New electric motor structure

Abstract

Disclosed in the present utility model is a new electric motor structure, comprising a unit, an electric motor controller and a support, wherein the unit comprises an electric motor housing, a stator assembly, a rotor assembly, a rotating shaft, a first fan and an air guide cover; the first fan is installed at a rear shaft extension end of the rotating shaft; the air guide cover is installed outside of the first fan, and has an air intake hole; the electric motor controller comprises a control circuit board, a heat sink, high-speed cooling fans and a shell; a high-power chip on the control circuit board is attached to a top plate of the heat sink; several cooling fins arranged at intervals are provided below the top plate of the heat sink; the cooling fins are arranged in an axial direction; the high-speed cooling fans are installed on one side of the heat sink; high-power capacitors extending from the control circuit board are located on the other side of the heat sink; and several air output holes are formed in a front side face of the shell. During low-rotational-speed operation, the high-speed cooling fans are used for providing sufficient air pressure, such that the temperature rise of the whole machine is not excessively high in harsh use environments, thereby prolonging the service life of the whole machine.

Description

A new motor structure Technical field:

[0001] The utility model relates to a novel motor structure. Background technology:

[0002] Modern motors utilize higher electromagnetic loads to improve material utilization. As the capacity of individual motors increases, improvements must be made to the motor cooling system to enhance heat dissipation. With the exception of a few small or specialized motors, most motors utilize fans to force air flow for cooling.

[0003] Existing PMSM or BLDC motors typically consist of two components: the motor itself and a controller. The motor itself includes the stator assembly, rotor assembly, and motor housing, while the controller primarily consists of a housing and control circuit board. Both the motor and the controller generate significant heat, and in high ambient temperatures, natural cooling often fails to meet design requirements. Therefore, additional heat dissipation devices are required, typically using simpler air cooling. The cooling fan generates sufficient pressure to propel the necessary air through the motor, keeping the overall temperature rise within a reasonable range.

[0004] However, due to different customer needs, whether to provide a complete machine (standalone machine + controller) or just a standalone machine, we are required to design the controller to be easy to disassemble, and provide two supply methods for customers to choose from.

[0005] Existing technology and its existing technical problems: Due to issues such as space and heat dissipation, existing motor designs often separate the stand-alone machine and the controller, that is, the entire machine is made into a split type, but this takes up a large space and has poor electromagnetic interference resistance; or the stand-alone machine and the controller are integrated, and there is a cooling fan at the tail of the stand-alone machine shaft extension, but this design requires a good operating environment for the entire machine, that is, it is limited by the use environment.

[0006] As we all know, when the ventilation area is constant, the greater the plane speed (the plane speed is determined by the rotor speed and wind pressure), the greater the air volume, the greater the amount of heat absorbed by the air, the more heat can be taken away during the air flow transfer, and the more obvious the heat dissipation effect.

[0007] However, during the initial stages of the motor's electromagnetic and structural design, the motor's speed and overall dimensions are already determined, essentially defining the cooling fan's outer diameter and rotor speed. If the motor operates at low speed for extended periods, insufficient cooling air pressure will flow through the controller and the unit's exterior. Combined with harsh operating environments, the unit's temperature rise can be excessive, significantly shortening its lifespan.

[0008] The above situation only applies to the complete machine. For the solution that only provides a single machine, the cooling fan at the rear of the motor is sufficient to dissipate heat from the motor. When designing this motor, it is necessary to consider both the complete machine and the single machine solution.

[0009] Summary of the invention:

[0010] The purpose of the utility model is to provide a new motor structure, which can solve the technical problem that in the prior art, a single machine and a controller are assembled together, the motor speed and the overall external dimensions are determined at the initial design stage, that is, the outer diameter size of the cooling fan and the rotor rotation speed are basically determined. When running at a low speed, there is not enough wind pressure to allow the cooling air to flow through the controller and the surface of the single machine. In addition, the operating environment is harsh, and the temperature rise of the whole machine will be too high, resulting in a significant shortening of the service life of the whole machine.

