Fan rotor integrated brushless DC motor

Abstract

The present invention provides a brushless DC motor with integrated blade rotor, which belongs to the field of brushless DC motors, and includes a rotor and a stator that are coaxially arranged and relatively rotated; the stator includes a stator coil and an annular frame, the number of the annular frames is two, the two annular frames are symmetrically arranged and locked as fan housings to position the rotor in the middle, the number of stator coils is multiple and evenly embedded on one side of the annular frame close to the rotor; a permanent magnet corresponding to the coil is arranged in the rotor. The present invention combines the blade with the motor rotor, arranges the functional part of the motor rotor on the outer ring of the rotor, and arranges the blade on the inner ring of the motor, and achieves greater efficiency through the design of blades with variable inclination angle and variable attack angle, which is suitable for heat dissipation and forced air supply in a variety of electronic or mechanical equipment.

Description

Technical Field

[0001] The invention belongs to the field of brushless DC motors, and relates to brushless motors, coreless motors, annular structure motors, and motors with integrated blade rotors, and in particular to a brushless DC motor with integrated blade rotors. Background Art

[0002] The study of the structure and evolution of the earth's interior has always been an academic problem. The research in this field will greatly affect all aspects of people's work and life, such as mineral exploration, earthquake prediction and engineering construction. The scientific research community has been conducting artificial exploration and theoretical research on geological structures. The research results need to be verified experimentally, but the change of geological structure is a very slow process. Therefore, it is necessary to simulate the structural deformation process of large time and space scales through experimental instruments. Due to the large time and space span of geological structural deformation, the corresponding simulation time is also very long. The centrifuge has the function of "time and space compression". The "supergravity field" generated by its high-speed rotation can shorten the time of physical simulation of geological structural deformation, and plays an irreplaceable role in solving problems such as large time and space scale geological structural deformation. But on the other hand, the components tested on the centrifuge are under the action of the supergravity field (up to 300g), and the shape and performance of the components will change significantly. Therefore, special components that can be applied to the supergravity field and guarantee their working performance are required to be used for centrifuge experiments.

[0003] The mechanism of the motor has not changed significantly over the years. With the development of rare earth permanent magnet and brushless DC motors, new forms of motor mechanisms have become possible. The structure of fans (or used in other fluids such as water) is mainly the way of installing fan blades on the motor output shaft. Combined with new manufacturing technologies such as 3D printing, new forms of fans can be manufactured. Summary of the invention

[0004] The problem to be solved by the present invention is to provide a brushless DC motor with integrated blade rotor, in which the fan blades and the motor rotor are combined into one, the functional part of the motor rotor is arranged on the outer ring of the rotor, and the fan blades are arranged on the inner ring of the motor. By designing the fan blades with variable inclination angle and variable attack angle, greater efficiency is achieved, and the motor is suitable for heat dissipation and forced air supply and other functions in a variety of electronic or mechanical equipment.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: a fan blade rotor integrated brushless DC motor, comprising a rotor and a stator which are coaxially arranged and relatively rotated;

[0006] The stator comprises a stator coil and an annular frame, the number of the annular frames is two, the two annular frames are symmetrically arranged and locked to serve as a fan housing to position the rotor in the middle, the number of the stator coils is multiple and evenly embedded on one side of the annular frame close to the rotor;

[0007] The rotor is provided with a permanent magnet corresponding to the coil.

[0008] Furthermore, a plurality of concave positioning grooves are evenly distributed on one side of the annular frame close to the rotor, the coil is a concentric flat winding structure and is embedded in the positioning groove, and a sealing glue for sealing is provided at the upper end of the positioning groove, and the sealing glue connects the coil and the annular frame as a whole.

[0009] Furthermore, the annular frame includes a positioning ring, a rotating column and reinforcing ribs, the positioning ring and the rotating column are coaxially arranged, the rotating column is arranged on the inner ring of the positioning ring and the two are fixed by multiple reinforcing ribs, the positioning groove is arranged on the side of the positioning ring close to the rotor, the cross-section of the positioning groove is an oblong hole structure, and the multiple positioning grooves are evenly distributed relative to the axis of the annular frame.

