DESC:EARLIEST PRIORITY DATE:
[0001] This Application claims priority from a Provisional patent application filed in India having Patent Application No. 202241054140, filed on September 21, 2022, and titled “AN ELECTRONIC COMMUTATION SYSTEM TO OPERATE ELECTRIC MOTORS”.
FIELD OF INVENTION

[0002] An embodiment of the present invention relates to electric motors and more particularly relates to an electronic commutation system to operate electric motors.

BACKGROUND

[0003] An electronic commutation system is configured to switch between phases i.e., single-phase, two-phase, and three-phase of a motor. The electronic commutation system enables switching the current applied to the motor's phases in a sequence that generates motion.

[0004] In order to create the desired movement in the motor, a controller must determine which phase of the motor needs to be switched on. One of the most popular methods to determine where a forcer is located within a magnetic field is with a hall effect sensor (or simply a hall sensor). The hall effect sensor (or simply hall sensor) is a type of sensor that detects the presence and magnitude of the magnetic field using the Hall effect.

[0005] The hall effect sensors are a staple of motor feedback because they are reliable, precise, and have a long useful life. The hall effect sensors do not need to make any contact, so they are useful in harsh environments, reliable in high shock environments, and highly resistant to wear and tear. The hall effect sensors provide electrical pulses when the magnet is aligned with sensing electronics. For this reason, they are suitable for high-speed applications and allow to pre-program of certain motor shaft angles.

[0006] In conventional motors or the electronic commutation system, the hall effect sensor is placed inside the motor. However, placing the hall effect sensor inside the motor is mechanically complicated and higher temperature inside the motor may affect the efficiency of the hall effect sensor. Additionally, calibrating hall effect sensor signals with motor signals is highly difficult.

[0007] The conventional motors use a knurling profile to lock a rotational holding cap with a shaft, thereby creating difficulty in reassembling the rotational holding cap with magnets in the exact same position once disassembled. Moreover, aligning outer magnets with the rotor magnets is mechanically difficult with ring-shaped or segmented arc-shaped magnets used in conventional motors. Hence, conventional motors are non-reliable in terms of accuracy and stability in performance. Thus, the position of the magnets in the motor or the electronic commutation system is of paramount importance for the stability and efficiency of the motor.

[0008] There are various technical problems with the commutation system in the prior art. In the existing technology, the commutation in the PMSM/BLDC motors is carried out using hall sensors. The arrangement of the hall sensor inside the motor deteriorates the hall sensors over time because of heat. Moreover, conventional motors use a knurling profile to lock a rotational holding cap with a shaft, thereby creating difficulty in reassembling the rotational holding cap with magnets in the exact same position once disassembled.

[0009] Therefore, there is a need for an efficient design and assembly of the electronic commutation system to operate electric motors. There is also a need for a separate assembly to protect the hall sensor from harsh environments near the electric motor. There is also a need for an efficient design and assembly to prevent the anti-rotational movement of the rotational holding cap on the motor shaft. Further, there is also a need to eliminate sensor deterioration over time due to heat inside the electric motor assembly.

SUMMARY

[0010] In accordance with an embodiment of the present invention, an electronic commutation system to operate electric motors is provided. The electronic commutation system includes a stepped shaft, a rotor, a commutator assembly, and a sensor holding assembly. The assembly of the electronic commutation system with one or more sensors provides accurate calibration during the operation of the electric motors.

[0011] The stepped shaft comprises a first step configured to have a keyway slot, a second step, and a third step configured to have a D-cut. The first step and the third step are proximally and distally positioned, respectively. The second step is configured to separate the first step and the third step. The rotor with a plurality of primary magnets is mounted on the first step of the stepped shaft to rotate the electric motor in a circular motion. The plurality of primary magnets is configured to create a magnetic field. The keyway slot on the stepped shaft is disposed of in a way that the centre line of one of the primary magnet from the plurality of primary magnets is aligned with the centre line of the D-cut of the stepped shaft for aligning the plurality of primary magnets with the electric motor.

