Integrated brushless motor

Abstract

The present invention discloses an integrated brushless motor, comprising a housing, a stator, a rotor, and an end cap. The end cap is fixed to the interior of the housing and forms a closed housing cavity with the rear end of the housing for mounting the stator and rotor. The rotor includes a rotating shaft with bearings extending through the rear end of the housing and the end cap at both ends. An ECU chamber for mounting an ECU control board is formed between the housing opening and the end cap. The housing cavity and the ECU chamber are located on either side of the end cap, respectively. The UVW three-phase copper busbar extends from the end cap into the ECU chamber. The rotor also includes a magnetic resistance position signal detection assembly fixed to the end of the rotating shaft. Integrating the ECU chamber into the motor creates a compact structure, requiring only one waterproof seal structure, simplifying the system's waterproof design. The motor housing and end cap also serve as ECU heat sinks, effectively reducing system volume and increasing system power density.

Description

Technical Field

[0001] The invention relates to an integrated brushless motor. Background Art

[0002] With the continuous improvement of permanent magnet material performance, brushless motors are becoming increasingly widely used in the automotive industry. The automotive industry has specific requirements for brushless motors: 1) limited installation space, lightweight motors with a certain output power, meaning high power density; 2) low cogging torque for improved comfort and stability; 3) low motor cost; and 4) low moment of inertia.

[0003] In traditional motor systems, the ECU and motor are separate components. Operating in water- and dust-prone environments requires separate waterproofing and sealing, resulting in complex structures and low reliability. Furthermore, the greatest challenges in brushless motor design are insufficient power density to meet system requirements and high cogging torque. The factors influencing brushless motor power density and cogging torque are numerous and complex. Improper selection of any electromagnetic parameter can reduce the motor's power density, increase cogging torque, and increase motor size. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an integrated brushless motor.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: an integrated brushless motor, including a casing, a stator, and a rotor, the stator including a stator core, a stator coil and a UVW three-phase copper busbar, the integrated brushless motor also including an end cover, the end cover being fixed to the inside of the casing and forming a closed casing inner cavity with the tail of the casing for installing the stator and the rotor, the rotor including a rotating shaft with two ends passing through the tail of the casing and the end cover by bearings, an ECU cavity for installing an ECU control board is also formed between the casing opening and the end cover, the casing inner cavity and the ECU cavity are respectively located on both sides of the end cover, the UVW three-phase copper busbar extends from the end cover into the ECU cavity, the rotor also includes a magnetoresistive position signal detection component fixed to the end of the rotating shaft, the magnetoresistive position signal detection component includes a detection magnet and a fixing bracket.

[0006] In certain embodiments, the end cover is provided with a plurality of openings for the UVW three-phase copper busbar to pass through.

[0007] In some embodiments, the rotor also includes a rotor core fixed on the rotating shaft, which has multiple sections distributed axially and staggered between adjacent sections. The rotating shaft and the rotor core mounting portion are connected by optical axis interference fit, and the inner circular surface of the rotor core is spline-shaped.

[0008] In some embodiments, the rotor core has two or three sections, which are equidistantly distributed along the axial direction, and the staggered angles between every two adjacent sections of the rotor core are the same.

[0009] In some embodiments, a plurality of rotor poles are evenly distributed on the outer peripheral surface of the rotor core. The rotor poles are tile-shaped magnetic steels with an eccentricity of 8.5-11.5 mm.

[0010] In some embodiments, the stator core is formed by splicing a plurality of stator teeth in a ring shape, and the stator coil is wound on the corresponding stator teeth using electromagnetic wire and is led out on one side to be connected to the UVW three-phase copper busbar.

[0011] In certain embodiments, the magnetoresistive position signal detection component is interference-coupled with the rotating shaft and extends out of the end cover into the ECU chamber.

[0012] In certain embodiments, the detection magnet is a high-performance circular magnet with NS bipolar magnetization, and the center of the detection magnet is concentric with the rotor.

[0013] In some embodiments, the fixing bracket is made of non-magnetic material.

[0014] In some embodiments, the housing opening has an interface portion that can be connected to a closed rear cover to form a closed waterproof chamber.

[0015] The scope of the present invention is not limited to technical solutions formed by a specific combination of the above-mentioned technical features, but also includes other technical solutions formed by any combination of the above-mentioned technical features or their equivalents. For example, technical solutions formed by replacing the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.

