An air-cooled integrated eVTOL electric propeller

Abstract

The utility model provides a kind of air cooling integration eVTOL electric propeller, including fairing and the coaxial arrangement of motor assembly and cooling fan covered by the fairing;Motor assembly includes the front end cap, rotor assembly and rear end cap that are coaxially distributed in turn, and motor controller is arranged between rotor assembly and front end cap;Front end cap, rotor assembly and rear end cap are all provided with the ventilation passage that is axially through;Cooling fan is set between front end cap and the fairing, and cooling fan has coaxial independent inner ring blade group and outer ring blade group;Cooling fan rotation makes that inner ring blade group, outer ring blade group generates axial negative pressure to inhale airflow respectively into inner ring flow channel and outer ring flow channel;Wherein, from front end cap to rotor assembly along the direction of ventilation passage forms inner ring flow channel;The gap of fairing and motor assembly forms outer ring flow channel. Realize under the premise of pure air cooling heat dissipation, effectively improve the heat dissipation efficiency and give consideration to system light weight.

Description

Technical Field

[0001] This utility model relates to the field of electric propulsion technology, and in particular to an air-cooled integrated eVTOL electric propulsion. Background Technology

[0002] The rapid development of the electric vertical takeoff and landing (eVTOL) industry has brought stringent design requirements to its core power unit—the electric propulsion system: it must achieve extreme lightweighting, compactness, and high reliability while ensuring high power density.

[0003] Current mainstream electric propulsion systems consist of independent motors and controllers. Due to their independent design, these systems suffer from drawbacks such as excessive weight, large space requirements, complex wiring, and low system efficiency.

[0004] While some manufacturers have attempted integrated designs of the motor and controller, they rely on a combination of air cooling and liquid cooling for heat dissipation. For example, Chinese utility model patent CN216699737U discloses a liquid-cooled and air-cooled integrated EVTOL motor. This design involves front and rear covers at the front and rear ends of the rotor, respectively, with a cooling fan inside the rotor connected to the front cover. This allows the rotor to simultaneously drive the cooling fan to dissipate heat from the motor body during rotation. Simultaneously, a circuit for the cooling medium, along with inlet and outlet ports connected to the circuit, is provided on the stator. A dedicated heat exchanger is used to circulate the cooling medium and remove heat from the motor body. Clearly, this solution significantly increases system complexity and the risk of failure, and it is difficult to meet the lightweight requirements of aerospace applications. Furthermore, existing air-cooling solutions often suffer from insufficient heat dissipation efficiency or weakened structural strength due to unreasonable airflow design, failing to meet the stringent requirements of eVTOL for high power density and compact space layout.

[0005] It is evident that there is an urgent need for a highly integrated, lightweight eVTOL electric propulsion design that relies solely on efficient air cooling. Utility Model Content

[0006] To address the aforementioned technical problems, this utility model provides an integrated air-cooled eVTOL electric thruster, comprising a fairing and a coaxially arranged motor assembly and cooling fan covered by the fairing; wherein:

[0007] The motor assembly includes a front cover, a rotor assembly, and a rear cover arranged coaxially in sequence, and a motor controller is provided between the rotor assembly and the front cover; the front cover, the rotor assembly, and the rear cover are all provided with axially through ventilation channels.

[0008] The cooling fan is disposed between the front end cover and the shroud. The cooling fan has a coaxial and independent inner ring blade group and an outer ring blade group. The rotation of the cooling fan causes the inner ring blade group and the outer ring blade group to generate axial negative pressure to draw airflow into the inner ring flow channel and the outer ring flow channel respectively. The inner ring flow channel is formed along the ventilation channel direction from the front end cover to the rotor assembly. The gap between the shroud and the motor assembly forms the outer ring flow channel.

[0009] Furthermore, the front end cover is provided with an axially penetrating air inlet, which is connected to the ventilation duct.

[0010] Furthermore, the fairing has a flow-guiding surface with a radius of curvature of 5-10 mm.

[0011] Furthermore, the fairing is fixed to the circumferential surface of the rear end cover by bolts.

[0012] Furthermore, the rotor assembly includes a hollow shaft, a rotor support, magnets, and carbon fiber; wherein:

[0013] The rotor support is interference-fitted with the hollow shaft, and the rotor support is provided with radially distributed through holes;

[0014] The magnet is fixed to the outer circumferential surface of the rotor bracket by magnet adhesive;

[0015] The carbon fiber is wound around the circumferential outer surface of the magnet.

[0016] Furthermore, the cooling fan is circumferentially fixed by engaging with the flat end of the rotor support shaft via a central keyway, and is axially constrained by snapping into the annular groove at the rotor support shaft end via a snap ring.

[0017] Furthermore, both the front end cover and the rear end cover are provided with bearing holes to support the rotor assembly.