[0012] The commutator assembly disposed on the step surface having the D-cut of the stepped shaft. The commutator assembly comprises a magnet holder, a plurality of secondary magnets, and a rotational holding cap. The magnet holder is configured with a plurality of slots on the rear side and one or more projections at an outer diameter of the magnet holder. The magnet holder comprises an assembly identification opening on the front side of the magnet holder. The assembly identification opening is configured to identify the plurality of secondary magnets aligned to the commutation system. The magnet holder has positioned in the rotational holding cap in a way that the vertical axis of the assembly identification opening is perpendicular to the centre line of the D-cut of the stepped shaft thereby aligning the plurality of secondary magnets in the magnet holder with the plurality of primary magnets of the rotor.

[0013] The plurality of secondary magnets disposed inside the plurality of slots configured to generate rotation of the electric motor by utilizing electric current. The poles of the plurality of secondary magnets so arranged in the magnet holder in a way that alternate poles are positioned next to each other.

[0014] The rotational holding cap is having one or more slot openings on an outer diameter to align with one or more projections of the magnet holder. The inner diameter of the rotational holding cap having the D-cut surface configured to position the commutator assembly on the D-cut of the stepped shaft, thereby preventing the anti-rotational movement of the rotational holding cap on the stepped shaft. A circlip fitted in a circlip groove on the stepped shaft at a front side of the rotational holding cap is configured to prevent an axial movement of the commutator assembly on the D-cut of the stepped shaft.

[0015] The sensor holding assembly is positioned on the stepped shaft next to the commutator assembly. The sensor holding assembly comprises a sensor holder, a circuit board, and a closing cap. The sensor holder is having one or more apertures configured to hold one or more sensors for determining the position of the rotating plurality of secondary magnets. The one or more sensors comprise one or more hall-effect sensors. The aperture on the sensor holder is positioned at an angle of 120 degrees apart from each other.

[0016] Further, the sensor holder is configured with a plurality of projections. The plurality of projections comprises one or more short projections, and one or more long projections. The one or more short projections are configured to align the circuit board on the sensor holder. The one or more long projections are configured to protect the circuit board from the closing cap by maintaining a distance.

[0017] The circuit board disposed on the sensor holder is configured to establish electric connectivity between one or more sensors through a wire harness. The circuit board comprises a first set of holes, a second set of holes, and a third set of holes. The first set of holes is configured to align with the one or more short projections on the magnet holder. The second set of holes is positioned on the circuit board at an angle of 120 degrees apart from each other and configured to receive terminals of the one or more sensors. The third set of holes is configured to receive one or more wire core cables of the wire harness to connect with the circuit board thereby establishing electric connectivity between one or more sensors.

[0018] The closing cap disposed on the circuit board is configured to protect the electronic commutation system from foreign particles and liquids. Further, the electronic commutation system comprises a rear bracket configured to hold the commutator assembly, the sensor holding assembly, and the stepped shaft by utilizing bearings to maintain the gap between the plurality of primary magnets of the rotor and a stator. The closing cap comprises a plurality of holes configured to fasten the closing cap to the rear bracket.

[0019] To further clarify the advantages and features of the present invention, a more particular description of the invention will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the invention and are therefore not to be considered limiting in scope. The invention will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

[0021] FIG. 1 represents an isometric view of an assembly of an electronic commutation system, in accordance with an embodiment of the present invention;

[0022] FIG. 2 represents a side view of the electronic commutation system, in accordance with an embodiment of the present invention;

[0023] FIG. 3 represents a) a front view and b) an isometric view of a plurality of magnets, in accordance with an embodiment of the present invention;

[0024] FIG. 4 represents a) a rear view, b) a front view, and c) an isometric view of a magnet holder, in accordance with an embodiment of the present invention;

[0025] FIG. 5 represents a) a rear view and b) an isometric view of an assembly of the plurality of magnets and the magnet holder, in accordance with an embodiment of the present invention;

