DESC:4. DESCRIPTION
Technical Field of the Invention

The presented invention features a motor design with built-in vibration-damping elements, effectively reducing vibrations and noise. This design is especially beneficial in applications with sensitive sensors or components, such as robotics, drones, gimbals, and specialized motors. By minimizing vibrations, the motor ensures smoother operation, improved performance, and greater accuracy, enhancing the overall functionality of various use cases.

Background of the Invention

Brushless DC (BLDC) motors are widely adopted across industrial automation, robotics, aerospace, automotive, and medical equipment due to their high efficiency, compact size, and extended operational life compared to conventional brushed motors. Their electronic commutation eliminates mechanical brushes, thereby reducing wear and maintenance while providing smoother torque characteristics. Despite these advantages, BLDC motors continue to suffer from a persistent challenge, vibrations generated during high-speed operation, unbalanced loads, or resonance with connected structures. These vibrations adversely affect precision, reliability, and longevity in applications where stability and accuracy are paramount.

In precision platforms such as unmanned aerial vehicles, robotic manipulators, camera gimbals, or surgical instruments, even small vibrational disturbances can compromise sensor accuracy, cause encoder drift, generate noisy data, and accelerate fatigue of critical components. In heavy-duty environments like aerospace or automotive assemblies, sustained vibration exposure may loosen fasteners, fatigue connectors, and reduce service life. Thus, vibration remains a limiting factor in the performance envelope of otherwise efficient BLDC motor systems.

Several prior art solutions have attempted to mitigate this issue by employing external vibration control mechanisms. Rubber mounts or foam pads are sometimes placed between the motor and its supporting frame to absorb shocks. Flexible couplings and vibration isolators are occasionally inserted between the motor shaft and the driven load to reduce oscillations. More sophisticated arrangements rely on tuned mass absorbers or separate vibration isolation modules that attach externally to the motor assembly. While these measures provide partial improvements, they are reactive in nature and not truly integrated into the motor design.

The limitations of these external approaches are significant. First, the addition of separate damping assemblies increases the overall size and weight of the system, which is particularly undesirable in drones, surgical devices, and aerospace platforms where strict weight limits apply. Second, external dampers are prone to misalignment, wear, and displacement over time, leading to reduced damping performance and frequent maintenance. Third, such solutions complicate integration by requiring custom brackets, frames, or structural redesigns, thereby reducing modularity and deployment flexibility. Moreover, most prior art systems fail to simultaneously address both axial and radial vibrations, resulting in incomplete suppression of dynamic disturbances.

These shortcomings underscore a dire need for an improved BLDC motor architecture that incorporates vibration damping within the motor body itself, thereby eliminating reliance on bulky external components. Such a solution should provide robust and reliable suppression of both axial and radial vibrations at their source, without increasing system weight or complexity. It should also be adaptable to varied mounting configurations, ensuring easy integration into diverse industrial, medical, and aerospace systems without extensive re-engineering. Furthermore, the solution must retain thermal conductivity, mechanical stability, and environmental durability to ensure long-term operation under demanding conditions.

The present invention addresses these challenges by introducing an internally damped BLDC motor system that integrates elastomeric lugs, a configurable motor mount, and vibration-isolating fastening components directly into the motor body. This arrangement achieves compactness, reliability, and enhanced vibration suppression, providing a superior alternative to existing solutions.

Objects of the Invention

The primary object of the present invention is to provide an internally damped Brushless DC (BLDC) motor system that directly integrates vibration damping mechanisms into the motor body itself. By embedding elastomeric lugs within the extended flange section of the motor housing, the invention aims to suppress both axial and radial vibrations at their source, thereby ensuring smoother operation, reduced noise, and enhanced accuracy in vibration-sensitive applications.

Another object of the invention is to establish a dual-stage damping arrangement that combines primary absorption through elastomeric lugs with secondary isolation achieved by washers, locking screws, and an end cap. This layered vibration control not only minimizes transmission of oscillations to the surrounding structure but also prolongs the service life of fasteners, mounts, and electronic components subjected to dynamic stresses.

It is a further object of the invention to provide a motor mounting system that is adaptable to diverse structural requirements. By incorporating configurable pitch circle diameters and multiple mounting hole geometries, the motor mount is designed for seamless integration into various platforms without the need for redesign or modification of existing hardware. This adaptability reduces deployment time and enables cross-industry applicability.

