CN1783655B - Electric blower and method for manufacturing the same - Google Patents

Abstract

An electric blower comprising: a fan part having a fan; a motor part mechanically connected to the fan so as to generate air flow, the motor including a stator with a plurality of windings respectively wound; a frame part for supporting the fan part and the motor part, the frame part has a plurality of airflow openings constituting the airflow passage from the fan part to the motor part; and a drive control circuit board, which is located between the fan part and the motor part, and has a drive control circuit , the control circuit is used to control the current supplied to the plurality of windings, and further has a plurality of connection terminals, each of the connection terminals has a through hole. In order to easily connect the end portions of the plurality of windings to the connection terminals of the circuit board, each end of the plurality of windings respectively protrudes through each through hole of the plurality of connection terminals, and the plurality of connection terminals are exposed on the frame portion. multiple airflow openings.

Description

Electric blower and method for manufacturing the same

technical field

This invention relates generally to electric blowers and, more particularly, to an electric blower including a drive control circuit board therein.

Background technique

In an electric blower including a drive control circuit board, it is necessary to maintain a certain space, and when assembling the blower, a winding process of a stator winding is performed in the space. In particular, the connection of the winding to the circuit board can be cumbersome if the diameter of the winding is relatively large. However, in the past, this situation was not considered.

Contents of the invention

It is thus an object of the present invention to realize a structure of an electric blower which, when assembling the blower, enables easy connection between the stator winding and the circuit board.

In order to achieve the above object, the electric blower of the present invention includes: a fan part having a fan; a motor part for driving the fan so as to generate air flow, the motor part including a stator wound by a plurality of windings; a frame part for For supporting the fan part and the motor part, the frame part has a plurality of airflow openings, constituting an airflow path leading from the fan part to the motor part; and a drive control circuit board, which is located between the fan part and the motor part, and There is a drive control circuit for controlling the current supplied to the plurality of windings, the circuit board further has a plurality of connection terminals, each of the plurality of connection terminals has a through hole; it is characterized in that, in the plurality of windings In a state where the end portion of each of the plurality of windings protrudes through the through hole of each of the plurality of connection terminals, the end portions of the plurality of windings are respectively electrically connected to the corresponding connection terminals, and, when the plurality of connection terminals are exposed to the In the state of the plurality of airflow openings of the frame portion, the drive control circuit board is supported by the frame portion.

Description of drawings

These objects and other objects and advantages of the present invention will become more apparent and can be more easily understood through the detailed description of the present preferred exemplary embodiments of the present invention in conjunction with the accompanying drawings, wherein:

1 is an exploded perspective view showing an electric blower according to a first embodiment of the present invention;

Figure 2 is a side view, partially cut away, showing the electric blower shown in Figure 1;

Fig. 3 a is a plan view, represents the frame that is used for the first embodiment;

Figure 3b is a side view, partially cut away, showing the frame shown in Figure 3a;

Fig. 4 is a plan view showing the drive control circuit board used in the first embodiment;

Fig. 5 is a circuit diagram showing the drive control circuit used in the first embodiment;

Figure 6a is a plan view showing the frame with the drive control circuit board shown in Figures 3a and 4;

Figure 6b is a plan view showing the other side of the frame shown in Figure 6a;

Fig. 7 is a perspective view showing the fixed metal plate used in the first embodiment;

Fig. 8 is a side view, partially cut away showing the electric blower according to the second embodiment; and

Fig. 9 is a plan view showing a frame with a drive control circuit board used in the second embodiment.

Detailed ways

The invention will now be described in more detail with reference to the accompanying drawings. Wherein, in the drawings, similar components use the same reference numerals, so that their detailed descriptions will not be repeated.

An embodiment of the present invention will be described below with reference to FIGS. 1 to 6 .

As shown in FIGS. 1 and 2 , an electric blower 1 of an embodiment includes: a fan part 3 , a motor part 5 and a frame part 7 . The fan section 3 includes a fan 311 for generating airflow and a fan case 312 for accommodating the fan 311 . The motor section 5 includes a motor 511 and a motor support 512 for supporting the motor 511 . Both the fan part 3 and the motor part 5 are assembled on the frame part 7 . The frame portion 7 includes a frame 711 . As shown in FIG. 3 a , the frame 711 includes a circular frame portion 712 and a cross-shaped rib 713 extending to the circular frame portion 712 so as to form a plurality of airflow openings 714 . A drive control circuit board 9 for driving the motor 511 is also assembled to the frame portion 7 .

