Patent Application
20220200401
This disclosure relates to a brushless motor assembly for a rotary tool, and particularly to a brushless motor assembly with high power density.
According to an embodiment of the invention, a power tool is provided including a housing and a brushless direct-current (BLDC) motor disposed within the housing.
In an embodiment, the motor includes a motor housing having a substantially cylindrical body and a radial member extending inwardly from the cylindrical body; a rotor assembly including rotor shaft extending along a longitudinal axis and a rotor supporting magnets mounted on the rotor shaft; and a stator assembly including a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween, and stator windings wound on the stator teeth. In an embodiment, the motor further includes stator terminals extending substantially parallel to the longitudinal axis from the stator assembly, the stator terminals being substantially aligned with centerlines of the slots of the stator assembly. A circuit board is mounted on the stator terminals adjacent the stator assembly, the circuit board including conductive traces facilitating a one of a delta or a series connection between the stator windings. In an embodiment, the circuit board is mounted inside the motor housing in contact with the radial member.
In an embodiment, the motor further includes magnetic sensors mounted on a first surface of the circuit board at a distance from the rotor assembly to magnetically interlace with the magnets of the rotor assembly.
In an embodiment, the motor further includes a control terminal block mounted on a second surface of the circuit board, the radial member of the motor housing including an opening arranged to receive the control terminal block therethrough, the control terminal block being detachably connectable to one or more control signal wires provided outside the motor housing.
In an embodiment, the motor further includes a power terminal block disposed on a rear surface of the circuit board and electrically coupled to the conductive traces to supply electric power to the stator windings.
In an embodiment, the radial member of the motor housing includes an opening arranged to receive the power terminal block therethrough, the power terminal block being oriented along a same radial plane as at least a portion of the radial member.
In an embodiment, the power terminal block includes conductive terminals projecting substantially parallel to the longitudinal axis from the rear surface of the circuit board.
In an embodiment, the motor further includes at least one insulating mount mounted on the rear surface of the circuit board, the insulating mount having at least one slot through which a corresponding one of conductive terminals extends away from the circuit board.
In an embodiment, the radial member of the motor housing includes legs forming openings therebetween, and the cylindrical body of the motor housing comprises air gaps adjoining the openings around the circuit board, the air gaps together with the circuit board forming a apertures for entry of air into the stator assembly.
In an embodiment, the apertures are substantially aligned with the stator windings.
In an embodiment, a power tool is provided including a housing; a brushless direct-current (BLDC) motor disposed within the housing. The motor includes a rotor assembly including rotor shaft extending along a longitudinal axis and a rotor supporting magnets mounted on the rotor shaft; a stator assembly including a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween, and stator windings wound on the stator teeth; and stator terminals extending substantially parallel to the longitudinal axis from the stator assembly, the stator terminals being substantially aligned with centerlines of the slots of the stator assembly. The tool further includes a first circuit board mounted on the stator terminals adjacent the stator assembly, the circuit board including conductive traces facilitating a one of a delta or a series connection between the stator windings; and a second circuit board disposed parallel to and proximate the first circuit board, the second circuit board accommodating of power switches electrically coupled to the conductive traces of the first circuit board for regulating a supply of electric power to the motor.
In an embodiment, a motor housing is provided having a substantially cylindrical body and a radial member extending inwardly from the cylindrical body, wherein the first circuit board is disposed inside the motor housing and the second circuit board is mounted outside the motor housing. In an embodiment, the radial member of the motor housing is positioned between the first circuit board and the second circuit board.
In an embodiment, the radial member of the motor housing includes legs forming openings therebetween, and the cylindrical body of the motor housing comprises air gaps adjoining the openings around the first circuit board. The air gaps together with the first circuit board forming apertures for entry of air into the stator assembly.
In an embodiment, the motor housing comprises support posts onto which the second circuit board is fastened.
In an embodiment, magnetic sensors are mounted on a first surface of the circuit board at a distance from the rotor assembly to magnetically interface with the magnets of the rotor assembly.
In an embodiment, motor terminals are mounted on the first circuit board and extending at least partially along the longitudinal axis, the ends of the motor terminals being received into corresponding slots of the second circuit board.
In an embodiment, the motor terminals are arranged at an equidistant angular orientation.
In an embodiment, the power tool is an electric edger including a blade guard, and the housing is mounted to the blade guard.