[0026] FIG. 6 represents a) a front view, b) a rear view, and c) an isometric view of a rotational holding cap, in accordance with an embodiment of the present invention;

[0027] FIG. 7 represents a) a front view and b) an isometric view of an assembly of the magnet holder and the rotational holding cap, in accordance with an embodiment of the present invention;

[0028] FIG. 8 represents a) a front view, b) a top view, and c) a detailed view of a rotor, in accordance with an embodiment of the present invention;

[0029] FIG. 9 represents a front view of an assembly of the rotational holding cap and the rotor, in accordance with an embodiment of the present invention;

[0030] FIG. 10 represents a) a front view and b) an isometric view of one or more hall effect sensors, in accordance with an embodiment of the present invention;

[0031] FIG. 11 represents a) a front view, b) a side view, c) an isometric view (hall sensor side), and d) the isometric view (PCB side) of a hall sensor holder, in accordance with an embodiment of the present invention;

[0032] FIG. 12 represents a) a rear view and b) an isometric view of an assembly of the hall sensor and the hall sensor holder, in accordance with an embodiment of the present invention;

[0033] FIG. 13 represents a) a front view and b) an isometric view of a printed circuit board (PCB), in accordance with an embodiment of the present invention;

[0034] FIG. 14 represents a) a front view and b) an isometric view of an assembly of the hall sensor holder and the printed circuit board, in accordance with an embodiment of the present invention;

[0035] FIG. 15 represents a wire harness, in accordance with an embodiment of the present invention;

[0036] FIG. 16 represents a front view of an assembly of the electronic commutation system, in accordance with an embodiment of the present invention; and

[0037] FIG. 17 represents a rear view of a closing cap, in accordance with an embodiment of the present invention.

[0038] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the method steps, chemical compounds, equipment, and parameters used herein may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0039] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0040] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more components, compounds, and ingredients preceded by "comprises... a" does not, without more constraints, preclude the existence of other components or compounds or ingredients, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0042] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0043] Embodiments of the present invention relate to an electronic commutation system to operate electric motors. The electric motors include but not limited to permanent magnet synchronous motors (PMSM) and/or brushless direct current electric motors (BLDC) in the present invention.

[0044] FIG. 1 represents an isometric view of an assembly of an electronic commutation system 100, in accordance with an embodiment of the present invention.

[0045] FIG. 2 represents a side view of the electronic commutation system 100, in accordance with an embodiment of the present invention.

[0046] In an embodiment, the electronic commutation system 100 comprises a commutator assembly 122. The commutator assembly 122 includes a magnet holder 106, a plurality of secondary magnets 116, and a rotational holding cap 108. The plurality of secondary magnets 116 is configured to generate rotation of the electric motor using electrical current passing through loops of wires (not shown). The plurality of secondary magnets 116 includes but is not limited to the rectangular cross section. Production and assembly of the plurality of secondary magnets 116 with rectangular cross sections are much easier than segmented arc shaped magnets used in conventional electronic commutation systems.

[0047] FIG. 3 represents a) a front view and b) an isometric view of the plurality of secondary magnets 116, in accordance with an embodiment of the present invention.

[0048] FIG. 4 represents a) a rear view, b) a front view, and c) an isometric view of the magnet holder 106, in accordance with an embodiment of the present invention.

[0049] The electronic commutation system 100 also includes the magnet holder 106 configured to hold the plurality of secondary magnets 116 in place. The magnet holder 106 is made up of plastic or non-magnetic materials which are circular in shape.

[0050] The magnet holder 106 includes a plurality of rectangular slots 402 configured to hold the plurality of secondary magnets 116. The magnet holder 106 contains one or more projections 404a, 404b, and 404c at an outer diameter of the magnet holder 106. In one embodiment, the magnet holder 106 contains three projections 404a, 404b, and 404c at the outer diameter of the magnet holder 106. The plurality of secondary magnets 116 is positioned inside the plurality of rectangular slots 402. The magnet holder 106 includes an assembly identification opening 406 on the front side of the magnet holder 106 which is necessary for proper alignment of the plurality of secondary magnets 116 in the electronic commutation system 100.