Another object of the invention is to optimize the motor body through the use of lightweight and thermally conductive alloys such as aluminum or magnesium. This ensures that while the system provides superior vibration control, it simultaneously maintains mechanical stability and efficient heat dissipation, enabling reliable operation even under high rotational speeds and sustained duty cycles.

A further object of the invention is to enhance environmental resilience by enclosing the motor in a sealed housing compliant with ingress protection standards such as IP65 or higher. This makes the system suitable for deployment in harsh environments, including aerospace, automotive, marine, and industrial domains, where dust, moisture, and corrosive agents would otherwise compromise motor reliability.

Ultimately, the object of the present invention is to provide a comprehensive, compact, and scalable solution that overcomes the limitations of prior art external damping systems. By addressing vibration control internally within the motor structure, the invention delivers significant improvements in operational precision, component longevity, maintenance reduction, and overall system performance across robotics, aerospace, industrial automation, and medical technologies.

Brief Summary of the Invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

The present invention discloses an internally damped Brushless DC (BLDC) motor system designed to overcome the persistent problem of vibration in conventional motor assemblies. Unlike prior art solutions that rely on external dampers or isolation systems, the invention integrates vibration suppression mechanisms directly within the motor body, ensuring compactness, improved reliability, and reduced dependency on external accessories.

In one aspect of the present invention, the BLDC motor system includes a motor body provided with an extended flange section that accommodates an integrated vibration damping system. The damping system comprises a plurality of elastomeric rubber lugs strategically positioned around the motor body to absorb axial and radial vibrations at their source. By targeting the root cause of vibrational disturbances, the invention delivers stable and smooth motor performance even under dynamic loading conditions.

In another aspect of the present invention, the motor system employs a dual-stage vibration control strategy. The primary damping function is provided by the elastomeric lugs embedded within the motor body, while secondary isolation is achieved through vibration-isolating washers, locking screws, and a motor end cap. This layered configuration ensures that vibrations generated during motor operation are effectively attenuated before they propagate to the external structure, thereby enhancing system durability and precision.

In yet another aspect of the present invention, the motor mount is designed to provide versatile integration. By supporting variable pitch circle diameters and mounting hole geometries, the motor can be seamlessly installed into a wide range of platforms without requiring structural redesign. This adaptability makes the invention particularly suitable for applications in robotics, aerospace, medical systems, and industrial automation where modularity and design flexibility are critical.

In a further aspect of the present invention, the motor body is fabricated from lightweight, thermally conductive materials such as aluminum or magnesium alloys. This material choice ensures effective heat dissipation and mechanical strength, thereby enabling continuous high-speed operation without compromising stability or longevity.

In yet another aspect of the present invention, the motor system is enclosed within a sealed housing that complies with ingress protection standards of IP65 or higher. This ensures environmental robustness and allows deployment in harsh operating conditions involving dust, moisture, or corrosive exposure.

Overall, the present invention provides a robust, scalable, and technically superior solution to vibration problems in BLDC motors. By integrating elastomeric damping, dual-stage isolation, adaptable mounts, and optimized materials directly into the motor design, the invention significantly enhances operational precision, reduces maintenance requirements, and extends system lifespan across a diverse range of high-performance applications.

Brief Description of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 illustrates a schematic diagram of an internally damped BLDC motor, in accordance with an exemplary embodiment of the present invention.

Fig. 2 illustrates a manufacturing block diagram of an internally damped BLDC motor, in accordance with an exemplary embodiment of the present invention.

Fig. 3 illustrates an operational block diagram of an internally damped BLDC motor, in accordance with an exemplary embodiment of the present invention.

Detailed Description of the Invention

It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

In accordance with exemplary embodiments of the present invention, the internally damped Brushless DC motor system is configured to address the long-standing problem of vibrations that occur during motor operation. The system incorporates an extended flange section within the motor housing that is structurally designed to accommodate vibration damping components. By embedding the damping arrangement inside the motor body rather than relying on external attachments, the system ensures compactness and directly suppresses vibrations at their source.