[0010] Furthermore, the outer ring of the positioning ring is provided with a plurality of fixing ears, and the fixing ears are provided with penetrating connecting holes, and the two positioning rings are fixedly locked by bolts arranged in the connecting holes and nuts cooperating with the bolts.

[0011] Furthermore, the rotor includes a center column, a rotor frame and a rotor outer ring which are coaxial and arranged in sequence from the inside to the outside, and a plurality of blades are evenly distributed between the center column and the rotor frame, one end of the blade is fixed to the center column, and the other end is fixed to the rotor frame, and the rotor outer ring is provided with a plurality of positioning holes for embedding permanent magnets.

[0012] Furthermore, the outer ring diameter of the rotor frame is smaller than the inner ring diameter of the positioning ring and the gap between the two is 0.3-0.6 mm.

[0013] Furthermore, the angle of attack of the fan blade near the center column is greater than the angle of attack near the rotor frame, the fluid density is set in direct proportion to the angle of attack, the fan blade near the center column is a forward-swept wing structure, and the fan blade away from the center column is a backward-swept wing structure.

[0014] Furthermore, the angle of attack is 80 to 90 degrees near the center column, the forward sweep angle is 0 to 10 degrees, the angle of attack is 2 to 8 degrees at the position where the sweep angle changes to the backward sweep angle, and the angle of attack near the rotor frame is 15 to 35 degrees.

[0015] Furthermore, the fan blade is a 3D printed integrated structure, the center column and the positioning ring are rotatably connected via a bearing assembly, the bearing assembly includes a bearing seat embedded in the center column, bearings are symmetrically provided at both ends of the bearing seat in a circumferential direction, and a support shaft is provided in the bearing seat.

[0016] Furthermore, the permanent magnet is a rare earth permanent magnet.

[0017] Compared with the prior art, the present invention has the following advantages and positive effects.

[0018] 1. The present invention is different from the flow mode of the traditional fan in which the fan pushes the fluid to the outer ring when the fluid flows through the fan. The fan gathers the fluid at the center of the fan, has higher concentration, and can achieve a higher flow rate. The motor rotor structure is located at the outer ring of the fan blade, which improves the torque efficiency of the motor. Under the same volume and the same power, a greater torque can be achieved, thereby obtaining a greater fluid speed. The double-layer, flat-arranged stator winding reduces the leakage magnetic loss, has a greater efficiency, and achieves a greater torque and speed in a smaller volume;

[0019] 2. The fan blades are integrated with the motor rotor, the functional part of the motor rotor is arranged on the outer ring of the rotor, and the fan blades are arranged on the inner ring of the motor. The fan blades with variable inclination angle and variable attack angle are designed to achieve greater efficiency;

[0020] 3. The design of the fan position and structure has greater advantages for specific occasions and is more widely used. Under the condition of equal efficiency and output torque, compared with traditional motors and traditional fan structures, this fan has a very large diameter-thickness ratio, which can easily reach 10:1 or even larger, and has irreplaceable advantages in occasions requiring large diameter and low thickness;

[0021] 4. In the pipeline, the part of the present application is placed on the outer wall of the pipeline, and the fan blade diameter is the same as the inner diameter of the pipeline, which can maximize the fan size and improve the fan efficiency;

[0022] 5. The fan blades are combined with the motor rotor as one, the functional part of the motor rotor is arranged on the outer ring of the rotor, and the fan blades are arranged on the inner ring of the motor. The fan blade design with variable inclination angle and variable attack angle can achieve greater efficiency, which is suitable for heat dissipation and forced air supply in a variety of electronic or mechanical equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0024] Figure 1 It is a structural schematic diagram of the fan blade rotor integrated brushless DC motor of the present invention;

[0025] Figure 2 is a cross-sectional view of the fan blade rotor integrated brushless DC motor of the present invention;

[0026] Figure 3 It is a structural schematic diagram of the stator of the present invention;

[0027] Figure 4 The present invention Figure 3Detailed drawing of Part A;

[0028] Figure 5 It is a schematic structural diagram of the rotor of the present invention.

