Refrigeration system, motor thereof and glue filling method of motor

Abstract

The application discloses a refrigeration system and a motor thereof and a glue pouring method of the motor. The motor comprises a stator, a rotor, a rotating shaft and an integrally formed fan. A fan hub of the fan has a first annular shell and a second annular shell surrounding the first annular shell. An upper end of the rotating shaft is embedded in the first annular shell and is integrally injection molded with the first annular shell. A magnetic yoke of the rotor is embedded in the second annular shell and is integrally injection molded with the second annular shell. In this way, the rotating parts of the motor have good consistency, and the end face runout, unbalance and other parameters of the rotating parts are easy to control, so that the motor runs stably and has low running noise. In addition, the motor further comprises a PCB board fixed at a lower end of the stator and an electric control component arranged on the PCB board. The PCB board and the electric control component are both sealed by the glue. In this way, the PCB board and the electric control component can be prevented from being dampened and disabled, and the failure rate of the PCB board and the electric control component is reduced.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a motor for a refrigeration system and a method for potting the motor. Background Technology

[0002] Some refrigeration systems (such as air-cooled refrigerators) typically use motors equipped with fans. These motors usually include components such as a rotor, shaft, yoke, and fan, which are then assembled together using a press-fit method to form a single structure. Imbalances and vibrations between the components can occur, resulting in relatively high noise levels.

[0003] In view of this, developing a motor for refrigeration systems that operates more smoothly and with less noise is a technical problem that needs to be solved by those skilled in the art. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a motor for a refrigeration system, the motor including a stator, a rotor, a shaft and an integrally formed fan; the fan hub has a first annular shell and a second annular shell surrounding the first annular shell; the upper end of the shaft is embedded in the first annular shell and integrally molded with the first annular shell, and the magnetic yoke of the rotor is embedded in the second annular shell and integrally molded with the second annular shell.

[0005] This design allows the shaft, rotor yoke, and fan to form a single injection-molded unit. Compared to structures formed by pressing the components together or connecting them with other connectors, this design offers better consistency, making parameters such as end-face runout and imbalance easier to control. This results in smoother fan operation and lower noise. Furthermore, the manufacturing process eliminates the need for repeated adjustments to fan blade runout and concentricity, simplifying the manufacturing process and reducing costs.

[0006] In addition, the present invention also provides a refrigeration system, the refrigeration system including a motor, the motor being any of the motors described above.

[0007] Furthermore, the present invention also provides a method for potting an electric motor, wherein the potting method is as follows:

[0008] First, configure a cable sleeve whose shape matches the outlet and whose hole shape matches the conductor, and then put the cable sleeve over the conductor.

[0009] Then, the stator is fixed to the outer periphery of the third annular shell, so that the PCB board and the electronic control assembly are located in the annular groove;

[0010] Next, install the cable sleeve on the cable outlet;

[0011] Then, the potting compound is poured in. Attached Figure Description

[0012] Figure 1 A schematic diagram of the overall structure of a specific embodiment of the motor provided by the present invention;

[0013] Figure 2 This is an exploded view of a specific embodiment;

[0014] Figure 3 This is a cross-sectional view of a specific embodiment;

[0015] Figure 4 This is a schematic diagram of the overall structure of the injection molded part in a specific embodiment;

[0016] Figure 5 This is a schematic diagram of the components inside the shaft hole in a specific embodiment;

[0017] Figure 6 This is a schematic diagram of the elastic limiting member in a specific embodiment.

[0018] in, Figures 1 to 4 The annotations in the accompanying drawings are explained as follows:

[0019] A. Injection molding as a whole;

[0020] 1. Fan, 11. Hub, 111. First annular shell, 112. Second annular shell, 113. Upper shell, 12. Fan blades, 13. Fan frame;

[0021] 2. Base, 21. Third annular shell, 22. Fourth annular shell, 221. Cable outlet, 23. Lower shell, 24. Annular frame, 25. Lug;

[0022] a. Annular groove, a1. Potting compound, b. Shaft hole, b1. Magnetic box, b2. Magnetic sheet, b3. Graphite sheet, b4. Elastic limiting component, b41. Through hole, b42. Long hole, b5. Bearing.

