Structure for mounting hall effect sensor of motor

A structure for mounting a Hall effect sensor, the structure including: a mounting bracket, a mounting plate, a left supporting column, a right supporting column, and a first supporting column. The left supporting column and the right supporting column are protruded upwards from top surfaces of two adjacent teeth at the inner side of a certain winding slot, respectively. The first supporting column is protruded upwards from the top surface of the circular yoke at the outer side of the winding slot. The mounting plate is disposed on top surfaces of the first supporting column, the left supporting column, and the right supporting column. The mounting bracket is installed at the bottom of the mounting plate. The Hall effect sensor is installed in the mounting bracket.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates to a structure for mounting a Hall effect sensor of a motor.

Description of the Related Art

Typically, a Hall effect sensor is installed on the control circuit board of a motor, and then the control circuit board is mounted on the end insulator of the stator assembly or the rear end cover of the motor. However, such installation is unreliable, the control circuit board is difficult to position, and the Hall effect sensor tends to detach from the control circuit board.

SUMMARY OF THE INVENTION

In view of the above-described problems, it is one objective of the invention to provide a structure for mounting a Hall effect sensor of a motor. The structure is simple and compact, the installation is convenient and firm, and the working reliability is high. The creepage distance between the Hall effect sensor and the coil windings can be enlarged, and the Hall effect sensor is high voltage resistant and difficult to breakdown.

To achieve the above objective, in accordance with one embodiment of the invention, there is provided a structure for mounting a Hall effect sensor of a motor. The motor comprises: a rotating shaft, a rotor assembly, a stator assembly, a housing assembly, and a Hall effect sensor. The stator assembly comprises: an iron core, an end insulation, and coil windings. The end insulation comprises: a circular yoke, a plurality of teeth, and winding slots. The housing assembly comprising a first cavity. The rotor assembly is disposed on the rotating shaft. The rotor assembly is nested within the stator assembly, and the rotor assembly and the stator assembly are disposed in the first cavity of the housing assembly. The end insulation is disposed on an end part of the iron core, and the coil windings are wound on the end insulation. The teeth are protruded inwards from the circular yoke, and winding slots are formed between two adjacent teeth. The structure for mounting the Hall effect sensor comprises: a mounting bracket, a mounting plate, a left supporting column, a right supporting column, and a first supporting column. The left supporting column and the right supporting column are protruded upwards from top surfaces of two adjacent teeth at an inner side of a certain winding slot, respectively. The first supporting column is protruded upwards from a top surface of the circular yoke at an outer side of the winding slot. The mounting plate is disposed on top surfaces of the first supporting column, the left supporting column, and the right supporting column. The mounting bracket is installed at a bottom of the mounting plate. The Hall effect sensor is installed in the mounting bracket.

In a class of this embodiment, the mounting bracket comprises a second cavity at a bottom thereof, and the Hall effect sensor is embedded in the second cavity.

In a class of this embodiment, a left base is disposed at a bottom of the left supporting column on the top surface of one tooth. A right base is disposed at a bottom of the right supporting column on the top surface of an adjacent tooth. A mounting slot is formed between the left base and the right base. The mounting bracket is embedded in the mounting slot and disposed on the top surfaces of the teeth.

In a class of this embodiment, an inner wall of the mounting slot, the left base, and the right base form a left neck and a right neck. Two sides of the mounting bracket are convex to form two fixture blocks. The mounting bracket is nested in the mounting slot, and the fixture blocks on the two sides of the mounting bracket are locked in the left neck and the right neck, respectively.

In a class of this embodiment, a plurality of first through holes is disposed at a top of the mounting bracket and communicates with the second cavity. A plurality of second through holes is disposed on the mounting plate for communicating with the first through holes. The Hall effect sensor is embedded in the second cavity, and pins of the Hall effect sensor pass through the first through holes and the second through holes and are in electric connection with an external device.

In a class of this embodiment, a plurality of positioning columns is protruded from a top surface of the mounting bracket. The mounting plate comprises mounting holes. The mounting bracket is mounted at a bottom of the mounting plate by assembling the positioning columns with the mounting holes. the mounting plate comprises a plurality of positioning holes, and the mounting plate is disposed on the top surfaces of the first supporting column, the left supporting column, and the right supporting column by assembling the positioning holes with the first supporting column, the left supporting column, and the right supporting column. The mounting plate also comprises a plurality of lead through holes.

In a class of this embodiment, an inner side panel is protruded upwards from an inner edge of the top surface of each tooth. The left base and the right base are connected to corresponding inner side panels, respectively.