In one embodiment, the damping system consists of elastomeric lugs that are engineered to absorb both axial vibrations, which occur along the shaft axis, and radial vibrations, which occur perpendicular to the axis. These elastomeric lugs are manufactured from high-damping materials such as silicone rubber, nitrile rubber, or polyurethane composites. The hardness of the elastomers is optimized within a specific Shore A range to provide sufficient load-bearing capacity while retaining flexibility for vibration absorption. The selection of such materials ensures consistent damping performance even under thermal cycling, moisture exposure, or prolonged mechanical stress.

In another embodiment, the damping arrangement is implemented in a symmetric radial configuration around the motor body. This arrangement ensures uniform load distribution and balanced absorption of vibrational energy from multiple directions. The symmetric placement also minimizes the risk of resonance amplification, thereby improving the dynamic stability of the motor during high-speed operation. The damping system is integrated in such a way that it directly contacts both the motor housing and the mounting interface, ensuring effective transfer and dissipation of vibrational energy before it propagates into the surrounding structure.

In a further embodiment, the system includes a secondary isolation stage achieved through fastening components. Washers formed from vibration-resistant materials such as spring steel or polymer composites are interposed between the motor housing and the mounting structure. These washers provide elastic compliance and prevent direct metal-to-metal contact, thereby suppressing the transmission of micro-vibrations. Locking screws with vibration-resistant retention features, such as self-locking threads or pre-applied thread-lock adhesives, are employed to secure the motor housing. The fastening arrangement is completed with an end cap that ensures the structural integrity of the assembly. Together, these fastening elements complement the primary elastomeric damping lugs, thereby creating a dual-stage vibration isolation system.

In yet another embodiment, the motor mounting arrangement is configured to accommodate a wide range of installation requirements. The mount is designed with multiple pitch circle diameters and variable hole geometries, allowing the motor to be fitted into diverse platforms without requiring redesign of supporting structures. This adaptability reduces integration effort and provides significant versatility for industries where motor configurations vary across applications.

In accordance with another embodiment, the motor housing is fabricated from lightweight and thermally conductive alloys such as aluminum or magnesium. The choice of these materials enables effective thermal dissipation, preventing overheating during continuous operation while maintaining structural rigidity. Surface treatments such as anodizing or passivation may further enhance corrosion resistance, making the system suitable for deployment in harsh environments.

In an additional embodiment, the motor system is enclosed within a sealed housing to meet ingress protection ratings of IP65 or higher. The sealed enclosure prevents the ingress of dust, moisture, and corrosive agents, thereby ensuring durability in aerospace, automotive, marine, and industrial environments. This environmental resilience further enhances the reliability and service life of the motor system.

In another embodiment, the operational effectiveness of the internally damped motor system is demonstrated through comparative vibration testing. Standard BLDC motors without internal damping exhibit amplified oscillations that compromise sensor accuracy and cause premature fatigue of surrounding assemblies. In contrast, the internally damped motor system significantly reduces vibration levels, resulting in improved positional stability of sensors, extended bearing life, and reduced acoustic noise. Performance evaluation under industry standards such as ISO vibration and noise protocols validates the superiority of the system.

In a further embodiment, the invention also contemplates the method of assembling the internally damped BLDC motor system. The assembly process involves fabricating the motor housing with dedicated cavities in the flange section, molding elastomeric lugs from damping polymers, inserting the lugs into the flange cavities, positioning the motor body within the adaptable mount, inserting washers between the housing and the mount, and fastening the motor body using screws and an end cap with locking features. Verification of damping effectiveness is performed through operational testing, wherein axial and radial vibrations are measured under dynamic loading conditions to ensure compliance with performance specifications.

Across these embodiments, the invention provides a compact, scalable, and technically robust solution that addresses the deficiencies of external vibration control systems. By integrating damping components within the motor structure, employing a dual-stage isolation strategy, and ensuring adaptability through configurable mounts, the invention achieves superior vibration suppression, thermal management, and environmental resilience. These improvements make the internally damped BLDC motor system highly suitable for robotics, aerospace, medical devices, automotive assemblies, and industrial automation systems that demand high precision and long-term reliability.

Reference to Figures
Referring now to Fig. 1, an exemplary embodiment of the internally damped Brushless DC (BLDC) motor system (100) is illustrated. The system comprises a motor body (2) that houses the stator, rotor, and associated windings. The motor body (2) is extended by a flange section specifically configured to accommodate an integrated vibration damping system (4). The damping system (4) consists of elastomeric lugs positioned within cavities of the flange. These lugs are strategically arranged to provide primary absorption of both axial vibrations, which are generated along the shaft axis, and radial vibrations, which occur perpendicular to the axis during operation. The integration of these elastomeric elements within the motor body (2) ensures that vibration suppression occurs directly at the source.