In this embodiment, a three-phase brushless DC motor driven by an inverter circuit, such as the motor 511, is used. It is known to provide a position detection unit for detecting the position of the rotor of the electric motor. The position detection unit includes a sensor magnet installed on the rotor and a position detection element, such as a Hall element, for electromagnetically detecting the sensor magnet. The detailed structure of the position detection unit will be described later.

As shown in FIG. 2 , a stator 513 and a rotor 514 fixed to a rotating shaft 516 of a motor 511 are accommodated in a motor support 512 such that the rotor 514 is located inside the stator 513 . The rotor 514 is formed of a plurality of Si-metal sheets (rotor core) stacked on each other and a plurality of permanent magnets, which are shown individually buried within the rotor. Similar to the rotor 514, the stator 513 is formed of a plurality of Si-metal sheets. Stator 513 includes windings 515 wound around bobbins (not shown). As shown in 5, a plurality of windings 515a, 515b, and 515c are connected in Y to form a U phase, a V phase, and a W phase. One ends of the respective windings 515 are usually connected so as to form a neutral point 517, and their other ends (shown in FIG. 1) are processed to extend upwards (towards the fan portion 3) inside the motor support 512.

The motor support 512 has a cylindrical wall and a bottom wall connected to the cylindrical wall so that air from the fan section 3 is sucked into the inside of the motor 511 through the upper opening of the support 512 . The upper bearing 11 is provided on the frame 711 and the lower bearing 13 is provided on the motor support 512, and each end of the rotating shaft 516 of the rotor 514 is rotatably supported on the upper and lower bearings 11 and 13. In the central portion of the bottom wall, there is a first cylindrical portion 519 which forms the lower bearing seat 13a for receiving the lower bearing 13 .

In the motor 511 , a plurality of sensor magnets 520 for indicating the positions of the magnetic poles of the rotor 514 are provided at regular intervals equal to the intervals of the magnetic poles of the rotor 514 . Thus, on the rotating shaft 516 of the rotor 514, there are a plurality of permanent magnets embedded in the rotor 514, and a plurality of sensor magnets 520 arranged at intervals equal to the pitches of the magnetic poles of the plurality of permanent magnets. The position of the magnetic poles of the sensor magnet 520 is detected by the Hall element 521 . The sensor circuit board 522 is provided on a sensor circuit board support 523 fixed to the rear plate portion 524 of the motor support 512 .

As shown in Figures 3a and 3b, the circular frame portion 712 of the frame 711 is formed in a cylindrical shape and has a diameter greater than the outer diameter of the motor support member 512. In addition, the inner diameter of the circular frame portion 712 is slightly larger than the outer diameter of the motor support member 512 diameter, so that the outer wall surface of the motor support member 512 matches the inner wall surface of the circular frame portion 712. As described above, the frame 711 has a plurality of airflow openings 714 (four in FIG. 3a). The circular frame portion 712 has a rear flat surface 715 as shown in Figure 3b, on which three stepped portions 716 are formed at equal distances along the circumferential direction. In the center of the frame 711, a second cylindrical portion 717 is formed, which forms an upper bearing seat 11a and hole 718. The upper bearing block 11a accommodates the upper bearing 11.

As shown in FIG. 2 , on the upper side of the frame 711 , the rectifying plate 313 is fixed to the second cylindrical portion 717 of the frame 711 . The fan 311 is also fixed to the rotation shaft 516 . The fan cover 312 is firmly fixed to the outer surface of the circular frame portion 712 of the frame 711 so as to cover the rectifying plate 313 and the fan 311 .

The fan cover 312 is equipped with an air intake 314 facing a fan opening 315 formed at a central portion of the fan 311 for sucking air into the fan 311 . In this embodiment, since the outer diameter of the fan case 312 is larger than the outer diameter of the motor support 512 , a step is created by the fan case 312 and the motor support 512 . The steps are joined by circular frame portions 712 to provide airflow passages.

As shown in FIG. 4 , the drive control circuit board 9 has a plurality of ear portions 911 (three in FIG. 4 ), and each ear portion corresponds to the stepped portion 716 of the circular frame portion 712, so that the ear portions 911 are respectively It is accommodated in the stepped portion 716 . The plate 9 comprises a circular base part 912 which is located within the inner space 719 of the circular frame part 712 when the ear part 911 is received at the step part 716 . The circular base portion 912 forms a central airflow opening 913 . Form three threaded holes 914 along the circumferential direction in the circular base portion 912, and as shown in FIG. A predetermined gap is formed between them.

Next, the drive control circuit formed on the drive control circuit board 9 of the electric blower 1 will be described with reference to FIG. 5 .