In a class of this embodiment, the housing assembly comprises: a housing, a front end cover and a rear end cover disposed at two ends of the housing, respectively. A middle of a top surface of the front end cover is protruded upwards to form an upper bearing seat. A bearing cavity is disposed in the upper bearing seat. An outer wall of the upper bearing seat is provided with a plurality of first stiffeners. A bottom wall of the bearing cavity is convex downwards from a bottom surface of the front end cover and forms a lower bearing seat. An outer wall of the lower bearing seat is provided with a plurality of second stiffeners.

In a class of this embodiment, the first stiffeners are radially disposed on the top surface of the front end cover. A plurality of through holes for heat dissipation is radially arranged between two adjacent first stiffeners.

In a class of this embodiment, an annular boss is disposed on an outer edge of the top surface of the front end cover, and two ends of the first stiffeners are connected to the outer wall of the upper bearing seat and the annular boss.

In a class of this embodiment, an outer edge of the front end cover protrudes a plurality of mounting feet, two sides of the mounting feet are provided with third stiffeners, and the third stiffeners are connected to the outer edge of the front end cover.

In a class of this embodiment, the number of the mounting feet is four; the mounting feet are radially disposed on the outer edge of the front end cover. The outer edge of the front end cover between two adjacent mounting feet protrudes arc panels, and two sides of each arc panel are connected to the two adjacent mounting feet.

In a class of this embodiment, the rear end cover comprises: a rear bearing seat, and four supporting arms extended from an outer wall of the rear bearing seat. The four supporting arms are arranged in a pattern of the character “X”. Two mounting seats are symmetrically disposed at the outer edge of the top surface of the front end cover. Screws pass through the supporting arms and the stator assembly and are inserted into the mounting seats to tightly cooperate with screw nuts whereby fixing the front end cover and the rear end cover on two ends of the housing, respectively.

Advantages according to embodiments of the invention are summarized as follows:

1) The rotor assembly is disposed on the rotating shaft. The rotor assembly is nested within the stator assembly. The cavity is disposed in the middle of the housing assembly, and the rotor assembly and the stator assembly are mounted in the cavity of the housing assembly. The stator assembly comprises: the iron core, the end insulation, and the coil windings. The end insulation is disposed on the end part of the iron core, and the coil windings are wound on the end insulation. The end insulation comprises: the circular yoke, the teeth protruded inwards from the circular yoke, and winding slots formed between two adjacent teeth. The left supporting column and the right supporting column are protruded upwards from top surfaces of two adjacent teeth at the inner side of the certain winding slot, respectively. The first supporting column is protruded upwards from the top surface of the circular yoke at the outer side of the winding slot. The mounting plate is disposed on top surfaces of the first supporting column, the left supporting column, and the right supporting column. The mounting bracket is installed at the bottom of the mounting plate. The Hall effect sensor is installed in the mounting bracket. The structure is simple and compact, the mounting plate, the mounting bracket, and the Hall effect sensor form an assembled structure and the assembled structure is installed on the end insulation, thereby realizing good integrity, convenient and firm installation, and high working stability. The creepage distance between the Hall effect sensor and the coil windings can be enlarged by regulating the relative distance between the mounting plate and the three supporting columns or regulating the relative positions of the mounting bracket and the mounting plate, so that the Hall effect sensor is able to resist high voltage and is difficult to breakdown.

2) The mounting bracket comprises the second cavity at the bottom thereof, and the Hall effect sensor is embedded in the second cavity. The mounting bracket is adapted to protect the Hall effect sensor effectively, thereby ensuring high reliability and preventing the Hall effect sensor from breakdown.

3) The left base is disposed at the bottom of the left supporting column on the top surface of one tooth. The right base is disposed at the bottom of the right supporting column on the top surface of the adjacent tooth. The mounting slot is formed between the left base and the right base. The mounting bracket is embedded in the mounting slot and disposed on the top surfaces of the teeth. The inner wall of the mounting slot, the left base, and the right base form the left neck and the right neck. Two sides of the mounting bracket are convex to form two fixture blocks. The mounting bracket is nested in the mounting slot, and the fixture blocks on the two sides of the mounting bracket are locked in the left neck and the right neck, respectively. The structure is simple, the mounting bracket features simple and firm installation and accurate positioning.