The motor body (2) is secured to a motor mount (10) that supports the system and enables mechanical connection to external structures. The motor mount (10) is designed with multiple pitch circle diameters and hole geometries to permit versatile integration into various platforms. Between the motor body (2) and the motor mount (10), washers (6) are introduced to provide secondary vibration isolation. These washers (6) are formed from vibration-resistant materials that permit slight elastic deformation, thereby suppressing the transmission of micro-vibrations into the mounting structure.

The fastening arrangement includes screws (8) that pass through the motor mount (10) into the motor body (2). These screws (8) are provided with vibration-resistant retention features, such as locking threads or adhesive coatings, to ensure that loosening does not occur during repeated dynamic loading. The fastening is further secured by a motor end cap (9), which provides structural closure of the flange section and maintains the integrity of the damping system (4). The combination of the washers (6), screws (8), and end cap (9) establishes a secondary isolation stage, thereby complementing the primary damping provided by the elastomeric lugs of the damping system (4).

Referring now to Fig. 2, the process of fabricating and assembling the motor system (100) is described. The motor body (2) is fabricated from lightweight and thermally conductive alloys, such as aluminum or magnesium, which are subsequently heat-treated and surface-finished for durability. The electromechanical core is assembled within the motor body (2), including the stator, rotor, and windings, followed by application of varnish or adhesive to secure the windings and ensure electrical insulation. The damping system (4) is prepared by molding elastomeric lugs from selected polymers with appropriate hardness characteristics. These lugs are inserted into the designated cavities of the flange section of the motor body (2).

The motor mount (10), washers (6), and screws (8) are prepared as part of the mounting hardware. The washers (6) are designed with specific elastic properties to act as vibration isolators, while the screws (8) are provided with locking features to resist loosening. During assembly, the motor body (2) with the integrated damping system (4) is placed within the motor mount (10), the washers (6) are positioned at contact points, and the assembly is secured with the screws (8) and the end cap (9). The final motor system (100) is then subjected to operational tests to verify structural integrity, vibration suppression, and reliable fastening under dynamic load conditions.

Referring further to Fig. 3, the functional sequence of the motor system (100) is described. When the motor is energized, the stator windings generate a rotating magnetic field that drives the rotor. Vibrational forces arising from electromagnetic interactions, load fluctuations, or structural resonances are absorbed by the elastomeric lugs of the damping system (4). The motor body (2), being anchored to the motor mount (10) through the washers (6) and screws (8), ensures that any residual vibrations are isolated before they can propagate into the supporting structure. This dual-stage damping process results in stable and quiet operation of the motor system (100).

In comparative terms, conventional BLDC motors without the damping system (4) and isolation hardware experience amplified oscillations and direct transmission of vibrations to the surrounding structure. In contrast, the motor system (100) described herein demonstrates significant suppression of both axial and radial vibrations, thereby enabling improved positional stability and reliability.

Best Method
The best method of carrying out the invention begins with the fabrication of the motor body (2). The motor body (2) is cast or machined from lightweight and thermally conductive alloys such as aluminum or magnesium. These materials are selected for their ability to provide mechanical stability while simultaneously ensuring effective heat dissipation during high-speed operation. Once fabricated, the motor body (2) is heat-treated to relieve internal stresses and surface-finished to provide resistance against wear and corrosion. The extended flange section of the motor body (2) is manufactured with cavities precisely dimensioned to receive the vibration damping system (4). These cavities are aligned to maintain symmetry, thereby allowing balanced insertion of damping components.

The electromechanical core, comprising the stator, rotor, and windings, is assembled within the motor body (2). The windings are secured with varnish or adhesives to improve insulation and minimize movement under electromagnetic forces. The rotor is dynamically balanced to eliminate eccentricities that could otherwise generate excess vibration. At this stage, the motor body (2) provides a rigid but adaptable framework for integrating the damping system (4) and the mounting hardware.