The brushless DC motor of the electric blower 1 is driven by AC current generated by the inverter circuit 15 . The inverter circuit 15 generates AC current from the power supplied from the DC power supply device 17 . The main part of the drive control circuit includes: an electric blower control unit 19 for controlling the operation of the blower 1, drive circuits 21a to 21f for controlling the inverter circuit 15, and power devices 23a to 23f constituting the inverter circuit 15, for example, MOS FET (Metal Oxide Semiconductor Field Effect Transistor). The drive control circuit includes high-side drive circuits 21a to 21c and low-side drive circuits 21d to 21f.

The DC power supply unit 17 is composed of a storage battery such as a nickel-cadmium (NiCd) battery, a nickel-metal hydride battery, or a lithium-ion battery, and supplies a DC voltage to the inverter circuit 15 . As shown in FIG. 5, the inverter circuit 15 is composed of six power devices 23a to 23f, each of which is connected to each other in a three-phase bridge manner. The power devices 23a to 23f are operated by pulse signals output from the electric blower control unit 19, which is mainly constituted by a microcomputer, so that the driving circuits 21a to 21f are driven by the pulse signals so as to supply power to the windings 515a to 515a of the electric blower 1. 515c provides AC current. The DC power supply unit 17 may be composed of a rectified commercial power supply instead of a storage battery.

As shown in FIG. 5 , the electric blower control unit 19 is connected to the operation unit 25 , the current detection element 27 and the input voltage detection element 29 . By selecting a switch in the operating unit 25, the operator can select a desired operation of the electric blower 1 (start, stop or power control, eg strong or weak). The current detection element 27 detects the current flowing in the inverter circuit 15 , and the input voltage detection unit 29 detects the input voltage from the DC power supply device 17 . The electric blower control unit 19 is also connected to the Hall element 521 in order to receive the magnetic pole position information of the sensor magnet 520 . In this embodiment, instead of the Hall element 521, as a method of detecting the magnetic pole position, an optical pulse encoder or other methods can be used to detect the induced voltages in the windings 515a, 515b, and 515c by means of a voltage phase detection device, wherein , the alternative method is not shown in the drawings. The windings 515a, 515b, and 515c form U phase, V phase, and W phase, and their respective one ends, for example, the start ends of the windings 515a, 515b, and 515c are commonly connected as a neutral point, and the other end, namely, the termination end, is connected to On the power devices 23a to 23f, as shown in FIG. 5, they are connected in a three-phase bridge manner.

The air flow path of the electric blower 1 will be described in detail below with reference to FIG. 2 .

When the rotation shaft 516 of the motor 511 rotates, the fan 311 rotates integrally with the shaft 516 to suck air from the outside into the inside of the blower 1 through the air inlet 314. The air sucked into the blower 1 flows along the centrifugal direction. The fan 311 is blown out from a plurality of exhaust ports 316 of the fan 311. The air from the exhaust port 316 further flows through an opening 317 of the disc-shaped rectifying plate 313 and reaches the rear side of the plate 313. The rear side of the plate 313 is provided with A plurality of arc-shaped vanes (not shown) extending to the center of the plate 313. The air from the opening 317 spirally flows along the plurality of vanes to the center of the plate 313, so that the air blown out from the exhaust port 316 is uniform The air flows along the plate 313. The air rectified by the plate 313 passes through a plurality of airflow openings 714 (shown in FIG. The central airflow opening 913 at the part reaches the motor part 5. The air guided to the motor part 5 cools the motor 511 and is blown out to the outside of the blower 1 through a plurality of openings 526 provided at the lower part of the motor support 512.

Next, the assembly steps of the electric blower 1 will be described with reference to FIG. 1 .

The method of assembling the electric blower 1 of one embodiment includes four main assembly steps. The first assembly step is the construction of the motor part 5 , fixing the stator 513 to the inside of the motor support 512 . The second assembly step is the construction of the rotating part 525 , fixing the rotating element, such as the rotor 514 , to the rotating shaft 516 . The third assembly step is the construction of the frame part 7 , and the drive control circuit board 9 is mounted on the frame 711 . The fourth assembling step is the configuration of the fan part 3 , assembling the fan 311 and the rectifying plate 313 . The first to fourth assembly steps will be described in more detail below.

The first assembly step will now be described. As shown in FIG. 2, the sensor circuit board 522 is firmly mounted on the sensor circuit board support 523, and then the rotor 513 wound with windings 515a, 515b, and 515c is fixed to the motor support 512 with screws. At this time, the length of each of the other ends 518 of the windings 515a, 515b, and 515c shown in FIG. Complete the assembly operation.

