JP5643815B2 - Brushless DC actuator with bobbin holding clip - Google Patents

Description

[Cross-reference of related applications]
This application is a continuation-in-part of US application Ser. No. 12 / 584,161, filed Sep. 1, 2009, entitled “Brushless DC Actuator” and claims its filing date and disclosure benefit.

  This application is also hereby incorporated by reference, as is the case with all documents mentioned herein, US provisional application 61 / 217,100, filed May 27, 2009, which is expressly incorporated herein by reference. And the filing date and disclosure benefit of US Provisional Application No. 61 / 269,834, filed June 30, 2009.

  The present invention relates generally to actuators, and more particularly to rotary brushless DC actuators with bobbin holding clips.

  An example of a prior art actuator is shown in US Pat. No. 5,880,551 entitled “Polyphase Motor Inherent for Driving Indicator Needle” and comprises a stationary member and a magnetized rotor excited by an electric coil. A multi-phase motor is described. The rotor has N pairs, more specifically 4 or 5 pairs of poles, which are radially magnetized in alternating directions. The securing member has at least two W-shaped circuits, each containing an electrical coil surrounding the central post. The W-shaped circuit is arranged such that when one of the central struts is opposite the magnetic transition, the other central post is approximately opposite the magnetic pole. The pole pieces associated with the central pillars of the two W-shaped circuits can be separated by an angle of 120 °.

  An electric motor comprises two main components, namely a rotor and a stator, which contain one or more bobbins attached to it, and the bobbins are allowed to move on the stator due to tolerance accumulation. . In some applications, the bobbin contains terminals that connect the bobbin to pins on the printed circuit board. However, as a result of vibration, the bobbin movement may result in loss of contact between the bobbin terminal and the printed circuit board, and thus loss of electrical contact. Overmolding to the bobbin stator was used to secure the bobbin to the stator. However, this method has proven to be quite expensive and can result in damage to the bobbin wires.

  The present invention is directed to a new actuator structure and clip structure for mounting a bobbin on an actuator motor assembly stator.

  The present invention generally includes a housing containing first and second housing portions defining each of the first and second cavities, and a rotor shaft mounted in the first cavity in the first housing portion. The motor assembly is positioned in the housing so as to overlap with the motor assembly, in which the rotor shaft of the motor assembly extends into the second cavity through the circuit board assembly, and the second housing is related to the circuit board assembly. A gear assembly located in a second cavity in the body and at least a portion of the motor assembly coupled to the rotor shaft and extending into the second cavity defined by the second housing and coupled to the gear assembly. The present invention is directed to an actuator assembly having an output shaft.

  In one embodiment, the gear assembly includes at least a first gear in the second cavity supported by a shaft in the second cavity and coupled to the rotor shaft. The second gear is located in the second cavity and is stacked on the first gear. The output shaft is connected to the second gear.

  In one embodiment, the housing includes an internal peripheral shoulder and the circuit board assembly includes a peripheral edge. The peripheral edge of the circuit board assembly is seated against the inner shoulder of the first housing part. Further, the first housing part includes a peripheral outer groove, and the second housing part defines a peripheral convex part that is fitted into the groove in the first housing part. The circuit board assembly separates the first and second cavities. Further, the first housing portion defines an upper peripheral rim, and the actuator further includes a plate in the housing that is seated on the upper peripheral rim of the first housing portion so as to be spaced apart from and parallel to the circuit board assembly. It has.

  Furthermore, the present invention is directed to a plate or clip in the housing that restrains the bobbin movement of the stator assembly of the motor assembly. The clip contains a stator and a ring plate that sits against a plurality of bobbins. In one embodiment, the ring plate is wavy and defines a plurality of curved portions that overlap each of the plurality of bobbins. The clip also includes a plurality of spaced-apart alignment fingers that extend outwardly from the outer surface of the ring plate and are adapted to be fitted into slots defined on each bobbin. A hole is defined in the plate and is adapted to receive each screw for securing the ring plate to the stator. Each curved portion of the ring plate defines each boss seated on each of the plurality of bobbins.

  Other advantages and features of the present invention will become readily apparent from the following detailed description of the preferred embodiments of the invention, the accompanying drawings and the appended claims.

