The present invention generally relates to a ceiling fan, and more specifically, to a motor of the ceiling fan having double bearings wherein first or top bearing is installed/inserted from top side of a top cover and a second or bottom bearing is installed from a bottom side of the top cover.
BACKGROUND OF THE INVENTION
[0002] There are numerous applications for fans of various sizes, particularly small fans that require continuous service and maintenance at high efficiency and with minimal noise. Nevertheless, in many such applications, the cost of the fan may be a substantial factor.
The ceiling fan encompasses an outer runner motor and includes a set of blades extending from a central shaft and rotated by an induction motor inside the fan assembly. An induction motor used in electric fans mainly comprises a rotor which rotates around a central shaft and a stator that remains stationary. The motor housing envelops the rotor as it revolves on bearings around the stator. Fan blades are attached to the motor housing. The motor housing of a conventional fan generally comprises an upper bracket and a lower bracket. A commonly used double bearing fan includes at least two bearings to support the motor and fan shaft at two different locations i.e. one at the upper bracket and another at the lower bracket.
[0003] Conventional structure and principle of existing ceiling-fan motor is substantially similar, for example, the ceiling-fan motor generally comprises motor top cover, bottom cover, shaft, stator, rotor, upper bearing, lower bearing, in the middle of motor upper cover and motor lower cover, form a cavity, motor shaft runs through motor upper

cover and motor lower cover and motor stator, upper bearing, lower bearing is installed on motor shaft from top to bottom, the upper bearing is fixedly connected with motor upper cover inwall wherein the lower bearing is fixedly connected with motor lower cover inwall, the rotor is connected with the inwall interference of motor upper cover and motor lower cover simultaneously and is positioned at motor stator periphery and rotor madial wall and motor stator lateral wall.
[0004] A particularly vulnerable portion of almost any fan, from the standpoint of wear, is the bearing assembly that supports the fan rotor. These ball bearings ensure negligible frictional loses when fan motor is revolving, resulting in improved motor efficiency. In such fans where bearings are located at two different locations, two separate brackets are needed for support as well to cover the fan from both sides. The upper bracket may be attached to the lower bracket via screw arrangement in a factory or by any other suitable method.
[0005] However, such ceiling fan cannot meet modern society to low energy consumption, high efficiency, the requirement of high benefit, and still there are some shortcomings in this ceiling-fan motor, electric machine structure is complicated, dismounting is inconvenient, motor internal overall space is loose, cause the volume of motor larger, because motor overall volume is larger, the weight of motor is also relatively large, so the energy consumption of motor when operation is higher, and use cost increases, due to complex structure, cause the technological process of production of motor complicated, integral production efficiency is also lower, electric machine structure, complex manufacturing, cause raw material loss, energy consumption larger, and production cost is higher.
[0006] US5654598A discloses a direct current (DC) brushless motor for automotive and HVAC applications utilizes a single angular contact bearing assembly to rotatably couple an exterior rotor to an interior

stator. The single angular contact bearing assembly can be a double horizontal row ball bearing, a four point contact bearing, and a crossed cylindrical roller bearing. The rotor is staked to the bearing assembly by a hub-shaft. A cooling fan is disposed on the top of the rotor to cool internal control circuitry within the motor. The stator includes a winding set connector which is slideably engaged within a cavity of a deep draw support member.
[0007] US20210270290A1 the disclosure relates to a ceiling fan assembly including a stator assembly having a non-rotating motor shaft and stator slidably and non-rotationally coupled to the non-rotating motor shaft, a rotor assembly, a first bearing slidably mounted to the non-rotating motor shaft and rotatably coupling the rotor assembly to the stator assembly, and a first spacer located between the first bearing and the stator assembly to fix the sliding location of the first bearing relative to the stator along the non-rotating motor shaft.
[0008] IN201741011073 provides a singly supported bracket assembly with illumination source in a fan that comprises an upper bracket supported at a central shaft of the fan by a first bearing, and a second bearing disposed in close proximity to each other around the central shaft inside the upper bracket. In addition to the singly supported fan, an illumination source is fixedly disposed at the lower portion of the upper bracket. A lower bracket with a light diffuser is positioned below the illumination source to allow the light to pass through the light diffuser, wherein the lower bracket is fixedly attached to the upper bracket. The BLDC motor is stator, rotor and PCB are mounted in the single supported assembly.
[0009] Assembling the known fan from its several parts is a comparatively difficult operation, requiring skilled workers. It has been found to be particularly difficult to install the shaft in the tubular member by means of the two bearings in such manner that they run

