Switched reluctance motor assembly and method of assembling the same

Abstract

Disclosed herein are a controller embedded switched reluctance motor assembly and a method of assembling thereof. Particularly, according to the present invention, a controller controlling the motor unit is installed in a housing, such that a separate process of installing the controller may be omitted, thereby facilitating assembling of the switched reluctance motor assembly. In addition, since a separate installation space of the controller is not required, a vacuum cleaner including the switched reluctance motor assembly may be miniaturized, and since the controller is installed in a state in which a motor unit and an insulator are coupled to each other and then installed in the housing, intermediate tests of the controller or the motor to unit may be easily performed, such that defects may be reduced. Further, the controller is in the housing, such that the controller may be protected from external disturbance.

What is claimed is: 
     
         1 . A switched reluctance motor assembly comprising:
 a shaft forming a rotational center of the motor;   a motor unit including a rotor and a stator so as to rotate the shaft;   an impeller coupled to an upper portion of the shaft in an axial direction so as to suck air through a suction port formed in a cover;   a diffuser transferring the air introduced by the impeller into the motor;   an insulator coupled to the motor unit so as to receive the motor unit therein;   a housing including the motor unit therein and formed so as to enclose outer peripheral portion of the shaft; and   a controller mounted in an inner portion of the housing to control the motor unit.   
     
     
         2 . The switched reluctance motor assembly as set forth in  claim 1 , wherein the insulator includes an upper insulator installed at an upper surface of the motor unit and a lower insulator installed at a lower surface of the motor unit, and
 the controller is installed to a lower surface of the lower insulator.   
     
     
         3 . The switched reluctance motor assembly as set forth in  claim 2 , wherein the lower insulator includes a lower insulator body having a plate shape and including a through hole at a central portion thereof so as to allow the shaft to penetrate therethrough and fixation parts extended from one portion of the lower insulator to the controller in a via shape, and
 the controller includes a control body having a plate shape and including a through hole at a central portion thereof so as to allow the shaft to penetrate therethrough and fixation holes formed in one portion of the control body having the fixation parts inserted thereinto.   
     
     
         4 . The switched reluctance motor assembly as set forth in  claim 3 , wherein the fixation part is formed in plural, and one of the fixation parts has a length longer than that of the others. 
     
     
         5 . The switched reluctance motor assembly as set forth in  claim 3 , wherein a vicinity of the fixation hole is inclined so that a thickness of the vicinity becomes gradually thin toward the center of the fixation hole. 
     
     
         6 . The switched reluctance motor assembly as set forth in  claim 3 , wherein the fixation part includes an extension part extended downwardly from the insulator body and an insertion via extended from a distal end of the extension part in a cylindrical shape to be inserted into the fixation hole and including a screw thread, and
 a nut having stopper protruding upwardly in the axial direction at an upper surface thereof as a part disposed at a lower surface of the fixation hole to be screwed to the insertion via,   a distal end of the stopper in a direction in which the screwed insertion via is unscrewed is formed to be vertical and a distal end of the stopper in a direction in which the insertion via is screwed is formed to be inclined, and   a lower surface of the controller is provided with a stopper insertion part grooved in the same shape as that of the stopper.   
     
     
         7 . The switched reluctance motor assembly as set forth in  claim 3 , wherein the fixation hole of the controller is provided with an elastic piece protruding inwardly, and
 a portion of an outer surface of the fixation part is provided with a groove grooved so that the elastic piece is inserted.   
     
     
         8 . The switched reluctance motor assembly as set forth in  claim 7 , wherein a lower surface of the fixation part has a wedge shape in which a width thereof is gradually reduced downwardly. 
     
     
         9 . The switched reluctance motor assembly as set forth in  claim 1 , further comprising:
 a sensor magnet installed at a lower surface of a lower balancing member of the motor unit; and   a hall sensor installed at a lower surface of the sensor magnet.   
     
     
         10 . The switched reluctance motor assembly as set forth in  claim 3 , further comprising a damper made of an elastic material and installed at the fixation part to absorb impact. 
     
     
         11 . A method of assembling a controller embedded switched reluctance motor assembly including an impeller and a diffuser that sucks air through a suction port formed in a cover to transfer the sucked air, a housing including a motor unit mounted therein so as to rotate a shaft interlocked with the impeller, an insulator installed to the motor unit, and a controller installed at an inner portion of the housing to control the motor unit, the method comprising:
 installing upper and lower insulators at upper and lower portions of the motor unit, respectively;   installing the controller at a lower surface of the lower insulator;   connecting the controller and the motor unit to each other; and   mounting the motor unit and the controller in the housing.