4) The plurality of first through holes is disposed at the top of the mounting bracket and communicates with the second cavity. The plurality of second through holes is disposed on the mounting plate for communicating with the first through holes. The Hall effect sensor is embedded in the second cavity, and pins of the Hall effect sensor pass through the first through holes and the second through holes and are in electric connection with the external device. The structure is simple and facilitates the electric connection between the Hall effect sensor and the control circuit board of the motor.

5) The plurality of positioning columns is protruded from the top surface of the mounting bracket. The mounting plate comprises mounting holes. The mounting bracket is mounted at the bottom of the mounting plate by assembling the positioning columns with the mounting holes. The mounting plate comprises the positioning holes, and the mounting plate is disposed on the top surfaces of the first supporting column, the left supporting column, and the right supporting column by assembling the positioning holes with the first supporting column, the left supporting column, and the right supporting column. The structure is simple, the installation thereof is convenient, firm, and reliable, and the installation efficiency is high.

6) The inner side panel is protruded upwards from the inner edge of the top surface of each tooth. The left base and the right base are connected to corresponding inner side panels, respectively. The structure is simple. The integrity of the left supporting column, the left base, and the inner side panel and the integrity of the right supporting column, the right base, and the inner side panel are improved, and the installation is much firm.

7) The upper bearing seat. The bearing cavity is disposed in the upper bearing seat. The outer wall of the upper bearing seat is provided with the first stiffeners. The bottom wall of the bearing cavity is convex downwards from the bottom surface of the front end cover and forms the lower bearing seat. The outer wall of the lower bearing seat is provided with the second stiffeners. The structure is simple, the integral strength of the front end cover is high, the heat dissipation is excellent, the service lives of the bearing and the motor are improved, and the reliability of the structure is high.

8) The first stiffeners are radially disposed on the top surface of the front end cover. The plurality of through holes for heat dissipation is radially arranged between two adjacent first stiffeners. The through holes for heat dissipation are able to improve the heat dissipation capacity of the front end cover as well as decrease the noise produced during the operation of the motor.

9) The annular boss is disposed on the outer edge of the top surface of the front end cover, and two ends of the first stiffeners are connected to the outer wall of the upper bearing seat and the annular boss. The outer edge of the front end cover protrudes the mounting feet, two sides of the mounting feet are provided with third stiffeners, and the third stiffeners are connected to the outer edge of the front end cover. The structure is simple, the integral strength of the front end cover is improved, and the service life thereof is prolonged.

10) The number of the mounting feet is four; the mounting feet are radially disposed on the outer edge of the front end cover. The outer edge of the front end cover between two adjacent mounting feet protrudes arc panels, and two sides of each arc panel are connected to the two adjacent mounting feet, so that the connection strength between the adjacent mounting feet are enhanced.

11) The rear end cover comprises: the rear bearing seat, and four supporting arms extended from the outer wall of the rear bearing seat. The four supporting arms are arranged in the pattern of the character “X”. Two mounting seats are symmetrically disposed at the outer edge of the top surface of the front end cover. Screws pass through the supporting arms and the stator assembly and are inserted into the mounting seats to tightly cooperate with screw nuts whereby fixing the front end cover and the rear end cover on two ends of the housing, respectively. The structure is simple, and the installation thereof is firm.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For further illustrating the invention, experiments detailing a structure for mounting a Hall effect sensor of a motor are described below. It should be noted that the following examples are intended to describe and not to limit the invention.

A structure for mounting a Hall effect sensor of a motor is illustrated inFIG. 1-16. The motor comprises: a rotating shaft1, a rotor assembly2, a stator assembly3, a housing assembly4, a Hall effect sensor5. The rotor assembly2is disposed on the rotating shaft1. The rotor assembly2is nested within the stator assembly2. A cavity41is disposed in the middle of the housing assembly4; and the rotor assembly2and the stator assembly3are mounted in the cavity41of the housing assembly. The stator assembly3comprises: an iron core6, an end insulation7, and coil windings8. The end insulation7is disposed on an end part of the iron core6, and the coil windings8are wound on the end insulation7. The end insulation7comprises: a circular yoke71, a plurality of teeth72protruded inwards from the circular yoke71, and winding slots73formed between two adjacent teeth72. A left supporting column721and a right supporting column722are protruded upwards from top surfaces of two adjacent teeth72at an inner side of a certain winding slot73, respectively. A first supporting column711is protruded upwards from a top surface of the circular yoke71at an outer side of the winding slot73. The mounting plate10is disposed on top surfaces of the first supporting column711, the left supporting column721, and the right supporting column722. The mounting bracket9is installed at a bottom of the mounting plate10. The Hall effect sensor5is installed in the mounting bracket9.