These and other features of the present invention can be best understood from the following description of the accompanying drawings.
FIG. 1 is a top perspective view of an actuator according to the present invention. FIG. 2 is a bottom perspective view of the actuator of FIG. FIG. 3 is an exploded perspective view of the actuator of FIGS. FIG. 4 is an enlarged longitudinal sectional view of the actuator taken along lines 4 to 4 in FIG. FIG. 5 is an enlarged top perspective view of the bobbin holder according to the present invention mounted on the stator and bobbin of the motor located in the housing of the actuator shown in FIGS. FIG. 6 is an enlarged perspective view of the bobbin holder of the present invention. 7 is an enlarged top plan view of the bobbin holder shown in FIG. FIG. 8 is an enlarged longitudinal sectional view of the bobbin holder taken along lines 8-8 in FIG. FIG. 9 is an enlarged cutaway side view of region A of the bobbin holder shown in FIG. FIG. 10 is an enlarged cutaway side view of region B of the bobbin retainer shown in FIG.

  1-4 depict an embodiment of a small brushless direct current (BLDC) rotary actuator 10 according to the present invention. The actuator 10 includes a housing 20 (FIGS. 1, 2 and 3), a motor assembly 98 (FIG. 3), a sensor assembly 180 (FIG. 3) and a gear assembly 220 (FIG. 3). The actuator 10 can be used in a wide variety of applications, including indicators, switches, valve movement and other applications where precise control of rotational movement is required.

  The housing 20 has two parts, a motor assembly housing portion 21 (FIGS. 1, 2, 3, 4 and 5) and a gear housing portion or cover 50 (FIGS. 1, 2, 3, and 4).

  The motor housing 21 (FIGS. 3 and 4) includes a substantially vertical peripheral side wall 25 (FIGS. 3 and 4) and a substantially horizontal surface or wall 27 (FIG. 4) that together define a central internal cavity 22 (FIGS. 4 and 5). ). A cylindrical groove or recess 29 (FIG. 4) extends into the wall 27 from the bottom center of the cavity 22.

  Offset grooves or shoulders 31 and 32 (FIGS. 3, 4 and 5) extending around a pair of perimeters are formed in the upper outer surface of the distal peripheral rim of the side wall 25 of the motor housing 21. The shoulder 33 (FIG. 4) is defined on the upper inner surface of the distal peripheral rim of the side wall 25 of the motor housing portion 21.

  The wire harness assembly 34 (FIG. 3) is coupled to the motor assembly housing portion 21. The wire harness assembly 34 extends from the harness bracket 82 (FIG. 3) through the opening 81 (FIG. 1) defined and extended into the motor housing portion 21 and extends outwardly into the internal cavity 22 thereof in an approximately L-shape. Contains metal connector terminals 80 (FIG. 3). The bracket 82 is adapted to be fixed to the motor housing portion 21 by each connector screw 83. The seal ring 84 (FIG. 3) is disposed between the bracket 82 and the outer surface of the wall 27 of the housing unit 21. The wire harness assembly 34 provides power, ground and control signals to the actuator 10.

  The gear housing or cover 50 (FIGS. 1-4) has a peripheral vertical side wall 51 (FIGS. 1-4) and an upper horizontal wall 53 (FIGS. 2-4) that together define a central internal gear cavity 52 (FIG. 4). contains. A groove or recess 61 (FIG. 4) extends inwardly from the bottom of the cavity 52 into the inner surface of the upper horizontal wall 53. Further, the upper horizontal wall 53 defines a cylindrical through hole 58 (FIGS. 2 and 4) that extends between its inner and outer surfaces and communicates with the internal gear housing cavity 52.

  In the illustrated embodiment, the mounting arm or bracket 55 (FIGS. 1-4) extends outward from each corner of the cover 50, more specifically, each corner of its wall 27, and includes a central through hole 56 (FIG. 1). 2) is prescribed. Fasteners such as screws or bolts 57 (FIG. 3) extend through each bracket hole 56 and are fitted with an object such as a frame, chassis, bracket, engine or manifold to which the brushless DC rotary actuator 10 is attached. Mounted on a screw thread (not shown).

