Motor assembly, assembly, device, and variable frequency drive unit

Abstract

The present invention discloses an electric machine assembly, comprising: an electric machine housing; an electric machine located within the electric machine housing and having a rotor; a middle plate arranged in a straight line with at least a part of the electric machine housing and close to the at least a part of the electric machine housing; an end plate arranged in a straight line with at least a part of the middle plate and close to the at least a part of the middle plate, such that the middle plate is located between the electric machine housing and the end plate, the end plate having a peripheral wall and an end wall, and the peripheral wall and the end wall together at least partially defining a cavity; and a variable frequency drive electronics unit arranged within the cavity and configured to supply power to the electric machine. The variable frequency drive electronics unit comprises: a circuit board, a plurality of power switch components mounted to the circuit board, and a plurality of power control components mounted to the circuit board.

Description

[0001] This application is a divisional application of an application with an international filing date of March 13, 2017, a Chinese national application number of 201780015441.0 (international application number PCT / US2017 / 022019), and an invention title of "Motor Assembly for Driving a Pump or Rotating Device Including a Power Plane with a Multilayer Power and Control Printed Circuit Board Assembly".

[0002] Cross - reference to related applications

[0003] This application claims the benefit of provisional patent application 62 / 307,037, filed on March 11, 2016, which is hereby incorporated by reference. Background of the invention 1. Field of the technology

[0005] This application relates to technologies for increasing the power density of the electronics of a variable - frequency drive and reducing the sensitivity of the electronics of a variable - frequency drive to high temperatures in order to mount variable - speed electronics inside a motor assembly; and more particularly to technologies such as using uniquely designed mid - plates and end - plates to reduce the sensitivity of the electronics of a variable - frequency drive to high temperatures.

[0006] 2. Brief description of related technologies

[0007] In the prior art, it is known that the electronics of a variable - frequency drive are generally sensitive to high temperatures and, when combined with a motor assembly, may malfunction or fail prematurely if operated at their maximum ratings, and it is known that the electronics need to be housed in a sealed enclosure within the motor housing, which protects the electronics from both harsh environments and excessive heat. Motors typically operate at much higher temperatures than safe electronic operation. When these two devices are combined, the losses (heat) generated from motor operation will cause high - temperature conditions, which are unhealthy for the operation of the variable - frequency drive.

[0008] From some perspectives, premium - efficiency motors can achieve efficiencies of 94 - 95%. Thus, 5 - 6% of their rating is wasted due to heat loss (measured relative to watt loss or heat). For a variable - frequency drive, it may achieve an efficiency of 96 - 97%. Thus, in a 50HP system, the heat - loss calculation can take the following form: 50HP×746 watts / HP = 37,300 watts, and 37,300 watts×10% = 3,730 watts of waste heat. Specifically, 4% of the total drive losses are divided as follows:

[0009] Approximately 85% is lost in the power modules housed in the end - plate, 10% is lost in the power - quality filter, and 6% is lost in the remainder of the motor.

[0010] In view of this, there is a need in the art to provide a better way to reduce the sensitivity of the electronics of a variable frequency drive to high temperatures, so as to substantially eliminate or reduce improper operation or premature failure of such electronics of such variable frequency drives when operating at their maximum ratings. Summary of the Invention

[0011] An object of the present invention is to install an electronic variable frequency drive in an enclosure of the same size as a standard National Electrical Manufacturers Association (NEMA) or International Electrotechnical Commission (IEC) rated motor of the same power rating, thereby allowing variable speed operation of the motor and any pump or rotating device it controls.

[0012] Basic Equipment

[0013] According to some embodiments, the present invention may take the form of a device, for example, a motor assembly such as for driving a pump or a rotating device, the motor assembly including at least one plate having two sides, one side having a central portion, an intermediate portion, and a peripheral portion.

[0014] The central portion may include or be configured with an opening to receive the at least one plate and dispose the at least one plate relative to a rotor (such as of a motor for driving a pump or a rotating device).

[0015] The intermediate portion may be configured between the inner circumference of the central portion and the peripheral portion, and may include a plurality of internal radial cooling fins that extend from the inner circumference of the central portion and diverge outwardly towards the peripheral portion to transfer heat from the central portion to the peripheral portion, thereby achieving internal heat conduction capacity.

[0016] The peripheral portion may include an outer circumferential surface having a plurality of external radial cooling fins that diverge outwardly away from the plate to transfer heat to the surrounding air, thereby achieving external heat convection capacity.

[0017] The at least one plate may be a middle plate, an end plate, or a combination thereof or take the form of a middle plate, an end plate, or a combination thereof, the middle plate, end plate, or combination thereof forming a part of a pump or a rotating device, which is in accordance with what is set forth herein.

[0018] Middle plate implementation plan

[0019] For example, the at least one plate may include a middle plate or take the form of a middle plate, the middle plate having a bearing housing flange portion that is configured to receive a motor bearing assembly and is also configured with an opening to receive a motor rotor shaft.

[0020] Embodiments of the middle plate may also include one or more of the following features:

[0021] The device can be or take the form of an electric motor assembly for driving a pump or a rotating device, which for example includes a combination of a rotor and an electric motor bearing assembly having a bearing assembly disposed on the rotor.

[0022] The other of the two sides can be a smooth side without internal or external cooling fins in the corresponding middle part.

[0023] The electric motor assembly can include an insulating layer disposed relative to the middle plate and configured to reduce the heat transfer rate, including all forms of heat transfer from conduction, convection, and radiation. By way of example, the insulating layer can be made of mica.

[0024] The electric motor assembly can include a power plane having electrical components (including the electronics of a variable frequency drive), and the middle plate can be configured such that the smooth side faces the power plane.

[0025] In operation, heat can be transferred via conduction from the rotor through the middle plate and the internal radial cooling fins to the external radial cooling fins, and then can also be transferred via convection from the external radial cooling fins to the surrounding air. The middle plate can be configured to absorb heat not only via conduction from the rotor through the bearing assembly, but also via convection through the external radial cooling fins located in the air chamber of the electric motor, including heat generated from the electric motor due to electrical and mechanical losses, including heat from the motor end windings, resistive current or eddy currents, or both, thereby causing direct heat conduction from the rotor and releasing heat into the air chamber of the electric motor.

[0026] The middle plate can be configured to provide a heat path from the motor end windings to the air flow outside the stator, or from the rotor through the bearing assembly to the surrounding environment, or both.

[0027] The electric motor assembly can include a front grease retainer and a rear grease retainer disposed on each side of the electric motor bearing housing.

[0028] The electric motor assembly can include an insulating washer assembly disposed on the middle plate to minimize the thermal contact between the middle plate and the end plate.

[0029] By way of example, the middle plate can be made of copper, aluminum, or cast iron.

[0030] The middle plate can include an external insulating layer that restricts the heat flow from the middle plate radiator to the power converter region having the power plane and restricts the heat entering the end plate electronics region that forms part of the end plate.

[0031] The internal radial cooling fins of the middle plate can be configured above and around the middle part and are substantially evenly and equidistantly spaced from each other.

[0032] External radial cooling fins of the middle plate may be configured above and around the peripheral portion and are evenly and equidistantly spaced from each other.

[0033] By way of example, the middle plate may have more external radial cooling fins than internal radial cooling fins, including more than twice as many.

[0034] End plate implementation plan

[0035] By way of further example, the at least one plate may include or take the form of an end plate, wherein an opening in the central portion is configured to receive and engage a motor rotor shaft.

[0036] The end plate embodiment may further include one or more of the following features:

[0037] The other of the two sides may be a smooth side without internal or external cooling fins in the corresponding middle portion.

[0038] The device may include a motor assembly that includes a power plane having electrical components (including electronics of a variable frequency drive), the end plate may be configured with an electronics housing chamber, and the power plane may be configured within the electronics housing chamber such that the smooth side faces the power plane.

[0039] The motor assembly may include an electronics module that is disposed between the power plane of the end plate and the smooth side within the electronics housing chamber.

[0040] External radial cooling fins of the end plate may be configured above and around the middle portion and are substantially evenly and equidistantly spaced from each other.

[0041] External radial cooling fins of the end plate may be configured above and around the peripheral portion and are evenly and equidistantly spaced from each other.

[0042] Power Plane Implementation

[0043] A device (e.g., a motor assembly such as for driving a pump or a rotating device) may include a power plane having a circular geometry for installation inside a space envelope having a similar circular geometry, the space envelope being formed on the end plate between an inner hub portion and a peripheral portion, the peripheral portion circumferentially extending around the space envelope of the end plate. The power plane may be a multi-layer circuit board or assembly having the following layers:

[0044] A power layer having at least one high-temperature power module for supplying power to the motor,

[0045] A control layer having at least one low-temperature control electronics module for controlling the power supplied to the motor, and

[0046] A thermal barrier and printed circuit board layer between the power layer and the control layer, which provides an electrical connection path between the power module of the power plane and the control electronic device module of the control layer, and also provides insulation between the power layer and the control layer.

[0047] The power plane implementation may also include one or more of the following features:

[0048] The power plane may be configured to perform at least the following actions:

[0049] Allow the at least one power module and the at least one control electronic device module to be mounted on opposite sides of the thermal barrier,

[0050] Provide an electrical connection path for interconnecting the at least one power module and the at least one control electronic device module, and for interconnecting the input / output power connection, the at least one power module and the at least one control electronic device module, and

[0051] Insulate and / or direct the heat emitted from one or more of the at least one power module, the at least one control electronic device module, and the motor shaft to the outer diameter of the power plane,

[0052] There is a higher air flow at this outer diameter.

[0053] The power plane may be configured as an annular power plane printed circuit board or assembly to fit within the space envelope of the end plate, thereby providing the maximum space for mounting the power layer and the control layer, and allowing the shaft of the motor rotor to pass through to drive the cooling fan.

[0054] The power layer may be configured with higher temperature power modules; the control layer may be configured with lower temperature control electronic modules and components and power quality filter components; and the thermal barrier and printed circuit board layer may be configured of a material having the structural thickness and strength to mount the control layer on one side and the power layer on the opposite side, and the material is configured to provide insulation to reduce heat transfer between the power layer and the control layer.

[0055] The thermal barrier and printed circuit board layer may be constructed of a laminated material including fiberglass, which provides structural strength and acts as an insulator separating the hotter power semiconductors of the power layer from the colder and more sensitive control electronics and power quality capacitors of the control layer.

