Claims:We claim:
1. An apparatus for housing a ceiling fan motor, the apparatus comprising:
a. atleast one bracket (107) having one or more extended vertical flanges (108);
b. a rotor yoke (101), wherein the rotor yoke (101) is wrapped (102), shaped and housed inside the bracket (107) in a required form;
c. the rotor yoke (101) having an inner surface (101a) and an outer surface (101b), wherein the inner surface (101a) of the rotor yoke (101) is attached with a plurality of magnets, wherein the outer surface (101b) of the rotor yoke (101) is projected and locked to the vertical flanges (108) of the bracket (107) by providing jimping (103) thereof and thereby avoiding the slipping of the rotor yoke (101), wherein the rotor yoke (101) rotates along with the bracket (107) during running conditions; and
d. a stator (104), wherein the stator (104) is placed in-between the rotor yoke (101) and enclosed in the bracket (107).
2. The apparatus as claimed in claim 1, wherein the apparatus (100) further comprises of a sensor cover (110) fixed with a sensor PCB, wherein the sensor cover (110) is fitted at the bottom of the bracket (107) through one or more locks (109), wherein the sensor cover (110) provides better remote signal coverage to the PCB or controller (106).
3. The apparatus as claimed in claim 2, wherein the sensor cover (110) is made of a Polypropylene H110MA.
4. The apparatus as claimed in claim1, wherein the rotor yoke (101) wrapping (102) is made from a steel material.
5. An apparatus for housing a ceiling fan motor, the apparatus further comprising:
a. atleast one bracket (107) having one or more extended vertical flanges (108);
b. a rotor yoke (101), wherein the rotor yoke (101) is wrapped (102), shaped and housed inside the bracket (107) in a required form;
c. the rotor yoke (101) having an inner surface (101a) and an outer surface (101b), wherein the inner surface (101a) of the rotor yoke (101) is attached with a plurality of magnets, wherein the outer surface (101a) of the rotor yoke (101) is projected and locked to the vertical flanges (108) by providing jimping (103) thereof;
d. a stator (104), wherein the stator (104) is placed in-between the rotor yoke (101) and enclosed in the bracket (107); and
e. one or more snap-locks (105) inserted into the stator (104), wherein the stator (104) holds and locks a controller or Printed Circuit Board (PCB) (106) through the snap-locks (105) to provide better commutation to the motor.
, Description:[0001] PREAMBLE TO THE DESCRIPTION:
[0002] The following specification particularly describes the invention and the manner in which it is to be performed:
[0003] DESCRIPTION OF THE INVENTION:
[0004] Technical field of the invention
[0005] The present invention relates an apparatus for housing a ceiling fan motor, which involves less cost for manufacturing thereof. More particularly, the present invention requires lesser manufacturing time and provides a yoke which does not slip during full load operating conditions.
[0006] Background of the invention
[0007] Ceiling fans are popular commercial and consumer items. They move air in a room to more evenly distribute the air and keep the room at a more constant temperature. Ceiling fans are often used to cool people by providing a stream of air over their bodies. The air stream enhances body cooling by evaporating any surface body moisture by removing heat from the surface of the skin.
[0008] Most ceiling fans are electrically powered. Ceiling fan motor includes a stator, a rotor, and blades connected to the rotor to be rotated by the motor. Regular ceiling fans commonly have a motor housing adapted for holding the fan motor. The ceiling fan includes a down rod assembly suspended from the ceiling with a motor shaft connected to a lower portion of the down rod assembly. The motor housing that surrounds the motor may be secured to either the motor shaft or the down rod assembly, which is stationary. Ceiling fans are commercially available in many shapes and configurations.
[0009] Various types of conventional ceiling fan apparatus are known in the prior art. Typically, Brushless DC (BLDC) ceiling fan motor uses a yoke along with magnets as a rotor which is clamped by both the top and bottom brackets. In conventional BLDC ceiling fan, the yoke is made from a tube. Typically, the manufacturing cost for making the yoke in conventional ceiling fans is more. Typically, in conventional the BLDC ceiling fan, the rotating member or yoke is clamped only in axial direction and may slip during full load operating conditions and thereby providing unstable operation at different speeds.
[0010] Hence, there is a need for an apparatus for housing a ceiling fan motor, which involves less cost for manufacturing thereof. More particularly, the present invention requires lesser manufacturing time and provides a yoke which does not slip during full load operating conditions.
[0011] Summary of the invention:
[0012] The present invention overcomes the drawbacks in the prior art and provides an apparatus for housing a ceiling fan motor. The apparatus comprises of atleast one bracket having one or more extended vertical flanges. A rotor yoke is wrapped, shaped and housed inside the bracket in a required form using a blanking process. The rotor yoke having an inner surface and an outer surface, wherein the inner surface of the rotor yoke is attached with a plurality of magnets, wherein the outer surface of the rotor yoke is projected and locked to the vertical flanges of the bracket by providing jimping thereof and thereby avoiding the slipping of the rotor yoke, wherein the rotor yoke rotates along with the bracket during running conditions. A stator is placed in-between the rotor yoke and enclosed in the bracket.