  Further, the vertical side surface 51 of the cover 50 is fitted into the shoulder 31 of the motor housing portion 21 when the motor housing portion 21 and the cover 50 are coupled together, and a distal convex portion 59 (see FIG. 4). ) Containing the peripheral rim around the perimeter. The seal ring 60 (FIGS. 3 and 4) is seated on the shoulder 32 of the motor housing portion 21, and between the housing portion 21 and the cover 50, more specifically, the outer surface of the side wall 25 of the motor housing portion 21. A seal is provided between the inner surface of the side wall 51 of the cover 50.

  In addition, the actuator 10 includes a motor assembly 98 (FIG. 3) that generally contains a rotor assembly 100 (FIGS. 3 and 4) and a stator assembly 150 (FIGS. 3, 4 and 5).

  The rotor assembly 100 is mounted in the cavity 22 of the motor housing 21 and has a yoke 102 (FIGS. 3 and 4) and a circular skirt 103 (FIGS. 3 and 4) and a cylindrical central pinion, post or shaft 104 (FIGS. 3 and 4). Contains FIGS. 3 and 4). The skirt 103 is spaced substantially parallel to each other within the generally vertical perimeter, parallel walls 108 and 109 (FIG. 4), and a generally horizontal upper radial perimeter wall or shoulder 107 (FIG. 4) integral with the top surfaces of the walls 108 and 109. 4). Both walls 108 and 109 define an inner peripheral slot 106 (FIG. 4).

  The motor gear 222 (FIGS. 3 and 4) is formed on the outer surface of the upper end of the rotor shaft 104. The bottom end of the shaft 104 is seated in a groove 29 defined in the bottom surface of the motor housing 21. A bearing 113 (FIGS. 3 and 4) is press fit into the groove 29 and supports the end of the shaft 104 for rotation relative to the motor housing 21. A thrust washer 115 (FIGS. 3 and 4) surrounds the bottom end of the shaft 104, seats against an internal shoulder 117 (FIG. 4) in the motor housing wall 27, surrounds the groove 29 and thus the rotor shaft 104 and thus the rotor assembly. 100 is supported and maintained vertically in the cavity 22 of the motor housing 21. A cylindrical motor magnet 110 (FIGS. 3 and 4) extends around the lower peripheral outer edge of the skirt wall 109 and is magnetized in the areas of alternating polarity N and S poles. A substantially donut-shaped sensor magnet 114 (FIGS. 3 and 4) sits on the upper outer surface of the skirt wall 107 and is magnetized in the alternating polar N and S pole areas. The magnets 110 and 114 are made of neodymium iron boron and may be magnetized by using an appropriate magnetizer.

  Further, the stator assembly 150 (FIGS. 3 and 4) is mounted in the cavity 22 of the lower motor housing portion 21 so as to surround the rotor assembly 100 and be separated therefrom. The stator assembly 150 contains a number of steel sheets 152 (FIGS. 3 and 4), a bobbin 154 (FIGS. 3 and 4) and a winding 156 (FIGS. 3, 4 and 5) and a central hole 172 (FIGS. 4 and 5). ). The thin plate 152 is substantially circular. Multiple sheets can be stacked to form the stator assembly 150. The rotor assembly 100 extends through the central stator opening 172. A copper winding 156 is wound around each plastic bobbin 154. Each winding 156 defines an end that is electrically connected to stator terminals 160a and 160b (FIGS. 3 and 5).

  Further details regarding the structure and operation of rotor and stator assemblies of the form disclosed in this application are disclosed in one or more of the following US patents and patent publications, the disclosures of which are hereby incorporated by reference.

  US Pat. No. 5,880,551 entitled “especially a multi-phase motor for driving indicator hands”, US Pat. No. 7,304,450 entitled “Motor reduction device that switches with absolute position signal” and “ The entire contents of US Pat. No. 7,466,092 entitled “Multiphase Motor” are incorporated herein by reference.

  A bobbin holding clip 310 (FIGS. 3, 4 and 5-10) holds the bobbin 154 to the stator assembly 150, which will be described in more detail below.

  FIG. 5 depicts one embodiment of a bobbin retainer or clip 310 according to the present invention that is secured to the top surface of a stator assembly 150 that is mounted in the cavity 22 of the motor housing 21.

  Stator assembly 150, which is generally ring-shaped in the described embodiment, includes three bobbins 154a, 154b and 154c secured thereto. Although not shown, the stator assembly 150 defines each finger (not shown) and each bobbin 154a, 154b, and 154c is similar to the manner in which the ring is slid onto the human finger. It will be appreciated that a central hole is defined that allows each bobbin 154a, 154b and 154c to slide over each stator finger.