perfectly coaxial, and to attach the fan blades in the proper locations on the dish. Unless so assembled there will be an imbalance in the fan, with severe wear and a high noise level when the ceiling fan is in operation.
[OOIO] But there is need of such arrangement of the bearings that they can be accommodated in a single cover so that by removing that cover or dismantling that particular portion, the repair of the fan motor can be done easily as bearings are a movable part that support the shaft or spindle of the fan as well as ensure its frictionless rotational movement.
[0011] Secondly, if there arises the need to repair the stator motor fan can be opened from one side by removing the bearings easily.
[0012] Further, if the proper resting space for the bearings is not provided like if the bearings are just mounted directly over the shafts then it may lead to misalignment or jerks to the shaft or bearings or may hinder in the proper rotation of the shaft of the fan.
[0013] So, the present invention discloses the solution to the prior arts and makes the repair of the fan to carry out in an easy manner with less use of time and reduces the labour cost and the overall cost of the fan also gets reduces as other bottom portion can be just made of to cover the bottom portion of the fan.
[0014] Accordingly, it is seen that a need has long existed for a ceiling fan with good motor longevity and that is consistently quiet. It is to the provision of such that the present invention is primarily directed.
[0015] Thus, improvement to conventional ceiling fan motors is necessary.
SUMMARY OF THE INVENTION

[0016] The object of the invention is the problems referred to above that exist for prior art, proposed a kind of small volume, simple in structure, easy accessibility, production and the lower use cost of a ceiling-fan motor.
[0017] In various aspects, the present application is directed to a motor assembly of a ceiling fan. More specifically, the motor assembly of the ceiling fan enclosed between the top cover and bottom cover of the of the ceiling fan.
[0018] A ceiling fan as according to the present invention has the following structure, wherein the motor assembly is enclosed in a motor housing wherein the housing includes a top cover and bottom cover connected together via connected means. The motor assembly includes various elements such as a Printed Circuit Board Assembly (PCBA) wherein the PCBA is placed or configured in a PCBA holder. The motor assembly further includes a stator with rotor wherein a spindle/shaft is centrally fixed onto the stator with rotor. A Cir-clip is configured to hold a top bearing in the motor assembly. A first washer and a second washer wherein a first washer is configured to provide resting surface to a wave spring washer and wherein a second washer is configured to protect inner and outer race of a bottom bearing. The motor assembly further comprises assembling the wave spring washer, the first washer and the circlip in top cover. However, the wave spring washer, the washer and the circlip are in arresting movement of top bearing at the top cover.
[0019] The motor assembly further comprises the top bearing and the bottom bearing wherein the top bearing and the bottom bearing are configured to align the spindle of the stator with motor. Furthermore, the top bearing is configured to install from top side of the top cover and the bottom bearing is configured to install from the bottom side of the top cover.
[0020] The top side of the top cover is configured to have a receptacle

to receive the top bearing, wherein the top bearing may be of the type of Double Z bearing which characterizes as a non-removable, non-contact bearing closure with a metal seal on both sides. The Double Z bearing seal doesn't make contact with the inner ring therefore, there is be no impact on the operational speed. Further, the bottom side of the top cover is configured to have a groove to receive the bottom bearing wherein the bottom bearing is a ball bearing use in the motor of the ceiling fan.
[0021] The housing of motor assembly of the ceiling fan is also provided with a central shaft/spindle which extends along an axis of the motor. In an embodiment, the rotor assembly is adapted to rotate about the central shaft, and the stator is positioned adjacent the wall of the bottom cover.
[0022] As according to an embodiment of the present invention, the distance between two bearings shortens, and precision between two bearings and axle center is improved, so the probability that motor shakes when operation reduces, and moves more stable.
[0023] With this structure, shaking and vibration of the motor associated with the rotation of the bearing housing can be significantly reduced, and thus the present invention can offer the ceiling fan with low noise and low vibration. In addition, a pressing process of multiple operations become unnecessary. This can reduce damage to the ball bearing in an assembly process as well as a reduction in man-hours.
[0024] The features and advantages described in the specification are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter.