[0023] 3 rotors, 31 magnetic yokes, 32 magnetic rings;

[0024] 4 rotating shafts, 41 limiting slots;

[0025] 5 stator, 51 iron core, 52 frame, 53 winding;

[0026] 6 PCB boards;

[0027] 7. Electrical control components, 71. Chip, 72. Peripheral functional circuit;

[0028] 8 wires. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] Figure 1 A schematic diagram of the overall structure of a specific embodiment of the motor provided by the present invention; Figure 2 This is an exploded view of a specific embodiment; Figure 3 This is a cross-sectional view of a specific embodiment; Figure 4 This is a schematic diagram of the overall structure of the injection molded part in a specific embodiment; Figure 5 This is a schematic diagram of the components inside the shaft hole in a specific embodiment; Figure 6 This is a schematic diagram of the elastic limiting member in a specific embodiment.

[0031] First, it should be noted that the terms "above" and "below" in the context are based on... Figures 1-3 From this perspective, the purpose is to clearly describe the technical solution, and it should not be understood as a limitation on the technical solution.

[0032] like Figures 1-3 As shown, the motor includes components such as fan 1, base 2, rotor 3, shaft 4, stator 5, PCB board 6, electrical control components 7, and wires 8.

[0033] The structure, function, and connection relationships between these components are described in detail below:

[0034] Fan 1

[0035] like Figure 2 and Figure 3 As shown, the fan 1 includes a hub 11, a blade 12, and a frame 13, which are integrally formed, specifically, they are integrally injection molded.

[0036] like Figure 2 and Figure 3 As shown, the fan hub 11 has a first annular shell 111, a second annular shell 112, and an upper shell 113. The second annular shell 112 is disposed around the first annular shell 111 and is coaxial with the first annular shell 111. The upper shell 113 is disposed at the upper end of the first annular shell 111 and the second annular shell 112.

[0037] Base 2

[0038] like Figure 2 and Figure 3 As shown, the base 2 includes a third annular shell 21, a fourth annular shell 22, a lower end shell 23, an annular frame 24, and a lug 25.

[0039] The third annular shell 21 surrounds the shaft hole b, and the upper end of the third annular shell 21 extends into the second annular shell 112.

[0040] The fourth annular shell 22 is arranged around the third annular shell 21 and is coaxial with the third annular shell 21, and the fourth annular shell 22 is provided with a cable outlet 221.

[0041] The lower shell 23 closes the bottom ends of the third annular shell 21 and the fourth annular shell 22. The third annular shell 21, the fourth annular shell 22 and the lower shell 23 together form an annular groove a.

[0042] Among them, the annular frame 24 is arranged around the fourth annular shell 22.

[0043] The lugs 25 are located on the outer periphery of the ring frame 24, and each lug 25 is provided with a connecting hole.

[0044] Rotor 3 and shaft 4

[0045] like Figure 3 As shown, the rotor 3 includes a magnetic yoke 31 and a magnetic ring 32 embedded inside the magnetic yoke 31. Furthermore, the magnetic yoke 31 is embedded in the aforementioned second annular shell 112 and is injection molded integrally with the second annular shell 112.

[0046] like Figure 3 As shown, the upper end of the rotating shaft 4 is embedded in the first annular shell 111 and is injection molded as a whole with the first annular shell 111.