[0018] Furthermore, the front end cover is provided with a first receiving chamber, and the rear end cover is provided with a second receiving chamber, with the openings of the first receiving chamber and the second receiving chamber facing each other; wherein:

[0019] The motor controller is fixed to the first receiving chamber by bolts;

[0020] The motor assembly also includes a stator assembly, which is thermally fitted to the second receiving chamber.

[0021] Preferably, dustproof nets are provided at the ends of both the front cover and the rear cover.

[0022] Preferably, the inner ring blade group has a blade tilt angle of 15°-25° and 12-15 blades; the outer ring blade group has a blade tilt angle of 30°-45° and 9-11 blades.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] This invention utilizes a synergistic heat dissipation structure where an axial inner air duct driven by a dual-ring fan penetrates the core heat-generating area of ​​the motor and an outer air duct covers the outer shell surface. Combined with the axial integration of the motor, electronic control, and fan, it effectively improves heat dissipation efficiency while maintaining system lightweight design under the premise of pure air cooling. Attached Figure Description

[0025] Figure 1 This is a cross-sectional view of the overall structure disclosed in an embodiment of the present utility model, showing the orientation of the inner and outer annular flow channels;

[0026] Figure 2 This is an exploded view of the overall structure disclosed in the embodiment of this utility model;

[0027] Figure 3 This is an exploded view of the rotor assembly disclosed in an embodiment of the present utility model;

[0028] Figure 4 This is a schematic diagram of the front cover structure disclosed in an embodiment of the present utility model, showing the location of the air inlet;

[0029] Figure 5 This is a schematic diagram of the cooling fan disclosed in an embodiment of the present utility model.

[0030] In the picture:

[0031] 100. Fairing;

[0032] 200. Motor assembly;

[0033] 210. Cooling fan; 211. Inner ring blade assembly; 212. Outer ring blade assembly;

[0034] 220. Front cover; 221. Air inlet;

[0035] 230. Motor controller;

[0036] 240. Rotor assembly; 241. Hollow shaft; 242. Rotor support; 243. Magnet; 244. Carbon fiber;

[0037] 250. Stator assembly;

[0038] 260. Rear end cover. Detailed Implementation

[0039] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0040] The present invention aims to provide an air-cooled integrated eVTOL electric thruster that can simultaneously ventilate the inside and outside of the electric thruster to remove heat, thereby achieving a highly integrated, lightweight eVTOL electric thruster that relies solely on pure air cooling.

[0041] The electric thruster mainly includes a fairing 100 and a coaxially arranged motor assembly 200 and cooling fan 210 enclosed by the fairing 100. In this embodiment, the fairing 100 has a guide surface with a radius of curvature of 5-10 mm. The motor assembly 200 includes an integrated motor controller 230, a rotor assembly 240, and a stator assembly 250.

[0042] The motor assembly 200 and the cooling fan 210 will be described in detail below.

[0043] First, the motor assembly 200 will be described in detail.

[0044] Please see Figure 2 The motor assembly 200 includes a front cover 220, a rotor assembly 240 and a rear cover 260 that are coaxially distributed in sequence.

[0045] The front cover 220 is provided with a first receiving chamber. For example... Figure 4 As shown, the front cover 220 is provided with an axially penetrating air inlet 221.

[0046] The motor controller 230 is located between the front cover 220 and the rotor assembly 240, and is fixed to the first receiving chamber by bolts.

[0047] Rotor assembly 240 includes a hollow shaft 241, a rotor support 242, magnets 243, and carbon fiber 244. (See attached image.) Figure 3 The rotor support 242 is interference-fitted with the hollow shaft 241 to ensure coaxiality and transmits torque via a flat key. The rotor support 242 also has radially distributed through holes. Magnets 243 are fixed to the outer circumferential surface of the rotor support 242 with magnet adhesive. Carbon fiber 244 is wound around the outer circumferential surface of the magnets 243 to ensure operational reliability.

[0048] The rear end cover 260 has a second receiving chamber, to which the stator assembly 250 is thermally fitted. The openings of the first receiving chamber of the front end cover 220 and the second receiving chamber of the rear end cover 260 are opposite. The fairing 100 is fixed to the circumferential surface of the rear end cover 260 by bolts.

[0049] In this embodiment, both the front cover 220 and the rear cover 260 are provided with bearing holes to support the rotor assembly 240.

[0050] Preferably, dustproof nets are provided at the ends of the front cover 220 and the rear cover 260, so that the whole machine meets the IP54 requirement.

[0051] Next, the cooling fan 210 will be described in detail.

[0052] The cooling fan 210 is located between the front cover 220 and the shroud 100. Specifically, the cooling fan 210 is circumferentially fixed by engaging with the flat end of the rotor bracket 242 shaft through the central keyway, and is axially constrained by snapping into the annular groove at the end of the rotor bracket 242 shaft through a snap ring.