  Each bobbin 154a, 154b and 154c contains a pair of spaced apart, parallel terminals 160a and 160b (FIGS. 3, 4 and 5) that extend generally vertically upward and outward from the top surface of each bobbin 154a, 154b and 154c. Each bobbin 154a, 154b and 154c defines an elongated vertical slot 326 (FIG. 5) between its respective terminals 160a and 160b.

  The terminals 160a and 160b of each bobbin 154a, 154b and 154c are adapted to be coupled to a printed circuit board 200 (FIG. 4) mounted on and positioned on the stator assembly 150, and more specifically, the printed circuit board. It is adapted to make electrical contact with a socket (not shown) on 200 (FIGS. 3 and 4).

  Since the terminals 160a and 160b must maintain continuous electrical contact with the printed circuit board 200, it is essential that the operations of the bobbins 154a, 154b and 154c be minimal. However, since the bobbins 154a, 154b, and 154c are separate elements from the stator assembly 150, the bobbins 154a, 154b, and 154c can be coupled to the stator assembly 150, for example, in response to vibration of the housing 20, unless restrained. Move against. The bobbin retainer 310 of the present invention minimizes such movement and the resulting loss of electrical contact, as will be described in more detail below.

  The bobbin retainer or clip 310 has opposed upper and lower surfaces 327 and 328 (FIGS. 5-10), an outer, generally vertical circumferential surface or surface 330 (FIGS. 5-9), and an interior generally Ring-shaped plate 324 (FIGS. 5-10) formed of a sturdy material, such as a metal flat plate or metal piece, containing a ring periphery or surface 332 (FIGS. 5-10) extending circumferentially around a vertical periphery Containing.

  The retainer 310, and more particularly, its ring plate 324 (FIGS. 5-10) projects outwardly from the outer ring surface 330 in a substantially vertical relationship with the surfaces 327 and 328 substantially perpendicular to the ring surface 330. 3 retainer alignment fingers 336, 338 and 340 (FIGS. 3, 5, 6, 7, 8 and 9). In the illustrated embodiment, 336, 338 and 340 are spaced from each other and extend around the periphery of the ring plate 324 at 120 ° intervals.

  In addition, the ring plate 324 extends through and protrudes through the faces 327 and 328 of the ring plate 324 through a first set of generally circular holes or through holes 342, 344 and 346 (FIGS. 5, 6 and 7) and a second set of substantially Circular holes or through holes 348, 350 and 352 (FIGS. 5, 6 and 7) are defined.

  The first set of through holes 342, 344 and 346 define the stator alignment through holes as will be described in more detail below. The second set of through holes 348, 350 and 352 define the retainer mounting through holes as will be described in more detail below.

  Through-holes 342 and 348 are located at approximately the center of ring plate 324 between fingers 336 and 338 in a spaced collinear relationship, where through-hole 342 is adjacent to finger 336 and through-hole 348 is adjacent to finger 338. To do. Through-holes 344 and 350 are located at approximately the center of ring plate 324 between fingers 338 and 340 in a spaced, collinear relationship, where through-hole 344 is adjacent to finger 338 and through-hole 350 is adjacent to finger 340. To do. Through-holes 346 and 352 are located at approximately the center of ring plate 324 between fingers 340 and 336 in a spaced, collinear relationship, where through-hole 346 is adjacent to finger 340 and through-hole 352 is adjacent to finger 336. To do.

  In the illustrated embodiment, the through holes 342, 344 and 346 are all the same diameter, and the through holes 348, 350 and 352 are all the same diameter, and the diameter of the through holes 342, 344 and 346 is the through hole. Slightly larger than the diameters of 348, 350 and 352. In one embodiment, each through hole 348, 350 and 352 may be slightly elongated or elongated.

  In addition, the retainer 310, and more specifically, its ring plate 324, is formed with three elongated notches 354, 356 and 358 (as shown) formed and extending in the ring inner surface 332 in the region opposite each finger 336, 338 and 340. 5, 6 and 7).