OBJECT OF THE INVENTION
[0025] It is therefore a primary object of the invention to provide a way to install the bearings separately from each other on the top cover so that either of them can be easily removed or inserted independently from the motor assembly.
[0026] The object of the invention is to provide a ceiling fan of the type mentioned that can be assembled in a very simple manner and by less skilled labor.
[0027] It is another object, feature, or advantage to provide a simple assembly of bearings by insering both the bearings at the top cover.
[0028] It is another object, feature, or advantage of the present invention to provide a convenient way to insert and remove the bearing separately in the motor assembly.
[0029] A still further object of the present invention is to secure the filament of the bearings and decrement in the interference while installing and removing the bearings.
[0030] A still further object, feature, or advantage of the present invention is to maintain the disctance between the bearings causing better concentricity of spindle.
[0031] A still further object or advantage of the present invention is to reduce the number of griding areas in the spindle/shaft.
[0032] A still further object of the present invention is to reduce the overall weight of the ceiling fan.
[0033] It is another object, feature, or advantage of the present

invention to provide reduction in bearing noise and bearing failure issues.
[0034] A still further object, feature, or advantage of the present invention is to provide a simple structure, relatively simple technological process of production of motor, time shorten whole production process, reduces energy and cost production, and convenient to use motor assembly of a ceiling fan.
[0035] One or more of these and/or other objects, features, or advantages will become apparent from the specification and claims that follow. No single embodiment of the present invention need exhibit each or any of the objects, features, or advantages and different embodiments may have different objects, features, or advantages.
[0036] The present invention is not to be limited by or to these objects, features, or advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0038] Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects in accordance with one or more embodiments.
[0039] The below figure depicts an illustrative embodiment of the invention. This depicted embodiment is to be understood as illustrative

of the invention and not as limiting in any way.
[0040] Referring particularly to the drawing for illustration only and not limitation, there is illustrated:
[0041] Figure 1 Illustrates the exploded view of the fan motor as according to an embodiment of the present invention.
[0042] Figure 2 illustrates the top side of the top cover as according to an embodiment of the present invention.
[0043] Figure 3 illustrates the bottom side of the top cover as according to an embodiment of the present invention.
[0044] Figure 4 illustrates the spindle as as according to an embodiment of the present invention.
[0045] Figure 5 illustrates inside view if the motor of the ceiling fan as according to an embodiment of the present invention.
DETAIL DESCRIPTION OF THE INVENTION
[0046] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternate and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.

[0047] The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes what we presently believe is the best mode of carrying out the invention. Additionally, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, 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.
[0048] References to "one embodiment," "an embodiment," "at least one embodiment," "one example," "an example," "for example," and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase "in an embodiment" does not necessarily refer to the same embodiment.
[0049] When the terms "front", "rear", "up", "down", "top", "bottom", "inner", "outer", "side", and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the invention, rather than restricting the invention.
[0050] The ceiling fan generally includes housing in which the motor assembly of the ceiling fan enclosed between the top cover and bottom cover of the of the ceiling fan. Furthermore, a metal rod is configured to centrally engage the motor assembly via one end of the metal rod.

Furthermore, the other end of the rod is used to hang the fan on the ceiling wall via some hanging mean.
[0051] The motor assembly (100) of a ceiling fan includes various elements such as cir-clip, washer, bearings, stator with rotor, spindle, PCBA etc. to work together and provide motion to the blades of the ceiling fan when power if supplied.
[0052] Fig. 1 describes an exploded view of the motor of the ceiling fan as according to the preferred embodiment of the present invention. The ceiling fan has a motor that converts electrical energy into mechanical energy. The motor assembly (100) of the ceiling fan includes various elements to provide torques up the electric motor, thereby causing it to start and run. A housing is made-up with the combination of top cover (110) and bottom cover (124) and the motor assembly (100) is enclosed in the such housing.
[0053] The housing of the motor assembly (100) included a top cover (110) which is circular or round in shape having a hole in the middle for provising a way to pass the shaft through it. The top cover (110) further provided with the male locking means (166) to snugly fitting with the female locking means of the bottom cover to to enclosed the motor assembly of the fan between the top cover and the bottom cover. The bottom cover (124) is made-up of preferably plastic material. The shell of the bottom cover fastened to the top cover by screws and having a plurality of ornaments on the outside. The bottom cover shell can be replaced to change the ornamental pattern and aesthetics of the ceiling fan.
[0054] According to an embodiment of the present invention, the elements used in the motor assembly comprising a PCBA (122), wherein the PCBA is configured in a PCBA holder (120) wherein the PCBA is connected with the PCBA holder by the connecting mean preferably of Ml4 NUT. The motor assembly further comprises a Cir-clip (102),

