Claims:1. A brushless direct current motor (BLDC motor) (100) comprising
a. a centre shaft (101) ;
b. a stator core (102) wounded by winding coil for generating a magnetic field for driving the motor;
c. a printed circuit board (PCB) (103) mounted on the shaft for energizing the motor;
d. bearings (104 &105) for receiving the shaft;
e. a rotor (106) with a permanent magnet, the rotor is rotatable relative to the stator core about a motor shaft axis;
wherein the stator core is formed of two sets of plurality of stator lamination plates/laminas (200, 300);
wherein the first set of laminas or lamination plates (200) having a circular inner opening (201) of a smaller diameter suitable for receiving the shaft, at least one slot (202) for receiving and housing the components of PCB and circumferentially spaced winding slots (203) extending outward from the inner opening for winding coil on the stator core;
the second set of laminas or lamination plates (300) having a circular inner opening (301) of a larger diameter for receiving and partially housing the bearing of the motor inside the opening and circumferentially spaced winding slots (302) extending outward from the inner opening for winding coil on the stator;
wherein the two sets of plurality of lamination plates or laminas (200, 300) are stacked face-to-face with corresponding winding slots substantially aligned to communicate with each other and stacked such that the cavities (401) are formed for receiving and partially housing the components of the PCB, and steps (402) are formed for receiving and partially housing the bearing of the motor within the formed steps;
wherein the PCB is customized with components placed in reverse, such that the components are placed within the formed cavity.
2. The BLDC motor as claimed in claim 1, wherein shaft (101) is made of Mild Steel.
3. The BLDC motor as claimed in claim 1, wherein the lamination plates or laminas (200, 300) are made of ferromagnetic material or conducting materials selected from cold rolled grain oriented steel (CRGO) or cold-rolled non-grain-oriented steel (CRNGO).
4. The BLDC motor as claimed in claim 1, wherein the PCB (103) is electrically connected to the stator core.
5. The BLDC motor as claimed in claim 1, wherein the PCB (103) comprises motor energizing circuit and components selected from SMPS and driver controller.
, Description:BRUSHLESS DIRECT CURRENT MOTOR WITH NOVEL ASSEMBLY OF STATOR CORE AND ELECTRONICS
FIELD OF THE INVENTION
[001] The present invention relates to a motor and more particularly to a brushless direct current motor with a novel assembly of stator core & electronics. The invention relates to a BLDC Motor with a stator at the centre, held by a shaft and the rotor on the outside, generally known as a HUB motor.
BACKGROUND OF THE INVENTION
[002] The stator core of a Brushless DC motor (BLDC motor) is mechanically mounted to the printed circuit board (PCB) by means of motor support posts or lugs and is separately electrically connected to the PC board by soldering winding ends to connection points on the board.
[003] Known BLDC motor’s (see fig. 1) in which the stator core are formed by stacking the same type of lamination plates or laminas as shown in fig. 1a, wherein the holes are smaller in diameter and are provided for reducing the weight of laminas. The laminas are stacked to form stator core (fig. 1b) and the other components are arranged as shown in fig. 1c.
[004] Other known BLDC motor’s (see fig. 2) in which the stator core is formed by stacking the lamination plates or laminas as shown in fig. 2a, wherein the central opening is larger in diameter and uses a bush for receiving shaft. The laminas are stacked to form stator core (fig. 2b) and the other components are arranged as shown in fig. 2c.
[005] Known devices uses stacking method by arranging first the bearing in first plane then the lamination plates/stator core in the next plane, followed by electronic printed circuit board (PCB) and finally bearing on top plane. Due to this stacking method the minimum height of BLDC motor is dependent on the height of the individual components. Further, the axis alignment of the bearing is more, as the distance between them is more, thereby giving rise to wobbling and imbalance in the motor, creating performance deterioration, thereby reducing efficiency and also bearing failure due to misalignment.
[006] Performance requirements as well as limitations on the size, mass and cost of the BLDC motor are important parameters. The manufacture and sale of small motors such as BLDC is a highly price competitive industry. Improvements in the design or manufacturing process which result in cost savings per motor has a significant commercial advantage in the marketplace.
[007] It is desirable to reduce the size, mass and/or cost of the electric motor and at the same time improve the performance of the motor and at least match the performance with the existing motors.
[008] The instant invention satisfies these needs, as well as others, and generally overcomes the deficiencies found in the background art or solves the problem mentioned in known arts.
OBJECT OF THE INVENTION
[009] The main object of the invention is to develop a Brushless Direct Current motor.
[0010] It is another object of the invention to provide a stator core with unique lamination plates or laminas.
[0011] It is yet another object of the invention to provide a Brushless Direct Current motor with reduced height, weight and cost.
[0012] It is still another object of the invention to provide a Brushless Direct Current motor with overall reduced cost.
