Magnetic Ring Bracket for Brushless DC Motor Rotor Alignment
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Solution Overview
Problem
Conventional brushless DC motors face issues with inconsistent magnetic field positioning, leading to noise, vibration, and reduced efficiency due to the relative difficulty in controlling the main and inductive magnetic fields, especially when using strong magnetic materials, and poor installability of Hall components.
Innovation Solution
A motor rotor system comprising a rotor iron core, a permanent magnet, and a magnetic ring bracket with a locating slot and positioning convex parts, along with a vibration-reduction device, ensuring precise alignment and consistency of the magnetic fields, and incorporating cooling fan blades to reduce interference and improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a first-level magnetic inductive ring is added behind a main magnetic field of a motor, then the motor can use sine wave control mode with a position sensor, but the relative position between the main magnetic field and the inductive magnetic field is not easy to be controlled and measurement accuracy is affected due to low accuracy
Solution Approach 1:
A magnetic ring bracket is introduced as an intermediary component between the rotor iron core and the magnetic ring. The bracket includes a locating slot that precisely positions the magnetic ring, ensuring accurate relative positioning between the main magnetic field and the inductive magnetic field. This mediator structure enables sine wave control mode while maintaining high measurement accuracy.
2Adaptability or versatility
If an adjustable Hall component is mounted behind the rear cover of a motor, then operators can adjust the Hall component to achieve the required relative position relationship between the main magnetic field and the inductive magnetic field, but the processability is poor, overall accuracy is low, motor performance has big differences, and installation is unfriendly
Solution Approach 1:
The magnetic ring bracket is pre-manufactured with a locating slot that precisely positions the magnetic ring. This preliminary positioning structure eliminates the need for field adjustment of the Hall component, improving ease of manufacture and installation while ensuring consistent motor performance across batches.
3Manufacturing precision
If the magnetic ring bracket uses a locating slot and positioning convex part structure, then the magnetic ring can be mounted at the outer side of the magnetic ring bracket with high positioning accuracy, but the device complexity increases
Solution Approach 1:
The magnetic ring bracket is designed as a separate, modular component with an integrated locating slot. This segmentation allows the positioning function to be built into the bracket itself, maintaining high positioning accuracy while keeping the overall structure manageable and suitable for mass production.
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 solution achieves excellent batch-to-batch consistency, reduces noise and vibration, enhances measuring accuracy, and facilitates easy installation, making it suitable for large-scale production and sine-wave control methods.
Implementation Method 1
a main magnetic field of a motor rotor uses strong magnetism; therefore a driving control signal has a higher consistency requirement for motor counter EMF and Hall output signals
Implementation Method 2
a vibration-reduction device, wherein the rubber ring is embedded in a gap formed between the outer iron core and the inner iron core
Implementation Method 3
A plurality of cooling fan blades extend out of the outer side wall of the annular inner ring
Data Source
AI summary
A motor rotor system including: an axis of rotation, a rotor iron core mounted on the axis of rotation, a permanent magnet, a magnetic ring bracket, and a magnetic ring. The permanent magnet, the magnetic ring bracket, and the magnetic ring are mounted on the rotor iron core. The magnetic ring is sheathed on the magnetic ring bracket. The magnetic ring bracket is located at one end of the rotor iron core and connected with an end face of the rotor iron core. The motor rotor system has excellent batch-to-batch consistency, simple structure, and convenient installation. It is suitable for large batch production and can be controlled using sine-wave driving control methods with a position sensor.