A motor controller and BLDC motor using the same

Abstract

The present invention discloses a motor controller and a motor used therein. The motor controller includes a control box and a control board installed in the control box. The control box is provided with at least two cavities, one of which is a circuit board installation cavity whose size matches that of the control board, and the control board is installed in the circuit board installation cavity. The motor controller has a simple structure, and motors of different powers and volumes can be standardized and generalized by using a control board and an installation cavity of uniform size, which can improve design and production efficiency, reduce costs and simplify management.

Description

Technical field:

[0001] The invention relates to a motor controller and a BLDC motor using the same. Background technology:

[0002] The existing motor includes a motor body and a motor controller installed at the bottom of the motor body. The motor controller includes a control box and a control board installed inside the control box. The control board is installed with a power module and a rectifier bridge module with high heat. Since the diameter of the motor is related to the motor power, the size of motors with different powers is also different, so the control board in the motor controller also needs to change its size according to the size of the motor, which causes a waste of resources.

[0003] At present, the applicant has developed a DC brushless motor with a diameter of 140, see the invention patent number: CN201420052124.X Application date: 2014.01.26 Publication (announcement) number: CN203708009U, titled: A DC permanent magnet synchronous motor with an external control card and an HVAC control system using the same, the motor structure is as follows Figure 1 , Figure 2 and Figure 3 As shown, the existing BLDC motor includes a motor body and a motor controller, the motor body includes a rotating shaft 1A, a permanent magnet rotor assembly 2A, a stator assembly 3A and a casing assembly, the permanent magnet rotor assembly 2A and the stator assembly 3A form a magnetic coupling and are installed on the casing assembly, the stator assembly 3 includes a stator core and a coil winding wound on the stator core, the casing assembly includes a cylindrical shell 4A, a front end cover 5A, and a rear end cover 6A, the permanent magnet rotor assembly 2A is installed on the rotating shaft 1A, the stator assembly 3A is connected with the cylindrical shell 4A and nested outside the permanent magnet rotor assembly 2A, the front end cover 5A and the rear end cover 6A are respectively installed at both ends of the cylindrical shell 4A, the rotating shaft 1A is supported on the bearings of the front end cover 5A and the rear end cover 6A, the above-mentioned motor controller is installed outside the casing assembly, a circuit board 9A is arranged inside the motor controller, the circuit board 9A is installed in a control box 7A, and the control box 7A is connected and installed with the rear end cover 6A. The control box of the motor has only one cavity for installing the circuit board. The heat dissipation structure of the control box is imperfect and the heat dissipation effect is poor. When the power of the motor body is increased, the heat dissipation structure of the original control box can no longer meet the requirements. It is necessary to independently design a new machine controller mechanism to improve the heat dissipation capacity and meet product requirements. Summary of the invention:

[0004] The purpose of the present invention is to provide a motor controller and a BLDC motor using the same, which can solve the technical problems of unreasonable structural layout and insufficient heat dissipation capacity of the existing motor controller and cannot meet the heat dissipation requirements of high-power motors.

[0005] The purpose of the present invention is achieved through the following technical solutions.

[0006] The first object of the present invention is to provide a motor controller, comprising a control box and a control board installed inside the control box, wherein the control box is provided with at least two cavities inside, one of which is set as a circuit board mounting cavity with a size matching that of the control board, and the control board is installed in the circuit board mounting cavity.

[0007] A rectifier bridge mounting cavity is provided on one side or the outer side of the circuit board mounting cavity, wherein the first bottom surface of the rectifier bridge mounting cavity is higher than the second bottom surface of the circuit board mounting cavity by a certain distance.

[0008] The control board is provided with a rectifier bridge, which radially protrudes out of the control board. The rectifier bridge is tightly placed on the first bottom surface of the rectifier bridge installation cavity and is locked by a first locking device.

[0009] An IGBT driver board is installed below the above-mentioned control board, and a number of power modules are installed on the IGBT driver board. The power modules radially protrude outside the IGBT driver board. A number of heat dissipation bosses protrude upward from the edge of the second bottom surface of the circuit board mounting cavity. A number of power modules are tightly attached to the number of heat dissipation bosses and locked by a second locking device.

[0010] The bottom of the control box is provided with a second heat dissipation boss at the periphery of the circuit board installation cavity, and a plurality of ventilation holes are arranged inside the second heat dissipation boss.

[0011] The ventilation holes mentioned above are located beside the rectifier bridge mounting cavity and the heat dissipation boss.

[0012] The outer surface of the bottom of the control box is provided with a plurality of heat dissipation ribs, and the ventilation hole outlet is arranged between two adjacent heat dissipation ribs.

[0013] The plurality of heat dissipation ribs of the control box described above are divided into longitudinal heat dissipation ribs and transverse heat dissipation ribs.

[0014] The first locking device includes a first pressure rod and two first screws, the two first screws are respectively installed at both ends of the first pressure rod, the first pressure rod presses the rectifier bridge, and the two first screws are fixed on both sides of the rectifier bridge installation cavity.