[0016] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art: the present invention provides an integrated brushless motor that integrates the ECU chamber into the motor, has a compact structure, and only requires one set of waterproof sealing structure, which simplifies the system waterproof design. At the same time, the motor housing and end cover also serve as the ECU radiator, which can effectively reduce the system volume and improve the system power density. It is particularly suitable for power steering systems and electric braking systems for modern traditional automobiles, new energy vehicles and intelligent unmanned vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0018] Figure 1 A cross-sectional view of a motor according to embodiment 1 of the present invention;

[0019] Figure 2 This is an expanded view of the stator coil of the motor according to embodiment 1 of the present invention;

[0020] Figure 3 1 is a schematic diagram of the three-dimensional structure of the motor rotor according to embodiment 1 of the present invention;

[0021] Figure 4 1 is a schematic diagram of the three-dimensional structure of the motor rotor core according to embodiment 1 of the present invention;

[0022] Among them: 1. Casing; 2. End cover; 3. Stator; 31. Stator core; 311. Stator teeth; 32. Stator coil; 33. UVW three-phase copper busbar; 4. Rotor; 41. Bearing; 42. Rotating shaft; 43. Rotor core; 44. Rotor pole; 45. Reluctance position signal detection component; 451. Detection magnet; 452. Fixing bracket; 5. ECU chamber. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0024] The present invention discloses an integrated brushless motor, comprising a housing 1, a stator 3, and a rotor 4. The stator 3 comprises a stator core 31, a stator coil 32, and a UVW three-phase copper busbar 33. The integrated brushless motor also comprises an end cover 2, which is fixed to the interior of the housing 1 and forms a closed housing inner cavity with the rear end of the housing 1 for accommodating the stator 3 and the rotor 4. An ECU chamber 5 for accommodating an ECU control board is also formed between the opening of the housing 1 and the end cover 2. The housing inner cavity and the ECU chamber 5 are respectively located on either side of the end cover 2. The UVW three-phase copper busbar 33 extends from the end cover 2 into the ECU chamber 5. The rotor 4 comprises a rotating shaft 42, with bearings 41 extending through the rear end of the housing 1 and the end cover 2 at both ends. The rotor 4 also comprises a magnetoresistive position signal detection assembly 45 fixed to the end of the rotating shaft 42. The magnetoresistive position signal detection assembly 45 comprises a detection magnet 451 and a fixing bracket 452. The opening of the housing 1 has an interface portion that can be connected to the closed rear cover to form a closed waterproof chamber. The motor body generally only provides installation space, and the ECU control board and the closed rear cover are assembled by the steering system manufacturer or the brake system manufacturer.

[0025] The end cover 2 is provided with a plurality of openings for the UVW three-phase copper busbar 33 to pass through. The UVW three-phase copper busbar 33 extends out of the end cover 2 into the ECU chamber 5 .

[0026] The rotor 4 includes a shaft 42, which is passed through the housing 1 and the end cover 2 via bearings 41 at both ends. It also includes a rotor core fixed to the shaft 42 and having two or three axially equidistant segments, with adjacent segments staggered. The stagger angles between adjacent segments are the same. The shaft 42 and the rotor core 43 are mounted using a smooth interference fit. The inner surface of the rotor core 43 is splined. The smooth interference fit between the shaft and the rotor core 43 simplifies the processing and reduces processing costs compared to a knurled interference fit structure. It also makes it easier to ensure the accuracy of the stagger angle during rotor core assembly. The outer surface of the rotor core 43 is evenly distributed with a number of rotor poles 44, each of which is a tile-shaped magnet with an eccentricity of 8.5-11.5 mm.

[0027] The rotor 4 also includes a magnetoresistive position signal detection component 45 fixed to the end of the rotating shaft 42. The magnetoresistive position signal detection component 45 includes a detection magnet 451 and a fixed bracket 452. The magnetoresistive position signal detection component 45 is interference-connected with the rotating shaft 42 and extends from the end of the end cover 2 into the ECU chamber 5. The detection magnet 451 is a high-performance circular magnet with NS two-pole magnetization, and the center of the detection magnet 451 is concentric with the rotor 4. The fixed bracket 452 is made of non-magnetic material.

