ring 90 is relatively small, each carbon brush 76 can be ensured to contact the slip ring 90, thereby reducing restrictions on the outer diameter of the carbon brushes 76. In some embodiments, the first central angle β1 and the second central angle β2 are both central angles close to the mounting portion 72. Thus, the mounting portion 72, the support portion, and the brush assembly 70 are all located on the same side of the slip ring 90, facilitating installation.

[0070] In some embodiments, the spring 75 is formed by processing a conductive metal sheet.

[0071] In some embodiments, as shown in Figures 10a and 10b , two adjacent carbon brushes 76 along the axial direction F1 are staggered in the axial direction F1, thereby increasing the circumferential span of all carbon brushes 76. When the slip ring 90 abuts all carbon brushes 76, the springs 75 connected to all carbon brushes 76 provide a wider force application angle to the slip ring 90, preventing the slip ring 90 from being bounced to the fixed end 751 by the elastic force of the springs 75.

[0072] In some embodiments, as shown in FIG5 , on a plane perpendicular to the axial direction F1, the central angle of the circumferential span of the projections of two adjacent carbon brushes 76 in the axial direction F1 is equal to the central angle of the circumferential span of the projections of all carbon brushes 76 in the axial direction with respect to the axial center. Therefore, all carbon brushes 76 are circumferentially distributed in a relatively concentrated area, forming an alternating staggered structure. This ensures that the force applied by each carbon brush 76 to the slip ring 90 has a relatively uniform angle, which helps improve the stability of the slip ring 90 during installation. In some embodiments, by using spring clips 75 of uniform length and alternatingly staggering adjacent spring clips 75, the central angle of the projection of two adjacent carbon brushes 76 in the axial direction F1 with respect to the axial center can be equal to the central angle of the circumferential span of the projections of all carbon brushes 76 with respect to the axial center. For example, when there are two brush assemblies 70, they can be staggered in the axial direction F1. This allows the springs 75 of the two brush assemblies 70 to press against the slip ring 90 in different directions, thereby maintaining a more stable state during rotation. When there are three brush assemblies 70, adjacent brush assemblies 70 are staggered in the axial direction F1, while the alternate brush assemblies 70 are aligned in the axial direction F1. This ensures that the slip ring 90 is always subjected to opposing elastic forces during rotation, thereby improving stability.

[0073] In some embodiments, as shown in Figures 3 and 14 , the contact surface 761 of the carbon brush 76 abuts the slip ring 90. Specifically, the contact surface 761 of each carbon brush 76 abuts one of the conductive rings 91. Specifically, when the carbon brush 76 is pushed by the slip ring 90, the deformation of the spring 75 generates an elastic force on the carbon brush 76, maintaining the contact surface 761 of the carbon brush 76 in contact with the conductive ring 91. In some embodiments, adjacent springs 75 are spaced apart along the axial direction F1, thereby maintaining insulation between adjacent conductive rings 91.

[0074] In some embodiments, the carbon brush 76 and the spring piece 75 are fixedly welded together, thereby helping to ensure connection stability and electrical conductivity between the carbon brush 76 and the spring piece 75 .

[0075] The spring piece 75 can be roughly in the shape of a "√", as shown in Figures 11a and 11b, or it can be other shapes with multiple bends, such as the shapes shown in Figures 13 and 14. The present invention does not limit the specific shape of the spring piece 75. In some embodiments, as shown in Figures 9 and 11b, the spring piece 75 includes a folded section 753 and a sheet-shaped section 754 connected to the folded section 753. The folded section 753 has greater rigidity than the sheet-shaped section 754. The free end 752 of the spring piece 75 is arranged on the folded section 753. A bending transition 730 is formed on the inner side of the conductive sheet 73. A portion of the sheet-shaped section 754 away from the folded section 753 is attached to the conductive sheet 73, and a portion of the sheet-shaped section 754 close to the folded section 753 is separated from the conductive sheet 73 via the bending transition 730. Specifically, the folded segment 753 has a curved transition shape. By adjusting the amplitude of the folded segment 753, the angle of the carbon brush 76 relative to the fixed end 751 of the spring 75 can be adjusted. The folded segment 753 has a more stable shape than the sheet segment 754, and the carbon brush 76 is fixedly connected to the folded segment 753, thereby maintaining a stable contact area between the carbon brush 76 and the folded segment 753. The portion of the sheet segment 754 adjacent to the folded segment 753 is separated from the conductive sheet 73 via the curved transition 730. Therefore, when the carbon brush 76 is pushed by the slip ring 90, this portion of the sheet segment 754 undergoes a bending elastic deformation. Compared to the bending elastic deformation of the sheet segment 754, the bending elastic deformation enables the sheet segment 754 to have better shape recovery, thereby allowing the carbon brush 76 to more reliably maintain contact with the slip ring 90. In some embodiments, the end of the conductive sheet 73 connected to the elastic sheet 75 is bent in a direction away from the free end 752 , so that a bent transition portion 730 is formed on the inner side of the conductive sheet 73 .