[0015] The second locking device includes a second pressing rod and a second screw. The second pressing rod presses the two power modules and locks them on the heat dissipation boss through the second screw. The periphery of the circuit board installation cavity is a cylinder.

[0016] The second object of the present invention is to provide a BLDC motor, comprising a motor body and a motor controller installed at the bottom of the motor body, the motor body comprising a stator assembly, a rotor assembly and a motor housing, characterized in that: the motor controller is the motor controller described above.

[0017] Compared with the prior art, the present invention has the following effects:

[0018] 1) The motor controller includes a control box and a control board installed in the control box, wherein the control box is provided with at least two cavities, one of which is set as a circuit board installation cavity with a size matching that of the control board, and the control board is installed in the circuit board installation cavity; the control box has a simple structure, and motors of different powers and volumes can be standardized and generalized by using a control board and installation cavity of uniform size, which can improve design and production efficiency, while reducing costs and simplifying management.

[0019] 2) Other advantages of the present invention are described in detail in the embodiment section. Description of the drawings:

[0020] Figure 1 It is a three-dimensional diagram of an existing BLDC motor;

[0021] Figure 2 It is a structural cross-sectional view of an existing BLDC motor;

[0022] Figure 3 is a stereogram of a motor controller of an existing BLDC motor;

[0023] Figure 4 is a bottom view of the motor controller provided by the first embodiment of the present invention;

[0024] Figure 5 This is a top view of the motor controller;

[0025] Figure 6 yes Figure 5 A-A section view;

[0026] Figure 7 This is an exploded view of the motor controller from an angle;

[0027] Figure 8 This is a top view of the control box in the motor controller;

[0028] Fig. 9 This is an angled stereogram of the control box in the motor controller;

[0029] Fig.10 This is another angled stereogram of the control box in the motor controller;

[0030] Fig.11It is an exploded view from another angle of the motor controller of the first embodiment of the present invention;

[0031] Fig.12 A circuit diagram of a motor controller according to an embodiment of the present invention.

[0032] Fig.13 is a structural schematic diagram of a BLDC motor provided by Embodiment 2 of the present invention;

[0033] Fig.14 It is an exploded diagram of the BLDC motor provided in the second embodiment of the present invention. Specific implementation method:

[0034] The present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0035] Embodiment 1:

[0036] like Figures 4 to 12 As shown, the present embodiment provides a motor controller, including a control box and a control board installed in the control box, wherein at least two cavities are provided inside the control box, one of which is set as a circuit board installation cavity 11 whose size matches that of the control board 2, and the control board 2 is installed in the circuit board installation cavity 11. The control box 1 has a simple structure, and motors of different powers and volumes can be standardized and generalized by using a control board 2 and an installation cavity 11 of uniform size, which can improve design and production efficiency, while reducing costs and simplifying management.

[0037] A rectifier bridge installation cavity 12 is provided on one side or outside of the circuit board installation cavity 11, wherein the first bottom surface 120 of the rectifier bridge installation cavity 12 is higher than the second bottom surface 110 of the circuit board installation cavity 11 by a certain distance. The structural layout is reasonable.

[0038] The control board 2 is provided with a rectifier bridge 21, which radially protrudes outside the control board 2 and is closely placed on the first bottom surface 120 of the rectifier bridge installation cavity 12 and locked by the first locking device 13. The rectifier bridge 21 is easy to install and has a good heat dissipation effect.

[0039] The bottom of the control box 1 is provided with a second heat dissipation boss 16 outside the circuit board mounting cavity 11, and the second heat dissipation boss has a plurality of ventilation holes 161. The second heat dissipation boss 16 and the ventilation holes 16 enhance ventilation and heat dissipation inside the control box 1.

[0040] An IGBT driver board 3 is installed below the control board 2, and a plurality of power modules 31 are installed on the IGBT driver board 3. The power modules 31 radially protrude outside the IGBT driver board 3. A plurality of heat dissipation bosses 14 protrude upward from the edge of the second bottom surface 110 of the circuit board installation cavity 11. The plurality of power modules 31 are tightly attached to the plurality of heat dissipation bosses 14 and locked by the second locking device 15. The power modules 31 are easy to install and have good heat dissipation effect.

[0041] The ventilation holes 161 are located beside the rectifier bridge installation cavity 12 and the heat dissipation boss 14, which further enhances the heat dissipation effect.

[0042] The bottom outer surface of the control box 1 is provided with a plurality of heat dissipation ribs 17 , and the outlet of the ventilation hole 161 is arranged between two adjacent heat dissipation ribs 17 .

[0043] The plurality of heat dissipation ribs 17 of the control box 1 are divided into longitudinal heat dissipation ribs 171 and transverse heat dissipation ribs 172. The heat dissipation ribs 17 cover the heat source area.