[0013] Other objects of the inventions will be apparent from the description of the invention herein below.
SUMMARY OF THE INVENTION
[0014] In an aspect of the present invention a Brushless Direct Current Motor (BLDC motor) is provided with reduced height, weight and cost, the BLDC motor comprises a centre shaft, a stator core, a rotor, a printed circuit board (PCB),bearings mounted on the shaft. The stator core is provided with cavities and steps, and customized printed circuit board (PCB), wherein the PCB components are partially or fully housed in the cavities and the bearing is fully or partially housed in the formed step of the stator core.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a better understanding of the invention, few embodiments are described below with reference to the accompanying figures, purely by way of example and non-limiting in which:
Fig.1 shows prior known lamination plates of stator core;
Fig. 2 shows prior known lamination plates of stator core;
Fig. 3 shows BLDC motor of the present invention;
Fig. 4 shows BLDC motor of the present invention;
Fig. 5 shows first (5a) and second set (5b) of the lamination plates of the stator core of the present invention BLDC motor;
Fig. 6 shows stacked lamination plates or stator core of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] For the better understanding of the objects, technology and advantages of the present invention, the instant invention will be further explained in detail with respect to embodiments and accompanying figures as given above. It should be understood that the specific embodiments described herein are only to be used for explaining the present invention but not used to limit the present invention.
[0017] The present invention relates to a brushless direct current motor provided primarily to reduce space, material used and thereby reducing the weight and cost significantly.
[0018] The present invention relates to a brushless direct current motor (BLDC) Novel Assembly of Stator Core and Electronics such as a printed circuit board provided with motor energizing circuit, controlling circuit and other components.
[0019] The present invention relates to a brushless direct current motor (BLDC) comprising:
• a centre shaft;
• a stator core;
• a rotor;
• a printed circuit board (PCB);
• bearings mounted on the shaft;
[0020] In an embodiment, the centre shaft is provided for mounting or anchoring the components i.e. PCB, bearings and stator core of the motor together and facilitates the rotation of the rotor along the bearings.
[0021] In a non-limiting exemplary embodiment, the centre shaft is made of mild steel.
[0022] In an embodiment, the stator core is wounded by winding coil for generating a magnetic field. The coil generates torque by interacting with a magnetic field formed from the permanent magnet and thereby driving the motor.
[0023] In an embodiment, the stator core is formed of two sets of plurality of stator lamination plates/laminas.
[0024] In a non-limiting exemplary embodiment, the lamination plates or laminas are made of ferromagnetic materials or conducting materials such as Cold Rolled Grain Oriented steel (CRGO)/ Cold-Rolled Non-Grain-Oriented steel (CRNGO).
[0025] In an embodiment, the rotor is provided with a permanent magnet, and the rotor is rotatable relative to the stator core about a motor shaft axis.
[0026] In a non-limiting exemplary embodiment, the rotor is made of aluminum housing.
[0027] In an embodiment, the BDLC motor according to the present invention is provided with a printed circuit board (PCB) mounted on the shaft for providing energy to the motor and is electrically connected to the stator core.
[0028] In certain embodiments, the PCB is coupled to upper or lower portion of the stator core.
[0029] In an embodiment, the PCB consists of motor energizing circuit and controlling circuit and slots for arranging various components such as SMPS, driver controller, hall effect sensor, and other additional components can be arranged depending on the requirement, e.g. for making the fan or any other electronic device smart device using the present invention motor, the PCB can be fitted with Bluetooth or WIFI receiver.
[0030] In an embodiment, the PCB is customized with components placed in reverse.
[0031] In an embodiment, the BLDC motor according to present invention comprises bearings, for receiving the centre shaft. The bearings are provided for supporting a shaft of the BLDC motor and installed to support rotation of the housing of the motor.
[0032] In an embodiment, the bearings used in the BLDC motor of the present invention are sintered bearings or ball bearings.
[0033] In an embodiment, first set of laminas or lamination plates is provided with a circular inner opening of a smaller diameter suitable for receiving the shaft. This opening or hole can also be designated as a shaft hole as it is provided to receive the centre shaft.
[0034] In an embodiment, the first set of laminas or lamination plates of the stator core is provided with at least one slot for receiving and housing the component of PCB such as SMPS, driver controller among others.
[0035] In an embodiment, the first set of laminas or lamination plates of the stator core is provided with circumferentially spaced winding slots extending outward from the inner opening of the stator core, these slots are provided for winding coil on the stator core.
[0036] In an embodiment, the second set of laminas or lamination plates of the stator core is provided with circular inner opening of a larger diameter for receiving and partially housing bearing of the motor inside the opening.
[0037] In an embodiment, the second set of laminas or lamination plates of the stator core is provided with circumferentially spaced winding slots extending outward from the inner opening of the stator core, these slots are provided for winding coil on the stator core.