[0011] A further object of the present invention is to provide a novel motor structure, wherein the controller can be quickly and conveniently disassembled from a single machine without affecting heat dissipation, and the single machine can be sold without further modification, which is flexible and convenient.

[0012] The purpose of this utility model is achieved through the following technical solutions.

[0013] A new motor structure includes a single unit, a motor controller and a bracket. The bracket is mounted on the top of the single unit and the motor controller is mounted on the bracket.

[0014] The single machine includes a motor housing, a stator assembly, a rotor assembly, a rotating shaft, a first fan and an air guide cover. The stator assembly and the rotor assembly are installed in the motor housing, and the rotor assembly is installed on the rotating shaft. The two ends of the rotating shaft extend from the two ends of the motor housing to form a front shaft extension end and a rear shaft extension end respectively. The first fan is installed on the rear shaft extension end. The air guide cover is installed outside the first fan. An air inlet hole is provided on one end surface of the air guide cover located behind the first fan.

[0015] The characteristics are as follows: the motor controller includes a control circuit board, a radiator, a high-speed cooling fan and a shell; the control circuit board, the radiator and the high-speed cooling fan are all installed in the cavity of the shell; the high-power chip on the control circuit board is attached to the top plate of the radiator; a plurality of spaced-apart cooling fins are arranged under the top plate of the radiator; the cooling fins are divided axially; a high-speed cooling fan is installed on one side of the radiator; the high-power capacitor extending from the control circuit board is located on the other side of the radiator; a plurality of air outlets are arranged on the front side of the shell.

[0016] The outer surface of the motor housing is provided with a plurality of first heat dissipation ribs arranged along the axial direction.

[0017] The housing comprises a top shell made of metal and a frame mounted under the top shell.

[0018] The aforementioned plurality of air outlet holes are arranged on the frame.

[0019] The frame is a plastic part with a rectangular cross section.

[0020] A plurality of second heat dissipation ribs are provided on the outer surface of the top shell.

[0021] The cross section of the above-mentioned bracket is shape, with reinforcing ribs set at the corners.

[0022] A notch is set above the top of the above-mentioned air guide cover, which is connected to the cavity inside the shell. Cold air enters from the air guide cover, and part of the cold air enters the cavity inside the shell, and is discharged after passing through the high-power capacitor, radiator, high-speed cooling fan and several air outlets. The other cold air passes through the outer surface of the motor casing to take away the heat of the single machine.

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

[0024] 1) The new motor structure of the utility model includes a stand-alone machine, a motor controller and a bracket. The stand-alone machine has a top-mounted bracket on which the motor controller is mounted. The stand-alone machine includes a motor housing, a stator assembly, a rotor assembly, a rotating shaft, a first fan and an air guide cover. The first fan is mounted on the rear axle extension end, and an air guide cover is mounted outside the first fan. An air inlet is provided on an end face of the air guide cover located behind the first fan. The motor controller includes a control circuit board, a radiator, a high-speed cooling fan and a shell. The control circuit board, the radiator and the high-speed cooling fan are all mounted in the cavity of the shell. The high-power chip on the control circuit board is attached to the top plate of the radiator. A number of spaced-apart cooling fins are provided below the top plate of the radiator. A high-speed cooling fan is installed on one side of the radiator. The high-power capacitor extending from the control circuit board is located on the other side of the radiator. A number of air outlets are provided on the front side of the shell. When the outer diameter of the first fan and the gear speed of the rotor are basically determined, the high-speed cooling fan is used to provide sufficient wind pressure when running at low speed, so that the cooling air flows through the inside of the controller and the surface of the single machine at the same time. Even in harsh operating environments, the temperature rise of the whole machine will not be too high, thereby extending the service life of the whole machine.