[0047] With this setting, such as Figure 4 As shown, the rotating shaft 4, the magnetic yoke 31 of the rotor 3, and the fan 1 are formed into a single injection-molded unit A. Compared to structures formed by pressing the components together or connecting them with other connectors, this design offers better consistency. Parameters such as end face runout and imbalance are easier to control, resulting in smoother operation and lower noise for the fan 1. Structures formed by pressing and assembling individual components tend to experience more severe end face runout and vibration during operation, generating greater noise and potentially failing to meet the noise requirements of the refrigeration system (e.g., the noise requirement for the entire refrigerator is 40 dB / m). Furthermore, when installed inside the refrigeration system, the electrical components of the motor have a shorter lifespan and a relatively higher failure rate.

[0048] Moreover, since the fan blades and rotor are injection molded as a single unit, the structure provided in this embodiment does not require repeated adjustments to the fan blade runout, concentricity, etc. during the manufacturing process, making the manufacturing process simpler and the manufacturing cost lower.

[0049] Specifically, such as Figure 5 As shown, the lower end of the rotating shaft 4 extends into the shaft hole b, and a bearing b5 is provided in the shaft hole b. The inner circumferential surface of the bearing b5 mates with the outer circumferential surface of the rotating shaft 4, and the outer circumferential surface of the bearing b5 mates with the inner circumferential wall of the third annular shell 21.

[0050] Furthermore, such as Figure 5As shown, a limiting groove 41 is provided at the lower end of the rotating shaft 4, and an elastic limiting member b4 is provided in the shaft hole b. The elastic limiting member b4 has a through hole b41 through which the rotating shaft 4 passes, and the inner edge of the elastic limiting member b4 extends into the limiting groove 41.

[0051] It is understood that the diameter of the through hole b41 is smaller than the diameter of the lower end of the rotating shaft 4. Therefore, the limiting member is set as an elastic limiting member b4. When the rotating shaft 4 is assembled, the lower end of the rotating shaft 4 will push against the elastic limiting member b4 to deform, so that the rotating shaft 4 can pass smoothly through the through hole b41.

[0052] By setting the limiting groove 41 and the elastic limiting member b4 as described above, after the rotating shaft 4 moves upward a certain distance, the lower end face of the elastic limiting member b4 abuts against the lower groove wall of the limiting groove 41, thereby limiting the rotating shaft 4 to continue moving upward, thus preventing the rotating shaft 4 and components such as the fan 1 and the magnetic yoke 31 that are integrated with it from detaching from the base 2.

[0053] In a specific embodiment, such as Figure 6 As shown, the periphery of the through hole b41 of the elastic limiting member b4 is provided with several elongated holes b42 (three in the figure) that communicate with the through hole b41, and a flap is formed between adjacent elongated holes b42. With this arrangement, when assembling the rotating shaft 4, the lower end of the rotating shaft 4 pushes down against each flap, and each flap deforms downward, causing the through hole b41 to open up, thereby facilitating the assembly of the rotating shaft 4.

[0054] Furthermore, the lower end of the rotating shaft 4 is magnetic, and, as... Figure 5 As shown, a magnetic box b1 is installed at the bottom of the shaft hole b, and a magnetic sheet b2 is disposed inside the magnetic box b1. The magnetic sheet b2 is located directly below the rotating shaft 4. Specifically, a graphite sheet b3 is disposed between the magnetic sheet b2 and the rotating shaft 4.

[0055] With this configuration, the magnetic plate b2 attracts the rotating shaft 4 along the axial direction, thereby reducing the axial vibration of the fan 1 and further reducing noise.

[0056] Stator 5

[0057] like Figure 3 As shown, the stator 5 is fixedly sleeved on the outer periphery of the aforementioned third annular shell 21 and located within the inner hole of the rotor 3. Specifically, the stator 5 includes an iron core 51, a frame 52, and windings 53 wound on both. More specifically, the iron core 51 is a gradually changing air gap iron core 51, which avoids the starting dead point.