[0051] FIG. 5 represents a) a rear view and b) an isometric view of an assembly of the plurality of secondary magnets 116 and the magnet holder 106, in accordance with an embodiment of the present invention.

[0052] FIG. 6 represents a) a front view, b) a rear view, and c) an isometric view of the rotational holding cap 108, in accordance with an embodiment of the present invention.

[0053] The electronic commutation system 100 also includes the rotational holding cap 108 configured to align the magnet holder 106. The rotational holding cap 108 is made up of, but not limited to plastics, metals, or alloys which are circular in shape.

[0054] The rotational holding cap 108 includes one or more slot openings 604a, 604b, and 604c for aligning the magnet holder 106. In one embodiment, the rotational holding cap 108 includes three slot openings for aligning the magnet holder 106. An inner diameter of the rotational holding cap 108 includes a D-cut 602. The D-cut 602 helps in keeping the rotational holding cap 108 in a fixed position and prevents anti-rotational movement of the rotational holding cap 108. The three projections 404a, 404b, and 404c in the magnet holder 106 get locked within the three slot openings 604a, 604b, and 604c in the rotational holding cap 108 which prevents the relative motion between the magnet holder 106 and the rotational holding cap 108.

[0055] FIG. 7 represents a) a front view and b) an isometric view of an assembly of the magnet holder 106 and the rotational holding cap 108, in accordance with an embodiment of the present invention. The assembly of the magnet holder 106 and the rotational holding cap 108 makes sure that the assembly identification opening 406 is straight to the D–cut 602. A vertical axis 126 of the assembly identification opening 406 and the centre line 128 of the D-cut 118 are aligned in the same straight line which is very important for aligning the plurality of secondary magnets 116 with a plurality of primary magnets 114 on a rotor 110. A circlip is fitted in a circlip groove in the stepped shaft 112. The circlip stays at a front face of the rotational holding cap 108 and the circlip prevents an axial movement of the rotational holding cap 108 (not shown in the figure).

[0056] FIG. 8 represents a) a front view, b) a top view, and c) a detailed view of the rotor 110, in accordance with an embodiment of the present invention. The rotor 110 includes the stepped shaft 112 at a centre of the rotor 110 to enable the circular motions of the rotor 110. The stepped shaft 112 comprises, but not limited to, a first step 130 configured to have a keyway slot 802, a second step 132, and a third step 134 configured to have a D-cut 118. The first step 130 and the third step 134 are proximally and distally positioned, respectively, and the second step 132 is configured to separate the first step 130 and the third step 134. Whereas the first step 130 is a large diameter step of the stepped shaft 112 equipped with the keyway slot 802 and the third step 134 is a medium diameter step equipped with the D-cut 118. The stepped shaft 112 with the keyway slot 802 (similar to D-cut 602) is configured to hold the plurality of the primary magnets 114 intact. The stepped shaft 112 and the keyway slot 802 are made in such a way that the centre line 128 of the stepped shaft 112 is aligned with a centre of the plurality of secondary magnets 116, thereby properly aligning the plurality of secondary magnets 116 in the motor. The stepped shaft 112 prevents the anti-rotational movement of the rotational holding cap 108 and relative motion between the stepped shaft 112 and the rotational holding cap 108.

[0057] The electronic commutation system 100 includes the rotor 110 configured to move the electric motor in circular motions. The rotor 110 includes the plurality of primary magnets 114 located on the surface of the rotor 110. The plurality of primary magnets 114 are configured to create a magnetic field for the conversion of electric energy to mechanical energy.

[0058] FIG. 9 represents a front view of an assembly of the rotational holding cap 108 and the rotor 110, in accordance with an embodiment of the present invention.