Next, the rotating part 525 will be assembled. The rotor 514 , the sensor magnet 520 , and the pair of bearings 11 and 13 are assembled to the rotating shaft 516 of the motor 511 . The rotor 514 and a yoke (not shown) for accommodating the sensor magnet 520 are respectively fixed to the rotation shaft 516, and then the sensor magnet 520 is mounted to the yoke. Further, the bearings 11 and 13 are inserted onto the rotating shaft 516, respectively.

The third assembly step is described below. As shown in FIG. 6 a , respectively place the drive control circuit board 9 in the inner space 719 of the circular frame portion 712 of the frame 711 , and accommodate the ear portion 911 of the board 9 into the stepped portion 716 . Then, the drive control circuit board 9 is fixed to the frame 711 via the spacers 915 by inserting screws through the screw holes 914 into the spacers 915, respectively. The spacer 915 maintains an air flow path in the inner space 719 between the circular frame portion 712 and the drive control circuit board 9 . Connection terminals 916a, 916b, and 916c are respectively formed between power devices 23 on board 9 arranged at an angle of 120 degrees. The other ends 518 of the winding 515 are respectively connected to corresponding connection terminals 916a, 916b and 916c. FIG. 6 b shows the fixed state of the drive control circuit board 9 on the frame 711 when viewed from the fan unit 3 . The connection terminals 916a, 916b, and 916c on the board 9 are exposed from the airflow openings 714 of the frame 711, respectively. Thus, a person who assembles the blower 1 can see the connection terminal 916 through the air flow opening portion 714 .

After the drive control circuit board 9 is fixed to the frame 711 , the power device 23 is assembled on one surface of the board 9 , which does not face the air flow opening 714 of the frame 711 as shown in FIG. 6 a .

Next, the motor part 5, the rotating part 525, and the frame part 7 are assembled. First, the upper bearing 11 of the rotating portion 525 is housed in the upper bearing housing 11 a of the frame 711 . At this time, in the motor section 5 , the other end portion 518 of each winding 515 extends through a through hole (not shown) provided on the connection terminal 916 and protrudes from the frame 711 through the air flow opening 714 of the frame 711 . Then, the lower bearing 13 is housed in the lower bearing housing 13 a of the motor support 512 . Then, the motor part 5 and the frame part 7 are firmly fixed as a whole with screws.

Further, the other ends of the windings 515a, 515b, and 515c protruding from the through holes of the connection terminals 916a, 916b, and 916c, respectively, are electrically connected to the corresponding terminals 916a, 916b, and 916c. The other end portions 518 (three in FIG. 1 ) are adjusted so that their length and tension are controlled while the operator observes their operation from the air flow opening portion 714 of the frame 711, and then the other end portions 518 are respectively soldered. End portion 518 is electrically and mechanically connected to connection terminals 916a, 916b, and 916c. Then, the protruding portion of each end 518 is cut off to complete the connection.

As described above, after the drive control circuit board 9 is fixed to the frame 711 , the other end 518 of each winding 515 protrudes through the corresponding through hole of the connection terminal 916 and is electrically connected to the terminal 916 . If the specification of the winding 515 in which a large current flows through the stator 513 is applied, a winding having a relatively large diameter is required, so that the assembly of the parts described above and the connection of such a winding with terminals can be rather cumbersome. However, in this embodiment described above, it is easy to complete the connection between the other end portion 518 of the winding 515 and the corresponding connection terminal 916, so that after the drive control circuit board 9 is fixed on the frame 711, the connection is performed. step, and then insert the other end portion 518 into the through hole of the connection terminal 916 . In addition, the connection step can be easily performed. This is because the connection terminals 916a, 916b and 916c on the board 9 are respectively exposed from the air flow opening portion 714 of the frame 711, so that a person performing the connection operation can observe the connection work through the air flow opening 714.

Finally, as described above, after the motor part 5, the rotating part 525, and the frame part 7 are assembled into one body, the fan part 3 is assembled.

The rectifying plate 313 is fixed to the frame 711 of the frame portion 7 with screws. The fan 311 is firmly mounted on the rotation shaft 516 of the motor 511 . Then, the fan cover 312 is firmly fixed on the outer surface of the rectifying plate 313 to complete the assembly steps of the electric blower 1 , as shown in FIG. 2 , so that the rectifying plate 313 and the fan 311 are covered by the fan cover 312 .

According to the assembly steps described above, since the other ends 518 of the windings 515 are provided on the drive circuit board 9 through holes through which they are respectively inserted, the additional ends of the windings between the motor 511 and the drive control circuit board 9 can be shortened. Connection path at the end.