The vibration damping system (4) is prepared by molding elastomeric lugs from high-damping polymers such as silicone rubber or nitrile rubber. These lugs are optimized with a Shore A hardness between 30 and 60, ensuring sufficient load-bearing capacity while retaining flexibility to absorb vibrations. Once molded, the elastomeric lugs of the damping system (4) are treated with bonding agents to improve adhesion and durability under operational stresses. The lugs are then inserted into the cavities of the flange section of the motor body (2). They are positioned in a symmetric radial arrangement so that vibrational loads are distributed evenly and suppressed uniformly in both axial and radial directions.

The motor mount (10) is prepared with multiple pitch circle diameters and mounting hole geometries, ensuring flexibility for installation across varied platforms. During assembly, the motor body (2) with the integrated damping system (4) is positioned within the motor mount (10). At the interface between the motor body (2) and the motor mount (10), vibration-isolating washers (6) are placed. The washers (6), fabricated from spring steel or polymer composites, provide secondary elastic compliance and reduce micro-vibrations that may bypass the primary damping system (4).

The fastening arrangement is completed with screws (8) and a motor end cap (9). The screws (8) are selected with vibration-resistant retention features such as locking threads, captive washers, or pre-applied adhesives. Torque control is applied during tightening of the screws (8) to maintain consistent clamping force without compressing the elastomeric components of the damping system (4) or the washers (6) beyond their optimal deformation limits. The motor end cap (9) is fixed to the flange section of the motor body (2) to close the assembly and ensure structural stability of the integrated damping system (4).

Once the motor system (100) is assembled, operational testing is conducted to validate the performance of the damping arrangement. When the motor system (100) is energized, vibrational forces generated by electromagnetic interactions or load fluctuations are first absorbed by the elastomeric lugs of the damping system (4). Any residual vibrations are subsequently attenuated by the washers (6), screws (8), and motor end cap (9), which together provide secondary isolation. The interaction of the damping system (4) and the fastening arrangement establishes a dual-stage damping mechanism, ensuring effective suppression of vibrations at both primary and secondary levels.

The best operational performance of the motor system (100) is achieved when the elastomeric lugs of the damping system (4) are uniformly distributed in a symmetric radial arrangement, the washers (6) are preloaded to maintain elastic compliance, and the screws (8) are tightened using torque-controlled tools to maintain stability without over-stressing the damping elements. Under these conditions, the motor body (2), motor mount (10), and damping system (4) function in unison to minimize vibrational disturbances, reduce structural fatigue, and ensure long-term reliability of the motor system (100).

Working Examples
In order to validate the effectiveness of the internally damped BLDC motor system (100), prototypes were fabricated and tested against conventional BLDC motors of equivalent power rating.

In one working example, a 200 W BLDC motor with a rotor speed of 10,000 revolutions per minute was constructed using the motor body (2) fabricated from aluminum alloy. The vibration damping system (4) was integrated into the flange section with elastomeric lugs molded from silicone rubber with a Shore A hardness of 45. Washers (6) fabricated from spring steel and screws (8) with self-locking threads were used in combination with an end cap (9) to provide the secondary isolation stage. The completed motor was assembled into a motor mount (10) and operated under a constant load condition of 1.2 Nm torque. Vibration measurements taken along the axial and radial directions demonstrated a reduction of approximately 65% in amplitude when compared to a conventional motor without internal damping.

In another working example, the elastomeric lugs of the damping system (4) were fabricated from nitrile rubber with a Shore A hardness of 55. The motor system (100) was operated under variable load conditions ranging between 0.5 Nm and 2.5 Nm. Comparative testing showed that the internally damped motor exhibited a 40% reduction in transmitted micro-vibrations at the motor mount (10) when washers (6) were preloaded during fastening. The reduction in vibration levels prevented loosening of screws (8) and ensured stable operation for over 500 hours of continuous testing.

In a further working example, a 500 W BLDC motor was fabricated using a magnesium alloy motor body (2) for lightweight construction. The elastomeric damping system (4) was arranged in a symmetric radial configuration with eight lugs distributed evenly around the flange. The motor system (100) demonstrated a 12 dB reduction in acoustic noise compared to conventional BLDC motors of similar size and capacity, measured at a distance of one meter under high-speed operation. The dual-stage damping arrangement, consisting of elastomeric lugs and the fastening elements (6, 8, 9), ensured that vibrational energy was absorbed before propagating to the external motor mount (10).

