A modular, customizable motor system and its combination method

Abstract

This invention discloses a modular, customizable motor system and its combination method, belonging to the field of motor system technology. It includes a power module, a functional module, and a control module. The power module includes a stator, a rotor, a pair of end caps, and a housing. The stator windings are fixedly connected inside the housing. The rotor passes through the central area of ​​the stator, and its two ends are rotatably connected to both ends inside the housing via bearings. The functional module includes a rear cover, several crown spring connectors, and an equal number of pin-type copper terminals. The control module is fixedly installed inside the rear cover and fixedly connected to several crown spring connectors. The pair of end caps are fixedly connected to both ends of the housing, with one end cap fixedly connected to the rear cover. The terminals of several pin-type copper terminals are fixedly connected to the end of the stator near the rear cover. The pin-type copper terminals are sequentially inserted into the crown spring connectors, achieving fast, reliable, and reversible electrical connections, solving the problems of poor soldering and difficult maintenance in traditional methods.

Description

Technical Field

[0001] This invention belongs to the field of motor system technology, and more specifically, relates to a modular motor system with customizable functions and a method for combining the two. Background Technology

[0002] Traditional motor systems suffer from the following technical drawbacks: 1. The winding leads are directly soldered with enameled wire, leading to maintenance difficulties and the risk of poor soldering; 2. The low integration between the controller and the motor body results in an excessively large system size; 3. Customization of functions requires a complete redesign of the overall structure, with a development cycle of 3-6 months; 4. Different functional versions need to be manufactured separately, resulting in a large number of different inventory items. Therefore, a modular motor system that can be flexibly customized and is easy to assemble and maintain quickly is needed. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a modular and customizable motor system and its combination method, which can meet the requirements of modularity, flexible customization of functions, and easy rapid assembly and maintenance.

[0004] This invention discloses a modular, customizable motor system and its combination method, comprising a power module, a functional module, and a control module. The power module includes a stator, a rotor, a pair of end caps, and a housing. The stator is fixedly connected inside the housing, and the rotor passes through the central region of the stator, with both ends rotatably connected to the two ends inside the housing via bearings. The functional module includes several crown spring connectors and an equal number of pin-type copper terminals. The control module includes a controller and a rear cover. The controller is fixedly installed inside the rear cover and welded to several crown spring connectors. The terminals of several pin-type copper terminals are fixedly connected to the end of the stator near the rear cover. The pair of end caps are fixedly connected to the two ends of the housing, with the end caps near the pin-type copper terminals and the rear cover connected by bolts. Each pin-type copper terminal is inserted into its corresponding crown spring connector. Through the mechanical insertion of pins and crown springs, the electrical connection is fast, reliable, and reversible, solving the problems of poor soldering and difficult maintenance in traditional methods.

[0005] As a further improvement of the present invention, the outer shell is provided with several limiting grooves at both ends, and a pair of end caps are provided with matching limiting protrusions on the side facing the outer shell. The limiting protrusions engage with the limiting grooves. A pair of end caps are provided with screw holes. The pair of end caps are fixedly connected by long bolts and pressed against the middle outer shell to fix it in place by the engagement of the limiting grooves and limiting protrusions, thereby enhancing the connection stability, positioning and locking in the axial and circumferential directions, and ensuring the overall rigidity and connection strength of the motor body structure.

[0006] As a further improvement of the present invention, one of the pair of end caps that is farther away from the rear cover is the front end cap, and the one that is closer to the rear cover is the rear end cap. The end of the rear end cap that is connected to the rear cover is also provided with a limiting protrusion, and the end of the rear cover that is connected to it is provided with a corresponding limiting groove. This is used to position the rear cover for easy installation and to enhance the anti-torsion and anti-loosening ability of the connecting parts, ensuring the accurate docking of the internal electrical pins.