[0076] In some embodiments, as shown in FIG9 , the edge of the folded segment 753 is provided with a folded structure. In other embodiments, the thickness of the folded segment 753 is greater than the thickness of the sheet segment 754. Specifically, along a direction close to the folded segment 753, a portion of the sheet segment 754 begins to separate from the conductive sheet 73 at the bend transition 730. The edge of the sheet segment 754 is approximately linear. In some embodiments, the free end 752 of the spring clip 75 is bent away from the support body 71. After the free end 752 of the spring clip 75 is bent away from the support body 71, the distance between the free end 752 of the spring clip 75 and the inner side of the support body 71 is increased. Therefore, even when the conductive ring 91 is at a large distance from the support body 71, the free end 752 of the spring clip 75 can fully contact the outer periphery of the conductive ring 91, thereby helping to increase the pressure between the free end 752 of the spring clip 75 and the conductive ring 91.

[0077] In some embodiments, as shown in Figures 5 and 10a , for two adjacent spring pieces 75 along the axial direction F1, the fixed ends 751 of the two spring pieces 75 are located in the same diametrical direction of the slip ring 90 (e.g., direction F4 as shown in Figure 10a ). The carbon brush 76 is circumferentially located between the two fixed ends 751. In a plane projection perpendicular to the axial direction F1, the fixed ends 751 of the two adjacent spring pieces 75 are located in the same diametrical direction of the slip ring 90. The slip ring 90 enters between the two fixed ends 751 along the predetermined installation direction F2. Because the fixed ends 751 of the two adjacent spring pieces 75 are located in the same diametrical direction of the slip ring 90, the angle between the two adjacent carbon brushes 76 relative to the slip ring 90 is increased, thereby expanding the angular contact range between the slip ring 90 and all carbon brushes 76. This prevents the slip ring 90 from sliding off the contact surface 761 of the carbon brush 76 due to a small support area during assembly, thereby improving the positional stability of the slip ring 90 during assembly.

[0078] In some embodiments, as shown in Figures 10a and 10b , when the spring 75 is in its free state, the direction from the fixed end 751 to the free end 752 is tilted toward the mounting portion 72 relative to the relative direction F4 between the two fixed ends 751. Therefore, when assembling the slip ring 90, the slip ring 90 must first enter the relative space between the fixed ends 751 of two adjacent springs 75, and then continue to move toward the mounting portion 72 along the predetermined installation direction F2 before coming into contact with the carbon brush 76. During the assembly process of the slip ring 90, the fixed end 751 maintains a stable position relative to the support body 71, so that the fixed end 751 can limit the slip ring 90 to a certain extent, preventing the slip ring 90 from bouncing away in the relative direction F4 due to the elastic force of the spring 75. In some embodiments, the distance between the two fixed ends 751 along the relative direction F4 is greater than the outer diameter of the slip ring 90.

[0079] In another embodiment, the distance between the two fixed ends 751 along the relative direction F4 may be smaller than the outer diameter of the slip ring 90 . The fixed ends 751 of two adjacent spring sheets 75 and the contact surface 761 enclose an arc whose curvature radius is not smaller than the radius of the slip ring 90 .