Across these working examples, the internally damped BLDC motor system (100) consistently demonstrated superior performance when compared to conventional BLDC motors. The use of elastomeric lugs within the damping system (4), complemented by washers (6), screws (8), and end cap (9), provided effective vibration suppression across multiple load and speed conditions. These examples confirm that the claimed system achieves reliable dual-stage damping in practice, thereby substantiating the inventive step described in the claims.

Applications, Advantages, Test Standards, and Results
In one application scenario, the internally damped BLDC motor system (100) is employed in robotic manipulators where high precision of end-effector positioning is required. Conventional motors without damping transmit vibrational energy to sensors, resulting in positional errors. In contrast, the integrated vibration damping system (4), supported by washers (6), screws (8), and end cap (9), suppresses these disturbances at the source. The motor body (2) and motor mount (10) remain stable under dynamic loads, thereby enabling robotic joints to maintain consistent accuracy during repetitive operations.

In another application scenario, the motor system (100) is used in unmanned aerial vehicles where weight and vibration are critical parameters. Traditional external damping devices add unnecessary weight and compromise aerodynamics. By integrating elastomeric lugs directly within the flange of the motor body (2), the invention achieves primary vibration absorption without additional bulk. The symmetric radial arrangement of the damping system (4) ensures that vibrations are uniformly reduced, improving flight stability and sensor performance. The washers (6) and screws (8) provide secondary isolation, ensuring that residual vibrations do not propagate through the airframe.

In a further application scenario, the motor system (100) is applied in surgical robotics where precision and low acoustic noise are essential. Vibrational disturbances in conventional systems can affect both accuracy and patient safety. The present invention mitigates these challenges by employing the dual-stage damping system. The elastomeric lugs of the damping system (4) attenuate axial and radial oscillations directly within the motor body (2), while the washers (6) and end cap (9) prevent residual vibrations from reaching the surgical platform. As a result, the surgical robotic system benefits from enhanced stability, precise control, and reduced fatigue of mechanical components.

The advantages of the motor system (100) arise primarily from its integrated and dual-stage damping architecture. By embedding the damping system (4) into the flange section of the motor body (2), the invention provides compactness and eliminates the need for external vibration absorbers. This internalization reduces system complexity and minimizes the risk of misalignment or displacement of external damping components. The washers (6), screws (8), and end cap (9) complement the elastomeric lugs by providing a secondary layer of vibration suppression, ensuring that even residual oscillations are isolated before transmission to the motor mount (10). The combined effect results in reduced acoustic noise, extended bearing life, and improved operational stability.

To validate these advantages, the motor system (100) is tested in accordance with established vibration and noise standards, including ISO 10846 for vibration isolation and IEC 60068 for mechanical shock and vibration endurance. Comparative testing against conventional BLDC motors without internal damping demonstrates significant reductions in both axial and radial vibration levels. For example, measurements show that conventional motors exhibit amplified vibration amplitudes under dynamic loading, whereas the motor system (100) with the integrated damping system (4) reduces these amplitudes to within acceptable thresholds defined by international standards. Acoustic measurements further confirm that the dual-stage damping reduces noise generation during high-speed operation, aligning with precision requirements in aerospace and medical domains.

The sufficiency of the disclosure is evidenced by the comparative results obtained during testing. The elastomeric lugs of the damping system (4), when optimized within the Shore A hardness range of 30 to 60, provide consistent attenuation across operational frequency bands. The washers (6), when preloaded, suppress micro-vibrations effectively, while the screws (8) with locking features ensure reliable fastening under repeated cycles of loading and unloading. The motor body (2), fabricated from lightweight alloys, provides both thermal conductivity and structural stability, while the sealed housing achieves ingress protection of IP65 or higher. Together, these features, tested and verified under international standards, demonstrate the clear technical contribution and inventive step of the motor system (100).

In summary, the present invention achieves superior vibration suppression through an integrated damping system (4) and dual-stage isolation using washers (6), screws (8), and end cap (9). The combination of compact structural integration, adaptability of the motor mount (10), and validated compliance with vibration and noise standards ensures that the motor system (100) provides a reliable and definitive solution to the limitations of conventional BLDC motors.