[0056] The power layer may include a circular power module arrangement configured on one side of the thermal barrier and printed circuit board layer to couple to the low inductance input and integrated output connections of the power plane, such as attached to the middle part of the end plate.

[0057] The at least one power module may include matrix converter power modules that are configured as part of a matrix converter to receive an AC input signaling including an AC waveform having a voltage and a frequency, and to provide a converted AC signaling including a converted AC waveform having a converted voltage and frequency to drive an electric motor.

[0058] The control layer may include at least one power quality filter component configured to reduce electrical noise and harmonic distortion levels.

[0059] The at least one power quality filter component may be directly attached to a thermal barrier and a printed circuit board layer, and is configured to be physically close to or adjacent to the matrix converter to reduce the amount of distortion emitted from matrix converter electronics in the matrix converter.

[0060] The at least one power module may include a power semiconductor module; the at least one control electronics module may include a power quality capacitor; and the power plane may include a low inductance and resistance input configured between the power semiconductor module and the power quality capacitor to reduce switching stress and electromagnetic interference.

[0061] The power plane may include one or more compact power quality filters integrated therein.

[0062] The power plane may include a built-in power quality filter configured to produce minimal harmonic distortion and to protect the variable speed drive from most power quality anomalies.

[0063] The power plane may be configured to combine power and control circuits into an integrated printed circuit board configuration for assembly convenience and dimensional compactness.

[0064] The power plane may include a combination of one or more of: current sensors, at least one gate driver, a power source, a clamping circuit, a power semiconductor module, and a power quality capacitor; and the electrical connection paths may be configured to interconnect input / output power connections and a combination of one or more of: current sensors, the at least one gate driver, a power source, a clamping circuit, a power semiconductor module, and a power quality capacitor.

[0065] The motor assembly may include an end plate; an inner hub portion may be configured to receive the shaft of the motor rotor; and a peripheral portion may include heat dissipating fins configured to dissipate heat generated by the at least one power module and the at least one control electronics module from the end plate.

[0066] The motor assembly may include a motor housing configured to function as a heat sink to allow for a compact size and thermally optimized operation of the power plane.

[0067] The motor assembly may include a rotating device or a pump or take the form of a rotating device or a pump, for example including an end plate having a power plane disposed therein.

[0068] advantage

[0069] Generally speaking, the present invention provides a better way to increase the power density of variable-frequency electronic devices and reduce the sensitivity of the electronic devices of variable-frequency drives to high temperatures so as to install variable-speed electronic devices within a motor assembly; thereby substantially eliminating or reducing improper operation or premature failure of such electronic devices of such variable-frequency drives when operating at their maximum ratings. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] The drawings include the following figures which are not necessarily drawn to scale:

[0071] Figure 1 is an exploded view of an apparatus according to some embodiments of the present invention, the apparatus being in the form of, for example, a motor assembly for driving a pump or a rotating device.

[0072] Figure 2A and Figure 2B is a cross-sectional view of a part of a motor assembly that is similar or identical to, for example, Figure 1 shown, where Figure 2A has an electronic device module, Figure 2B and without an electronic device module.

[0073] Figure 3 shows a mid-plate according to some embodiments of the present invention - including Figure 3 A and Figure 3 B, according to some embodiments of the present invention, Figure 3 Figure 3A shows a perspective view of the motor side of the mid-plate, and Figure 3B shows Figure 3 a perspective view of the power plane side of the mid-plate shown in Figure 3A, the mid-plate being configured, for example, to be disposed in Figure 1 or the motor assembly shown in Figure 2.

[0074] Figure 4 shows an end plate according to some embodiments of the present invention - including Figure 4 A and Figure 4 B, according to some embodiments of the present invention, Figure 4 Figure 4A shows a perspective view of the fan side of the end plate, and Figure 4B shows Figure 4 a perspective view of the mid-plate side of the end plate shown in Figure 4A, the end plate being configured, for example, to be disposed in Figure 1 or the motor assembly shown in Figure 2.

[0075] Figure 5 includes Figure 5A , Figure 5B , Figure 5C and Figure 5D , Figure 5A showing a photograph of an electric machine assembly that has labeled and identified the electric machine frame, mid-plate, end-plate, junction box, and fan; Figure 5B a perspective view of an electric machine assembly showing a partial exploded view that includes the junction box; Figure 5C a perspective view of an electric machine assembly showing a partial exploded view that includes the combination of the electric machine and mid-plate, end-plate, fan, and shroud; and Figure 5D showing an exploded view of a self-contained drive module assembly, all in accordance with some embodiments of the present invention.

[0076] Figure 6 Includes Figure 6 A, which shows a schematic diagram of a bidirectional switch for implementing a portion of a power function (e.g., of a power plane) in accordance with some embodiments of the present invention; and also includes FIG. 6B, which shows a photograph of an example of a bidirectional switch power module for implementing a portion of a power function in accordance with some embodiments of the present invention.

[0077] Figure 7 showing a photograph of an electric machine end-plate having a power plane in accordance with some embodiments of the present invention, the power plane having a matrix converter disposed therein, such as an example configured with a main power source, controller, gate drive layer, clamping capacitor (CC), and input filter capacitor (IFC).

[0078] Figure 8 showing a typical graph of the input voltage and current waveforms of a 40HP EMD (also known as a variable frequency or variable speed drive).

[0079] Fig. 9 Includes Fig. 9 A, which shows a schematic top view of an end-plate having a space envelope formed therein between an inner hub portion and a peripheral portion, the schematic including arrows indicating the flow of heat away from the inner hub portion and toward the peripheral portion, for example, when operating in accordance with some embodiments of the present invention; and includes Fig. 9 B, which shows Fig. 9 a schematic side cross-sectional view of the end-plate of A, the schematic having corresponding arrows indicating the flow of heat away from the inner hub portion of the end-plate and toward the peripheral portion when operating in accordance with some embodiments of the present invention.

[0080] Figure 10 includes Fig. 10A and Fig. 10B , wherein Fig. 10Ais a photograph of an end plate with an example of a possible clamp resistor implementation according to some embodiments of the present invention; and Fig. 10B is a photograph of a circular power plane printed circuit board layer according to some embodiments of the present invention, for example including an example of connections to three shunt resistors and gate driver connections. For example, the printed circuit board layer is configured to connect a power module, inputs, and outputs to a laminate that has a top layer for connections and three remaining layers that share the input and output connections.

[0081] Fig.11 is an exploded view of a device according to some embodiments of the present invention, for example in the form of a motor assembly for driving a pump or a rotating device.

[0082] Fig. 12A and Fig. 12B is, for example, a cross-sectional view of a part of a motor assembly similar or identical to that shown in Fig.11 where Fig. 12A has an electronic device module, Fig. 12B without an electronic device module.

[0083] Fig.13 shows a mid-plate according to some embodiments of the present invention - including Fig.13 A(1), Figure 13A(2) and Fig.13 B, according to some embodiments of the present invention, Fig.13 A(1) shows a perspective view of the motor side of the mid-plate, and Fig.13 A(2) shows Figure 3 a perspective view of the power plane side of the mid-plate shown in A(1), which is, for example, configured to be in Fig.11 or Fig. 12A and Fig. 12B shown in the motor assembly; and Fig.13 B shows a photograph of one side of the mid-plate according to some embodiments of the present invention, which is, for example, configured to be in Fig.11 or Fig. 12A and Fig. 12B shown in the motor assembly.

[0084] Fig.14 shows an end plate according to some embodiments of the present invention - including Fig.14 A and Figure 14B, according to some embodiments of the present invention, Fig.14 A shows a perspective view of the fan side of the end plate, and Fig.14 B shows Fig.14 a perspective view of the mid-plate side of the end plate shown in A, which is, for example, configured to be in Fig.11 or Fig. 12A and Fig. 12BIn the motor component device shown.

[0085] Fig.15 A photograph of a motor component according to some embodiments of the present invention is shown, and the photograph has marked and identified the motor frame, the middle plate, the end plate, and the fan.

[0086] Fig.16 A photograph of a motor end plate according to some embodiments of the present invention is shown, and the motor end plate has a power plane disposed therein, and the power plane is configured with a printed circuit board (PCB) and a matrix converter.

[0087] Fig.17 including Fig.17 A, Fig.17 B and Fig. 17C , Fig.17 A shows a schematic top view of an end plate having a space envelope formed therein between the inner hub portion and the peripheral portion, and the schematic includes arrows indicating that heat flows away from the inner hub portion and towards the peripheral portion, for example, when operating according to some embodiments of the present invention; Fig.17 B shows Fig.17 a schematic side cross-sectional view of the end plate in A, and the schematic has corresponding arrows indicating that heat flows away from the inner hub portion of the end plate and towards the peripheral portion when operating according to some embodiments of the present invention; and Fig. 17C shows Fig.17 a schematic side cross-sectional view of the end plate in B according to some embodiments of the present invention, and the end plate has various modules and components disposed in the space envelope, including a circular power module arrangement, a low-inductance input and integrated output connection of the power plane, cryogenic electronic components (such as mounted on the power plane), and power quality filtering capacitors.

[0088] Fig.18A A power module layout forming part of a motor component is shown, all according to some embodiments of the present invention.

[0089] Fig.18B A photograph of the final assembly of a matrix converter disposed in an end plate according to some embodiments of the present invention is shown, and the final assembly has, for example, a power plane printed circuit board on which a gate driver power source, a clamp circuit control, an input filter capacitor, a clamp capacitor, and a control card are assembled.

[0090] The accompanying drawings include examples of possible implementations; and the scope of the present invention is not intended to be limited to the implementations shown therein. For example, the scope of the present invention is intended to include other implementations in addition to or other than those shown in the accompanying drawings, and embodiments using other implementations in addition to or other than those shown in the accompanying drawings are contemplated, which other implementations may be configured within the spirit of the present invention disclosed in its entirety in this application. Detailed Description

[0091] Basic equipment 10

[0092] Figure 1 and Fig.11 illustrates a device (generally designated 10, 10'), which may for example include or take the form of an electric motor assembly 10 for driving a pump or a rotating device (not shown). The electric motor assembly 10 includes an electric motor M having a stator J (see Figure 2A , Figure 2B ; Fig. 12A , Fig. 12B ) disposed therein; a rotor R coupled to the electric motor M; a mid-plate E having a bearing housing flange portion A (see Figure 2A , Figure 2B ; Fig. 12A , Fig. 12B ); a rear electric motor bearing assembly (generally designated H) having a bearing assembly BA, front B and rear C grease retainers; a fan F; an integrated insulation layer G; a gasket assembly GA ( Fig.11 ); an end plate D; a power plane P ( Figure 2A , Figure 2B , Fig.11 , Fig. 12A , Fig. 12B ) and a shroud S. The electric motor frame MF also includes a junction box TB, as shown for example in Figure 1 and Fig.11 . The power plane P may be configured to include electronics, such as including a variable frequency drive, which is configured to control the operation of the electric motor M, which in turn drives a pump or other rotating device. The power plane P will be described in more detail, for example, with respect to Figures 6 to 10B and Fig.16 , Figure 17C, Fig.18A and Fig.18B shown.

