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Home Generators or Motors Method-of-making-a-brushless-motor-with-inside-mounted-single-bearing

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Details
Inventors: Horski, Marek;
Assignee: Siemens Electric Ltd. (Brampton, CA)
Primary Examiner: Hall; Carl E.
Assistant Examiner:
Attorney, Agent or Firm:

A direct current (DC) brushless motor for automotive and HVAC applications utilizes a single angular contact bearing assembly to rotatably couple an exterior rotor to an interior stator. The single angular contact bearing assembly can be a double horizontal row ball bearing, a four point contact bearing, and a crossed cylindrical roller bearing. The rotor is staked to the bearing assembly by a hub-shaft. A cooling fan is disposed on the top of the rotor to cool internal control circuitry within the motor. The stator includes a winding set connector which is slideably engaged within a cavity of a deep draw support member.

DETAILED DESCRIPTION The present invention relates to a brushless motor including an inside stator assembly including a support member, an outside rotor assembly, a single angular contact bearing, and a shaft.
The outside rotor assembly is disposed about the inside stator assembly.
The single angular contact bearing has an outside race and an inside race.
The shaft is coupled to the rotor and fit into the inside race of the single angular contact bearing.
The rotor assembly is rotatably coupled to the support member via the shaft and the single contact bearing.
The present invention also relates to a method of manufacturing a brushless motor including a stator assembly, a rotor assembly, an electronic control module, a shaft, and a bearing assembly.
The stator assembly includes a plurality of ribs, a winding set connector, and a support member.
The support member is slidably engaged with the winding set connector.
The method includes steps of placing the winding set connector into an assembly position, winding a plurality of conductors about the hooks of the winding set connector and the ribs of the stator assembly, electrically connecting the hooks to the conductors, sliding the winding set connector to an operational position, electrically coupling the tabs of the winding set connector to the electronic control module, and rotatably coupling the rotor assembly to the stator assembly via the shaft and bearing assembly.
The assembly position exposes the plurality of hooks on the winding set connector through apertures in the support member, and the hooks are electrically coupled to the plurality of tabs on the winding set connector.
The present invention also relates to a brushless motor for automotive applications.
The brushless motor includes an exterior rotor, and an interior stator including a support member having a cavity, a bearing means for rotatably coupling the exterior rotor to the interior stator, and a hub-shaft.
The hub-shaft is coupled to the rotor assembly and coupled to fit the bearing means



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