[0080] In some embodiments, as shown in conjunction with FIG5 and FIG11a, at least two conductive sheets 73 are sequentially distributed along the axial direction F1. For two adjacent conductive sheets 73 along the axial direction F1, the sections where the two conductive sheets 73 connect to the fixed end 751 are staggered, and the conductive sheets 73 extend along a shorter path toward the fixed end 751 of the corresponding elastic sheet 75. For two conductive sheets 73 separated by a conductive sheet 73 along the axial direction F1, the sections where the two conductive sheets 73 connect to the fixed end 751 are separated by a larger distance along the axial direction F1. This distance is at least greater than the dimension of the conductive sheet 73 along the axial direction F1, thereby ensuring insulation between the conductive sheets 73.

[0081] The above embodiments are merely descriptions of the preferred embodiments of the present application and do not limit the scope of the present application. Without departing from the design spirit of the present application, various modifications and improvements made to the technical solutions of the present application by ordinary engineering and technical personnel in this field should fall within the scope of protection determined by the claims of the present application.

Claims

1. A brush assembly, characterized in that, Comprising: A support body; And At least two brush members arranged at intervals along the axial direction; each of the brush members includes a spring piece and a carbon brush; each spring piece includes a fixed end fixedly connected to the support body and a free end opposite to the fixed end; each carbon brush is fixed to the free end of its corresponding spring piece and has a contact surface for sliding contact with a slip ring; the contact surface deviates from the external orientation of the carbon brush and bypasses the support body and all spring pieces.

2. The brush assembly according to claim 1, wherein, In a plane perpendicular to the axial direction, the first central angle corresponding to the projections of all free ends is not greater than the second central angle corresponding to the projections of all fixed ends, where the first central angle is the central angle of the span of the projections of all free ends in the circumferential direction with respect to the axis, the second central angle is the central angle of the span of the projections of all fixed ends in the circumferential direction with respect to the axis, and the axis is the projection of the central axis of the slip ring in a plane perpendicular to the axial direction when the carbon brush and the slip ring are in an assembled state.

3. The brush assembly according to claim 2, wherein, The two axially adjacent carbon brushes are arranged staggeredly in the axial direction.

4. The brush assembly according to claim 3, characterized in that, In a plane perpendicular to the axial direction, the central angle of the projections of two axially adjacent carbon brushes with respect to the axis is equal to the central angle of the span of the projections of all carbon brushes in the circumferential direction with respect to the axis.

5. The brush assembly according to any one of claims 1 to 2, characterized in that, The support body includes a mounting portion and a supporting portion, one end of the supporting portion is connected to the mounting portion, the other end is connected to the fixed end of the spring piece, and the distance between the free end and the mounting portion is less than the distance between the fixed end and the mounting portion.

6. The brush assembly according to claim 5, wherein A first guiding groove is provided on the side surface of the mounting portion for axial guiding and radial limiting when the brush assembly is installed in a first concave position of a stator housing.

7. The brush assembly according to claim 5, characterized in that, A second guiding groove is provided on the mounting portion for radial guiding and axial limiting when the brush assembly is docked to a second concave position of an end cover.

8. The brush assembly according to claim 5, characterized in that, The mounting portion includes at least two seat sub-components arranged adjacent to each other along the axial direction, and each seat sub-component is in snap-fit connection with the adjacent seat sub-component; the supporting portion includes at least two conductive sheets, one end of each conductive sheet passes through one of the seat sub-components, and the other end is connected to the fixed end of a spring piece.

9. The brush assembly according to claim 8, wherein, A positioning groove is provided on each seat sub-component, and each conductive sheet is at least partially inserted into the positioning groove of its corresponding seat sub-component.

10. A conduction device, characterized in that, Comprising a slip ring and the brush assembly according to any one of claims 1 to 9, the slip ring includes at least two conductive rings insulated from each other, and the contact surface of each carbon brush abuts against one of the conductive rings.

11. An inner-rotor motor, comprising a stator assembly and a rotor assembly rotatably disposed within the stator assembly, characterized in that, The stator assembly includes a stator housing, magnets provided on the inner wall surface of the stator housing, and the brush assembly according to any one of claims 1 to 9, the magnets form a magnetic field stationary relative to the stator housing; the rotor assembly includes an iron core, a rotating shaft inserted into the iron core, and coils wound around the iron core; a slip ring electrically connected to the coils is sleeved on the rotating shaft, and the contact surface of the brush assembly abuts against the slip ring.

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