  As shown in FIGS. 2 and 4, the retainer 310, and more specifically, its ring plate 324, includes the ring plate 324 as a first set of curved regions 360, 362 and 364 (FIGS. 6 and 7) and regions 360, 362. And 364 bent in the manufacturing process so as to define a second set of curved regions 366, 368 and 370 (FIGS. 6 and 7) that curve in the opposite direction to the curves of 364 and 364. A first set of curved regions 360, 362 and 364 is defined in the region of the ring plate 324 that contains each finger 336, 338 and 340. A second set of curved regions 366, 368 and 370 are defined in the region of the ring plate 324 approximately between each of the through holes 342 and 348, 344 and 350 and 346 and 352.

  In the arrangement of FIGS. 6, 7 and 8 where the surface 327 of the ring plate 324 is the top surface of the ring plate 324, the curved regions 360, 362 and 364 define each convex region, and the curved regions 366, 368 and 370 The ring plate 324 is formed in a vertical pattern of wavy curves that define a concave region and are continuous together.

  As shown in FIGS. 8 and 9, each curved region 360, 362 and 364 is further laterally between the outer and inner surfaces 330 and 332 of the ring plate 324 in an arrangement substantially perpendicular to the curve of each region 360, 362 and 364. An extending recess, trough or boss 365 (FIGS. 5, 6, 7 and 8) is defined.

  As also shown in FIGS. 8 and 9, the ring plate 324 further includes a plurality of ears or bumps 372, 374 and 376 formed on the ring surface 327 adjacent to the ring vertical inner surface 332 and projecting outward therefrom (FIGS. 5, 6). 7 and 8). Bump 372 is formed on the surface 327 between through holes 346 and 352 and thus between fingers 336 and 340, and bump 374 is formed on the surface 327 between through holes 342 and 348 and thus between fingers 336 and 338, Further, the bump 376 is formed on the surface 327 between the through holes 344 and 350 and thus between the fingers 338 and 340.

  According to the present invention shown in FIG. 5, the retainer 310 is seated on the top surface of the stator assembly 150 with the surface 328 of the ring plate 324 seated against the top surface of the stator assembly 150, and each retainer finger thereof. 336, 338 and 340 are aligned with and seated in slots 336 of each terminal 160a and 160b of each bobbin 154a, 154b and 154c, and each curved ring portion 360, 362 and 364 is in each bobbin 154a, 154b and 154c. Overlapping the top surface, each boss 365 is seated against the top surface of each bobbin 154a, 154b, and 154c, and each mounting through hole 348, 350, and 352 is aligned with each through hole (not shown) in the stator 150. The

  Although not shown, each stator alignment through hole 342, 344 and 346 formed in the ring plate 324 is there during assembly to allow alignment of the stator 150 as is well known to those skilled in the art. It will be appreciated that it defines an access or inlet opening for a stator alignment pin (not shown) that is adapted to be inserted. When the stator assembly 150 in the housing 20 is properly aligned, each stator mounting screw 380, 382 and 384 (FIGS. 3 and 5) is connected to each mounting through-hole 348, 350 and 352 in the ring plate 324. The through holes (not shown) in the stator 150 are penetrated to fix the stator assembly 150 to the housing 20 and the retainer 310 to the upper surface of the stator assembly 150.

  More specifically, when the mounting screws 380, 382 and 384 are tightened, the ring plate 324, more specifically, each curved portion 360, 362 and 364 thereof is compressed against the upper surface of each bobbin 154a, 154b and 154c. A print that exerts a spring force and ensures, captures and minimizes the relative movement between the bobbins 154a, 154b and 154c and the stator 150, and thus one of the bobbin terminals 160a and 160b and the terminals 160a and 160b extend therein. Contact loss between each contact socket (not shown) in the circuit board 200 is prevented.

  In accordance with the present invention, the bosses or depressions 365 formed in each curved region 360, 362 and 364 are seated against the upper surface of each bobbin 154a, 154b and 154c to provide sharp edges or burrs on the ring plate 324. Defines a flat surface that prevents the insulation of the wire wound around each bobbin 154a, 154b and 154c from being compromised. Notches 354, 356, and 358 in ring plate 324 provide a gap between the front frame of each bobbin 154 a, 154 b, and 154 c and the inner surface 332 of ring plate 324. Ears 372, 374, and 376 are anti-nesting features that facilitate separating the individual plates 324 in the manufacturing process and ensuring that only one retainer 310 is installed during assembly.