[0029] Reference numerals:

[0030] 1. Stator; 11. Positioning ring; 12. Rotating column; 13. Reinforcing rib; 14. Positioning groove; 15. Fixing ear; 151. Connecting hole; 2. Rotor; 21. Fan blade; 22. Center column; 23. Rotor frame; 24. Rotor outer ring; 241. Positioning hole; 3. Bolt; 4. Nut; 5. Bearing seat; 6. Bearing; 7. Support shaft. DETAILED DESCRIPTION

[0031] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0032] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and the like are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", and the like may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0033] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0034] In the present application, a Cartesian coordinate system is used to define the directions of the X-axis and the Y-axis. For details, please refer to the drawings in the specification.

[0035] The specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0036] like Figure 1-Figure 5As shown, the present invention is a fan-rotor integrated brushless DC motor, comprising a rotor 2 and a stator 1 which are coaxially arranged and relatively rotated;

[0037] The stator 1 includes a stator coil and an annular frame. There are two annular frames. The two annular frames are symmetrically arranged and locked to serve as fan casings to position the rotor 2 in the middle. There are multiple stator coils and they are evenly embedded on one side of the annular frame close to the rotor 2. The rotor 2 is provided with permanent magnets corresponding to the coils. The stator 1 is arranged in two layers, upper and lower. In this structure, there are 12 stator coils, which are symmetrically arranged on both sides of the permanent magnet of the rotor 2. The permanent magnet is sandwiched between the upper and lower layers of stator coils. The number of stator coils can be adjusted according to the actual volume, function and control method. According to the relationship between the number of winding pairs and the number of magnetic poles of a brushless motor, it can be seen that for motors with different power and different speed requirements, the motor performance can be changed by changing the number of stator coil pairs and the number of permanent magnet pairs. For example: for a 12N14P motor (N is the number of stator coils, P is the number of magnets) of the same size and number of turns, compared with a 9N10P motor, under the same drive voltage, drive current and drive frequency, the 12N14P motor has a larger torque, but a lower speed. The number of permanent magnets can be adjusted according to the actual application and the number of stator coils. The principle is the same as above. The lead wires of the stator winding are led out from the outside of the stator 1 housing. The motor is a brushless motor driven by a brushless motor driver.

[0038] Preferably, a plurality of concave positioning grooves 14 are evenly distributed on one side of the annular frame close to the rotor 2. The coil is a concentric flat winding structure and is embedded in the positioning groove 14. The coil is arranged flatly, and the direction of the magnetic lines of force is perpendicular to the rotation plane of the motor. Under the same performance, the overall thickness and diameter ratio of the motor can be smaller. The motor is flatter in the height direction, occupies less space, has a more compact structure, and has a wider range of applications. At the same time, it is less subject to bending deformation and has smaller deformation under high speed and heavy load. This coreless structure is more compact as a whole, has no hysteresis, has strong speed regulation characteristics, has very high motor efficiency at high speed, and has a fast response characteristic. A sealing sealant is provided at the upper end of the positioning groove 14. The sealing sealant connects the coil and the annular frame as a whole to achieve the purpose of dustproof, waterproof and insulation.

[0039] Preferably, the annular frame includes a positioning ring 11, a rotating column 12 and a reinforcing rib 13. The positioning ring 11 and the rotating column 12 are coaxially arranged. The rotating column 12 is arranged on the inner ring of the positioning ring 11 and the two are fixed by multiple reinforcing ribs 13. The positioning groove 14 is arranged on the side of the positioning ring 11 close to the rotor 2. The cross-section of the positioning groove 14 is an oblong hole structure. Multiple positioning grooves 14 are evenly distributed relative to the axis of the annular frame.

[0040] Preferably, the outer ring of the positioning ring 11 is provided with a plurality of fixing ears 15 , and the fixing ears 15 are provided with penetrating connecting holes 151 . The two positioning rings 11 are fixedly locked by bolts 3 arranged in the connecting holes 151 and nuts 4 cooperating with the bolts 3 .