Industrial Applicability
The internally damped BLDC motor system (100) as disclosed in the present invention is industrially applicable in the design, manufacture, and deployment of motors where vibration suppression, structural stability, and environmental durability are essential. The integration of the vibration damping system (4) within the motor body (2), combined with secondary isolation through washers (6), screws (8), and end cap (9), enables reliable operation under high-speed and variable load conditions. The adaptability of the motor mount (10) to multiple pitch circle diameters ensures compatibility with diverse industrial platforms without redesign. The use of lightweight, thermally conductive alloys for the motor body (2) and the sealing of the system to ingress protection levels of IP65 or higher make the invention suitable for continuous use in industrial automation, aerospace, automotive, robotics, medical devices, and marine equipment. Accordingly, the invention is capable of being made and used in any industry requiring precise and vibration-stable BLDC motors.
,CLAIMS:5. CLAIMS
We claim
1. An internally damped Brushless DC (BLDC) motor system (100), comprising:
a motor body (2) housing a stator, a rotor, and windings, the motor body (2) including an extended flange section;
a motor mount (10) configured to mechanically support and connect the motor body (2) to an external structure; and
a plurality of fastening elements including washers (6), screws (8), and a motor end cap (9) for securing the motor body (2) to the motor mount (10),
Characterized in that,
the motor body (2) incorporates an integrated vibration damping system (4) disposed within the extended flange section;
the vibration damping system (4) comprises a plurality of elastomeric rubber lugs symmetrically positioned around the motor body (2) to provide primary absorption of axial and radial vibrations generated during motor operation;
the washers (6), screws (8), and motor end cap (9) provide secondary vibration isolation, thereby establishing a dual-stage damping arrangement;
the elastomeric rubber lugs (4) are precision-engineered from high-damping elastomeric materials such as silicone or nitrile rubber with Shore A hardness between 30 and 60, thereby ensuring optimized vibration attenuation across operational frequencies;
the motor mount (10) includes a configurable flange interface adaptable to multiple pitch circle diameters (PCDs) and hole geometries for versatile system integration;
the motor body (2) is constructed from lightweight, thermally conductive alloys such as aluminum or magnesium, ensuring heat dissipation and mechanical stability; and
the motor system (100) is enclosed in a sealed housing providing ingress protection of at least IP65, thereby ensuring environmental durability and long-term operational stability in aerospace, robotics, and industrial automation applications.

2. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the elastomeric rubber lugs (4) are directly embedded between the motor body (2) and the motor mount (10), thereby eliminating external dampers and reducing assembly complexity.

3. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the elastomeric rubber lugs (4) are arranged in a symmetric radial pattern around the extended flange section of the motor body (2), enabling uniform absorption of multidirectional vibrational loads.

4. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the washers (6) are fabricated from spring steel or polymeric composites exhibiting elastic and damping properties to further reduce transmission of micro-vibrations from the motor body (2) to the motor mount (10).

5. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the screws (8) are provided with vibration-resistant retention features selected from thread-lock adhesives, captive spring washers, or self-locking threads to prevent loosening under cyclic vibration.

6. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the motor body (2) includes thermal dissipation pathways formed by fins or ribbed structures integrated into the flange section, thereby enhancing heat transfer during high-speed operation.

7. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the damping system (4) is engineered to comply with vibration isolation standards including ISO 10846 and IEC 60068, ensuring validated suppression of mechanical noise and fatigue-induced wear.

8. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the sealed housing of the motor body (2) is compliant with ingress protection rating IP67, thereby providing enhanced resistance to dust, water, and corrosive agents in aerospace and marine applications.

9. The internally damped BLDC motor system (100) as claimed in claim 1, wherein the dual-stage damping arrangement reduces vibration-induced resonance, thereby improving positional accuracy of sensors, encoders, and control circuits integrated with the motor system (100).

10. A method of assembling the internally damped BLDC motor system (100) as claimed in claim 1, the method comprising:
fabricating the motor body (2) with an extended flange section to accommodate cavities for the vibration damping system (4);
molding and inserting elastomeric rubber lugs (4) into the flange section;
positioning the motor body (2) within the motor mount (10) configured for the required pitch circle diameter;
placing vibration-isolating washers (6) between the motor body (2) and the motor mount (10);
securing the motor body (2) to the motor mount (10) using screws (8) and a motor end cap (9) with vibration-resistant retention features; and
verifying damping efficiency by mechanically testing axial and radial vibration suppression under operational load conditions.

6. DATE AND SIGNATURE

Dated this on 29th September 2025
Signature

(Mr. Srinivas Maddipati)
IN/PA 3124
Agent for Applicant