[0053] The front cover 220, rotor assembly 240, and rear cover 260 are all provided with axially through ventilation channels. The air inlet 221 at the end of the front cover 220 is connected to the ventilation channel. The circumferential surface of the rear cover 260 is distributed with heat dissipation fins for a spiral airflow design, further improving heat dissipation efficiency.

[0054] In this embodiment, the cooling fan 210 has a coaxial and independent inner ring blade assembly 211 and an outer ring blade assembly 212, such as Figure 5 As shown. Preferably, the inner ring blade group 211 has a blade tilt angle of 15°-25° and 9-12 blades; the outer ring blade group 212 has a blade tilt angle of 30°-45° and 7-9 blades.

[0055] Please see Figure 1 The rotation of the cooling fan 210 generates axial negative pressure in the inner ring blade assembly 211 and the outer ring blade assembly 212, drawing airflow into the inner and outer ring channels respectively. The inner ring channel is formed along the ventilation duct direction from the front end cover 220 to the rotor assembly 240; the gap between the shroud 100 and the motor assembly 200 forms the outer ring channel.

[0056] The principle of pure air-cooled dual-channel heat dissipation in this embodiment is as follows: the rotor assembly 240 is fixed to the propeller by bolts; when the motor is powered on, the rotor assembly 240 drives the propeller to rotate, which in turn drives the cooling fan 210 to rotate along with the rotor assembly 240. Since the cooling fan 210 has an inner and outer ring design, when the cooling fan 210 is running, on the one hand, the inner ring air passes through the front cover 220 and the rotor support 242, and is then blown out through the rear cover 260 to cool the inside of the electric propulsion system; on the other hand, the outer ring air is blown out through the gap between the rectifier and the motor assembly 200 to cool the outside of the electric propulsion system.

[0057] Compared to liquid cooling, this embodiment has a simple and reliable structure; compared to systems with separate motors and electronic controls, it reduces weight and can meet the market demand for small and medium-sized eVOLT multi-rotor electric propulsion.

[0058] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An air-cooled integrated eVTOL electric propulsor, characterized by, Includes a fairing (100) and a coaxially arranged motor assembly (200) and cooling fan (210) covered by the fairing (100); wherein: The motor assembly (200) includes a front cover (220), a rotor assembly (240), and a rear cover (260) arranged coaxially in sequence. A motor controller (230) is provided between the rotor assembly (240) and the front cover (220). The front cover (220), the rotor assembly (240), and the rear cover (260) are all provided with axially penetrating ventilation channels. The cooling fan (210) is disposed between the front end cover (220) and the shroud (100). The cooling fan (210) has a coaxial and independent inner ring blade group (211) and an outer ring blade group (212). The rotation of the cooling fan (210) causes the inner ring blade group (211) and the outer ring blade group (212) to generate axial negative pressure to draw airflow into the inner ring flow channel and the outer ring flow channel respectively. The inner ring flow channel is formed along the ventilation channel direction from the front end cover (220) to the rotor assembly (240). The gap between the shroud (100) and the motor assembly (200) forms the outer ring flow channel.

2. The fan integrated eVTOL electric propulsor of claim 1, wherein, The front cover (220) is provided with an axially penetrating air inlet (221), which is connected to the ventilation duct.

3. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, The fairing (100) has a flow-guiding surface with a radius of curvature of 5-10 mm.

4. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, The fairing (100) is fixed to the circumferential surface of the rear end cover (260) by bolts.

5. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, The rotor assembly (240) includes a hollow shaft (241), a rotor support (242), magnets (243), and carbon fiber (244); wherein: The rotor support (242) is interference-fitted with the hollow shaft (241), and the rotor support (242) is provided with radially distributed through holes; The magnet (243) is fixed to the outer circumferential surface of the rotor bracket (242) by magnet glue; The carbon fiber (244) is wound around the circumferential outer surface of the magnet (243).

6. The air-cooled integrated eVTOL electric thruster according to claim 5, characterized in that, The cooling fan (210) is circumferentially fixed by engaging with the flat end of the rotor bracket (242) shaft through the central keyway, and is axially constrained by snapping into the annular groove at the shaft end of the rotor bracket (242).

7. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, Both the front end cover (220) and the rear end cover (260) are provided with bearing holes to support the rotor assembly (240).

8. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, The front cover (220) is provided with a first receiving chamber, and the rear cover (260) is provided with a second receiving chamber, the openings of the first receiving chamber and the second receiving chamber being opposite to each other; wherein: The motor controller (230) is fixed to the first receiving chamber by bolts; The motor assembly (200) further includes a stator assembly (250), which is thermally fixed to the second receiving chamber.

9. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, Dustproof nets are provided at the ends of both the front cover (220) and the rear cover (260).

10. The air-cooled integrated eVTOL electric thruster according to claim 1, characterized in that, The inner ring blade group (211) has a blade tilt angle of 15°-25° and a number of 9-12 blades; the outer ring blade group (212) has a blade tilt angle of 30°-45° and a number of 7-9 blades.

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