[0093] By way of example, according to some embodiments of the present invention, the electric motor assembly 10 may have or be configured with a novel and unique mid-plate E, end plate D, or a combination thereof, for example, as is consistent with that set forth below with respect to Figure 3 to Figure 4 .

[0094] Figure 3 and Fig.13 : Medium plate E

[0095] For example, Figure 3 and Fig.13 show the middle plates E, E', E", each middle plate having two side surfaces S 1 , S 2 , including a motor side surface S 1 having a central portion E 2 , an intermediate portion E 3 and a peripheral portion E 1 .

[0096] The intermediate portion E 2 may be disposed between the inner circumference E 1 ' of the central portion E 1 and the peripheral portion E 3 , which is in accordance with that shown in 3A and 13A(1). The intermediate portion E 2 may include a plurality of internal radial cooling fins E 2 ', which extend from a part of the inner circumference E 1 ' of the central portion E 1 ' and diverge outward (e.g., away from each other) towards the peripheral portion E 3 to transfer heat from the central portion E 1 to the peripheral portion E 3 , thereby achieving internal heat conduction capacity.

[0097] The peripheral portion E 3 may include an outer circumferential surface E 3 ' having a plurality of external radial cooling fins E 3 ", which diverge away from the peripheral portion E 3 to transfer heat to the surrounding air, thereby achieving external heat convection capacity.

[0098] The central portion E 1 may include a bearing housing flange portion A (also see Figures 1 to 2A , Figure 2B; Fig.11 , Fig. 12A , Fig. 12B ), which is configured to receive a motor bearing assembly H and is also configured with an opening O to receive and engage a rotor R. The motor assembly 10 may include a combination of a rotor R and a motor bearing assembly H( Figures 1 to 2A , Figure 2B ; Fig.11 , Fig. 12A , Fig. 12B ) disposed on the rotor R.

[0099] Figure 3 B, Fig.13 A(2) shows the power plane side surface S in these two side surfaces2 The side surface of the power plane, for example, can be the corresponding middle part E 2,2 A smooth side surface without cooling fins.

[0100] The motor assembly 10 can include a thermal insulator TI ( Figure 1 ) or an insulating layer G ( Fig. 12A to FIG. 12B). The thermal insulator or insulating layer is arranged relative to the middle plate E and the end plate D and is configured to reduce the heat transfer rate, including all forms of heat transfer from conduction, convection, and radiation.

[0101] Fig.13 FIG. 14B shows an alternative embodiment of the middle plate (generally indicated as E”). Fig.13 A. Similar elements in FIG. 13B are labeled with similar reference numerals. By way of example, Fig.13 A, Fig.13 One difference between the respective middle plates E' and E” in FIGS. 14A and 14B is that the middle plate E' includes a bearing housing flange portion A (for example, also shown in Figure 3 FIG. 14A), while the middle plate E” does not include this portion. Embodiments of the middle plate with such a bearing housing flange portion A and embodiments without this portion are envisioned, and the scope of the present invention is intended to include middle plates with such a bearing housing flange portion A and embodiments without this portion.

[0102] In accordance with Figure 3 as shown, internal radial cooling fins E 2 ' can be configured on and around the middle part E 2 and are spaced apart from each other substantially uniformly and equidistantly. External radial cooling fins E 3 ” can be configured on and around the peripheral part E 3 and are spaced apart from each other substantially uniformly and equidistantly. By way of example, in accordance with Figure 3 as shown, the middle plate E can be configured with more external radial cooling fins E 2 ” than internal radial cooling fins E 3 ', for example, including more than twice as many. In Figure 3 FIG. 14A, the middle plate E is shown as having 30 (for example, in contrast, Fig.13 the middle plate E' in FIG. 14A(1) has 36) internal radial cooling fins E 2 ' that are spaced apart from each other substantially uniformly and equidistantly. In Figure 3 FIG. 14A(1), the middle plate E(1) is shown as having 48 (for example, in contrast, Fig.13 the middle plate E' in FIG. 14A(1) has 94) external radial cooling fins E 3”. However, the scope of this embodiment is not intended to be limited to the number of internal radial cooling fins E 2 ', the number of external radial cooling fins E 3 ", or the numerical relationship between the number of internal radial cooling fins E 2 ' and the number of external radial cooling fins E 3 ". For example, embodiments are envisioned in which the number of internal radial cooling fins E 2 ' and the number of external radial cooling fins E 3 " are greater than or less than Figure 3 the number shown, and the scope of the present invention is intended to include such implementations. Embodiments are also envisioned in which the numerical relationship between the number of internal radial cooling fins E 2 ' and the number of external radial cooling fins E 3 " is different from Figure 3 the numerical relationship shown, and the scope of the present invention is intended to include such implementations.

[0103] In Figure 3 and Fig.13 A(1), the middle plates E' and E" include other features that may not themselves form part of the present invention, including an external retaining member E 5 ' configured with holes E 5 for receiving fasteners (not shown), for example to couple the middle plates E' and E' to some other component of the motor assembly such as a motor frame MF( Figure 1 and Fig.11 ), and including two or three external retaining members E 6 ' configured with holes E 6 for receiving fasteners (not shown), for example to couple the middle plates E' and E" to some other component of the motor assembly such as a motor frame MF( Figure 1 and Fig.11 ).

[0104] In fact, the middle plate embodiments according to the present invention as set forth herein consist of a system with several highly engineered elements:

[0105] By way of example, the motor assembly 10 can be configured with a specially designed motor housing to improve thermal efficiency, and the motor housing consists of the following elements:

[0106] 1) The middle plate E (also known as the motor end plate) can be made of copper, aluminum, or cast iron, and the rear motor bearing or bearing housing H is incorporated into the middle plate E. The middle plate E can be optimized to conduct heat away from the non-driven end bearing of the pump, the stator S and rotor R of the motor, while insulating the electronic devices that form part of the power plane P. This innovative configuration according to the present invention places the bearing housing flange portion A inside the middle plate E or E' (as shown in Figure 1 and Fig.11 ), and thus, the middle plate E or E’ will effectively serve as the structural support for the rotor R.

[0107] 2) The special radiator fins E 2 ',E 3 ” can be designed to achieve low audible noise and increased surface area, thereby allowing for greater thermal efficiency.

[0108] 3) A unique geometry with a circular design can be achieved to provide optimized space and manufacturing convenience.

[0109] 4) A circular geometry can be achieved that allows for the configuration of power electronic modules ( Figure 1 and 11 ) and electronic devices (Figures 2 and 12A), thus allowing the rotor / shaft R to pass through to power the cooling fans F ( Figure 1 and Fig.11 ).

[0110] The middle plate E or E’ can include one or more of the following:

[0111] The middle plate E or E’ can be configured to accommodate the rear motor bearing H;

[0112] The middle plate E or E’ can be configured relative to the power plane component P;

[0113] The middle plate E or E' can be configured with or incorporate a bearing oil / grease tube.

[0114] The middle plate E or E' can be configured such that heat can be redirected radially rather than axially. The middle plate E or E' can also be configured to use the radial cooling fins E 2 ’ to redirect heat from the motor end windings of the motor M to the peripheral portion or edge E of the middle plate E or E' 3 .

[0115] The middle plate E or E’ can be configured to provide a thermal path for the air flow from the motor end windings to the outside of the stator J.

[0116] The middle plate E or E’ can be configured to provide a thermal path from the rotor R through the bearing assembly H to the surrounding environment.

[0117] The middle plate E or E’ can be configured to form and provide the structural support for the rotor R.

[0118] The front B and rear C grease guards can also be used in combination with the middle plate E or E'.

[0119] The integrated insulation layer G outside the middle plate E or E' restricts the heat flow from the middle plate radiator to the power converter area and restricts the heat entering the end plate electronic device area.

[0120] Minimized thermal contact can be achieved between the middle plate E or E' and the end plate D via the insulation washer G that forms part of the gasket assembly GA.

[0121] Middle Plate: Theory of Operation

[0122] The middle plate E or E' is configured with a unique design that combines a circular geometry with internal and external radiator fins E 2 ', E 3 ”, for example, which is in line with Figure 1 and Fig.11 as shown. The internal fins E 2 ’ are positioned along the inner circumference E 1 ’ of the middle plate E or E', leaving space at the center of the rotor bearing housing H. The external fins E 3 ” are distributed throughout the outer diameter / circumference of the middle plate E or E', thus achieving external convection capabilities, for example, which is in line with Figure 1 and Fig.11 as shown.

[0123] The middle plate E or E' also has a thin insulation layer G on the electronic device side of the middle plate E. This thin insulation layer is smooth and finless, for example as shown in Figure 2. This thin insulation layer G will allow various configurations of the power electronic module and electronic devices, while still allowing the shaft / rotor R to pass through to power the cooling fan F. The main functions of this design are threefold. The middle plate E or E' acts as a structural support for the motor M and the motor rotor R, a radiator at the non-drive end, and a thermal insulator for the electronic device chamber, which forms part of the end plate D, for example.

[0124] Thermal conductors are usually made of metal due to their high level of thermal conductivity and ability to absorb heat. Thus, by way of example, the middle plate E or E' can be made of aluminum, copper, or cast iron. Compared with other special materials, these metals have a high level of thermal conductivity, good structural stiffness, and are cost-effective.

[0125] In operation, the middle plate E or E' achieves its functions through conduction and convection, where conduction should be understood as heat transfer between solids in contact with each other, and where convection should be understood as heat transfer between a solid and a fluid. Conduction will occur between the shaft / rotor R and the middle plate E or E' through the bearing housing H, while convection occurs in the radiator fins E2 ',E 3 occurs between it and the air.