[0025] 2) Other advantages of the present invention are described in detail in the embodiment section. Description of the drawings:

[0026] Figure 1 is a perspective view from one angle provided by the present invention;

[0027] FIG2 is a perspective view from another angle provided by the present invention;

[0028] FIG3 is an exploded view of an angle provided by the present invention;

[0029] FIG4 is an exploded view from another angle provided by the present invention;

[0030] Figure 5 is a left side view of the present invention;

[0031] FIG6 is a cross-sectional view taken along line AA of FIG5 ;

[0032] FIG7 is a perspective view of a motor controller provided by the present invention from one angle;

[0033] FIG8 is a perspective view of the motor controller provided by the present invention from another angle;

[0034] FIG9 is a schematic diagram of the installation of the radiator and the high-speed cooling fan provided by the present invention;

[0035] FIG10 is a schematic diagram of the installation of a control circuit board, a radiator, and a high-speed cooling fan provided by the present invention.

[0036] FIG11 is a schematic diagram of the airflow direction when the utility model is working. Specific implementation method:

[0037] The present invention will be described in further detail below through specific embodiments and in conjunction with the accompanying drawings.

[0038] Example 1:

[0039] As shown in Figures 1 to 11, this embodiment provides a new motor structure, including a stand-alone unit 1, a motor controller 2, and a bracket 3. The bracket 3 is mounted on the top of the stand-alone unit 1, and the motor controller 2 is mounted on the bracket 3, wherein:

[0040] The single machine 1 includes a motor housing 11, a stator assembly 12, a rotor assembly 13, a rotating shaft 14, a first fan 15 and an air guide hood 16. The stator assembly 12 and the rotor assembly 13 are mounted inside the motor housing 11. The rotor assembly 13 is mounted on the rotating shaft 14. The two ends of the rotating shaft 14 extend from the two ends of the motor housing 11 to form a front shaft extension end 141 and a rear shaft extension end 142 respectively. The first fan 15 is mounted on the rear shaft extension end 142. The air guide hood 16 is mounted outside the first fan 15. An air inlet hole 162 is provided on an end surface 161 of the air guide hood 16 located behind the first fan 15.

[0041] The motor controller 2 is characterized in that it includes a control circuit board 21, a heat sink 22, a high-speed cooling fan 23, and a housing 24. The control circuit board 21, heat sink 22, and high-speed cooling fan 23 are all mounted in a cavity 240 of the housing 24. A high-power chip 211 on the control circuit board 21 is attached to the top plate 221 of the heat sink 22. A plurality of spaced-apart cooling fins 222 are disposed below the top plate 221 of the heat sink 22. The cooling fins 222 are arranged axially. The high-speed cooling fan 23 is mounted on one side of the heat sink 22, and a high-power capacitor 212 extending from the control circuit board 21 is located on the other side of the heat sink 22. A plurality of air outlets 241 are disposed on the front side 242 of the housing 24. When the outer diameter of the first fan 15 and the gear speed of the rotor are basically determined, the high-speed cooling fan 23 provides sufficient air pressure during low-speed operation, allowing cooling air to flow simultaneously through the interior of the controller 2 and the surface of the unit 1. Even in harsh operating environments, the temperature rise of the entire unit will not be excessive, thereby extending the service life of the entire unit. In addition, the motor controller 2 and the bracket 3 can be easily disassembled from the stand-alone machine 1 without affecting the heat dissipation of the motor 1. The stand-alone machine can be sold without further modification, which is flexible and convenient.

[0042] The outer surface of the motor housing 11 is provided with a plurality of first heat dissipation ribs 110 arranged along the axial direction, which can accelerate heat dissipation.

[0043] The housing 24 comprises a top shell 24a made of metal and a frame 24b mounted below the top shell 24a. The plurality of air outlets 241 are arranged on the frame 24b, which is reasonably arranged and convenient to manufacture.

[0044] The frame 24b is a plastic part with a rectangular cross section.

[0045] The outer surface of the top shell 24a is provided with a plurality of second heat dissipation ribs 243 to accelerate heat dissipation.

[0046] The cross section of the above-mentioned bracket 3 is The shape of the structure is such that reinforcing ribs 31 are provided at the corners to increase the structural strength.