[0041] Preferably, the rotor 2 includes a center column 22, a rotor frame 23 and a rotor outer ring 24 which are coaxial and arranged in sequence from the inside to the outside. A plurality of blades 21 are evenly distributed between the center column 22 and the rotor frame 23. One end of the blade 21 is fixed to the center column 22, and the other end is fixed to the rotor frame 23. A plurality of positioning holes 241 for embedding permanent magnets are provided on the rotor outer ring 24. The functions of the motor rotor 2 and the fan function are integrated on the rotor 2 of the fan structure.

[0042] Preferably, the outer diameter of the rotor frame 23 is smaller than the inner diameter of the positioning ring 11 and the gap therebetween is 0.3-0.6 mm.

[0043] Preferably, the shape of the fan blade 21 is designed with a variable angle of attack and a variable sweep angle. The angle of attack and the sweep angle are different at different positions of the fan blade 21. The angle of attack of the fan blade 21 near the center column 22 is greater than the angle of attack near the rotor frame 23. The fluid density is directly proportional to the angle of attack. The fan blade 21 near the center column 22 is a forward-swept wing structure, and the fan blade 21 away from the center column 22 is a swept-back wing structure, which is similar to the design of the turbofan of a turbofan engine and is suitable for the power of an aircraft or a ship; the linear velocity of the fan blade 21 near the center column 22 is relatively small, and a larger angle of attack and forward sweep angle are adopted; the linear velocity of the fan blade 21 away from the center column 22 is relatively large, and a smaller angle of attack and backward sweep angle are adopted, so as to make full use of the air flow characteristics of the fan blade 21 at different positions to improve efficiency. The greater the fluid density, the greater the angle of attack. The forward-swept wing is suitable for low speeds, and the swept-back wing is suitable for high speeds.

[0044] Preferably, the angle of attack is 80 to 90 degrees near the center column 22, the forward sweep angle is 0 to 10 degrees, the angle of attack is 2 to 8 degrees at the position where the sweep angle changes to the backward sweep angle, and the angle of attack near the rotor frame 23 is 15 to 35 degrees.

[0045] Preferably, the fan blade 21 is a 3D printed integrated structure. 3D printing can complete the production of parts with relatively complex structures that are difficult to process. As long as the three-dimensional drawing of the part is completed and imported into the 3D printing equipment, the printing of the part can be realized. In the present application, the structure of the fan blade 21 is relatively complex and the processing cost is relatively high. In addition, the set structure of the fan blade 21 is different in different situations, and large-scale mass production is impossible. 3D printing can reduce the cost of mass production. The center column 22 is rotatably connected to the positioning ring 11 through the bearing 6 assembly. The bearing 6 assembly includes a bearing seat 5 embedded in the center column 22. Bearings 6 are symmetrically provided at both ends of the bearing seat 5 in the circumferential direction. A support shaft 7 is provided in the bearing seat 5. This structure is simple and the subsequent maintenance cost is low.

[0046] Preferably, the permanent magnet is a rare earth permanent magnet, and the permanent magnet adopts a fan-shaped structure. In this structure, the number of permanent magnets is set to 14. The rare earth permanent magnet is an alloy composed of samarium, neodymium mixed rare earth metals and transition metals (such as cobalt, iron, etc.), which is pressed and sintered by a powder metallurgy method and magnetized in a magnetic field. It is a permanent magnet material with the highest comprehensive performance and improves the performance of the product. Under the same structure, the use of rare earth permanent magnets can be more miniaturized and the structure is more compact.