[0059] FIG. 10 represents a) a front view and b) an isometric view of one or more sensor 600, in accordance with an embodiment of the present invention.

[0060] The electronic commutation system 100 includes one or more sensors 600 configured to respond to alternating north and south poles. The one or more sensors 600 comprises one or more hall-effect sensors 600.

[0061] The one or more hall effect sensors 600 include one or more terminals 62, 64, and 66. The one or more terminals 62, 64, and 66 include positive terminal 62, ground terminal 64, and output terminal 66.

[0062] FIG. 11 represents a) a front view, b) a side view, c) an isometric view (hall sensor side), and d) an isometric view (PCB side) of the hall sensor holder 102, in accordance with an embodiment of the present invention.

[0063] The electronic commutation system 100 includes a sensor holding assembly 124 positioned on the stepped shaft 112 next to the commutator assembly 122. The sensor holding assembly 124 comprises a sensor holder 102, a circuit board 104, and a closing cap 202. The sensor holder 102 is configured to hold the one or more hall effect sensors 600. The sensor holder 102 is made up of, but not limited to plastic which is circular in shape.

[0064] The sensor holder 102 includes one or more apertures 804 where one or more hall effect sensors 600 are placed. In one embodiment, the sensor holder 102 includes three apertures 804 where the three hall effect sensors 600 are placed at 120 degrees apart from each other. The sensor holder 102 includes one or more short projections 810 for aligning a circuit board (PCB) 104. In one embodiment, the sensor holder 102 includes two short projections 810a and 810b. Here in one embodiment, the circuit board 104 is a printed circuit board (PCB) 104.

[0065] The sensor holder 102 further includes one or more long projections 808 configured to protect the PCB 104. In one embodiment, the sensor holder 102 includes three long projections 808. The sensor holder 102 also includes one or more holes 806 configured to screw to a rear bracket (shown in fig 16). In one embodiment, the sensor holder 102 includes three holes 806 for fitting into the rear bracket.

[0066] FIG. 12 represents a) a rear view and b) an isometric view of an assembly of the one or more hall effect sensors 600 and the sensor holder 102, in accordance with an embodiment of the present invention. The one or more terminals 62, 64 and 66 of the one or more hall effect sensors 600 are passed through holes provided in the sensor holder 102, and the housing of the one or more hall sensors 600 is in rectangular shape.

[0067] FIG. 13 represents a) a front view and b) an isometric view of the printed circuit board (PCB) 104, in accordance with an embodiment of the present invention.

[0068] The electronic commutation system 100 also includes the Printed circuit board (PCB) 104 configured to establish electric connectivity between the one or more hall effect sensors 600.

[0069] The PCB 104 includes a first set of holes 814a and 814b configured to function as mounting holes to fix the PCB 104 in the sensor holder 102. In one embodiment, the PCB 104 includes two mounting holes 814a and 814b. The PCB 104 includes a second set of holes 812 configured to solder the one or more terminals 62, 64, and 66 of the one or more hall effect sensors 600. The second set of holes 812 includes three sets 812a, 812b, and 812c of three holes placed at 120 degrees apart from each other. The PCB 104 includes a third set of holes 816 configured to solder one or more wire core cables (shown in Fig 15). The third set of holes 816 includes five holes to solder five wire core cables.

[0070] FIG. 14 represents a) a front view and b) an isometric view of an assembly of the sensor holder 102 and the printed circuit board 104, in accordance with an embodiment of the present invention.

[0071] FIG. 15 represents the wire harness 900, in accordance with an embodiment of the present invention.

[0072] The electronic commutation system 100 further includes a wire harness 900. The wire harness 900 includes one or more wire insulated core cables with different colours.

[0073] In one embodiment, the wire harness 900 includes five wire insulated core cables which represent positive 818, negative 820, and three outputs 822, 824, and 826 from the three hall effect sensors 600.

[0074] FIG. 16 represents a front view of an assembly of the electronic commutation system 100, in accordance with an embodiment of the present invention.

