Integrated dirct drive motor and control

Abstract

An outer rotor motor is provided for use in a machine. The motor includes a rotor and a stator. A control board assembly configured to control at least one operational characteristic of the motor is mounted at least in part radially inside the stator.

What is claimed is: 
     
         1 . An outer rotor motor for use in a machine, said motor comprising:
 a rotor rotatable about an axis;   a generally toroidal stator spaced at least in part radially inside the rotor,   said stator including a core;   a control board assembly being configured to control at least one operational characteristic of the motor,   said control board assembly mounted at least in part radially inside the stator to be at least substantially circumscribed by the stator,   said control board assembly including—
 a base, and 
 an electronic component supported on the base and positioned at least in part radially inside the stator; and 
   structure covering at least part of the core,   said structure supporting the control board assembly.   
     
     
         2 . The motor as claimed in  claim 1 ,
 said structure including a generally radially oriented surface on which the control board assembly is supported.   
     
     
         3 . The motor as claimed in  claim 2 ,
 said surface extending at least substantially continuously circumferentially.   
     
     
         4 . The motor as claimed in  claim 3 ,
 said surface being generally annular and extending at least substantially continuously about the axis.   
     
     
         5 . The motor as claimed in  claim 2 ,
 said control board assembly being affixed to the surface.   
     
     
         6 . The motor as claimed in  claim 5 ,
 said control board assembly being affixed to the surface by a screw.   
     
     
         7 . The motor as claimed in  claim 2 ,
 said stator core presenting an end face and a central aperture extending from the end face,   said base being placed against the surface,   said electronic components extending from the base into the central aperture.   
     
     
         8 . The motor as claimed in  claim 1 ,
 said structure comprising insulating structure electrically insulatively covering at least part of the core.   
     
     
         9 . The motor as claimed in  claim 8 ,
 said insulating structure comprising a synthetic resin material.   
     
     
         10 . The motor as claimed in  claim 8 ,
 said stator core including a plurality of teeth that are at least in part spaced arcuately from one another,   each of said teeth including an upper surface and a lower surface,   said insulating structure including a plurality of first tabs corresponding to the teeth and covering the corresponding upper surfaces,   said insulating structure including a plurality of second tabs corresponding to the teeth and covering the corresponding lower surfaces.   
     
     
         11 . The motor as claimed in  claim 10 ,
 said stator including wiring wound around the teeth and the first and second tabs.   
     
     
         12 . The motor as claimed in  claim 10 ,
 said plurality of first tabs being non-integrally formed with said plurality of second tabs.   
     
     
         13 . The motor as claimed in  claim 1 ,
 said motor including mounting structure configured to support the stator and fix the stator to the machine.   
     
     
         14 . The motor as claimed in  claim 13 ,
 said mounting structure forming the structure on which the control board assembly is supported.   
     
     
         15 . The motor as claimed in  claim 13 ,
 said mounting structure taking a generally toroidal form,   said control board assembly being disposed at least in part radially inside the mounting structure to be at least substantially circumscribed by the mounting structure.   
     
     
         16 . The motor as claimed in  claim 13 ,
 said motor including a shaft,   said mounting structure at least substantially circumscribing the shaft.   
     
     
         17 . The motor as claimed in  claim 13 ,
 said mounting structure being located generally radially inside the stator,   said mounting structure being positioned relative to the stator such that relative rotation between the stator and the mounting structure is prevented.   
     
     
         18 . The motor as claimed in  claim 13 ,
 said mounting structure comprising an electrically insulative material, whereby the mounting structure is operable to electrically insulate the stator core.   
     
     
         19 . The motor as claimed in  claim 13 ,
 said stator including wiring,   said mounting structure including—
 a wiring outlet at which the wiring converges for connection to a power source, and 
 wire routing structure configured to facilitate routing of the wiring to the wiring outlet. 
   
     
     
         20 . The motor as claimed in  claim 13 ,
 said motor including a cover affixed to the mounting structure.   
     
     
         21 . The motor as claimed in  claim 20 ,
 said stator including wiring,   said cover and said mounting structure cooperatively defining a wiring receiver for receiving a portion of the wiring.