  The sensor assembly 180 (FIG. 3) is mounted on and under the sensor magnet 114 (FIGS. 3 and 4) and the generally flat printed circuit board 200 (FIGS. 3 and 4) mounted in the housing 20. And at least one Hall effect sensor 210 (FIG. 4) that hangs down.

  The printed circuit board 200 defines a peripheral peripheral edge 200a (FIGS. 3 and 4) that follows the contour of the inner shoulder 33 of the wall 25 of the motor housing 21 and sits thereon. The circuit board 200 overlies the motor housing cavity 22 and thus the rotor assembly and stator assemblies 100 and 150 seated in the cavity 22. The circuit board 200 has an upper or surface 201 (FIGS. 3 and 4) and a bottom or surface 202 (FIG. 4), and defines a central hole 203 (FIG. 4) and a plurality of plated through holes 205 (FIG. 4). In the illustrated embodiment, the upper end of the shaft 104 of the rotor 100 containing the gear 222 extends through the substrate central hole 203 into the cavity 52 defined by the cover 50.

  A plurality of electrical components, including a processor or controller (not shown) and other passive active electrical components 208 (FIGS. 3 and 4) are attached to the upper side 201 of the circuit board 200. Hall effect sensor 210 is attached to bottom side 202 of circuit board 200. Hall effect sensor 210 senses the magnetic field generated by rotor sensor magnet 114. Stator terminals 160a and 160b (FIGS. 3 and 4) extend outwardly from the stator assembly 150 and are inserted into any selected plated through hole 205 in the substrate 200 that covers the stator assembly 150; It is held by interference fit or soldering.

  Although not shown in any of the drawings, the connector terminal 80 in the motor housing 21 (FIG. 3) is similarly inserted into any selected plated through hole 205 in the substrate 200, and an interference fit, soldering, etc. It will be understood that

  As further shown in FIG. 3, the plurality of screws 206 extend through the holes in the substrate 200 and the housing 21, and fix the substrate 200 to the inner shoulder 33 of the wall 25 of the motor housing portion 21.

  As shown in FIGS. 3 and 4, the actuator 10 is further located in the housing 20 and covers the circuit board 200 so as to be seated on the upper rim of the wall 25 of the motor housing portion 21 in a relationship of being separated from and parallel to the circuit board 200. An intermediate plate 212 containing a peripheral edge 213 is provided. The plate 212 includes a top surface 211 and a bottom surface 214. The upper surface 213 defines at least first and second recesses or grooves 215 and 216 and a central through hole 217. The end of the rotor shaft 104 forming the gear 222 extends into the gear housing cavity 52 through the hole 217.

  A bearing 218 is press fit into the opening 217 and supports the rotor shaft 104 to rotate relative to the plate 212. A thrust washer 219 surrounds the end of the rotor shaft 104 with the gear 222 and seats against a shoulder formed on the bottom surface 214 of the plate 212, which is necessary for the rotor assembly 100 in the housing 20 relative to the housing portion 21 and the plate 212. Support and maintain vertical alignment and support.

  The gear assembly 220 (FIGS. 3 and 4) is located on the plate 212 in the cavity 52 of the cover 50. The gear assembly 220 includes a gear 222 that surrounds the distal upper end of the rotor shaft 104, followed by stacked gears: an intermediate full gear 224, a full pinion gear 226, and a full output gear 228 (FIGS. 3 and 4). The gears 222, 224, 226 and 228 can be formed of plastic. In the illustrated embodiment, at least a portion of the gear assembly 220 covers the motor assembly 98.

  As described above, the gear 222 is formed at the distal upper end of the rotor shaft 104. The gear 222 is connected to and drives an intermediate gear 224 that is adjacent to and coplanar with the motor gear 222 and overlies at least a portion of the motor assembly 98. The pinion gear 226 is located approximately on the center of the intermediate gear 224 and connected thereto. The pinion gear 226 drives an output gear 228 that is adjacent and coplanar with the pinion gear 226, is stacked on the intermediate gear 224, and overlaps at least a portion of the motor assembly 98. Both intermediate gear 224 and pinion gear 226 define a central internal through hole 225 (FIG. 4).