[0126] In operation, an air-cooled radiator (e.g., such as component E 3 ”) can act as a cooling mechanism. They conduct heat from the objects they contact and transfer the heat to the air by convection. For normal operation, the radiator must be hotter than the ambient temperature, and the surface area contact should be maximized to ensure effective heat transfer. In the context of the motor housing design of the present invention, the middle plate E or E’ conducts the heat generated due to the electrical and mechanical losses of the motor M to the ambient air outside.

[0127] The losses of the rotor R can be attributed to electrical losses (e.g., resistive current and eddy current) caused by, for example, the current flowing through the aluminum bars located in the rotor R. These losses cause the rotor R to release heat into the air chamber of the motor and conduct directly into the shaft / rotor R. The middle plate E or E’ will absorb this heat not only by conduction from the shaft / rotor R through the bearing assembly H into the middle plate E or E', but also via convection through the radiator fins E 2 ’ or E 3 ” in the internal air chamber of the motor.

[0128] The purpose of the thermal insulator G is to reduce the rate of heat transfer between two solids / fluids. As will be understood by those skilled in the art, insulators reduce all forms of heat transfer, and they are or can take the following forms: conduction, convection, and radiation. Thermal insulators are typically made of materials with high resistance to heat conduction, due to their ability to dissipate heat. Thus, the insulating layer will be made of mica, fiberglass, thermoplastics, or some inexpensive materials with low levels of heat conduction and good structural stiffness.

[0129] This design is incorporated into the middle plate E or E’ by an additional layer attached to the middle plate E or E’, as shown in FIG. 2 for example. The insulating layer G can be composed of mica or some other optimal insulator, and this insulating layer acts as a thermal insulator for the electronic components forming part of the power plane P. This insulation acts as a barrier to avoid the losses from the motor M so as to redirect the heat towards the radiator fins E 2 ' or E 3 ”. The middle plate E or E’ also houses the bearing housing H, which in turn supports the rotor and the motor shaft R.

[0130] The overall design of the middle plate E or E' makes it a new type of component that serves multiple functions simultaneously. The middle plate E mechanically supports the non-driving end of the motor M, and since the middle plate E or E' contains a shaft bearing attachment in its center, it allows the rotor R to rotate. The middle plate E or E’ conducts the heat of the motor effectively to the outside of the motor body, thus allowing the motor M to operate reliably at an effective temperature. Third, the insulator G insulates the electronic devices from the elevated motor temperature and allows the components to operate at a temperature below their maximum ratings.

[0131] advantage

[0132] The advantages of the present invention may include one or more of the following:

[0133] 1) It allows the manufacture of embedded electronic motor drives (e.g., variable frequency drives) at a power level greater than the power levels currently generated in the prior art.

[0134] 2) It allows the manufacture of variable speed motors in the same footprint as current industrial motors at a power level greater than the power levels currently generated in the prior art.

[0135] 3) Via the internal and external radiator fins E 2 ’ or E 3 ”, the middle plate E provides a heat conduction path for the motor winding heat and the non-driving end bearing heat.

[0136] 4) Via the integrated insulation, the middle plate E or E’ provides a barrier to prevent the heat from the motor from reaching the sensitive electronic devices.

[0137] 5) Due to its compact size, the middle plate E or E’ allows, for example, matrix converters to be designed to be installed in hazardous locations containing corrosives, moisture, and Class 1, Division 2 hazardous locations.

[0138] Figure 4 and Fig.14 : end plates D, D'

[0139] Figure 4 The at least one plate is shown in the form of end plates D, D' having two sides, wherein the fan side FS has a central portion D 1 , an intermediate portion D 2 , and a peripheral portion D 3 .

[0140] The central portion D 1 may be configured with an opening O to receive the end plates D, D’ and to arrange the end plates D, D' relative to the rotor R (Figs. 1 and Fig.11 ).

[0141] The intermediate portion D 2 may be configured in the central portion D 1Inner circumferential D 1 ' and the peripheral part D 3 Therein. The middle part D 2 may include internal radial cooling fins D 2 ', which extend from the inner circumference D 1 of the central part D 1 ’ and diverge outwardly towards the peripheral part D 3 to transfer heat from the central part D 1 to the peripheral part D 3 , thereby achieving internal heat conduction capacity.

[0142] The peripheral part D 3 may include an outer circumferential surface D 3 ” having external radial cooling fins D 3 ' (best shown as indicated in FIGS. 4B and Fig.14 B), and these external radial cooling fins diverge outwardly away from the end plates D to transfer heat to the surrounding air, thereby achieving external heat convection capacity.

[0143] Figure 4 B and Fig.14 B show the midplane side MPS of these two sides, and this midplane side may be, for example, a smooth side corresponding to the middle part D 2,2 without cooling fins.

[0144] The power plane P may include electrical components, including the electronics of the variable frequency drive, and the end plates D, D’ may be configured such that the smooth side MPS faces the power plane P, as shown in FIG. 2 for example. The electronic device module EM may be arranged between the power plane P and the smooth side MPS, as Figure 2A shown.

[0145] In line with Figure 4 and Fig.14 shown, the internal radial cooling fins D 2 ’ may be configured above and around the middle part D 2 and are substantially uniformly and equidistantly spaced from each other. The external radial cooling fins D 3 ” may be configured above and around the peripheral part E 3 and are substantially uniformly and equidistantly spaced from each other. By way of example, in line with Figure 4 shown, the end plates D, D’ may be configured such that the internal radial cooling fins D 2 ’ extend and diverge outwardly towards the external radial cooling fins D 3 ” and are connected to these external radial cooling fins, as Figure 4 A and Fig.14As shown in A. However, the scope of this embodiment is not intended to be limited to the number of internal radial cooling fins D 2 ', the number of external radial cooling fins D 3 ", or the numerical or physical relationship between the internal radial cooling fins D 2 ' and the external radial cooling fins D 3 ". For example, embodiments are envisioned where the number of internal radial cooling fins D 2 ' and the number of external radial cooling fins D 3 " are greater than or less than Figure 4 A and Fig.14 A, and the scope of the present invention is intended to include such implementations. Embodiments of the following implementations are also envisioned, and the scope of the present invention is intended to include such implementations: the physical relationship between the internal radial cooling fins D 2 ' and the external radial cooling fins D 3 " is different from Figure 4 and Fig.14 shown, for example including cases where the internal radial cooling fins D 2 ' and the external radial cooling fins D 3 " are not connected, and cases where the number of internal radial cooling fins D Fig.14 A and 2 ' is greater than or less than the number of external radial cooling fins D 3 " when compared to the number shown in

[0146] In Figure 4 and Fig.14 , the end plates D, D' may include other features that may not form part of the present invention, including an external retaining member D 5 ' configured with holes D 5 for receiving fasteners (not shown), for example to couple the end plates D, D' to some other component of the motor assembly such as the motor frame MF ( Figure 1 and Fig.11 ), and including two or three external retaining members D 6 ' configured with holes D 6 for receiving fasteners (not shown), for example to couple the end plates D, D' to some other component of the motor assembly such as the motor frame MF ( Figure 1 and Fig.11 ).

[0147] In addition to those set forth above, by way of further example, several other highly engineered elements of the motor assembly 10 may also include the end plates D, D'; and the motor housing specially designed to accommodate electronics and improve thermal efficiency may also include:

[0148] The motor end plates D, D’ can be made of metal (such as aluminum), for example. The end plates D, D’ can be optimized to conduct heat away from the electronic devices P and / or EM accommodated within the end plate enclosure, for example, by having an insulating gasket GA to minimize the thermal contact between the middle plate E and the end plates D, D'.

[0149] Special radiator fins D 2 ', D 3 can be designed to achieve low audible noise and increased surface area, thus allowing for greater thermal efficiency.

[0150] A unique geometry enabling a circular design can be achieved to provide optimized space and manufacturing convenience.

[0151] A circular geometry allowing the configuration of power electronic modules and electronic devices (Figure 2 and Fig. 17C ) can be achieved, thereby allowing the shaft R to pass through to power the cooling fan F.

[0152] End Plates: Theory of Operation

[0153] The design of the end plates D, D' incorporates a circular geometry, which consists of an electronic device housing chamber (generally indicated as D 7 ) formed on the side of the middle plate for the electronic devices and radiator fins D 2 ', D 3 ” on the fan side of the end plate D. (As shown in Figure 4 B, the electronic device housing chamber D 7 is formed as a hollow intermediate portion between the central part D 1 and the peripheral part D 3 of the end plates D, D’.) This design allows the electronic components P, EM (Figure 2) to be accommodated within the electronic device housing chamber D 7 of the end plate D and provides sufficient cooling due to the radiator fins D 2 ', D 3 ”. The electronic device housing chamber D 7 is integrated on a smooth middle plate side of the end plates D, D', where the inner diameter is hollow (as shown in Figure 4 B) to leave space for the installation of power electronic modules and printed circuit boards. The radiator fins D 2 ', D 3 ” are formed on the fan side of the end plates D, D' in a radially arranged manner, and these radiator fins extend from the center of the motor shaft or the central part D 1 and extend outward across the outer axial surface. The radiator fins D 2 ', D 3 ” share the same basic pattern as those radiator fins constructed on the bearing support plates called “middle plates” E, E'. ( Figure 3 and Fig.13 ). The end plates D, D’ also have space in the center to allow the shaft / rotor R to pass through for powering the cooling fan F ( Figure 1 to FIG. 2). The end plates D, D' have two functions: acting as a radiator for the waste heat emitted from the electronic devices, and serving as a sealed enclosure that provides a place for the electronic components to be installed and protected from the harsh environment.

[0154] The end plates D, D’ act through both conduction and convection. As will be understood by those skilled in the art, in accordance with what has been set forth above, conduction is the heat transfer between solids in contact with each other, and convection is the heat transfer between a solid and a fluid. Conduction will occur due to the power modules (such as EM) being mounted on the inner surfaces of the end plates D, D’. The electronic printed circuit boards and components will generate waste heat during operation. This heat will be absorbed by the radiator feature of the end plate. Then all the heat will be released through the convection through the fins D 2 ', D 3 ” and the cooling fan F. Convection will mainly occur between the radiator fins D 2 ', D 3 ” and the ambient air.

[0155] As a heat conductor, this design can work best when constructed of metal. This is because it has a relatively high level of heat conduction and the ability to absorb heat. Therefore, the end plates D, D’ will typically be made of metal (such as aluminum). By way of example, this material is selected for its structural stiffness, excellent ability to conduct heat, and cost-effectiveness compared to other considerations, but the scope of the present invention is intended to include other types or kinds of metals that are now known or will be subsequently developed in the future.