In the embodiment described above, the electrical connection between the winding 515 and the connection terminal 916 of the circuit board 9 is made using solder. However, other methods may also be used. As shown in FIG. 7, a fixing metal plate 917 having a notch portion 917a on one side thereof may be used. A fixing metal plate 917 is provided on the connection terminal 916 in advance. The other end portion 518 of the winding 515 protrudes through a hole 918 on the drive control circuit board 9 and is then fixed to a notch portion 917 a of the board 917 .

Next, a second embodiment of the present invention will be described. In FIGS. 8 and 9, elements similar to those of the first embodiment in the second embodiment are given the same reference numerals, and thus, detailed descriptions thereof will not be repeated.

Fig. 8 is a partially broken side view of the electric blower of the second embodiment. Fig. 9 is a plan view showing an example of the internal structure of a part of the electric blower.

In this embodiment, instead of the power devices 23a, 23b, 23c, 23d, 23e and 23f in FIG. 6a, power devices 23'a, 23'b, 23'c, 23'c, 23'd, 23'e and 23'f. When assembling such a power device 23', the main body of the power device 23' is fixed to the surface of the circular frame portion 712 of the frame 711 with screws. After the ears 911 of the drive control circuit board 9 are respectively accommodated in the stepped parts 716 of the circular frame part 712, the power devices 23' are fixed to the circular frame part 712 so that the terminals of each power device 23' to the respective connection terminals (not shown) provided on the board 9 . Each terminal of the power device is electrically and mechanically connected to each connection terminal with solder.

In the second embodiment described above, after the power device 23' is mechanically fixed on the frame 711, solder is used to connect each terminal of the filter device 23' to the drive control circuit board 9. Thus, the power The terminals of the device 23' will not exert mechanical stress. In addition, since each power device 23' is directly fixed to the frame 711, the heat radiation from the power device 23' will increase, and since the power device 23' is not Adversely affected by the airflow inside the blower 1, the loss of the airflow path can be minimized.

The invention has been described above with respect to specific embodiments. However, other implementations based on the principles of the invention will be apparent to those skilled in the art. Such embodiments are also included within the scope of the claims.

Claims (4)

1. An electric blower, comprising: a fan section having a fan; a motor part for driving the fan so as to generate airflow, the motor part including a stator wound by a plurality of windings; a frame portion for supporting the fan portion and the motor portion, the frame portion having a plurality of airflow openings constituting an airflow path leading from the fan portion to the motor portion; and A drive control circuit board, which is located between the fan part and the motor part, and has a drive control circuit for controlling the current supplied to the plurality of windings, and the circuit board further has a plurality of connection terminals, and the plurality of connection terminals Each of the terminals has a through hole; It is characterized in that, in a state where an end portion of each of the plurality of windings respectively protrudes through the through hole of each of the plurality of connection terminals and reaches the fan portion side of the drive control circuit board, the orientation of the plurality of windings toward the End portions of the fan portion are electrically connected to corresponding connection terminals, and the drive control circuit board is supported by the frame portion with the plurality of connection terminals exposed to the plurality of airflow openings of the frame portion. 2. The electric blower according to claim 1, wherein the frame portion has a circular frame portion, and the drive control circuit of the drive control circuit board includes a plurality of power devices, each of which has a main body and a Terminals for switching current supplied to the plurality of windings, the main body of each power device is fixed to the circular frame portion, and the terminals of the plurality of power devices are electrically connected to corresponding connection terminals of the drive control circuit board. 3. A method of assembling an electric blower comprising: a fan part, a motor part having a stator respectively wound by a plurality of windings, and a frame part having a frame and a drive control circuit board, the method comprising the following step: supporting the drive control circuit board by the frame in a state where the plurality of connection terminals provided on the drive circuit board are exposed to the plurality of airflow opening portions of the frame portion; protruding each end portion of the plurality of windings toward the fan portion through each through hole formed on each connection terminal of the circuit board; securing the motor portion to the frame portion; and While adjusting from the airflow opening portion, at the fan portion side of the drive control circuit board, each end portion of the plurality of windings reaching the fan portion side of the drive control circuit board is respectively connected to the circuit board Each connection terminal is connected. 4. The method according to claim 3, wherein the drive control circuit board includes a plurality of power devices, each of the power devices includes a main body and electrical terminals, and the method further includes the following steps: fixing the main body of each power device to the frame of the frame part; and After the main body of the power device is fixed on the frame, each electrical terminal of the power device is electrically connected with the connection terminal of the drive control circuit board.

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