In an embodiment, the above-described embodiments provide a BLDC motor in a power tool that has a ratio of motor size constant (Km) to an electrical envelope of the motor of at least 820 N.mh/√W per m{circumflex over ( )}3, more particularly at least 850 N.mh/√W per m{circumflex over ( )}3, more particularly at least 900 N.mh/√W per m{circumflex over ( )}3, more particularly at least 940 N.mh/√W per m{circumflex over ( )}3, more particularly at least 980 N.mh/√W per m{circumflex over ( )}3, and more particularly at least 1020 N.mh/√W per m{circumflex over ( )}3. The electrical envelope of the motor is defined as the volume of the motor in which electrical and electronic components of the motor, including Hall sensors, magnet wires, and magnets, and wire connections, are located. In an embodiment, a ratio of he motor size constant Km to a magnetic envelope of the motor is at least 810 N.mh/√W, more particularly at least 850 N.mh/√W, more particularly at least 890 N.mh/√W, more particularly at least 930 N.mh/√W, and more particularly at least 970 N.mh/√W. The magnetic envelope of the motor is defined as the area of the motor in magnetic components of the motor, including magnet wires and magnets, are located.
The following description illustrates the claimed invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the claimed invention. Additionally, it is to be understood that the disclosure 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 disclosure 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.
In an embodiment, the motor case 16 attaches to a rear end of the gear case 14 and houses a motor 100 operatively connected to the gear set 22. In an embodiment, the motor 28 is a brushless direct-current (BLDC) motor that rotatably drives a rotor shaft 102, which in turn rotatably drives the output spindle 24 via the gearset 22.
In an embodiment, the handle portion 18 extends from a rear end of the motor case 16 and includes a trigger assembly 36 operatively connected to a switch module 38 disposed within the handle portion 18, which is in turn coupled to a control module 40 disposed close to the battery receiver 20 for controlling the battery discharge and the operation of the motor 100. The battery receiver 20 is provided at a rear end of the handle portion 18 for detachable engagement with a battery pack (not shown) to provide power to the motor 100.
In an exemplary embodiment, the battery pack may be a 60-volt max lithium-ion type battery pack, although battery packs with other battery chemistries, shapes, voltage levels, etc. may be used in other embodiments. In various embodiments, the battery receiver 20 and battery pack may be a sliding pack disclosed in U.S. Pat. No. 8,573,324, hereby incorporated by reference. However, any suitable battery receiver and battery back configuration, such as a tower pack or a convertible 20V/60V battery pack as disclosed in U.S. patent application Ser. No. 14/715,258 filed May 18, 2015, also incorporated by reference, can be used. The present embodiment is disclosed as a cordless, battery-powered tool. However, in alternate embodiments power tool can be corded, AC-powered tools. For instance, in place of the battery receiver and battery pack, the power tool 10 include an AC power cord coupled to a transformer block to condition and transform the AC power for use by the components of the power tools. Power tool 10 may for example include a rectifier circuit adapted to generate a positive current waveform from the AC power line. An example of such a tool and circuit may be found in US Patent Publication No. 2015/0111480, filed Oct. 18, 2013, which is incorporated herein by reference in its entirety.
In an embodiment, the control module 40 is electronically coupled to a power module 42 provided in this embodiment adjacent the motor 100 to control flow of electric power to the motor 100. Power module 42 may alternatively be provided as a part of the same package as the control module 40 or disposed at a different location of the power tool. In an embodiment, the power module 42 includes six power switches (e.g., FETs or IGBTs) configured as a three-phase inverter switch. The control module 40 controls a switching operation of the power module 42 to regulate a supply of power from the battery pack to the motor 100. The control module 40 uses the input from the switch module 38 to set a target speed for the motor 100. When the trigger assembly 36 is released, in an embodiment, the control module 40 activates the low-side switches or the high-side switches of the power module 42 simultaneously for regenerative electronic braking of the motor. A description of the power and control modules and electronic braking of the motor can be found in US Patent Publication No. 2017/0234484, filed Feb. 10, 2017, which is incorporated herein by reference in its entirety.