[0156] The end plates D, D’ can be installed between the middle plates E, E' and the cooling fan F, as Figure 1 shown in FIGS. 2 and 5. The thermal contact between the middle plates E, E' and the end plates D, D' is restricted by the thermal insulator G, as shown in FIG. 2. This shields the electronic devices from the waste heat from the motor and bearings. The end plates D, D’ act as an enclosure for the components as a whole and protect these components from the harsh environment and excessive heat.

[0157] In addition to shielding the electronic devices from the heat, this design is also capable of discharging this heat into the ambient air and maintaining a viable operating temperature. This function is achieved by both the radiator fins D 2 ', D 3 ” and the cooling fan F. Since the fins D 2 ', D 3"Distributed along the large surface area of end plates D, D'; these fins can conduct heat from the power module and the air chamber to the outside of the end plate chamber. Once outside the end plate chamber, the heat is removed by convection. The cooling fan F provides proper air flow within the entire surface of the metal (e.g., aluminum) fins of end plates D, D' and helps keep the temperature of the components below their maximum ratings.

[0158] Heat sink D 2 ', D 3 "Act as a cooling mechanism. They conduct heat from the objects they contact and transfer the heat to the air by convection. For proper operation, the heat sink fins D 2 ’, D 3 "Must be hotter than the ambient temperature, and the surface area contact should be maximized to ensure efficient heat transfer. In the case of end plates D, D', they will absorb the heat generated from the air chamber of the power module and the variable frequency drive (VFD) and transfer this heat to the ambient air outside.

[0159] Overall, the design of end plates D, D' allows them to perform multiple functions during operation. First, it provides a protective enclosure to house all the electronics. Second, it acts as a heat sink to remove the heat generated by the losses in the components, thus protecting these components from excessive temperatures. The unique geometry of end plates D, D' allows these components to be placed in the same enclosure as a standard motor rated for use in normally hazardous areas. Finally, the heat sink fins D 2 ', D 3 "And the cooling fan F help handle the heat distribution throughout end plates D, D'. Utilizing all these features, end plates D, D' allow the electronics to operate smoothly during operation and keep their temperature below the maximum ratings.

[0160] advantage :

[0161] The advantages of the present invention may include the following:

[0162] Via the external heat sink fins D 2 ', D 3 ", end plates D, D' provide a heat conduction path for the power module heat.

[0163] Allow the electronic variable speed drive to be accommodated within the footprint of the current motor M.

[0164] Due to its compact size, it allows power electronics to be installed in hazardous locations containing corrosives or moisture.

[0165] Allow the manufacture of embedded electronic motor drives at power levels greater than the currently generated power levels.

[0166] The power electronics devices will be housed in the motor end plates D, D' and sealed between the mid - plates E, E'.

[0167] The end plate D, D’ design will allow for easy removal from the motor and easy disconnection of power and communication connections.

[0168] The combined end - plate / mid - plate design shall have IP66 protection. All wiring / cables pass through static seals that seal at the mid - plate E to the motor M, end - plates D, D' to mid - plates E, E', and at the power electronics devices of the end - plates, for sealing at the outer diameter (OD) and inner diameter (ID). Dynamic seals at the shaft / mid - plate.

[0169] FIG. 5A to FIG. 5D

[0170] Figure 5A and Figure 5B The motor assembly 10 is shown, which has a main junction box TB and a junction box housing disposed thereon. The main junction box provides a sealed junction point for the motor, motor drive, drive interface, and external power wiring, and the junction box housing has a power inductor PI disposed therein, as shown. The main junction box TB includes a junction box cover TBC, a junction box gasket TBG, and junction box screws for attaching the junction box cover to the junction box housing TBH.

[0171] Figure 5C The motor assembly is shown in an exploded view, which briefly illustrates the electrical and mechanical connections of the end - plate (D) to the motor frame (MF). Figure 5C The end - plate (D) is also shown as a fully self - contained drive module as shown in 5D, which provides portability for repair or quick replacement with a new end - plate (D) drive module in a suitable environment when the old end - plate is damaged, thus giving the overall motor assembly design a "plug - and - play" style unique to the field of motor assemblies. By way of example, Figure 5C The junction box connector wires CW (e.g., which may be more or fewer wires than specifically shown), connector cover CC, connector hardware CH, dust seal DS, and end - plate mounting hardware MH are shown.

[0172] Figure 5D A self - contained drive module assembly is shown, for example, which includes end - plate D, junction box TB, wire channel WC, connector cover CC, connector cover hardware CCH, electronics module EM (see also Figure 7 and Fig. 10B ), end - plate cover gasket / insulator GI, end - plate cover EC, and end - plate cover hardware ECH.

[0173] Generally speaking, compared with Figure 5C and Figure 5DTo conform to what is shown, the process of removing the end plate D is as follows:

[0174] 1) Remove the shroud hardware (not shown) and the shroud S( Figure 5C ),

[0175] 2) Remove the fan fixing screws / hardware (not shown) and the fan F( Figure 5C ),

[0176] 3) Remove the connector cover hardware CCH and the connector cover CC,

[0177] 4) Disconnect the end plate connector (not shown) from the junction box connector wire TBCW,

[0178] 5) Remove the end plate mounting hardware ECH and the self - contained drive end plate (D) module EM.

[0179] The replaceable self - contained drive end plate (D) module EM can be reassembled onto the end plate D using the same steps.

[0180] Figures 6 to 10B : Power plane P

[0181] According to some embodiments, the invention disclosed herein may consist of a system or device, for example, having or in the form of a power plane P, which is configured to provide power and control functions, such as to operate a motor assembly to drive a pump or a rotating device. The power plane P has several highly engineered elements as follows:

[0182] By way of example, the power plane P may have a circular geometry for mounting within a space envelope SE( Figure 5D and Fig. 9 B) formed between an inner hub portion D 1 and a peripheral portion D 3 of the end plates D, D' (see, for example, Figure 1 , Figure 4 , Fig. 9 , Figure 11, Fig.14 ), where the peripheral portion circumferentially encloses the space envelope SE (also known as the electronic device housing chamber D 7 (see Figure 4 B, Figure 5D and Fig.14 B)). The power plane P can be a multi - layer circuit board or assembly, for example, having: a power layer, a control layer, and a thermal barrier and printed circuit board layer P(1). The power layer includes high - temperature power modules, such as a circular power module P / CM (see, for example, Fig. 17C), so as to supply power to an electric motor M (such as a pump or a rotating device). The control layer includes a lower temperature control electronics module, such as a power quality filtering capacitor IFC (for example, see Fig. 17C ), so as to control the power supplied to the electric motor M. Fig. 10B The thermal barrier and the printed circuit board layer P(1) in Fig. 10B are arranged between the power layer and the control layer, and provide an electrical connection path between the power module of the power plane and the control electronics module of the control layer, and also provide thermal insulation between the power layer and the control layer.

[0183] By way of example, the power plane P may be configured to at least perform the following actions:

[0184] 1) Allow power modules such as element P / CM (for example, see Fig. 10B ) to be mounted on the opposite side of the thermal barrier (such as the element P(1) shown in Fig. 10B and Fig. 17C ) and control electronics modules such as element IFC (for example, see Fig. 10B and Fig. 17C );

[0185] 2) Provide an electrical connection path (for example, see the connections C in Figure 7 and Fig.18B 1 , C 2 , C 3 and the gate driver or layer connection GDC) to interconnect a power module such as element P / CM and a control electronics module such as element IFC, and also to interconnect the input / output power connection (see Fig.18A , to understand the PEEK support PS(2), the input phase connection and the input phase line of the belt connection), a power module such as element P / CM (for example, see Fig. 17C ) and a control electronics module such as element IFC (for example, see Fig. 17C ), and

[0186] Fig. 17C 3) Insulate and / or direct the heat emitted from one or more of a power module such as element P / CM (for example, see Fig. 17C ), a control electronics module such as element IFC (for example, see Fig. 9 ) and the shaft or rotor R of the electric motor M to the outer diameter of the power plane, where there is a higher air flow, for example, this is in accordance with what is shown in Fig. 9 A and B.

[0187] Fig. 10B The power plane P may be configured as an annular power plane printed circuit board or assembly (such as Fig. 10BThe element P(1) therein is adapted to fit within the space envelope SE of the end plates D, D' so as to provide maximum space for mounting the power layer and the control layer and to allow the shaft or rotor R to pass therethrough for powering the cooling fan F (see Figure 1 and 11 ).

[0188] The power layer may be configured with an arrangement of higher temperature power modules (e.g., such as the element P / CM (FIG. 17C)). The control layer may be configured with an arrangement of lower temperature control electronics and power quality filter components (e.g., such as the element IFC( Figure 7 and Fig. 17C )). The thermal barrier and the printed circuit board layer P(1) may be configured of a material having the structural thickness and strength to mount the control layer on one side and the power layer on the opposite side. The fiberglass material is configured to provide insulation to reduce heat transfer between the power layer and the control layer.

[0189] It should be understood that the power layer and the control layer may include other modules or components within the spirit of the present invention, such as in accordance with what is disclosed herein, including one or more control cards, clamping capacitors, gate driver power sources, etc., such as as Fig. 10B and Fig.18B shown.

[0190] Theory of Operation :

[0191] In fact, the power plane P (see also Figure 1 and Fig.11 ) is a component that will be mounted within the space envelope SE of the end plates D, D' (FIGS. 1 and Fig.17 B) (e.g., see Fig.17 B). It shares the same circular geometry, which will allow the shaft or rotor R to pass therethrough for powering the cooling fan F( Figure 1 and FIG. 11). By way of example, the circular geometry may take the form of an annulus or a disc or may be characterized as an annulus or a disc, such as in accordance with what is disclosed herein. This will also allow for ease of manufacture and installation of its components. The power plane P consists of a number of elements, such as those shown and described relative to Figures 6 to 10B . These elements may include matrix converter power modules, matrix converter control electronics, power quality filter capacitors, and printed circuit boards, such as in accordance with what is disclosed herein. The power plane P has three functions:

[0192] (1) To provide a new geometry that allows the mounting of power modules and control electronics,

[0193] (2) To provide an electrical connection path for all modules and components mounted thereon, including power modules and control electronics, and

[0194] (3) Insulate / direct the heat emitted from all electronic power modules, control electronics, and the motor shaft R( Figure 1 and FIG. 11).