[0007] As a further improvement of the present invention, the rear cover is provided with a plurality of limiting grooves at one end facing the rear end cover, and the rear end cover is provided with matching limiting protrusions. The limiting protrusions engage with the limiting grooves, which facilitates positioning and enhances the connection strength between the rear cover and the rear end cover.

[0008] As a further improvement of the present invention, the stator includes a stator winding and a pair of coil frames. Several internally penetrating support bones extend evenly from one end of the coil frames. The pair of coil frames are inserted into the stator winding along the opposite direction of the support bones. The pair of coil frames have winding grooves formed at the positions between each adjacent support bone on the opposite end face of each other. This simplifies the winding process, improves production efficiency and winding consistency, reduces the overall frame weight, and improves process quality and reliability.

[0009] As a further improvement of the present invention, the control module is selected as a Hall plate or a control board. The control module is installed inside the rear cover by potting process and is fixedly connected to several crown spring connectors.

[0010] As a further improvement of the present invention, when the control module is selected as a Hall plate, it also includes a Hall magnetic ring. The Hall magnetic ring is fixedly connected to one end of the rotor near the rear cover. The sensor on the Hall plate is arranged opposite to the Hall magnetic ring to ensure that the Hall magnetic ring and the Hall plate are coupled to detect the rotor position. Only the corresponding Hall rear cover assembly needs to be installed, and the sensing system will automatically align and work, avoiding the process of adjusting the sensor position and simplifying the process.

[0011] As a further improvement of the present invention, the crown spring connector has a built-in double helical spring, which provides stable and durable radial contact pressure, ensuring a low-resistance and highly reliable electrical connection with the pin-type copper terminals, and can withstand frequent insertion and removal and vibration environments; the pin-type copper terminals adopt a trapezoidal cross-section design to increase the contact area, reduce contact resistance, reduce heat generation during power-on, and enhance mechanical connection strength and guidance.

[0012] As a further improvement of the present invention, several clearance slots are provided on the outside of the stator winding and coil frame to prevent interference during installation, and to form an axial heat dissipation channel between the stator and the housing or to reduce the weight of the material.

[0013] As a further improvement of the present invention, an annular heat dissipation channel is provided inside the rear cover to effectively dissipate the heat generated by the control module, prevent it from overheating and being damaged, and improve the reliability and lifespan of the entire system under continuous high load operation.

[0014] A method for assembling the modular, customizable motor system includes the following steps: Step 1: Provide the standardized power module; Step 2: Based on the target functional requirements, select and prepare the corresponding functional modules and the control modules integrated thereon; Step 3: Align and assemble the functional module and the power module until the limiting groove on the rear cover contacts the corresponding limiting protrusion of the power module, so that the pin-type copper terminal is inserted into the crown spring connector at a preset depth to complete the electrical connection and mechanical fixation.

[0015] As a further improvement of the present invention, the modular functional customizable motor system is divided into basic configuration, economic configuration and intelligent configuration according to the target functional requirements; When configured as the basic type, the rear cover assembly is omitted, and the functional module is not integrated with the control module, but is directly connected to an external driver. When configured as an economy model, the control module is a Hall plate integrated with the rear cover and has a Hall magnetic ring connected to the corresponding end of the rotor. When configured as intelligent, the control module is a built-in drive controller integrated with the rear cover potting.