The mounting bracket9comprises a second cavity91at a bottom thereof, and the Hall effect sensor5is embedded in the second cavity91. A left base723is disposed at a bottom of the left supporting column721on the top surface of one tooth72. A right base722is disposed at a bottom of the right supporting column722on the top surface of an adjacent tooth72. A mounting slot74is formed between the left base723and the right base724. The mounting bracket9is embedded in the mounting slot74and disposed on the top surfaces of the teeth72. An inner wall of the mounting slot74, the left base723, and the right base724form a left neck741and a right neck742. Two sides of the mounting bracket9are convex to form two fixture blocks92. The mounting bracket9is nested in the mounting slot74, and the fixture blocks92on the two sides of the mounting bracket9are locked in the left neck741and the right neck742, respectively.

A plurality of first through holes93is disposed at a top of the mounting bracket9and communicates with the second cavity91. A plurality of second through holes101is disposed on the mounting plate10for communicating with the first through holes93. The Hall effect sensor5is embedded in the second cavity91, and pins51of the Hall effect sensor5pass through the first through holes93and the second through holes101and are in electric connection with an external device. A plurality of positioning columns94is protruded from a top surface of the mounting bracket9. The mounting plate10comprises mounting holes102. The mounting bracket9is mounted at a bottom of the mounting plate10by assembling the positioning columns94with the mounting holes102. The mounting plate10comprises a plurality of positioning holes103, and the mounting plate10is disposed on the top surfaces of the first supporting column711, the left supporting column721, and the right supporting column722by assembling the positioning holes103with the first supporting column711, the left supporting column721, and the right supporting column722. The mounting plate10also comprises a plurality of lead through holes104. An inner side panel725is protruded upwards from an inner edge of the top surface of each tooth72. The left base723and the right base724are connected to corresponding inner side panels725, respectively.

The housing assembly4comprises: a housing42, a front end cover43and a rear end cover44disposed at two ends of the housing42, respectively. A middle of a top surface of the front end cover43is protruded upwards to form an upper bearing seat431. A bearing cavity430is disposed in the upper bearing seat431. An outer wall of the upper bearing seat431is provided with a plurality of first stiffeners432. A bottom wall of the bearing cavity430is convex downwards from a bottom surface of the front end cover43and forms a lower bearing seat433. An outer wall of the lower bearing seat433is provided with a plurality of second stiffeners434. The first stiffeners432are radially disposed on the top surface of the front end cover43. A plurality of through holes435for heat dissipation is radially arranged between two adjacent first stiffeners432. An annular boss436is disposed on an outer edge of the top surface of the front end cover43, and two ends of the first stiffeners432are connected to the outer wall of the upper bearing seat431and the annular boss436.

An outer edge of the front end cover43protrudes a plurality of mounting feet437, two sides of the mounting feet437are provided with third stiffeners4370, and the third stiffeners4370are connected to the outer edge of the front end cover43. The number of the mounting feet437is four; the mounting feet437are radially disposed on the outer edge of the front end cover43. The outer edge of the front end cover43between two adjacent mounting feet437protrudes arc panels438, and two sides of each arc panel438are connected to the two adjacent mounting feet437. The rear end cover44comprises: a rear bearing seat441, and four supporting arms442extended from an outer wall of the rear bearing seat441. The four supporting arms442are arranged in a pattern of the character “X”. Two mounting seats439are symmetrically disposed at the outer edge of the top surface of the front end cover43. Screws11pass through the supporting arms442and the stator assembly3and are inserted into the mounting seats439to tightly cooperate with screw nuts whereby mounting the front end cover43and the rear end cover44on two ends of the housing42, respectively.

The principle of the structure for installing the Hall effect sensor is as follows: A left supporting column721and a right supporting column722are protruded upwards from top surfaces of two adjacent teeth72at an inner side of a certain winding slot73, respectively. A first supporting column711is protruded upwards from a top surface of the circular yoke71at an outer side of the winding slot73. The mounting plate10is disposed on top surfaces of the first supporting column711, the left supporting column721, and the right supporting column722. The mounting bracket9is installed at a bottom of the mounting plate10. The Hall effect sensor5is installed in the mounting bracket9. The structure is simple and compact, the mounting plate, the mounting bracket, and the Hall effect sensor forms an assembled structure and the assembled structure is installed on the end insulation, thereby featuring good integrity, convenient and firm installation, and high reliability. The creepage distance between the Hall effect sensor and the coil windings are enlarged, and the Hall effect sensor is able to resist high voltage and difficult to breakdown.