In an embodiment, motor 100 includes a motor housing (or motor can) 110 configured and shaped to house and support the motor 100 components. In an embodiment, motor housing 110 includes a generally cylindrical body 112 that includes an open end for receiving the motor 100 components. On the other end of the body 112, a series of radial members 114 are formed. Radial members 114 extend towards from the body 112 towards a central bearing pocket 116. In this embodiment, radial members 114 include a series of openings therebetween, though radial members 114 may be alternatively with a primarily solid wall. In an embodiment, the body 112 further includes a series of air gaps 118 in conjunction with the openings. Air gaps 118 are formed between a series of legs 119 formed at the end of the body 112 adjoining the radial members 114.
In an embodiment, motor 100 further includes a stator assembly 120 and a rotor assembly 140. In an embodiment, stator assembly 120 is disposed outside the rotor assembly 140, though many principles of this disclosure may also apply to an outer-rotor motor. In an embodiment, motor 100 further includes a circuit board 150 secured to an end of the stator assembly 120 inside the motor housing 110. These features are described herein in detail.
In an embodiment, rotor assembly 140 includes a rotor 142 that is preferably made up on a series of laminations mounted on the rotor shaft 102 and disposed within the stator assembly 140. In an embodiment, a series of discrete permanent magnets 144 are embedded within the rotor 142 in a N-S-N-S orientation extending along a longitudinal axis of the rotor shaft 102. The magnetic interface between the magnets 144 and the stator windings 128, as phases of the motor 100 are sequentially energized, cause rotation of the rotor assembly 140 within the stator assembly 120. In an embodiment, rotor 142 includes a series of humped surfaces 146 in-line with centers of the permanent magnets 144 for noise and vibration reduction.
Referring back to
Referring back to
In an embodiment, rear and front rotor bearings 147 and 148 are mounted on the rotor shaft 102, in this example on opposite sides of the rotor 142, to provide radial and/or axial support for the rotor assembly 140 relative to the power tool 10, the motor housing 110, and/or stator assembly 120. In the illustrated example, the rear bearing 147 is received within bearing pocket 116 of the motor housing 110 and front bearing 148 is supported via a wall or support structure of the tool housing 12. The rear and front rotor bearings 147 and 148 maintain a small airgap round the rotor 142 relative to the stator 122 to allow rotation of the rotor 142 within the stator 122 while maintaining radial and axial structural support for the rotor assembly 140. In an embodiment, central opening 156 of the circuit board 150 has a greater diameter than the rear rotor bearing 147 so the rear rotor bearing 147 can be passed through the central opening 156 and securely received within the bearing pocket 116 during the assembly process.
In an embodiment, circuit board 150 (herein also referred to as Hall board) is provided inside the motor housing 110 adjacent the axial end of the stator assembly 120 and sandwiched between the stator 120 and the radial members 114 of the motor housing 110. In an embodiment, circuit board 150 is disc-shaped including a central opening 156 through which the rotor shaft 102 extends for piloting into the central bearing pocket 116 of the motor housing 110.
In an embodiment, circuit board 150 includes one or more magnetic (Hall) sensors 151 that interact with the rotor assembly 140. Signals from the Hall sensors 151 are used to detect the angular position of the rotor assembly 140. In an embodiment, Hall sensors 151 are positioned in sufficiently close proximity to the rotor magnets to directly sense the angular position of the rotor 142 by sensing the magnetic flux of the rotor magnets. Alternatively, in an embodiment, an additional sense magnet ring (not shown) may be disposed on the rotor shaft 102 adjacent he rotor 102 in close proximity to the Hall sensors 151. Additionally, in an embodiment, circuit board 150 includes conductive traces to connect the stator windings 128 in a series and/or parallel and delta and/or wye configuration.
In an embodiment, circuit board 150 includes a series of openings 164 arranged close to the outer circumference arranged to receive ends of stator terminals 170. Stator terminals 170, as described later in detail, are mounted on the rear end insulator 130 of the stator assembly 120 between the respective stator windings 128 and connect to a front surface of the circuit board 150 (facing the stator assembly 120) to electrically connect the stator windings 128 to the conductive traces of the circuit board 150. In an embodiment, openings 164 are conductive vias to facilitate electrical connection between the stator terminals 170 and the metal traces and routings.
In an embodiment, circuit board 150 further includes a control terminal block 152 that includes a ribbon connector for communicating with the control module 40. The control terminal block 152 includes at least three signals from the Hall sensors 151. The circuit board 15 further includes a power terminal block 154 for providing power from the power module 42 to the stator windings 128. In an embodiment, control terminal block 152 and power terminal block 154 are mounted on a rear surface of the circuit board 150 (facing away from the stator assembly 120) on opposite sides of the central opening 156.