[0075] The electronic commutation system 100 includes the rear bracket 830 configured to hold an assembly of electronic commutation system 100. The rear bracket 830 is an end cover of the electronic commutation system 100 which completely encloses the rear side of the electronic commutation system 100. The rear bracket 830 also helps in holding the stepped shaft 112 with a bearing so that a uniform gap is maintained between the plurality of primary magnets 114 and a stator (not shown in the figure). The rear bracket 830 accommodates the electronic commutation system 100. Depending on the application, the rear bracket 830 is made up of (but not limited to) materials such as metals, metal alloys, and plastics. Fig 16 shows the front view of the assembled electronic commutation system 100 including the stepped shaft 112 at the centre. The figure also shows the PCB 104 surrounded by the sensor holder 102 and mounted on the stepped shaft 112. The whole assembly of the stepped shaft 112, the PCB 104, and the sensor holder 102 is fixed within the rear bracket 830.

[0076] FIG. 17 represents a rear view of the closing cap 202, in accordance with an embodiment of the present invention. The electronic commutation system 100 includes the closing cap 202 configured to protect the assembly of electronic commutation system 100. The closing cap 202 protects the electronic commutation system 100 from foreign particles and liquids. Depending on the application, the closing cap 202 is made up of, but not limited to, metals, metal alloys, and plastics. The closing cap 202 includes six holes 202a, 202b, 202c, 202d, 202e, and 202f to screw the closing cap 202 with the rear bracket 830. The closing cap 202 is prepared appropriately for the rear bracket 830 enclosure.

[0077] The closing cap 202 touches the three projections in the sensor holder 102. The three projections in the sensor holder 102 stop the closing cap 202 from touching the printed circuit board 104.

[0078] The present invention provides the electronic commutation system 100 to operate the electric motors. The keyway slot (D–cut) 802 in the stepped shaft 112 and the rotational holding cap 108 makes the plurality of secondary magnets 116 aligned properly with the rotor poles and prevents relative motion between the stepped shaft 112 and the rotational holding cap 108. The magnet holder 106 design enables holding the rectangular magnets in proper alignment. The plurality of secondary magnets 116 having rectangular shapes are cost-effective and easy to manufacture. The magnet holder 106 eliminates the chance of the plurality of secondary magnets 116 flying away because one side of the magnet holder 106 is closed where the plurality of secondary magnets 116 are placed, and the other side touches the face of the rotational holding cap 108. The magnet holder 106 is locked with the rotational holding cap 108 which prevents relative movement. The sensor holder 102 may be assembled only in one way which prevents calibration error. The electronic commutation system 100 provided by the present invention is efficient and cost-effective in operating the electric motors. The present invention provides easy manufacturing, assembly, and calibration of the electronic commutation system 100. The electronic commutation system 100 provided by the present invention is reliable, robust, easy to maintain and shows accuracy in performance. One-way assembly of the electronic commutation system 100 by choosing three appropriate angles of the hall sensor holder 102 makes the electronic commutation system 100 assembly very efficient which helps in repeating the same motor performance while disassembly and assembly.

[0079] While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0080] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