[0013] In preferred embodiment of the invention, the apparatus further comprises of a sensor cover fixed with a sensor PCB, wherein the sensor cover is fitted at the bottom of the bracket through one or more locks, wherein the sensor cover provides better remote signal coverage to the PCB or controller.
[0014] In preferred embodiment of the invention, the sensor cover is made of a Polypropylene H110MA.
[0015] In preferred embodiment of the invention, the rotor yoke wrapping is made from a steel material.
[0016] In another embodiment of the invention, the apparatus further comprises of atleast one bracket having one or more extended vertical flanges. A rotor yoke is wrapped, shaped and housed inside the bracket in a required form using a blanking process. The rotor yoke having an inner surface and an outer surface, wherein the inner surface of the rotor yoke is attached with a plurality of magnets, wherein the outer surface of the rotor yoke is projected and locked to the vertical flanges by providing jimping thereof. A stator, wherein the stator is placed in-between the rotor yoke and enclosed in the bracket. One or more snap-locks inserted in the stator, wherein the stator holds and locks a controller or Printed Circuit Board (PCB) through the snap-locks to provide better commutation to the motor.
[0017] The present invention provides an apparatus for the ceiling fan, which requires less cost for manufacturing thereof and also involves less manufacturing time for assembling therein. The present invention uses a snap lock design for assembling the controller to the stator shaft. Further, the present invention does not use the fasteners for assembling controller to the stator shaft.
[0018] The present invention provides an apparatus for the ceiling fan which is simple, cost effective and easy to assemble and is suitable for the applications in ceiling fans.
[0019] It is to be understood that both the foregoing general description and the following details description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
[0020] Brief description of the drawings:
[0021] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0022] Figure 1 shows a perspective view of the rotor yoke, according to one embodiment of the invention.
[0023] Figure 2 shows a perspective view of the stator, according to one embodiment of the invention.
[0024] Figure 3 shows a bottom view of the bracket, according to one embodiment of the invention.
[0025] Figure 4shows a perspective view of the sensor cover, according to one embodiment of the invention.
[0026] Detailed description of the invention:
[0027] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention.
[0028] The present invention provides an apparatus for the ceiling fan, which requires less cost for manufacturing thereof and also involves less manufacturing time for assembling therein. The present invention uses a snap lock design for assembling the controller to the stator shaft. Further, the present invention does not use the fasteners for assembling controller to the stator shaft.
[0029] Figure 1shows a perspective view of the rotor yoke, according to one embodiment of the invention. In a preferred embodiment, the rotor yoke (101) is wrapped (102) and shaped into a circular form using a blanking process. The rotor yoke (101) wrapping is made from a steel material. The rotor yoke (101) has an inner surface (101a) and an outer surface (101b). The inner surface (101a) of the rotor yoke (101) is attached with a plurality of magnets. The outer surface (101b) of the rotor yoke (101) is projected and locked to the vertical flanges of the bracket by providing jimping (103) thereof and thereby avoiding the slipping of the rotor yoke (101), during full load operating conditions in the ceiling fans.
[0030] Figure 2 shows a perspective view of the stator, according to one embodiment of the invention. In a preferred embodiment, the stator (104) is inserted with one or more snap-locks (105). The stator (104) holds and locks a controller (106) or Printed Circuit Board (PCB) through the snap-locks (104) to provide better commutation to the Brushless DC (BLDC)motor. The stator (104) is placed in-between the rotor yoke (101) and enclosed in the brackets.
[0031] Figure 3shows a bottom view of the bracket, according to one embodiment of the invention. In a preferred embodiment, the bracket (107) has one or more extended vertical flanges (108). The bottom of the bracket is fitted with a sensor cover (110) through one or more locks (109). The outer surface (101b) of the rotor yoke (101) is projected and locked to the vertical flanges (108) of the bracket by providing jimping (103) thereof and thereby avoiding the slipping of the rotor yoke (101), during full load operating conditions in the ceiling fans. The sensor cover (110) is fixed with a sensor PCB to provide better remote signal coverage to the PCB or controller (106).
[0032] Figure 4shows a perspective view of the sensor cover, according to one embodiment of the invention. In a preferred embodiment, the sensor cover (110) has four locks (109). The sensor cover (110) is fixed with the sensor PCB and is attached at the bottom of the bracket (107). The sensor cover (110) is made of a Polypropylene H110MAwith natural white colored material for better remote signal coverage. The sensor cover (110) provides better remote signal coverage to the PCB (106) or controller at the stator side.
[0033] The present invention provides an apparatus for the ceiling fan, which requires less cost for manufacturing thereof and also involves less manufacturing time for assembling therein. The present invention uses a snap lock design for assembling the controller to the stator shaft. Further, the present invention does not use the fasteners for assembling controller to the stator shaft.
[0034] The present invention provides an apparatus for the ceiling fan which is simple, cost effective and easy to assemble and is suitable for the applications in ceiling fans.