wherein the cir-clip (102) is used to hold top bearing in motor assembly. A top bearing (108) which is preferably of a type of Double Z bearing. A washer (104) is used to provide resting surface to wave spring washer. A wave spring washer (106) is used absorb shock like normal spring works in a conventional fan. Another washer (114) is used to protect inner and outer race of bearing. A bottom bearing (112) is used to align spindle with top and bottom cover.
[0055] According to an embodiment of the present invention, a circlip (102) is used to hold top bearing (108) in motor assembly (100). The cir¬clip is also known as a C-clip, Rotor Clip, snap ring or Jesus clip is a type of fastener or retaining ring consisting of a semi-flexible metal ring with open ends which can be snapped into place, into a machined groove on a dowel pin or other part to permit rotation but to prevent lateral movement.
[0056] According to an embodiment of the present invention, a wave spring washer (106), is required to absorb shock in the ceiling fan. The motor assembly further comprises a first washer (104) which is of slight conical shape, which provides an axial force when deformed. The wave spring washer (106), the first washer (104) and the circlip (102) are assembled in top cover in such a way that the wave spring washer (106), the washer (104) and the circlip (102) are in arresting movement of top bearing at the top cover.
[0057] According to an embodiment of the present invention, the wave spring washer (106), the first washer (104) and the circlip (102) are assembled in top cover in such a way that the wave spring washer (106), the washer (104) and the circlip (102) are in arresting movement of top bearing (108) at the top cover (110).
[0058] According to a preferred embodiment of the present invention, the top bearing (108) is configured to install from top side (150) of the top cover (110) and the bottom bearing (112) is configured to install from

the bottom side (160) of the top cover (110).
[0059] The motor assembly (100) also contains a rotor assembly and a stator assembly (116). The stator assembly is located adjacent the housing outer wall wherein the rotor assembly is positioned inside of the stator. The rotor assembly includes windings or laminations mounted about a hub which is further centrally adjacent to the shaft/spindle (130). The top bearing (108) and the bottom bearing (112) at the top cover (110) are provided to enable the rotor assembly to rotate about the shaft (130).
[0060] A second washer (114) inserted between the lower portion (136) of the shaft (130) which is used to protect inner and outer race of bearing.
[0061] Additionally, the motor outer housing or enclosure may be manufactured from injection atormoulded thermoplastic materials having thermal conductivity at least an order of magnitude lower than metal covers used with AC induction motors, allowing a close fitting design of motor cover and blades, achieving substantial ingress protection against dust and water, thus facilitating easy cleaning.
[0062] Alternatively, mixtures of different plastics can be used such as in particular PPE / PA (polyphenylene oxide / polyamide) or PPO / PP (polyphenylene ether / polypropylene) is made.
[0063] The housing further comprising the fan's blades connecting means to connect the ceiling fan's blades through a vibration limiting or dampening material to the rotor, such that the fan blades will be rotated by the rotor.
[0064] The stator with rotor (116) consists of a main (running) winding and an auxiliary (Starting) winding. The starting winding is connected in parallel with the main winding and displaced from the main winding by an angle of 90° physically. A capacitor and a starting switch are

connected in series with the starting winding. As the polarity of current changes, a rotating magnetic field is created. This magnetic field induces current in the laminations of the rotor, causing it to spin around the stationary stator, in which ball bearings(rotor)spin around the centre point(stator). Further, the rotor is the rotating part of the fan. In a single phase IM, the rotor is inside the stator with an air gap of 0.3 - 0.5 mm. But in a ceiling fan, the rotor is around the stator. When the supply is given, the rotor starts to rotate.
[0065] In another embodiment of the present invention, the stator unit and the rotor unit do not have to rely on the axle for assembly and positioning. In packaging, the axle can be separate from the stator unit and the rotor unit to significantly reduce the packaging volume of the ceiling fan motor, increasing convenience for transportation and inventory management.
[0066] As according to an embodiment of the present invention, a connecting bolt is screwed to washer (104) and spring washer (106), and a pin (not illustrated) is inserted into pin-insert-hole created in thread so as to prevent nut from coming off.
[0067] Fig. 2 describes the top side (150) of the top cover (110). The top cover is is a plate shape circular cover which is configured with a receptacle (154) to receive the top bearing (108) from the top side (150) of the cover (110). The top cover also include with holes (156) in order to make connection with the blades of the ceiling fan by using nuts and bolts. The receptacle (154) at the top side of the top cover included a step (152) in order to receive and fit the top bearing inside the receptacle (154). Further, the top bearing insert or installed in the top side of the top cover may be the type of Double Z bearing.
[0068] The bottom side (160) of the top cover (110) is described in Fig. 3. The bottom side (160) is configured with a groove (164) to receive the bottom bearing (112) from the bottom side (160) of the top cover (110).