[0195] The matrix converter is a main system configured on the power plane P, and this main system is represented as shown, for example, as Figure 6 shown, Figure 6 including Figure 6 A, which shows a schematic diagram of a bidirectional switch, and this bidirectional switch uses, for example, IGBT technology to achieve the required power function( Figure 6 A); and also includes FIG. 6B, which shows a photograph of an example of a bidirectional switch power module for achieving the required power function. (As those skilled in the art will understand, an insulated gate bipolar transistor (IGBT) is a three-terminal power semiconductor device mainly used as an electronic switch, which combines high efficiency and fast switching when it was developed. For example, Infineon Technologies AG distributes various products using such IGBT technology.) The purpose of having Figure 6 such a circuit as shown in A is to allow the matrix converter to convert an AC input of fixed voltage and frequency into the required AC output waveform. Conventionally, in the prior art, the input AC power must be converted into a DC waveform before being synthesized into the AC output. According to some embodiments of the present invention, the matrix converter can be configured to perform this process with fewer components and in fewer steps. Among the electronic modules, the power quality filter IFC can be configured as the main component (see Figure 7 ). In this case, its function is to reduce the level of electrical noise and harmonic distortion, for example, which is in line with Figure 8 shown. In some embodiments according to the present invention, this power quality filter component can preferably be directly attached to a printed circuit board (such as component P(1)) as close as possible to the matrix converter. This greatly improves its ability to reduce the amount of distortion emitted from the matrix converter electronics. The overall geometry and dimensions of the power plane P allow for the convenience of manufacturing and installing the power modules and control electronics.

[0196] In Figure 1 and Fig.11 this power plane portion of the overall motor assembly shown, heat will be emitted from at least two sources: the power semiconductor module and the shaft or rotor R( Figure 1 and Fig.11 ). In line with what is set forth herein, the power semiconductor module can include one or more of the following: Fig. 17C the circular power module arrangement shown or Fig.18A the power module layout shown, Fig. 10BThe layout of the power module and the clamping module in or Fig. 10B The layout of the power / clamping module in. Although the middle plates E, E' (for example, see Figure 1 , Figure 2A , Figure 2B and Figure 3 ; Fig.11 , Fig. 12A , Fig. 12B , Fig.13 ) can be configured with an insulating layer (as described above) to protect the electronic devices, there may still be residual heat from the shaft or the rotor R. This is because there is a temperature difference between the fan side of the motor assembly ( Figure 1 and Fig.11 ) and the middle plate part. It should also be understood that the semiconductors in the power plane P will naturally generate heat during operation. The challenge is to maintain the operating temperature at which the electronic devices operate normally, for example, making it lower than the failure point of the electronic devices.

[0197] Therefore, thermal insulation and dissipation are two functions that the power plane P must perform. The former related to insulation is achieved through the multilayer circuit board implementation disclosed herein. The multilayer circuit board can be constructed from laminated materials such as fiberglass, which, by way of example, increases its thickness and strength. Fiberglass is known and should be understood as a strong and lightweight material used in insulation applications. This allows the power plane P to act as a thermal barrier between the hotter power module, power quality capacitor, and control electronics.

[0198] For the latter, the heat will be dissipated through the radiator fins D on the end plates D, D' 2 ' and / or D 3 ” ( Figure 4 and Fig.14 ). The radiator fins D 2 ' and / or D 3 ” will be air-cooled and act as a cooling mechanism. They operate through two forms of heat transfer: conduction and convection, where conduction should be understood as the heat transfer between solids in contact with each other, and convection should be understood as the heat transfer between a solid and a fluid. First, heat transfer will occur between the printed circuit board and the semiconductor. Then it travels to the end plates D, D' and the radiator fins D 2 ' and / or D 3 ”. Finally, convection occurs between the heat sink fins D 3 ” and the ambient air, which, for example, surrounds the overall motor assembly 10 ( Figure 1 ) and disperses the heat. For normal operation, the fins D 3 ” must be colder to absorb heat and must rise to a hot enough temperature to allow the heat to diffuse into the ambient air. Since the power plane P is also connected to the middle part D of the end plate D2 Share similar geometric shapes, so heat will be evenly distributed along this surface.

[0199] The overall configuration of this multi-purpose power plane P makes it an important contribution to the prior art. The spatial envelope SE( Figure 4 B, Figure 5D , Fig.17 B) from the end plates D, D' allocates space for the overall power plane P and allows it to support both power modules and control electronics. Additionally, the power plane P approaches the radiator fins D 2 ' and / or D 3 ”; thus enabling it to cool the electronics at operable temperatures. The fiberglass circuit board construction of the layer or element P(1) acts as an excellent insulator; thus separating the hotter power semiconductors from the sensitive control electronics and power quality capacitors. These combined components allow the power plane P to facilitate operating conditions and keep the temperature of the control electronics well below the maximum temperature level.

[0200] advantage

[0201] The advantages of this power plane implementation may include one or more of the following:

[0202] The printed circuit board layer P(1) can be configured to act as a thermal barrier between the hotter power module and the cooler control electronics and power quality capacitor regions.

[0203] The overall power plane implementation can be configured to direct heat to the outer diameter where there is higher air flow and away from the control circuit, such as shown by the Fig. 9 best representation.

[0204] The overall printed circuit board assembly provides a low inductance and resistance input between the power quality capacitor and the power semiconductor module, thereby reducing switching stress and electromagnetic interference, such as is consistent with the Figure 8 curve shown in the diagram.

[0205] The overall power plane implementation can be configured with a unique compact power quality filter arrangement integrated into the power plane P.

[0206] The overall power plane implementation can be configured with a built-in power quality filter that produces minimal harmonic distortion and protects variable frequency electronics from most power quality anomalies.

[0207] The overall power plane implementation can be configured with or as a unique annular power plane printed circuit board (PCB), such as shaped like component P(1), to fit within the space envelope SE of the motor end plate D, thereby providing maximum space utilization and simplifying construction and manufacturing. (By way of example, see Figure 1 and Fig.11 shown, as well as Figure 7 、 Fig.16 and Fig.18B shown)

[0208] This annulus allows the motor shaft or rotor R( Figure 1 and Fig.11 ) to pass through to power the cooling fan F.

[0209] The overall power plane implementation combines power and control modules, circuits, or components into an integrated printed circuit board assembly, such as as Fig.18B shown, to achieve ease of assembly and compactness of size.

[0210] The overall power plane implementation provides interconnections to input / output power, current sensors, gate driver GDPS, clamp control circuit CC, power / clamp semiconductor modules, power quality capacitors IFC, for example, in cases where limited wiring and connectors are required, thereby allowing robust and reliable operation.

[0211] The overall power plane implementation allows for the fabrication of an embedded electronic motor drive within the space envelope of the motor at power levels greater than those currently produced in the market.

[0212] The motor frame or housing MF( Figure 5A and Fig.15 ) effectively serves as a heat sink to allow for a compact size and thermally optimized operation of the power plane P and matrix converter configuration.

[0213] Scope of the Invention

[0214] It should be understood that any feature, characteristic, alternative, or variation described herein for a specific embodiment can also be applied, used, or combined with any other embodiment described herein, unless otherwise specified herein. Additionally, the figures herein are not drawn to scale.

[0215] Although the invention has been described and illustrated for its exemplary embodiments, these embodiments can be subjected to the foregoing as well as various other additions and omissions without departing from the spirit and scope of the invention.

Claims

1. A motor assembly, comprising: a motor housing; a motor located within the motor housing and having a rotor; a middle plate arranged to be in line with at least a part of the motor housing and close to the at least a part of the motor housing; an end plate arranged to be in line with at least a part of the middle plate and close to the at least a part of the middle plate such that the middle plate is located between the motor housing and the end plate, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity; and a variable frequency drive electronics unit arranged within the cavity and configured to supply power to the motor, the variable frequency drive electronics unit comprising: a circuit board; a plurality of power switch components; and a plurality of power control components, wherein the circuit board is arranged between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are distributed around the center of the circuit board.

2. The motor assembly according to claim 1, further comprising a thermal insulator disposed between the middle plate and the end plate.

3. The motor assembly according to claim 1, wherein, the variable frequency drive electronics unit implements a matrix converter for converting an AC input signal into a converted AC output signal.

4. The motor assembly according to claim 1, wherein, the plurality of power control components include a plurality of power quality filter components mounted to the circuit board around the center of the circuit board.

5. The motor assembly according to claim 1, wherein, one or both of the peripheral wall and the end wall include radiator fins configured to dissipate heat generated by the plurality of power switch components and the plurality of power control components.

6. The motor assembly according to claim 1, wherein, the motor assembly drives a pump or a rotating device.

7. The motor assembly according to claim 1, wherein, the middle plate includes a plurality of internal radiator fins on an inner surface of the middle plate, the plurality of internal radiator fins extending radially between the center and the periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

8. The motor assembly according to claim 7, wherein, the middle plate further includes external radiator fins on and around a peripheral portion of the middle plate, the external radiator fins configured to dissipate heat from the middle plate.

9. The motor assembly according to claim 8, wherein, the middle plate has an opening configured to receive at least a part of the rotor passing therethrough, the rotor extending through a bearing assembly coupled to the middle plate, the plurality of internal radiator fins configured to direct heat from the rotor to the periphery of the middle plate.

10. A motor assembly, comprising: a motor housing; a motor located within the motor housing and having a rotor; A middle plate, the middle plate being arranged to be in a straight line with at least a part of the motor housing and close to the at least a part of the motor housing; An end plate, the end plate being arranged to be in a straight line with at least a part of the middle plate and close to the at least a part of the middle plate, such that the middle plate is located between the motor housing and the end plate, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity; And A variable frequency drive electronics unit, the variable frequency drive electronics unit being arranged in the cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components; and A plurality of power control components, wherein the circuit board is arranged between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are circumferentially distributed around the center of the circuit board.

11. The motor assembly according to claim 10, further comprising a thermal insulator disposed between the middle plate and the end plate.

12. The motor assembly according to claim 10, Wherein, The variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

13. The motor assembly according to claim 10, Wherein, The plurality of power control components include a plurality of power quality filter components mounted to the circuit board around the center of the circuit board.

14. The motor assembly according to claim 10, Wherein, One or both of the peripheral wall and the end wall include radiator fins configured to dissipate heat generated by the plurality of power switch components and the plurality of power control components.