In an embodiment, as best shown in
In an embodiment, rear end insulator 130 of the stator assembly 120 includes a series of axial support members 134 provided to support the stator terminals 170 in the axial direction of the motor 100. Each axial support member 134 includes two posts that form an opening in between for securely receiving and supporting one of the stator terminals 170. In an embodiment, six axial support members 134 support six stator terminals 170 between the respective sets of stator windings 128.
In an embodiment, two or more (in this example, three) of the axial support members 134 include threaded openings 136. The circuit board 150 is secured to the stator assembly 120 via a series of fasteners 166 received through corresponding openings of the circuit board 150 into the threaded openings 136 of the rear end insulator 130.
In an embodiment, referring to
In an embodiment, referring to
In an embodiment, as stated above, control and power terminal blocks 152 and 154 of the circuit board 150 are received between radial members 114 of motor housing 110 to facilitate coupling with control and power cords received from the control and power modules 40 and 42 of the power tool 10. As such, in an embodiment, as best seen in
In an embodiment, as stated above, circuit board 150 includes conductive traces to connect the stator windings 128 in a series and/or parallel and delta and/or wye configuration. In order to maximize the surface areas of the conductive traces in the circuit board 150, according to an embodiment, circuit board 150 is multi-layered printed circuit board, as described here with reference to
In an embodiment, conductive traces 153, 155 and 157 are respectively connected to U, V and W conductive terminals 158. As shown in the circuit diagram of
In an embodiment, start and finish ends of each of the stator windings 128 are electrically coupled to its two adjacent stator terminal 170, and as discussed below in detail, connections between opposing stator windings 128 of the same phase in a series of parallel connection, as well as connections between stator windings 128 of different phases in a wye or delta configuration, are facilitated via metal routings and/or traces on the circuit board 150. This arrangement eliminates the need for excessive routing of cross-over wire portions 180 that connect the stator windings 128 on the stator assembly 120.
In an embodiment, all stator windings 128 and cross-over wire portions 180 may be wound on the stator 122 using a single continuous magnet wire. The single continuous magnet wire is wound fully for a designated number of turns on one stator tooth 126, passed through the tang portion 174 of an adjacent stator terminal 170, wound fully on the adjacent stator tooth 126 for the designated number of turns, passed through a subsequent tang portion 174, and this process is continued until all stator windings 128 are fully wound with the designated number of turns. The two ends of the magnet wire may be wrapped around the tang portion 174 of the same stator terminal 170.
In an embodiment, using a smaller diameter magnet wire increases the overall slot fill and wire density within each slot. For example, winding the stator slots fully using a 19 AWG (American Wire Gauge) magnet wire (i.e., a 0.91 mm conductor diameter) may yield only a 51.14% slot fill per unit of area, because the large diameter of the magnet wire results in a less efficient overlay of the wires and larger airgaps between the wires. By contrast, winding the stator slots fully using a 21.5 AWG magnet wire (i.e., a 0.68 mm conductor diameter) yields a 58.61% slot fill. Similarly, winding the stator slots using a 23 AWG magnet wire (i.e., a 0.57 mm conductor diameter) yields a 62.98% slot fill. Increasing slot fill and wire density results in a reduction in the electrical resistance of the motor.
It is well understood that the number of turns of stator windings 128 on each tooth 126 is correlated to the desired torque output of the motor. The more number of turns of the stator windings, the higher the torque output of the motor. According, in order to increase slot fill and reduce electrical resistance of the motor while maintaining the desired number of turns of the stator windings 128 on each tooth 126, in an embodiment of the invention, two or more sets of stator windings having relatively smaller diameters are provided on each tooth and wound in parallel, as described herein in detail.
In an embodiment, as best seen in
This arrangement increases slot fill and reduce electrical resistance of a motor for a given desired number of turns of the stator windings as required by the rated torque output of the motor. For example, in a motor where 19 number of turns of the stator windings is required to achieve a desired torque rating, two sets of stator windings 128a and 128b may be wound on each stator tooth 126 as described above, each at 19 number of turns and using a 21.5 AWG magnet wires. The parallel configuration of the 21.5 AWG stator windings 128a and 128 on each stator tooth 126 provides equivalent torque rating as a single set of stator windings using a 19 AWG magnet wire at 19 number of turns, but with a higher slot density and thus reduced electrical resistance.