[0016] Compared to existing technologies, the advantages of this invention are as follows: It fundamentally improves the reliability of electrical connections by replacing traditional direct soldering with pluggable interfaces using pin-type copper terminals and crown spring connectors; non-modular motor function customization requires redesigning the overall structure, with a development cycle of 3-6 months, while motors produced using modular designs for power, function, and control, along with potting integration processes, can be modularly interchanged on-site, optimizing the process of redesigning for function customization; it achieves a systemic breakthrough in rapidly responding to diverse customer needs, significantly reducing inventory costs, and simplifying production and maintenance processes. The stator features a through-type support frame and winding slots, simplifying the winding process, improving production efficiency and winding consistency, reducing the overall frame weight, and enhancing process quality and reliability. The crown spring connector incorporates a double helical spring, providing stable and durable radial contact pressure to ensure a low-resistance, high-reliability electrical connection with the pin-type copper terminals, and can withstand frequent insertion / removal and vibration environments. The pin-type copper terminals adopt a trapezoidal cross-section design, increasing the contact area, reducing contact resistance, reducing heat generation during power-on, and enhancing mechanical connection strength and guidance. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the exploded structure of the module of the present invention; Figure 3 This is a front sectional view of the present invention; Figure 4 This is an exploded view of the stator structure of the present invention; Figure 5 This is an exploded view of the rotor and control module structure of the present invention; Figure 6 This is a frontal view of the explosion diagram of the present invention; Figure 7 This is a schematic diagram of the crown spring connector and pin-type copper terminal structure of the present invention; Figure 8 This is a schematic diagram of the heat dissipation channel structure of the present invention; Figure 9 This is a schematic diagram of the sealing ring structure of the present invention; Figure 10 This is a schematic diagram of the external load connection structure of the present invention; Figure 11 This is a schematic diagram of the structure of Embodiment 2 of the present invention; Figure 12 This is an exploded view of the structure of Embodiment 3 of the present invention.

[0018] Explanation of the labels in the diagram: Power module a; Functional module b; Control module c; Stator 1; Stator winding 11; Coil frame 12; Support frame 121; Winding slot 122; Rotor 2; Rotor core 21; Shaft 22; End cover 3; Front cover 31; Rear cover 32; Limiting protrusion 33; Sealing ring 34; Housing 4; Limiting groove 41; Clearance groove 42; Rear cover 5; Heat dissipation channel 51; Crown spring connector 6; Double helical spring 61; Pin-type copper terminal 7; Hall magnetic ring 8; Hall plate 9; Control board 10; External load 20. Detailed Implementation

[0019] A method for assembling a modular, customizable motor system, wherein the modular, customizable motor system is divided into a basic configuration, an economic configuration, and an intelligent configuration according to target functional requirements, and the assembly selection includes the following steps: Step 1: Provide the standardized power module a; Step 2: Based on the target functional requirements, select and prepare the corresponding functional module b and the control module c integrated thereon; Step 3: Align and assemble the functional module b with the power module a until the limiting structure on the rear cover 5 contacts the corresponding end face of the power module a, so that the pin-type copper terminal 7 is inserted into the crown spring connector 6 at a preset depth to complete the electrical connection and mechanical fixation.

[0020] Specific Implementation Example 1: This example is an economical motor system. Please refer to [link / reference]. Figures 1-10 This invention relates to a modular, customizable motor system and its assembly method, comprising a power module a, a functional module b, and a control module c. The power module a includes a stator 1, a rotor 2, end covers 3, and a housing 4. The stator 1 is fixedly connected inside the housing 4. The end covers 3 include a front cover 31 and a rear cover 32. The housing 4 is installed between the front cover 31 and the rear cover 32. The rotor 2 passes through the central region of the stator 1, and its two ends are rotatably connected to the front cover 31 and the rear cover 32 at both ends via bearings. The functional module b includes several crown spring connectors 6 and several pin-type copper terminals 7. The terminal heads of the pin-type copper terminals 7 are fixedly connected to the stator 1. At the end furthest from the front cover 31, the control module c includes a rear cover 5, a Hall magnetic ring 8, and a Hall plate 9. The rear cover 5 is fixedly connected to the rear cover 32 by bolts driven into the side. The Hall plate 9 is installed inside the rear cover 5 by epoxy resin potting process. Several crown spring connectors 6 are fixedly connected to the Hall plate 9 at one end and plugged into the pin-type copper terminals 7 at the other end to realize the electrical connection between the Hall plate 9 and the stator 1. The Hall magnetic ring 8 is fixedly connected to the end of the rotor 2 near the rear cover 5. The sensor on the Hall plate 9 is set opposite to the Hall magnetic ring 8 to ensure that the Hall magnetic ring 8 and the Hall plate 9 are coupled to detect the position of the rotor 2.