15. The motor assembly according to claim 10, Wherein, The motor assembly drives a pump or a rotating device.

16. The motor assembly according to claim 10, Wherein, The middle plate includes a plurality of internal radiator fins on an inner surface of the middle plate, the plurality of internal radiator fins extending radially between the center and the periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

17. An assembly, Comprising: A middle plate having a first end configured to be in a straight line with at least a part of a motor housing of a motor and disposed close to the at least a part of the motor housing; An end plate configured to be in a straight line with a second end of the middle plate opposite to the first end and disposed close to the second end, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity; And A variable frequency drive electronics unit, the variable frequency drive electronics unit being arranged in the cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components; and A plurality of power control components, wherein the circuit board is arranged between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are distributed around the center of the circuit board.

18. The assembly according to claim 17, wherein, the plurality of power control components include a plurality of power quality filter components.

19. The assembly according to claim 17, wherein, the middle plate includes a plurality of internal heat sink fins on the inner surface of the middle plate, the plurality of internal heat sink fins extending radially between the center and the periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

20. The assembly according to claim 19, wherein, the middle plate further includes external heat sink fins on and around the peripheral portion of the middle plate, the external heat sink fins configured to dissipate heat from the middle plate.

21. The assembly according to claim 20, wherein the middle plate has an opening configured to receive at least partially therethrough the rotor of the motor, the rotor extending through a bearing assembly coupled to the middle plate, and the plurality of internal heat sink fins are configured to direct heat from the rotor to the periphery of the middle plate.

22. The assembly according to claim 17, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

23. A motor assembly, comprising: a motor housing; a motor located within the motor housing and having a rotor; a junction box disposed on the motor housing; a middle plate disposed in alignment with at least a portion of the motor housing and adjacent to the at least a portion of the motor housing, and the middle plate having an opening configured to receive at least partially therethrough the rotor, the rotor extending through a bearing assembly coupled to the middle plate; an end plate disposed in alignment with at least a portion of the middle plate and adjacent to the at least a portion of the middle plate such that the middle plate is located between the motor housing and the end plate, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity, the end plate including one or more electrical connection paths aligned with the junction box, wherein the one or more electrical connection paths are spaced apart from the peripheral wall and the end wall defining the cavity; a fan, wherein the end plate is disposed between the fan and the middle plate, and wherein operation of the fan cools the end plate; and a variable frequency drive electronics unit disposed within the cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: a circuit board; and a plurality of power switch components mounted to the circuit board.

24. The motor assembly according to claim 23, wherein, The one or more electrical connection paths include a pair of line channels.

25. The motor assembly according to claim 23, wherein, the middle plate includes a plurality of internal heat sink fins located on an inner surface of the middle plate, the plurality of internal heat sink fins extending radially between a center of the middle plate and a periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

26. The motor assembly according to claim 23, wherein, the middle plate further includes external heat sink fins located on and around a peripheral portion of the middle plate, the external heat sink fins configured to dissipate heat from the middle plate.

27. The motor assembly according to claim 26, wherein, the plurality of internal heat sink fins are configured to direct heat from the rotor to the periphery of the middle plate.

28. The motor assembly according to claim 23, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

29. The motor assembly according to claim 23, wherein, the variable frequency drive electronics unit further includes a plurality of power control components, the plurality of power control components including a plurality of power quality filter components mounted to the circuit board around a center of the circuit board.

30. The motor assembly according to claim 23, wherein, the motor assembly drives a pump or a rotating device.

31. The motor assembly according to claim 23, further comprising a fan, the fan being arranged in line with the end plate such that the end plate is disposed between the fan and the middle plate.

32. The motor assembly according to claim 23, wherein, one or both of the peripheral wall and the end wall include heat sink fins configured to dissipate heat generated by the plurality of power switch components and the plurality of power control components.

33. A motor assembly, comprising: a motor housing; a motor located within the motor housing and having a rotor; a middle plate disposed in line with and adjacent to at least a portion of the motor housing, the middle plate having an opening configured to receive at least a portion of the rotor passing therethrough, the rotor extending through a bearing assembly coupled to the middle plate; an end plate disposed in line with and adjacent to at least a portion of the middle plate such that the middle plate is located between the motor housing and the end plate, the end plate including a housing and one or more electrical connection paths aligned with a junction box, wherein the one or more electrical connection paths are spaced from a peripheral wall and an end wall defining the housing; a fan, wherein the end plate is disposed between the fan and the middle plate, and wherein operation of the fan cools the end plate; and a variable frequency drive electronics unit disposed within the housing and configured to supply power to the motor, the variable frequency drive electronics unit including: a circuit board; and A plurality of power switch components mounted to the circuit board.

34. The motor assembly according to claim 33, wherein, the junction box is supported by the motor housing, and wherein the one or more electrical connection paths are configured to facilitate an electrical connection between the variable frequency drive electronics unit and the junction box.

35. The motor assembly according to claim 33, wherein, the middle plate includes a plurality of internal heat sink fins on an inner surface of the middle plate, the plurality of internal heat sink fins extending radially between a center of the middle plate and a periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

36. The motor assembly according to claim 35, wherein, the middle plate further includes external heat sink fins on and around a peripheral portion of the middle plate, the external heat sink fins configured to dissipate heat from the middle plate.

37. The motor assembly according to claim 36, wherein, the plurality of internal heat sink fins are configured to direct heat from the rotor to the periphery of the middle plate.

38. The motor assembly according to claim 33, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

39. The motor assembly according to claim 33, wherein, the variable frequency drive electronics unit further includes a plurality of power control components, the plurality of power control components including a plurality of power quality filter components mounted around a center of the circuit board to the circuit board.

40. The motor assembly according to claim 33, wherein, the motor assembly drives a pump or a rotating device.

41. The motor assembly according to claim 33, further comprising a fan, the fan being arranged in line with the end plate such that the end plate is disposed between the fan and the middle plate.

42. The motor assembly according to claim 33, wherein, one or both of the peripheral wall of the end plate and the end wall of the end plate include heat sink fins configured to dissipate heat generated by the plurality of power switch components and the plurality of power control components.

43. The motor assembly according to claim 33, further comprising a thermal insulator disposed between the middle plate and the end plate.

44. The motor assembly according to claim 33, wherein, the housing is a sealed housing.

45. A motor assembly, comprising: a motor housing; a motor located within the motor housing and having a rotor; an end plate disposed in line with the motor housing, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity, the end plate including one or more connectors extending beyond a periphery of the motor housing and aligned with a junction box on the motor housing, wherein the one or more connectors are spaced apart from the peripheral wall and the end wall defining the cavity; and A variable frequency drive electronic device unit, the variable frequency drive electronic device unit being disposed within the cavity and configured to supply power to the motor, the variable frequency drive electronic device unit comprising: A circuit board; and A plurality of power switch components mounted to the circuit board, wherein one or more wires of the variable frequency drive electronic device unit are routed to the junction box via the one or more connectors.

46. The motor assembly according to claim 45, wherein, the one or more connectors are a pair of connectors.

47. The motor assembly according to claim 45, further comprising a middle plate, the middle plate being arranged in alignment with at least a part of the motor housing and adjacent to the at least a part of the motor housing, the middle plate being disposed between the motor housing and the end plate.

48. The assembly according to claim 47, wherein, the middle plate includes a plurality of internal heat sink fins located on an inner surface of the middle plate, the plurality of internal heat sink fins extending radially between a center and a periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

49. The motor assembly according to claim 48, wherein, the middle plate has an opening configured to receive at least a part of the rotor passing therethrough, the rotor extending through a bearing assembly coupled to the middle plate, the plurality of internal heat sink fins being configured to direct heat from the rotor to the periphery of the middle plate.

50. The motor assembly according to claim 45, wherein, the variable frequency drive electronic device unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

51. The motor assembly according to claim 45, further comprising a plurality of power control components mounted to the circuit board around a center of the circuit board.

52. The motor assembly according to claim 45, wherein, the motor assembly drives a pump or a rotating device.

53. A motor assembly, comprising: A motor housing; A motor located within the motor housing and having a rotor; An end plate arranged in alignment with the motor housing, the end plate having a peripheral wall and an end wall, the peripheral wall and the end wall together at least partially defining a cavity, the end plate including a pair of spaced-apart connectors for connection to a junction box on the motor housing, wherein the pair of spaced-apart connectors extend beyond a periphery of the motor housing and are aligned with the junction box; and A variable frequency drive electronic device unit, the variable frequency drive electronic device unit being disposed within the cavity and configured to supply power to the motor, the variable frequency drive electronic device unit comprising: A circuit board; and A plurality of power switch components mounted to the circuit board, wherein one or more wires of the variable frequency drive electronic device unit are routed to the junction box via the pair of spaced-apart connectors.

54. The motor assembly according to claim 53, wherein, the pair of spaced-apart connectors are spaced from the peripheral wall and the end wall defining the cavity.

55. The motor assembly according to claim 53, wherein, each of the pair of spaced-apart connectors includes a passage through which the one or more wires exit the cavity.

56. The motor assembly according to claim 53, further comprising a middle plate disposed in alignment with and adjacent to at least a portion of the motor housing, the middle plate being positioned between the motor housing and the end plate.

57. The assembly according to claim 56, wherein, the middle plate includes a plurality of internal heat sink fins on an inner surface of the middle plate, the plurality of internal heat sink fins extending radially between a center and a periphery of the middle plate and configured to direct heat to the periphery of the middle plate.

58. The motor assembly according to claim 56, wherein, the middle plate has an opening configured to receive at least a portion of the rotor passing therethrough, the rotor extending through a bearing assembly coupled to the middle plate, and the plurality of internal heat sink fins are configured to direct heat from the rotor to the periphery of the middle plate.

59. The motor assembly according to claim 53, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

60. An assembly, comprising: an end plate configured to be disposed in alignment with a motor housing, the end plate having a peripheral wall and an end wall that together at least partially define a cavity, the end plate including one or more connectors configured to connect to a junction box on the motor housing, wherein the one or more connectors extend beyond a periphery of the motor housing and are aligned with the junction box, and wherein the one or more connectors are spaced apart from the peripheral wall and the end wall that define the cavity; and a variable frequency drive electronics unit disposed within the cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: a circuit board; and a plurality of power switch components mounted to the circuit board, wherein one or more wires of the variable frequency drive electronics unit are routed to the junction box via the one or more connectors.

61. The assembly according to claim 60, wherein, the one or more connectors are a pair of connectors.

62. The assembly according to claim 60, wherein, the one or more connectors include a passage through which the one or more wires exit the cavity.