[0047] A notch 163 is provided above the top of the aforementioned air guide hood 16, and the notch 163 is connected to the cavity 240 inside the shell 24. Cold air enters from the air guide hood 16, and a portion of the cold air enters the cavity 240 inside the shell 24, and is discharged after passing through the high-power capacitor 212, the radiator 22, the high-speed cooling fan 23 and a number of air outlets 241. The other portion of the cold air passes through the outer surface of the motor housing 11 and takes away the heat of the unit 1. A dual-fan layout of a first fan 15 and a high-speed cooling fan 23 is adopted. The first fan 15 is responsible for sucking air, and the high-speed cooling fan 23 is responsible for blowing air. The cooperation between the two can accelerate air flow and heat dissipation. When running at a low speed, the high-speed cooling fan 23 is used to provide sufficient wind pressure, so that the cooling air flows through the interior of the controller 2 and the surface of the unit 1 at the same time. Even under harsh operating conditions, the temperature rise of the entire unit will not be too high, thereby extending the service life of the entire unit. The arrows in Figure 11 indicate the direction of the air flow.

[0048] The above embodiments are preferred implementations of the present invention, but the implementations of the present invention are not limited thereto. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention are equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. A novel motor structure, comprising a single machine (1), a motor controller (2) and a bracket (3), wherein the bracket (3) is mounted on the top of the single machine (1), and the motor controller (2) is mounted on the bracket (3), wherein: The single machine (1) comprises a motor housing (11), a stator assembly (12), a rotor assembly (13), a rotating shaft (14), a first fan (15) and an air guide cover (16); the stator assembly (12) and the rotor assembly (13) are mounted inside the motor housing (11); the rotor assembly (13) is mounted on the rotating shaft (14); two ends of the rotating shaft (14) extend from two ends of the motor housing (11) to form a front shaft extension end (141) and a rear shaft extension end (142) respectively; the first fan (15) is mounted on the rear shaft extension end (142); the air guide cover (16) is mounted outside the first fan (15); an air inlet hole (162) is arranged on an end surface (161) of the air guide cover (16) located behind the first fan (15); The invention is characterized in that: the motor controller (2) comprises a control circuit board (21), a radiator (22), a high-speed cooling fan (23) and a shell (24); the control circuit board (21), the radiator (22) and the high-speed cooling fan (23) are all installed in a cavity (240) of the shell (24); a high-power chip (211) on the control circuit board (21) is attached to a top plate (221) of the radiator (22); a plurality of heat dissipation fins (222) arranged at intervals are arranged below the top plate (221) of the radiator (22); the heat dissipation fins (222) are divided along the axial direction; a high-speed cooling fan (23) is installed on one side of the radiator (22); a high-power capacitor (212) extending from the control circuit board (21) is located on the other side of the radiator (22); and a plurality of air outlets (241) are arranged on the front side (242) of the shell (24).

2. A novel motor structure according to claim 1, characterized in that: The outer surface of the motor housing (11) is provided with a plurality of first heat dissipation ribs (110) arranged along the axial direction.

3. A novel motor structure according to claim 1 or 2, characterized in that: The housing (24) comprises a top shell (24a) made of metal material and a frame (24b) installed under the top shell (24a).

4. A novel motor structure according to claim 3, characterized in that: A plurality of air outlet holes (241) are arranged on the frame (24b).

5. A novel motor structure according to claim 4, characterized in that: The frame (24b) is a plastic part, and its cross section is a rectangular structure.

6. A novel motor structure according to claim 5, characterized in that: A plurality of second heat dissipation ribs (243) are arranged on the outer surface of the top shell (24a).

7. A novel motor structure according to claim 3, characterized in that: The cross section of the bracket (3) is shape, with reinforcing ribs (31) arranged at the corners.

8. A novel motor structure according to claim 3, characterized in that: A notch (163) is provided above the top of the air guide cover (16), and the notch (163) is communicated with the cavity (240) inside the shell (24). Cold air enters from the air guide cover (16), a part of the cold air enters the cavity (240) inside the shell (24), passes through the high-power capacitor (212), the radiator (22), the high-speed cooling fan (23) and a plurality of air outlets (241), and is then discharged. Another part of the cold air passes through the outer surface of the motor housing (11) to take away the heat of the single machine (1).

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