[0038] In certain embodiments, the two sets of plurality of lamination plates or laminas are stacked (riveted/ locking) to form stator core.
[0039] In certain embodiments, the two sets of plurality of lamination plates or laminas are stacked by either of the sets at above or below and accordingly the PCB is placed at the top or bottom portion of the stator core.
[0040] In an embodiment, the two sets of plurality of lamination plates or laminas are stacked face-to-face with corresponding winding slots substantially aligned to communicate with each other and stacked such that the cavities formed for receiving and partially housing the components of the PCB, and steps are formed for receiving and partially housing the bearing of the motor within the formed steps.
[0041] In certain embodiments, the PCB is customized with components placed in reverse, such that the components are placed within the formed cavity.
[0042] In a non-limiting embodiment, referring to fig. 3 and 4, the BLDC motor (100) of the present invention comprises:
• a centre shaft (101)
• a stator core (102)
• a printed circuit board (PCB) (103);
• bearings (104 and 105); and
• a rotor (106).
[0043] In a non-limiting embodiment referring to fig. 3 and 4, the centre shaft (101) is provided for mounting or anchoring the components i.e. PCB, bearings and stator core of the motor together and facilitates the rotation of the stator along the bearings.
[0044] In an embodiment referring to fig. 3 and 4, the rotor (106) is provided with a permanent magnet (107), and the rotor is rotatable relative to the stator core about a motor shaft axis.
[0045] In certain embodiments, the PCB is coupled to upper or lower portion of the stator core.
[0046] In a non-limiting embodiment referring to fig 5 and fig 6, the stator core is formed of two sets of plurality of stator lamination plates/laminas (fig. 5a and fig 5b).
[0047] In a non-limiting embodiment referring to fig. 5, the first set of laminas or lamination plates (fig. 5a, 200) is provided with a circular inner opening (201) of a smaller diameter suitable for receiving the shaft. This opening or hole (201) can also be designated as a shaft hole as it is provided to receive the centre shaft.
[0048] In a non-limiting embodiment referring to fig. 5, the first set of laminas or lamination plates (fig. 5b, 200) of the stator core is provided with at least one slot (202) for receiving and housing the component of PCB such as SMPS, driver controller among others.x`
[0049] In a non-limiting embodiment referring to fig 5, the first set of laminas or lamination plates (fig. 5a, 200) of the stator core is provided with circumferentially spaced winding slots (203) extending outward from the inner opening of the stator core, these slots (203) are provided for winding coil on the stator core.
[0050] In a non-limiting embodiment referring to fig 5, the second set of laminas or lamination plates (fig.5b, 300) of the stator core is provided with circular inner opening (301) of a larger diameter for receiving and partially housing bearing of the motor inside the opening.
[0051] In a non-limiting embodiment referring to fig 5, the second set of laminas or lamination plates (fig. 5b, 300) of the stator core is provided with circumferentially spaced winding slots (302) extending outward from the inner opening of the stator core, these slots (302) are provided for winding coil on the stator core.
[0052] In certain embodiments, the two sets of plurality of lamination plates or laminas are stacked (riveted/ locking) to form stator core.
[0053] In certain embodiments, the two sets of plurality of lamination plates or laminas are stacked by either of the sets at above or below and accordingly the PCB is placed at the top or bottom portion of the stator core.
[0054] In a non-limiting embodiments referring to fig. 5 and 6, the two sets of plurality of lamination plates or laminas (200, 300) are stacked face-to-face with corresponding winding slots substantially aligned to communicate with each other to form stator core and stacked such that the cavities (401) are formed for receiving and partially housing the components of the PCB, and steps (402) are formed for receiving and partially housing the bearing of the motor within the formed steps.
[0055] The present invention further provides formation of BLDC motor by arranging the components as shown in fig 3 and 4.
[0056] The BLDC motor of the present invention can be used in ceiling fan, and other electronic devices which uses BLDC motor for e.g. electric vehicles, drones etc.
[0057] The present BLDC motor has the following advantages mentioned in the below paragraph, which are provided as a result of design of stator lamination plates/laminas, the method of stacking the lamination plates (laminas) to form stator core, formation of cavities and steps, and the customization and arrangement of PCB, and placing the bearing in the steps.
[0058] Few advantages of BDLC motor of the present invention are:
• overall reduced height of motor
• distance between the bearing is reduced, thereby providing reduced wobbling effect
• overall reduced weight of motor
• reduced height and weight of motor results in reduction in weight of fan (using the present BLDC motor) which in turn would require less inertia to start and rotate the fan and
• overall reduced cost.
[0059] The above description of the invention should not be construed as limiting the invention because those skilled in the art to which this invention pertains will be able to devise other forms thereof within the ambit of the appended claims.