[0021] In a further embodiment, such as Figure 6 as well as Figures 9-10 As shown, the outer end of the front cover 31 is fixedly connected to the external load 20, and a sealing ring 34 is fixedly installed on the outer end of the front cover 31. The outer shell 4 is provided with several limiting grooves 41 at both ends. The front cover 31 and the rear cover 32 are provided with matching limiting protrusions 33 on the side facing the outer shell 4. The limiting protrusions 33 are engaged with the limiting grooves 41. The front cover 31 and the rear cover 32 are provided with screw holes. The front cover 31 and the rear cover 32 are fixedly connected by long bolts and pressed against the outer shell 4 to fix them.

[0022] In a further embodiment, such as Figure 6 As shown, the rear cover 5 has several limiting grooves 41 at one end facing the rear end cover 32, and the rear end cover 32 has matching limiting protrusions 33. The limiting protrusions 33 engage with the limiting grooves 41 to facilitate positioning and enhance the connection strength between the rear cover 5 and the rear end cover 32.

[0023] In a further embodiment, such as Figure 4As shown, the stator 1 includes a stator winding 11 and a pair of coil frames 12. Several internally penetrating support ribs 121 extend evenly from one end of the coil frame 12. The pair of coil frames 12 are inserted into the stator winding 11 along the opposite direction of the support ribs 121. The stator winding 11 is fixedly sleeved on the support ribs 121 of the pair of coil frames 12. The end faces on both sides of the coil frame 12 extend in the opposite direction at the position between each adjacent support rib 121 to form a winding groove 122, providing space for coil winding. The stator winding 11 and the coil frame 12 are provided with clearance grooves 42 on the outside for matching and connecting the long bolts of the front end cover 31 and the rear end cover 32, preventing interference when the long bolts are installed, forming an axial heat dissipation channel between the stator and the outer shell or reducing the weight of the material.

[0024] In a further embodiment, such as Figure 5 As shown, the rotor 2 includes a rotor core 21 and a rotating shaft 22. The two ends of the rotating shaft 22 are rotatably connected to the front end cover 31 and the rear end cover 32 through bearings. The rotor core 21 is fixed in the middle of the rotating shaft 22 and placed in the central area of ​​the coil frame 12.

[0025] In a further embodiment, such as Figure 7 As shown, the crown spring connector 6 has a built-in double helical spring 61 to ensure stable contact resistance, ensure a low-resistance, high-reliability electrical connection with the pin-type copper terminal 7, and withstand frequent insertion and removal and vibration environments; the pin-type copper terminal 7 adopts a trapezoidal cross-section design to increase the contact area, reduce contact resistance, reduce heat generation during power-on, and enhance mechanical connection strength and guidance.

[0026] In a further embodiment, such as Figure 8 As shown, the rear cover 5 has an annular heat dissipation channel 51 inside, which effectively dissipates the heat generated by the control module c, prevents it from overheating and being damaged, and improves the reliability and lifespan of the entire system under continuous high load operation.

[0027] Specific Implementation Example 2: This example is a basic motor system. Please refer to [link / reference needed]. Figure 11 The difference from Embodiment 1 is that the rear cover 5 component is omitted, and the functional module b is not connected to the control module c, but is directly connected to the external driver.

[0028] Specific Implementation Example 3: This example is an intelligent motor system. Please refer to [link / reference]. Figure 12 The difference from Embodiment 1 is that the control module c is selected as control board 10. The control board 10 is installed inside the rear cover 5 by epoxy resin potting process and is fixedly connected to several crown spring connectors 6.