[0028] Example 1:

[0029] This integrated brushless motor has three phases, a rated voltage of 24V, a rated current of 85A, a rated speed of 1000rpm, and a rated torque of 8.3Nm. The stator and rotor have a 12-slot, 10-pole design. The rotor core has three magnetic pole segments distributed along its axial direction, with adjacent segments staggered by 2°. The rotor pole eccentricity is 11.5mm. The cogging torque of this brushless motor is ≤25mN.m at 10rpm.

[0030] Example 2:

[0031] This integrated brushless motor has three phases, a rated voltage of 12V, a rated current of 99A, a rated speed of 2000rpm, a maximum speed of 8000rpm, and a rated torque of 3.1Nm. The stator and rotor have a 12-slot, 8-pole design. The rotor core has two axially distributed magnetic pole units, with adjacent magnetic pole units staggered by 7.5°. The rotor pole eccentricity is 9.5mm. The cogging torque of this brushless motor is ≤15mN.m at 10rpm.

[0032] In this embodiment, by rationally optimizing the stator and rotor structures and electromagnetic parameters, the structure and processing technology are simplified, and the cogging torque of the motor is reduced; the ECU chamber is integrated into the motor, the structure is compact, and only one set of waterproof sealing structure is required, which simplifies the waterproof design of the system. At the same time, the motor housing and end cover also serve as ECU radiators, which can effectively reduce the system volume and improve the system power density. It is particularly suitable for power steering systems and electric brake systems for modern traditional automobiles, new energy vehicles and intelligent unmanned vehicles.

[0033] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed by the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection defined in the claims.

Claims

1. An integrated brushless motor, comprising a housing (1), a stator (3), and a rotor (4), wherein the stator (3) comprises a stator core (31), a stator coil (32), and a UVW three-phase copper busbar (33), characterized in that: The integrated brushless motor further comprises an end cover (2), the end cover (2) being fixed inside the housing (1) and forming a closed housing inner cavity with the tail of the housing (1) for accommodating the stator (3) and the rotor (4); the rotor (4) comprising a rotating shaft (42) with two ends passing through the tail of the housing (1) and the end cover (2) via bearings (41); an ECU chamber (5) for accommodating an ECU control panel is further formed between the opening of the housing (1) and the end cover (2), the housing inner cavity and the ECU chamber (5) being respectively located on both sides of the end cover (2); the UVW three-phase copper busbar (33) extending from the end cover (2) into the ECU chamber (5); the rotor (4) further comprising a magnetoresistive position signal detection component (45) fixed to the end of the rotating shaft (42), the magnetoresistive position signal detection component (45) comprising a detection magnet (451) and a fixing bracket (452); the rotor (4) further comprising a magnetoresistive position signal detection component (45) The invention comprises a rotor core (43) fixed on the rotating shaft (42) and having two or three sections distributed along the axial direction and staggered between adjacent sections. The staggered angles between each adjacent section of the rotor core (43) are the same. The mounting portion of the rotating shaft (42) and the rotor core (43) adopts an optical axis interference connection. The inner surface of the rotor core (43) is in a spline shape. The magnetic resistance position signal detection component (45) is interference-connected with the rotating shaft (42) and extends out of the end cover ( 2) the end portion is connected to the ECU chamber (5); a plurality of rotor poles (44) are evenly distributed on the outer peripheral surface of the rotor core (43), and the rotor poles (44) are tile-shaped magnetic steel with an eccentricity of 8.5-11.5 mm; the stator core (31) is formed by annular splicing of a plurality of stator teeth (311), and the stator coil (32) is wound on the corresponding stator teeth (311) with electromagnetic wire, and is led out on one side and connected to the UVW three-phase copper busbar (33).

2. The integrated brushless motor according to claim 1, characterized in that: The end cover (2) is provided with a plurality of openings for the UVW three-phase copper busbar (33) to pass through.

3. The integrated brushless motor according to claim 1, characterized in that: The detection magnetic steel (451) adopts NS bipolar magnetized high-performance circular magnetic steel, and the center of the detection magnetic steel (451) is concentric with the rotor (4).

4. The integrated brushless motor according to claim 1, characterized in that: The fixing bracket (452) is made of non-magnetic conductive material.

5. The integrated brushless motor according to claim 1, characterized in that: The opening portion of the housing (1) has an interface portion that can be connected to a closed rear cover plate to form a closed waterproof chamber.

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