Brushless DC Motor Hall Sensor External Mounting
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Solution Overview
Problem
High-performance brushless DC motors using magnetic materials for rotor iron cores face issues with large volume, high cost, and inaccurate signal sensing due to strong magnetism, and existing solutions for arranging Hall elements and magnetic rings are not cost-effective or reliable.
Innovation Solution
A brushless DC motor design featuring an external magnetic ring and Hall element with a structured installation kit and circuit board, where the magnetic ring is mounted on a rotating shaft with a circular bracket and locknut, and the Hall element is positioned outside a groove on the motor casing, ensuring low interference and precise sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If sintered rubidium iron boron made of strong magnetic materials are used for a rotor iron core, then the magnetic strength is improved, but the Hall element will suffer from great interference when sensing signals, affecting measurement accuracy
Solution Approach 1:
The Hall element and magnetic ring are extracted from the internal motor casing and relocated to the external end cover area. This spatial separation removes the Hall element from the strong magnetic field environment inside the motor, eliminating magnetic interference while maintaining sensing functionality through the end cover structure.
Solution Approach 2:
The end cover acts as an intermediary structure that houses the Hall element and magnetic ring externally. This intermediate structure provides a transition zone that allows the Hall element to sense the magnetic field from the rotor without being directly exposed to the strong magnetic materials in the rotor iron core, thus reducing interference.
2Volume of moving object
If weak magnetic ferrite or bonded rubidium iron boron are used in a rotor iron core, then the motor volume and material consumption are reduced, but the magnetic strength becomes insufficient requiring larger components
Solution Approach 1:
The invention changes the operating parameters of the Hall element by relocating it externally with optimized positioning relative to the magnetic ring. This allows the use of weaker magnetic materials in the rotor iron core while maintaining adequate magnetic field strength for sensing through the external configuration and precise positioning of the Hall element.
3Volume of moving object
If the Hall element and magnetic ring are arranged inside the motor casing, then the structure is compact, but the mounting structure layout is unreasonable, installation is unfriendly, and reliability is poor
Solution Approach 1:
The motor structure is segmented into internal components (rotor, stator) and external components (Hall element assembly on end cover). This segmentation allows the Hall element and magnetic ring to be installed separately on the end cover, making installation more friendly and reliable while maintaining overall structural compactness through the integrated end cover design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design results in a compact, cost-effective, and reliable motor with improved sensing accuracy and stability, reducing noise and enhancing control efficiency.
Implementation Method 1
a Hall induction device is arranged outside the groove and close to the magnetic ring
Data Source
AI summary
A brushless DC motor including a motor casing, a stator component, and a rotor component. The stator component and the rotor component are respectively arranged inside the motor casing. The rotor component includes a rotor iron core and a rotating shaft supporting the rotor iron core. A shaft extension end of the rotating shaft is arranged with a magnetic ring. One end of the motor casing is provided with an end cover. The center of the outer end surface of the end cover is provided with a groove. The magnetic ring is arranged inside the groove. A Hall induction device is arranged outside the groove and close to the magnetic ring. The motor is reasonably structured, compact, cost-effective, installation friendly, and highly reliable.