[0047] In actual use, the stator 1 is set to two and each is embedded with a stator coil. The stator winding is composed of two layers of stator coils. The lead wires of the stator winding are led out from the outside of the stator 1 shell. The structure is a brushless motor, which is driven by a brushless motor driver. When the driver applies a driving current to the stator winding, a rotating magnetic field is generated in the stator winding. The permanent magnet embedded in the rotor 2 is subjected to a force perpendicular to the radius of the rotor 2 under the action of the rotating magnetic field, so the rotor 2 starts to rotate as a whole. While the rotor 2 rotates, the blades 21 of the inner ring of the rotor 2 rotate together, and drive the air (or other fluid) to flow through the fan blade 21 area in a direction perpendicular to the plane of the rotor 2. Since the central area of ​​the blade 21 has only a small windward area, the resistance when the air flows through is very small, and a concentrated airflow can be formed to flow through the fan area composed of the blades 21 at high speed.

[0048] Since the magnetic fields generated by the upper and lower groups of corresponding stator coils have the same direction and the permanent magnets embedded in the rotor 2 are located in the middle of the magnetic field, the magnetic leakage of this structure is very small, which can achieve higher efficiency.

[0049] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. The fan rotor integrated brushless DC motor is characterized by: It includes a rotor and a stator which are coaxially arranged and rotate relative to each other; The stator comprises a stator coil and an annular frame, the number of the annular frames is two, the two annular frames are symmetrically arranged and locked to serve as a fan housing to position the rotor in the middle, the number of the stator coils is multiple and evenly embedded on one side of the annular frame close to the rotor; A permanent magnet corresponding to the coil is arranged in the rotor; A plurality of inwardly concave positioning grooves are uniformly arranged on one side of the annular frame close to the rotor, the coil is a concentric flat winding structure and is embedded in the positioning grooves, and a sealing glue for sealing is provided at the upper end of the positioning groove, and the sealing glue connects the coil and the annular frame as a whole; The annular frame includes a positioning ring, a rotating column and reinforcing ribs, the positioning ring and the rotating column are coaxially arranged, the rotating column is arranged on the inner ring of the positioning ring and the two are fixed by a plurality of reinforcing ribs, the positioning groove is arranged on a side of the positioning ring close to the rotor, the cross section of the positioning groove is an oblong hole structure, and a plurality of the positioning grooves are evenly distributed relative to the axis of the annular frame; The outer ring of the positioning ring is provided with a plurality of fixing ears, and the fixing ears are provided with connecting holes penetrating therethrough, and the two positioning rings are fixedly locked by bolts arranged in the connecting holes and nuts matched with the bolts; The rotor includes a central column, a rotor frame and a rotor outer ring which are coaxial and arranged in sequence from the inside to the outside. A plurality of blades are evenly distributed between the central column and the rotor frame. One end of the blade is fixed to the central column, and the other end is fixed to the rotor frame. The rotor outer ring is provided with a plurality of positioning holes for embedding permanent magnets.

2. The blade-rotor integrated brushless DC motor according to claim 1, characterized in that: The outer ring diameter of the rotor frame is smaller than the inner ring diameter of the positioning ring, and the gap between the two is 0.3-0.6 mm.

3. The blade-rotor integrated brushless DC motor according to claim 1, characterized in that: The angle of attack of the fan blade near the center column is greater than the angle of attack near the rotor frame, and the fluid density is set in direct proportion to the angle of attack. The fan blade near the center column is a forward-swept wing structure, and the fan blade away from the center column is a backward-swept wing structure.

4. The blade-rotor integrated brushless DC motor according to claim 3, characterized in that: The angle of attack is 80 to 90 degrees near the center column, the forward sweep angle is 0 to 10 degrees, the angle of attack is 2 to 8 degrees at the position where the sweep angle changes to the backward sweep angle, and the angle of attack is 15 to 35 degrees near the rotor frame.

5. The blade-rotor integrated brushless DC motor according to any one of claims 1 to 4, characterized in that: The fan blade is an integrated 3D printed structure. The center column and the positioning ring are rotatably connected via a bearing assembly. The bearing assembly includes a bearing seat embedded in the center column. Bearings are symmetrically provided at both ends of the bearing seat in a circumferential direction, and a support shaft is provided in the bearing seat.

6. The blade-rotor integrated brushless DC motor according to any one of claims 1 to 4, characterized in that: The permanent magnet is a rare earth permanent magnet.

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