,CLAIMS:I/ We Claim:
1. An assembly of an electronic commutation system (100) to operate electric motors, comprising:
a stepped shaft (112) comprising a first step (130) configured to have a keyway slot (802), a second step (132), and a third step (134) configured to have a D-cut (118),
wherein the first step (130) and the third step (134) are proximally and distally positioned, respectively,
the second step (132) configured to separate the first step (130) and the third step (134);
a rotor (110) with a plurality of primary magnets (114) mounted on the first step (130) of the stepped shaft (112) to rotate the electric motor in a circular motion,
wherein the plurality of primary magnets (114) configured to create a magnetic field,
wherein the keyway slot (802) on the first step (130) is disposed in a way that a centre line of one of the primary magnet (114) from the plurality of primary magnets (114) aligned with a centre line (128) of the D-cut (118) of the stepped shaft (112) for alignment of the plurality of primary magnets (114) with the electric motor;
a commutator assembly (122) disposed on the third step (134) having the D-cut (118), wherein the commutator assembly (122) comprises:
a magnet holder (106) having a plurality of slots (402) on a rear side and one or more projections (404a, 404b, and 404c) at an outer diameter of the magnet holder (106);
a plurality of secondary magnets (116) disposed inside the plurality of slots (402) configured to generate rotation of the electric motor by utilizing electric current;
a rotational holding cap (108) having one or more slot openings (604a, 604b, and 604c) on an outer diameter to align with the one or more projections (404a, 404b, and 404c) of the magnet holder (106);
wherein an inner diameter of the rotational holding cap (108) having a D-cut surface (602) configured to position the commutator assembly (122) on the D-cut (118) of the stepped shaft (112), thereby preventing an anti-rotational movement of the rotational holding cap (108) on the stepped shaft (112); and
a sensor holding assembly (124) positioned on the stepped shaft (112) next to the commutator assembly (122), wherein the sensor holding assembly (124) comprises:
a sensor holder (102) having one or more apertures (804) configured to hold one or more sensors (600) for determining the position of the rotating plurality of secondary magnets (116);
a circuit board (104) disposed on the sensor holder (102) configured to establish electric connectivity between one or more sensors (600) through a wire harness (900); and
a closing cap (202) disposed on the circuit board (104) configured to protect the electronic commutation system (100) from foreign particles and liquids,
whereby the assembly of the electronic commutation system (100) with the one or more sensors provide optimized calibration during the operation of the electric motors.
2. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein
the magnet holder (106) comprises an assembly identification opening (406) on a front side of the magnet holder (106), configured to identify the plurality of secondary magnets (116), is aligned to the commutation system (100); and
the magnet holder (106) positioned in the rotational holding cap (108) in a way that the vertical axis (126) of the assembly identification opening (406) is perpendicular to the centre line (128) of the D-cut (118) of the stepped shaft (112), thereby aligning the plurality of secondary magnets (116) in the magnet holder (106) with the plurality of primary magnets (114) of the rotor (110).
3. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the poles of the plurality of secondary magnets (116) arranged in the magnet holder (106) in a way that alternates poles are positioned next to each other.
4. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein a circlip fitted in a circlip groove on the stepped shaft (112) at a front side of the rotational holding cap (108) configured to prevent an axial movement of the commutator assembly (122) on the D-cut (118) of the stepped shaft (112).
5. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the one or more sensors (600) comprise a hall-effect sensor.
6. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the apertures (804) on the sensor holder (102) positioned at an angle of 120 degrees apart from each other.
7. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the sensor holder (102) configured with a plurality of projections,
the plurality of projections comprising:
one or more short projections (810) configured to align the circuit board (104) on the sensor holder (102); and
one or more long projections (808) configured to protect the circuit board (104) from the closing cap (202) by maintaining a distance.
8. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the circuit board (104) comprises:
a first set of holes (814) configured to align with the one or more short projections (810) on the magnet holder (106);
a second set of holes (812) positioned on the circuit board (104) at an angle of 120 degrees apart from each other, and configured to receive terminals of the one or more sensors (600); and
a third set of holes (816) configured to receive one or more wire core cables of the wire harness (900) to connect with the circuit board (104) thereby establishing electric connectivity between one or more sensors (600).
9. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the electronic commutation system (100) comprises a rear bracket (830) configured to hold the commutator assembly (122), the sensor holding assembly (124) and the stepped shaft (112) by utilizing bearings to maintain a gap between the plurality of primary magnets (114) of the rotor (110) and a stator.
10. The assembly of an electronic commutation system (100) as claimed in claim 1, wherein the closing cap (202) comprises a plurality of holes (202a, 202b, 202c, 202d, 202e, and 202f) configured to fasten the closing cap (202) to the rear bracket (830).
Dated this 13th day of September 2023

Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
Agent for applicant