63. The assembly according to claim 60, wherein, the plurality of power switch components are circumferentially distributed around a center of the circuit board.

64. The assembly according to claim 60, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

65. A motor assembly, comprising: a motor housing; a motor at least partially disposed within the motor housing; A mid-plate, the mid-plate being arranged in a straight line with at least a part of the motor housing and being close to the at least a part of the motor housing, the mid-plate having a peripheral wall and a bottom wall, the peripheral wall and the bottom wall together defining a first cavity, the mid-plate including a plurality of internal radiator fins located on the bottom wall, the plurality of internal radiator fins extending radially between the center of the mid-plate and the peripheral wall of the mid-plate and configured to direct heat to the peripheral wall of the mid-plate; An end-plate, the end-plate being arranged in a straight line with at least a part of the mid-plate and being close to the at least a part of the mid-plate such that the mid-plate is located between the motor housing and the end-plate, the end-plate having a second cavity; And A variable frequency drive electronics unit, the variable frequency drive electronics unit being disposed in the second cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components; and A plurality of power control components, wherein the circuit board is arranged between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are distributed around the center of the circuit board.

66. The motor assembly according to claim 65, Wherein, The variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

67. The motor assembly according to claim 66, Wherein, The plurality of power control components include a plurality of power quality filter components mounted to the circuit board around the center of the circuit board.

68. The motor assembly according to claim 65, Wherein, The end-plate includes radiator fins configured to dissipate heat from the end-plate.

69. The motor assembly according to claim 68, further comprising a fan, the fan being mounted in a straight line with the end-plate and coupled to the rotor of the motor, the fan being capable of rotating through the rotor to cause air to flow through at least a part of the radiator fins to dissipate heat from the end-plate.

70. The motor assembly according to claim 65, Wherein, The mid-plate further includes external radiator fins located on and around the peripheral portion of the mid-plate, the external radiator fins being configured to dissipate heat from the mid-plate.

71. The motor assembly according to claim 70, Wherein, The mid-plate has an opening configured to receive at least partially therethrough the rotor of the motor, the rotor extending through a bearing assembly coupled to the mid-plate, the plurality of internal radiator fins being configured to direct heat from the rotor to the periphery of the mid-plate.

72. A motor assembly, Comprising: A motor housing; A motor, the motor being at least partially disposed in the motor housing and having a rotor; A middle plate, the middle plate being arranged in a straight line with at least a part of the motor housing and being close to the at least a part of the motor housing, the middle plate having a peripheral wall and a bottom wall, the peripheral wall and the bottom wall together defining a first cavity, the middle plate having an opening configured to receive the rotor that at least partially passes through it, the rotor extending through a bearing assembly coupled to the middle plate, the middle plate including a plurality of internal radiator fins located on the bottom wall, the plurality of internal radiator fins extending radially between the center of the middle plate and the peripheral wall of the middle plate and configured to direct heat from the rotor to the peripheral wall of the middle plate; An end plate, the end plate being arranged in a straight line with at least a part of the middle plate and being close to the at least a part of the middle plate such that the middle plate is located between the motor housing and the end plate, the end plate having a second cavity and a plurality of radiator fins configured to dissipate heat from the end plate; A fan, the fan being mounted in a straight line with the end plate and coupled to the rotor, wherein the fan is capable of rotating to cause air to flow through at least a part of the plurality of radiator fins of the end plate to dissipate heat from the end plate; And A variable frequency drive electronics unit, the variable frequency drive electronics unit being disposed in the second cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components; and A plurality of power control components, wherein the circuit board is arranged between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are distributed around the center of the circuit board.

73. The motor assembly according to claim 72, wherein, The variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

74. The motor assembly according to claim 72, wherein, The plurality of power control components include a plurality of power quality filter components mounted to the circuit board.

75. The motor assembly according to claim 72, wherein, The middle plate further includes external radiator fins located on a peripheral portion of the middle plate, the external radiator fins being configured to dissipate heat from the middle plate.

76. The motor assembly according to claim 75, wherein, The plurality of internal radiator fins are configured to direct heat from the rotor to the periphery of the middle plate.

77. An assembly, comprising: A middle plate, the middle plate being configured to be in a straight line with at least a part of a motor housing and being disposed close to the at least a part of the motor housing, the middle plate having a peripheral wall and a bottom wall, the peripheral wall and the bottom wall together defining a first cavity, the middle plate including a plurality of internal radiator fins located on the bottom wall, the plurality of internal radiator fins extending radially between the center of the middle plate and the peripheral wall of the middle plate and configured to direct heat to the peripheral wall of the middle plate; An end plate, the end plate being configured to be in line with at least a portion of the middle plate and disposed adjacent to the at least a portion of the middle plate such that the middle plate is disposed between the motor housing and the end plate, the end plate having a second cavity and a plurality of radiator fins on a surface of the end plate configured to dissipate heat from the end plate; and A variable frequency drive electronics unit, the variable frequency drive electronics unit being disposed within the second cavity and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components; and A plurality of power control components, wherein the circuit board is disposed between the plurality of power switch components and the plurality of power control components, and wherein the plurality of power control components or the plurality of power switch components or both the plurality of power control components and the plurality of power switch components are distributed around the center of the circuit board.

78. The assembly according to claim 77, wherein, The variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

79. The assembly according to claim 77, wherein, The plurality of power control components include a plurality of power quality filter components mounted to the circuit board around the center of the circuit board.

80. The assembly according to claim 77, wherein, The middle plate further includes external radiator fins on and around a peripheral portion of the middle plate, the external radiator fins being configured to dissipate heat from the middle plate.

81. The assembly according to claim 80, wherein, The middle plate has an opening configured to receive at least a portion of the rotor of the motor passing therethrough, the rotor extending through a bearing assembly coupled to the middle plate, and the plurality of internal radiator fins are configured to direct heat from the rotor to a periphery of the middle plate.

82. The assembly according to claim 77, further comprising a fan, the fan being mounted in line with the end plate and coupled to the rotor of the motor, the fan being capable of rotating to cause air to flow over at least a portion of the radiator fins of the end plate to dissipate heat from the end plate.

83. A motor assembly, comprising: A motor housing; A motor, the motor being located within the motor housing; A rotor, the rotor being coupled to the motor and extending along an axis beyond the motor housing; A drive electronics housing, the drive electronics housing being mounted in line with the motor housing, the drive electronics housing including: A peripheral wall; and An internal volume defined by an inner surface of the peripheral wall; and A variable frequency drive electronics unit, the variable frequency drive electronics unit being disposed within the internal volume and configured to supply power to the motor, the variable frequency drive electronics unit including: A circuit board; A plurality of power switch components, the plurality of power switch components being mounted to a first side of the circuit board and arranged around the center of the circuit board; and A plurality of power control components, the plurality of power control components being mounted to a second side of the circuit board opposite the first side.

84. The motor assembly according to claim 83, wherein, the drive electronics housing is configured for removably mounting to the motor assembly.

85. The motor assembly according to claim 83, wherein, the variable frequency drive electronics unit implements a matrix converter that converts an AC input signal into a converted AC output signal.

86. The motor assembly according to claim 83, wherein, the plurality of power control components include a plurality of power quality filter components mounted to the second side of the circuit board around the center of the circuit board.

87. The motor assembly according to claim 83, wherein, the drive electronics housing includes radiator fins configured to dissipate heat generated by the plurality of power switch components and the plurality of power control components.

88. The motor assembly according to claim 83, wherein, the motor assembly drives a pump or a rotating device.

89. The motor assembly according to claim 83, further comprising a middle plate mounted between the motor housing and the drive electronics housing in line with the motor housing, the middle plate including a plurality of cooling fins configured to direct heat to the periphery of the middle plate.

90. The motor assembly according to claim 89, wherein, the middle plate has an opening configured to receive the rotor, and the cooling fins are configured to direct heat generated by the rotation of the rotor to the periphery of the middle plate.

91. The motor assembly according to claim 90, wherein, the drive electronics housing includes an opening configured to receive the rotor, the motor assembly further includes a cooling fan driven by the rotor, and the drive electronics housing is located between the cooling fan and the middle plate.

92. An apparatus, comprising: a drive electronics housing configured for co-linear mounting with a motor housing, the drive electronics housing including: a peripheral wall; and an internal volume defined by an inner surface of the peripheral wall; a variable frequency drive electronics unit disposed within the internal volume and configured to supply power to a motor, the variable frequency drive electronics unit including: a circuit board; a plurality of power switch components mounted to a first side of the circuit board and arranged around the center of the circuit board; and a plurality of power control components mounted to a second side of the circuit board opposite the first side.

93. The apparatus according to claim 92, wherein, the plurality of power control components are arranged around the center of the circuit board.

94. The apparatus according to claim 93, wherein, the plurality of power control components include power quality filter components.

95. The apparatus according to claim 92, wherein, the drive electronics housing is configured for removable mounting.

96. The device according to claim 93, wherein, the drive electronics housing is an end plate configured to be removably mounted to a mid-plate, the mid-plate being mounted in a straight line between the motor housing and the end plate and being in line with the motor housing.

97. The device according to claim 92, wherein, the power switch component forms part of a matrix converter.

98. The device according to claim 92, wherein, the drive electronics housing includes one or more channels for accommodating power lines that extend between the variable frequency drive electronics unit and the motor when the variable frequency drive electronics unit is installed.

99. A variable frequency drive unit, comprising: a circuit board; variable frequency drive electronics configured to provide a variable frequency power drive signal to a motor, the variable frequency drive electronics including: power switch electronics including a plurality of power switch components mounted to a first side of the circuit board and arranged around the center of the circuit board; power control electronics including a plurality of power control components mounted to a second side of the circuit board opposite the first side; and one or more connection paths extending from the first side of the circuit board to the second side of the circuit board and configured to electrically couple the power switch electronics and the power control electronics, the circuit board being configured to provide thermal insulation between the power switch electronics and the power control electronics.

100. The variable frequency drive unit according to claim 99, wherein, the plurality of power switch components are arranged in a circular pattern and the plurality of power control components are arranged in a circular pattern.

101. The variable frequency drive unit according to claim 100, wherein, the plurality of power control components include power quality filter components.

102. The variable frequency drive unit according to claim 99, wherein, the circuit board includes a circular perimeter, and wherein the circuit board on which the power switch components and the power control components are mounted is sized to fit within a circular space envelope of the drive electronics housing.

103. The variable frequency drive unit according to claim 99, wherein, the power switch component forms part of a matrix converter.

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