Similarly, in an embodiment, three sets of stator windings may be wound in parallel using 23 AWG magnet wires to further improve slot fill, reduce motor resistance, improve power output, and improve thermal efficiency of the motor. Table 1 below summarizes these findings.
In an embodiment, the diameter of the magnet wire used for the first set of stator windings 128a may be different from the diameter of the magnet wire used for the second set of stator windings. 128b. While this process may complicate the manufacturing process and require use of two winding machines for the same motor, it can provide an optimal slot fill. In yet another embodiment, the number of turns of the first set of stator windings 128a may be different from the number of turns of the second set of stator windings 128b.
In an embodiment, in order to maximize the area of the slots available for disposition of stator windings 128, the thickness E of the stator tooth is reduced to approximately 2 times, and in particularly to 1.9 to 2.1 times, the thickness D of the stator core 124. Further, as shown in
This design substantially achieves the desired wire layout of
The results discussed above are summarized in Table 2 below:
The maximum number of turns of different sized magnet wires for each of the stators described above are summarized in Table 3 below:
In an embodiment, electrical envelope in this figure designates the total volume of the motor 100 where electrical and electro-magnetic components, including the circuit board 150 and all the wiring connections between the stator windings 128, are located. The electrical envelope is the volume of the motor that is peripherally bound by a generally cylindrical boundary 302 extending along a radially outermost portion of the stator assembly 120 and having a diameter OD. The electrical envelope is further axially bound by a front plane 304 at a frontmost point of the stator assembly and the rotor, in this example the frontmost tip of the stator windings 128, and a rear plane 306 at a rearmost point of the electro-magnetic part of circuit board 150, in this example the surface of the circuit board 150 opposite the stator assembly 120. Electrical envelope has a length EL.
In an embodiment, the magnetic envelope is bound the generally cylindrical boundary 302, the front plane 304, a rear plane 308 at a rearmost point of the stator windings 128. The magnetic envelope has a length ML that is smaller than the length EL.
Four examples of motor 100 are provided in this table including different numbers of parallel sets of stator windings per tooth. The motor electrical envelope for these exemplary motors 100 are of the same geometry (including stator diameter of 51 mm and electrical length LE of 40 mm) and same volume (approximately 81,670 mm{circumflex over ( )}3 in this example). The motor magnetic envelope for these exemplary motors 100 are also of the same geometry (including stator diameter of 51 mm and magnetic length ML of 36.4 mm) and same volume (approximately 74,400 mm{circumflex over ( )}3 in this example). By comparison, three exemplary conventional motors are also included. The comparative conventional BLDC motors have the same diameter (example 1), smaller diameter (example 2), and larger diameter (example 3), but the lengths of the respective motors are modified to maintain the same electric envelope (approximately 81,670 mm{circumflex over ( )}3) and magnetic envelope (approximately 74,400 mm{circumflex over ( )}3 ) as the four exemplary motors 100.
As can be seen, given the same motor electrical envelope and magnetic envelope described above, the motor maximum power output for motor 100 increases from 1840 watts to 1895 watts (a 3% increase) when using two parallel windings per tooth, to 1922 watts (a 4% increase) when using three parallel windings per tooth, and to 1950 watts (a 6% increase) when using four parallel windings per tooth. Any of these configurations represents significant increases of maximum power output over conventional BLDC motors of the same size. It can be seen that the conventional BLDC motors having equivalent motor envelope and electrical envelope to motor 100 produce maximum power output in the range of approximately 1000 watts to 1500 watts, i.e., approximately 18% to 45% less than motor 100 given the same size electrical envelope and same size magnetic envelope.
Furthermore, the motor size (Km) constant of motor 100 increases from when using two or more sets of parallel windings per tooth. As understood by those skilled in the art, the Km constant is a parameter for determining the efficiency and capacity of a motor. The Km constant is calculated as a function of the torque constant Kt and the resistance of the motor R, Km=Kt/R2 or Km=Kt*I/P, where torque constant Kt is the torque produced divided by motor current. Thus, the Km constant represents the capability of the motor to produce power normalized by resistance of the motor. In an embodiment, the Km constant of motor 100 increases from 0.0762 N.m/√W to 0.0804 N.m/√W (a 5% increase) when using two parallel windings per tooth, to 0.0826 N.m/√W (an 8% increase) when using three parallel windings per tooth, and to 0.0851 N.m/√W (a 10% increase) when using four parallel windings per tooth.