Claims

1. A modular functionally customizable electric machine system, characterized by: It includes power module (a) and function module (b), power module (a) includes stator (1), rotor (2), a pair of end cover (3) and shell (4), stator (1) is fixedly connected to the inside of shell (4), rotor (2) passes through the central region of stator (1) and is rotatably connected to the inside of shell (4) at both ends respectively, function module (b) includes a plurality of crown spring connector (6) and the same number of pin type copper terminal (7), a pair of end cover (3) is fixedly connected to the both ends of shell (4) respectively, the terminal head of a plurality of pin type copper terminal (7) is fixedly connected to the end face of stator (1), the other end is inserted into the corresponding crown spring connector (6) inside, the end of crown spring connector (6) not connected with pin type copper terminal (7) can be connected with additional structure or external driver.

2. A modular functionally customizable electric motor system according to claim 1, characterized in that: It also includes control module (c), control module (c) includes controller and rear cover (5), rear cover (5) and end cover (3) close to pin type copper terminal (7) are connected by bolts, controller is fixedly installed in the inside of rear cover (5) and is welded with a plurality of crown spring connector (6).

3. A modular functionally customizable electric motor system according to claim 2, characterized in that: Shell (4) is provided with a plurality of limiting grooves (41) at both ends, rear cover (5) is provided with a pair of limiting convex blocks (33) matched with it at the end towards rear end cover (32), limiting convex blocks (33) are engaged with limiting grooves (41), a pair of end cover (3) are provided with screw holes on the side towards shell (4), a pair of end cover (3) are fixedly connected by long bolts and are pressed towards the middle shell (4) to be fixed.

4. The modular functionally customizable electric machine system of claim 1, wherein: Stator (1) includes stator winding (11) and a pair of coil holder (12), a plurality of internally front and rear through support bones (121) are uniformly extended from one end of coil holder (12), a pair of coil holder (12) are inserted into the inside of stator winding (11) along the opposite direction of support bone (121), stator winding (11) is sleeved on the support bone (121) of a pair of coil holder (12), a pair of coil holder (12) are extended and formed with wire grooves (122) at the position between each adjacent support bone (121) on the side end face opposite to each other.

5. The modular functionally customizable electric machine system of claim 2, wherein: The controller in control module (c) selects Hall board (9) or control board (10), the control module (c) is fixedly installed in the inside of rear cover (5) by potting process and is fixedly connected with a plurality of crown spring connector (6).

6. A modular functionally customizable electric motor system according to claim 5, characterized in that: When the control module (c) is selected as Hall board (9), it also includes Hall magnetic ring (8), Hall magnetic ring (8) is fixedly connected to the end of rotor (2) close to rear cover (5), the sensor on Hall board (9) is arranged opposite to the Hall magnetic ring (8), to ensure that Hall magnetic ring (8) and Hall board (9) are coupled to detect the position of rotor (2).

7. The modular functionally customizable electric machine system of claim 1, wherein: Crown spring connector (6) is built-in double helical spring (61), pin type copper terminal (7) adopts trapezoidal section design.

8. The modular functionally customizable electric machine system of claim 3, wherein: Stator winding (11) and coil holder (12) are provided with a plurality of avoidance grooves (42) outside.

9. A modular, functionally customizable electric machine system according to any one of claims 3-8, characterized in that, It includes the following steps: Step one: provide standardized power module (a); Step two: according to the target function requirement, select and prepare the corresponding function module (b) and the control module (c) integrated thereon; Step three: align the function module (b) with the power module (a) and assemble, if with control module (c), through the limiting groove (41) on the rear cover (5) and the corresponding limiting block (33) of the power module (a), the contact makes the pin type copper terminal (7) inserted into the crown spring connector (6) with a preset depth, completes the electrical connection and mechanical fixation.

10. The combination method of claim 9, wherein, The modular function customizable motor system is divided into basic configuration, economic configuration and intelligent configuration according to the target function requirement; When configured as basic type, the crown spring connector (6) of the function module (b) is directly connected with external driver; When configured as economic type, the controller is a hall board (9) which is integrated with the rear cover (5), and the corresponding end of the rotor (2) is connected with the hall magnetic ring (8); When configured as intelligent type, the controller is a built-in drive controller (10) which is integrated with the rear cover (5).

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