The groove (164) at the bottom side of the top cover included a step (162) in order to receive and fit the bottom bearing inside the groove (164). The bottom side of the top cover further comprises connecting means (166) to make connections between the top cover and the bottom cover.
[0069] Fig. 4 describes a spindle/shaft (130) wherein the shaft is a stationary cylindrical rod which extends along an axis of the motor. The rotor assembly is adapted to rotate about the central shaft, and the stator is positioned adjacent the housing outer wall. The shaft upper portion (134) extends above the stator with motor and has a helical thread which are longitudinally spaced from each other. The spindle further includes a lower portion (136) which extends downwardly beyond the stator with rotor, the lower portion (136) has wire passage hole through which the electrical wires of the motor may pass.The stator has a plastic injection moulded core with the main motor shaft pressed in to position and retained by splines and circlip.
[0070] As according to an embodiment of the present invention, the shaft is grinded at the single portion (132) by a grinding process. For the grinding process, the two emery wheels of a grinding machine arranged side by side which are set on radial feed guide rail, a drive mitor of one of them emery wheel has motor and adjusts guide rail, it is vertical with radial feed guide rail movement direction that motor is adjusted the guide rail moving direction, adjust the axial location that guide rail changes this emery wheel by mobile motor, adopt two emery wheels gear at grinding armature spindle two ends respectively.
[0071] Figure 5 describes inside view of the motor of the ceiling fan. A printed circuit board assembly (PCBA) is installed in the PCBA holder (120). The motor controller PCBA (122) with InfraRed signal detector is mounted in the centre of the motor. The PCBA is installed in the up-side down direction in the housing of the motor aseembly as shown in Figure 5 of the present invention. Further, a Ml4 NUT with the required

dimensions preferably but not limited to the dimensions of M14* 1.5 mm is needed to connect the Printed Circuit Board Assembly (PCBA) holder (120) with the PCBA (122).
[0072] The present invention has been described with reference to some drawings and a preferred embodiment purely for the sake of understanding and not by way of any limitation and the present invention includes all legitimate developments within the scope of what has been described herein before and claimed in the appended claims.

WE CLAIM:

1. A motor assembly (100) enclosed between a top cover (110) and a bottom cover (124) of a ceiling fan, the motor assembly (100) comprising:
a PCBA (122), wherein the PCBA is configured in a PCBA holder (120);
a stator with rotor (116), wherein the stator is fixed with a spindle (130);
a Cir-clip (102) is configured to hold a top bearing (108) in the motor assembly (100);
a first washer (104) is configured to provide resting surface to a wave spring washer (106);
a second washer (114) is configured to protect inner and outer race of a bottom bearing (112);
wherein the wave spring washer (106), the first washer (104) and the circlip (102) are assembled in top cover in such a way that the wave spring washer (106), the washer (104) and the circlip (102) are in arresting movement of top bearing at the top cover;
wherein the top bearing (108) and the bottom bearing (112) are configured to align the spindle with top cover (110) and bottom cover (124), and
wherein the top bearing (108) is configured to install from top side (150) of the top cover (110) and the bottom bearing (112) is configured to install from the bottom side (160) of the top cover (110).

2. The motor assembly (100) as claimed in claim 1, wherein the wave spring washer (106) is configured to absorb shock in the ceiling fan.
3. The motor assembly (100) as claimed in claim 1, wherein the top bearing (108) assembled at top side of top cover is a Double Z bearing.
4. The motor assembly (100) as claimed in claim 1, wherein the bottom cover (124) is made-up of plastic or CRCA or Aluminum.
5. The motor assembly (100) as claimed in claim 1, wherein the top bearing (108) at the top cover (110) is made up of dust proof material.
6. The motor assembly (100) as claimed in claim 1, wherein the top side (126) of the top cover (110) having a groove (164) and bottom side (128) of the top cover (110) and having a receptacles (154) which are configured to receive bottom bearing (112) and top bearing (108), respectively.
7. The motor assembly (100) as claimed in claim 6, wherein the groove (164) in the bottom side (160) of the top cover (110) is configured to have step (162) to arrange the bottom bearing (112) and, wherein the receptacles (154) the top side (150) of the top cover (110) is configured to have a step (152) to arrange the top bearing (108).
8. The motor assembly (100) as claimed in claim 1, wherein the PCBA is arranged in the upside down direction in the PCBA holder.