Any of these configurations represents a significant increase the Km constant over conventional BLDC motors having equivalent motor envelope and electrical envelope to motor 100. It can be seen that the Km constants of the conventional BLDC motors having equivalent motor envelope and electrical envelope to motor 100 are in the range of approximately 0.0471 to 0.0636 N.m/√W, i.e., approximately 18% to 50% less than the motor 100 given the same size electrical envelope and same size magnetic envelope.
In an embodiment, to evaluate the motor performance irrespective of the size of the motor, a ratio of the Km constant to the electrical envelope and/or the magnetic envelope is provided.
In an embodiment, the ratio of the Km constant to the electrical envelope of the motor is greater than 900 (N.m/√W)/m{circumflex over ( )}3 in an embodiment, particularly greater than 940 (N.m/√W)/m{circumflex over ( )}3 in an embodiment, more particularly greater than 980 (N.m/√W)/m{circumflex over ( )}3, and even more particularly greater than 1020 (N.m/√W)/m{circumflex over ( )}3. When using two or more sets of parallel coils per tooth, the ratio of the Km constant to electrical envelope of the motor is greater than 1080 (N.m/√W)/m{circumflex over ( )}3 when using two parallel coils per tooth, greater than 1100 (N.m/√W)/m{circumflex over ( )}3 when using three parallel coils per tooth, and greater than 1140 (N.m/√W)/m{circumflex over ( )}3 when using four parallel coils per tooth. By comparison, the ratios of the Km constant to electrical envelope of conventional BLDC motors are at most 855 (N.m/√W)/m{circumflex over ( )}3. This represents a performance increase, even when using merely a single set of coils per tooth on motor 100.
In an embodiment, the ratio of the Km constant to the magnetic envelope of the motor is greater than 810 (N.m/√W)/m{circumflex over ( )}3 in an embodiment, particularly greater than 850 (N.m/√W)/m{circumflex over ( )}3 in an embodiment, and more particularly greater than 890 (N.m/√W)/m{circumflex over ( )}3, and even more particularly greater than 930 (N.m/√W)/m{circumflex over ( )}3. When using two or more sets of parallel coils per tooth, the ratio of the Km constant to electrical envelope of the motor is greater than 970 (N.m/√W)/m{circumflex over ( )}3 when using two parallel coils per tooth, greater than 1000 (N.m/√W)/m{circumflex over ( )}3 when using three parallel coils per tooth, and greater than 1030 (N.m/√W)/m{circumflex over ( )}3 when using four parallel coils per tooth. By comparison, the ratios of the Km constant to electrical envelope of conventional BLDC motors are at most 780 (N.m/√W)/m{circumflex over ( )}3. This represents a performance increase, even when using merely a single set of coils per tooth on motor 100.
In an embodiment, motor housing 110 is provided with a series of support posts 410 positioned to structurally support the power module 42. In an embodiment, the power module 42 is mounted above the support posts 410 and secured to the posts 410 via fasteners 424. In an embodiment, each support post 410 includes two legs 412 that project around the power module 42.
In an embodiment, end tips of the terminals 402 are received into corresponding slots of the power circuit board 420. This allows the power circuit board 420 to make a direct electrical connection to the terminals 402, and thus the stator windings 128, without a need for intermediary wires. Accordingly, this embodiments provides a two circuit board arrangement disposed in parallel rearward of the stator assembly 120, with circuit board 150 being located inside the motor housing 110 and configured to support Hall sensors 151 and metal traces for interconnection of the stator windings 128, and power circuit board 420 being located outside the motor housing 110 and configured to support the power switches for driving the stator windings 128.
The above-described configuration of the motor 100, particularly in combination with the power module 42 mounted directly to the rear of the motor housing 110, provides high power in a small package highly desirable for many power tool, industrial tools, motorized outdoor products, and home appliances.
Example embodiments have been provided so that this disclosure will be thorough, and to fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Terms of degree such as “generally,” “substantially,” “approximately,” and “about” may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and/or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and/or sections being described.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This patent application claims the benefit of U.S. Provisional Application No. 63/129,797 filed Dec. 23, 2020, which incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63129797 | Dec 2020 | US |