  A metal intermediate gear shaft 236 (FIGS. 3 and 4) extends through each hole defined in the gears 224 and 226. The upper end of the shaft 236 is press-fitted into a recess 61 defined in the inner surface of the cover 50, and the bottom end of the shaft 236 is press-fitted into a recess 215 defined in the plate 212. A pair of bearings 248 (FIGS. 3 and 4) that are press fit into the holes 225 and one is sandwiched between the plate 212 and the bottom surface of the gear 224, and the other is the inner surface of the cover 50 and the top surface of the pinion gear 226. A pair of thrust washers 249 sandwiched between the shaft 236 and the shaft 236, and thus the gears 224 and 226, rotate with respect to the plate 212 and the cover 50. In the illustrated embodiment, the intermediate gear shaft 236 is spaced apart and parallel to the rotor shaft 104.

  Output gear 228 (FIGS. 3 and 4) defines a central cylindrical through hole or opening 230 (FIG. 4) that receives the central portion of output shaft 240 (FIGS. 3 and 4).

  The upper end of the output shaft 240 projects through a cylindrical through hole 58 formed in the cover 50 and is adapted to receive the male end of a shaft (not shown) of a device such as a valve, switch, indicator, etc. to which the actuator 10 is coupled. An upper spline female groove or recess is defined. The bottom end of the output shaft 240 extends into a recess 216 defined in the plate 212. The first output shaft bearing 244 (FIGS. 3 and 4) is press fit into the through hole 58 of the cover 50, and the second output shaft bearing 245 (FIGS. 3 and 4) is press fit into the recess 216 in the plate 212. The output shaft 240 and the gear 228 are supported so as to rotate with respect to the plate 212. A pair of thrust washers 246 and 247 support the shaft 240 and the gear 228 with respect to the cover 50 and the plate 212. The washer 246 is sandwiched between the upper surface of the gear 228 and the inner surface of the cover 50, while the washer 247 is sandwiched between the bottom surface of the gear 228 and the plate 212.

  A rubber output seal 242 (FIGS. 3 and 4) seals the area between the output shaft 240 and the cylindrical inner wall of the cover 50 that defines the through hole 58. The upper end of the output shaft 240 protruding from the through hole 58 can be coupled to an object that is desired to be operated accurately or precisely, such as a valve. 1-4, output shaft 240 overlies motor assembly 98, circuit board 200 and plate 212 in a spaced apart, parallel relationship with both rotor shaft 104 and intermediate gear shaft 236. In the embodiment of actuator 10 shown in FIGS. .

  In operation, Hall effect sensor 210 senses the magnetic field generated by sensor magnet 114 (FIGS. 3 and 4) and provides a signal indication of the position of rotor assembly 100 to a processor (not shown). The processor adjusts the direction of the current through winding 156 so that each associated column is switched in time to become an N-pole or S-pole electromagnet that attracts or moves away from the motor magnet 110 that rotates the rotor assembly 100. Switch to communicate. The rotation of rotor assembly 100 drives motor gear 222, which drives intermediate gear 224 and pinion gear 226, which in turn drives output gear 228 and output shaft 240. Thereby, the processor can accurately determine and control the rotational position of the output shaft 240.