[0044] The first locking device 13 comprises a first pressure rod 131 and two first screws 132. The two first screws 132 are respectively installed at both ends of the first pressure rod 131. The first pressure rod 131 presses the rectifier bridge 21, and the two first screws 132 are fixed on both sides of the rectifier bridge installation cavity 12. The first locking device 13 has a simple structure and is easy to install. The outer periphery of the circuit board installation cavity 11 is a cylindrical body 19. A plurality of support columns 18 are arranged at the edge of the circuit board installation cavity 11, and screw holes are arranged on the support columns 18. The control board 2 is supported on the support columns 18, and the control board 2 is locked by screwing screws into the screw holes.

[0045] The second locking device 15 comprises a second pressing rod 151 and a second screw 152. The second pressing rod 151 presses the two power modules 31 and is locked on the heat dissipation boss 14 through the second screw 152. The periphery of the circuit board mounting cavity 11 is a cylinder 19. The second locking device 15 has a simple structure and is easy to install.

[0046] Fig.12 The motor controller of the present invention is arranged with a microprocessor, a rotor position detection circuit, an analog signal detection circuit, an inverter circuit, a sorting bridge and a capacitor C1, wherein the microprocessor, the analog signal detection circuit, the sorting bridge and the capacitor C1 are integrated in a control board 2, the power module 31 of the inverter circuit is integrated in an IGBT drive board 3, the power module 31 is an IGBT, and the rotor position detection circuit is separately integrated in a Hall circuit board.

[0047] Embodiment 2:

[0048] like Fig.13 , Fig.14As shown, this embodiment provides a BLDC motor, including a motor body 91 and a motor controller 92 installed at the bottom of the motor body 91, the motor body 91 includes a stator assembly, a rotor assembly and a motor housing, and is characterized in that: the motor controller 92 is the motor controller described in Example 1.

[0049] By improving the structure of the motor controller 92, the heat dissipation effect of the motor controller 92 is enhanced and the production cost is saved.

[0050] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited thereto. Any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principle of the present invention are all equivalent replacement methods and are included in the protection scope of the present invention.

Claims

1. A motor controller, comprising a control box (1) and a control board (2) installed in the control box (1), characterized in that: The control box is provided with at least two cavities inside, one of which is set as a circuit board installation cavity (11) with a size matching that of the control board (2), and the control board (2) is installed in the circuit board installation cavity (11); A rectifier bridge mounting cavity (12) is provided on one side or the outside of the circuit board mounting cavity (11), wherein a first bottom surface (120) of the rectifier bridge mounting cavity (12) is higher than a second bottom surface (110) of the circuit board mounting cavity (11) by a certain distance; The control board (2) is provided with a rectifier bridge (21), the rectifier bridge (21) radially protrudes outside the control board (2), the rectifier bridge (21) is closely placed on the first bottom surface (120) of the rectifier bridge installation cavity (12) and is locked by a first locking device (13); The bottom of the control box (1) is provided with a second heat dissipation boss (16) outside the circuit board mounting cavity (11), and the second heat dissipation boss has a plurality of ventilation holes (161) inside. ； An IGBT drive board (3) is mounted below the control board (2), a plurality of power modules (31) are mounted on the IGBT drive board (3), the power modules (31) radially protrude outside the IGBT drive board (3), a plurality of heat dissipation bosses (14) protrude upward from the edge of the second bottom surface (110) of the circuit board mounting cavity (11), and the plurality of power modules (31) are tightly attached to the plurality of heat dissipation bosses (14) and are locked by a second locking device (15).

2. A motor controller according to claim 1, characterized in that: The ventilation hole (161) is located beside the rectifier bridge installation cavity (12) and the heat dissipation boss (14).

3. A motor controller according to claim 2, characterized in that: The outer surface of the bottom of the control box (1) is provided with a plurality of heat dissipation ribs (17), and the outlet of the ventilation hole (161) is arranged between two adjacent heat dissipation ribs (17).

4. A motor controller according to claim 3, characterized in that: The plurality of heat dissipation ribs (17) of the control box (1) are divided into longitudinal heat dissipation ribs (171) and transverse heat dissipation ribs (172).

5. A motor controller according to claim 1, characterized in that: The first locking device (13) comprises a first pressure rod (131) and two first screws (132), wherein the two first screws (132) are respectively mounted at two ends of the first pressure rod (131), the first pressure rod (131) presses the rectifier bridge (21), and the two first screws (132) are fixed on two sides of the rectifier bridge mounting cavity (12).

6. A motor controller according to claim 5, characterized in that: The second locking device (15) comprises a second pressing rod (151) and a second screw (152); the second pressing rod (151) presses the two power modules (31) and locks them on the heat dissipation boss (14) through the second screw (152); and the periphery of the circuit board mounting cavity (11) is a cylinder (19).

7. A BLDC motor, comprising a motor body (91) and a motor controller (92) mounted at the bottom of the motor body (91), wherein the motor body (91) comprises a stator assembly, a rotor assembly and a motor housing, and characterized in that: The motor controller (92) is the motor controller as claimed in any one of claims 1 to 6.

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