While the invention has been taught by specific reference to the embodiments described above, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. . The described embodiments are to be construed as illustrative in all respects and not as restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
The following is a copy of each claim in the claims as filed.
[Claim 1]
A housing having first and second housing portions defining each of the first and second cavities;
A motor assembly having a rotor shaft, mounted in the first cavity in the first housing portion;
A circuit board assembly positioned in the housing in an overlapping relationship with the motor assembly, wherein the rotor shaft extends through the circuit board assembly into the second cavity;
A gear assembly located in the second cavity in the second housing portion and connected to the rotor shaft in a relationship overlapping at least a portion of the circuit board assembly and the motor assembly; and
An actuator assembly comprising an output shaft extending into the second cavity defined by the second housing portion and coupled to the gear assembly.
[Claim 2]
The actuator assembly of claim 1, wherein the gear assembly comprises at least a first gear in the second cavity supported by a shaft in the second cavity and coupled to the rotor shaft.
[Claim 3]
The actuator assembly of claim 2, wherein the gear assembly comprises a second gear positioned in the second cavity and stacked on the first gear.
[Claim 4]
The actuator assembly of claim 3, wherein the output shaft is coupled to the second gear.
[Claim 5]
The first housing part has an internal peripheral shoulder, the circuit board assembly has a peripheral edge, and the peripheral edge of the circuit board assembly is seated on the internal shoulder of the first housing part. 1. Actuator assembly.
[Claim 6]
2. The actuator assembly according to claim 1, wherein the first housing portion has a peripheral outer groove, and the second housing portion defines a peripheral convex portion that is fitted into the groove in the first housing portion.
[Claim 7]
The actuator assembly of claim 1, wherein the circuit board assembly separates the first and second cavities.
[Claim 8]
The first housing portion defines an upper peripheral rim, and the actuator seats a plate seated on the upper peripheral rim of the first housing portion in a spaced apart parallel relationship on the circuit board assembly. The actuator assembly of claim 1, further comprising in the body.
[Claim 9]
A housing defining a cavity,
A motor mounted in the cavity in the housing and having a rotor having a rotor shaft and a stator having at least one bobbin;
A plate in the cavity in the housing that is seated on the bobbin and secured to the stator to hold the bobbin on the stator;
An actuator comprising: a gear assembly positioned in the cavity in the housing and coupled to the rotor shaft; and an output shaft extending into the cavity in the housing and coupled to the gear assembly.
[Claim 10]
The actuator of claim 9, wherein the bobbin has a pair of terminals defining a slot therebetween, and the plate has a retainer alignment finger that fits into the slot in the bobbin.
[Claim 11]
At least one stator mounting screw secures the stator to the housing and the plate is defined therein to receive the stator mounting screw to secure the plate to the stator. The actuator of claim 10 having a through hole.
[Claim 12]
A plurality of bobbins each having a pair of terminals defining a slot therebetween are held on the stator and the plate is in the form of a ring seated against the plurality of bobbins, the ring being in each of the slots 12. The actuator of claim 11, wherein the actuator further comprises at least one stator alignment through hole having three spaced fingers mated to the ring, the ring defining an access opening for a stator alignment pin.
[Claim 13]
The actuator of claim 12, wherein the ring has a wavy curved pattern.
[Claim 14]
A clip for holding a plurality of bobbins on a stator,
A ring plate that is seated on the stator and the plurality of bobbins, and that defines a plurality of curved regions that are wavy and overlap the bobbins.
A plurality of spaced alignment fingers adapted to extend outwardly from an outer surface of the ring plate and fit into respective slots defined on each bobbin; and the ring defined in the plate A clip comprising a plurality of first through holes adapted to receive respective screws for securing a plate to the stator.
[Claim 15]
The clip of claim 14, wherein each of the curved regions of the ring plate defines a boss seated on each of the plurality of bobbins.

US Pat. No. 5,737,968

Claims (6)

A housing defining a cavity,
A motor mounted in the cavity in the housing and having a rotor having a rotor shaft and a stator having at least one bobbin;
A plate in the cavity in the housing that is seated on the bobbin and secured to the stator to hold the bobbin on the stator;
A gear assembly positioned in the cavity in the housing and coupled to the rotor shaft; and an output shaft extending into the cavity in the housing and coupled to the gear assembly ;
Said bobbin having a pair of terminals defining a slot therebetween, actuators having retainer alignment fingers said plate is fitted in said slots in the bobbin. At least one stator mounting screw secures the stator to the housing and the plate is defined therein to receive the stator mounting screw to secure the plate to the stator. the actuator of claim 1 having a through-hole. A plurality of bobbins each having a pair of terminals defining a slot therebetween are held on the stator and the plate is in the form of a ring seated against the plurality of bobbins, the ring being in each of the slots 3. The actuator of claim 2 having three spaced fingers mated to said ring, said ring further defining at least one stator alignment through hole defining an access opening for a stator alignment pin. 4. The actuator of claim 3 , wherein the ring has a wavy curved pattern. A clip for holding a plurality of bobbins on a stator,
A ring plate that is seated on the stator and the plurality of bobbins, and that defines a plurality of curved regions that are wavy and overlap the bobbins.
A plurality of spaced alignment fingers adapted to extend outwardly from an outer surface of the ring plate and fit into respective slots defined on each bobbin; and the ring defined in the plate A clip comprising a plurality of first through holes adapted to receive respective screws for securing a plate to the stator. 6. The clip of claim 5 , wherein each said curved region of said ring plate defines a boss seated on each of said plurality of bobbins.

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