[0058] PCB board 6, electrical control components 7 and wires 8

[0059] like Figure 3As shown, PCB board 6 is fixed to the lower end of stator 5. Electrical control assembly 7 is fixed to the lower end face of PCB board 6. One end of wire 8 is electrically connected to electrical control assembly 7, and the other end extends from the outlet 221. After stator 5 is assembled in place, both PCB board 6 and electrical control assembly 7 are located within the annular groove a of base 2. Furthermore, potting compound a1 is filled into the annular groove a to seal PCB board 6 and electrical control assembly 7.

[0060] This configuration, which places the motor inside the refrigeration system, protects the PCB board 6 and the electrical control components 7 from condensation or water droplets formed inside the refrigeration system, avoiding the problem of moisture-induced failure of the PCB board 6 and the electrical control components 7. In addition, it also provides insulation and flame retardancy.

[0061] Preferably, the potting compound a1 is a two-component electronic thermal silicone. This type of silicone has good low-temperature resistance (able to withstand temperatures as low as -60°C), thus avoiding the problem of low-temperature failure. Moreover, this type of silicone has good thermal conductivity, which is beneficial for heat dissipation of the PCB board 6 and the electronic control component 7, further avoiding the problem of overheating failure of the PCB board 6 and the electronic control component 7.

[0062] Specifically, such as Figure 3 As shown, the electronic control component 7 includes a chip 71 and a peripheral functional circuit 72 electrically connected to the chip 71 to realize the function of the chip 71.

[0063] More specifically, the chip 71 integrates Hall position sensor functionality, PWM speed control functionality, active soft switching functionality, reverse voltage functionality, rotor 3 lockout functionality, undervoltage protection functionality, thermal shutdown functionality, FG output protection functionality, and ESD protection functionality.

[0064] The PWM speed control function refers to adjusting the rotational speed by adjusting the duty cycle of the PWM signal. This speed control method has high adjustment accuracy (adjustment error less than ±2%); moreover, the input PWM can still provide a large torque even at a low duty cycle, ensuring that rotor 3 can start normally; and once the rotation of rotor 3 is detected, the output will be linearly adjusted according to the duty cycle of the input PWM, so that the minimum speed output can be set as needed.

[0065] Among them, the active soft-switching function can eliminate the peak current generated during startup and automatically adjust the commutation time without increasing power consumption, without relying on the magnetic field strength of rotor 3, thereby reducing the commutation noise of the motor and enabling the motor to have excellent low-noise performance at any speed.

[0066] Furthermore, the chip 71 can integrate pull-up resistors between the PWM and its voltage input pin to reduce the number of electrical components in the peripheral functional circuit 72.

[0067] More specifically, the electrical components of the peripheral functional circuit 72 include:

[0068] A fuse serves as a short-circuit protection device.

[0069] The first transient diode serves as a surge protector and overvoltage protection.

[0070] The capacitor and the second transient diode absorb the back EMF.

[0071] The first resistor connects the low-voltage DC power supply from the external control board to chip 71.

[0072] The second resistor serves to pull the voltage level high.

[0073] In addition, the present invention also provides a refrigeration system having the aforementioned motor, specifically a refrigerator.

[0074] Furthermore, the present invention also provides a potting method, which is as follows:

[0075] First, configure a wire sheath that is compatible with the shape of the above-mentioned outlet 221 and the hole shape of the above-mentioned conductor 8, and then put the wire sheath over the conductor 8.

[0076] Then, the stator 5 is assembled into place, so that the PCB board 6 and the electrical control assembly 7 are located in the annular groove a of the base 2;

[0077] After that, as Figure 4 As shown, install the cable sleeve at the cable outlet 221;

[0078] Then, the potting compound a1 is poured in.

[0079] The present invention has been described in detail above as a refrigeration system, its motor, and a method for potting the motor. Specific examples have been used to illustrate the principles and implementation methods of the invention. The descriptions of these embodiments are merely for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A motor for a refrigeration system, characterized in that, The motor includes a stator (5), a rotor (3), a shaft (4), and an integrally formed fan (1); the fan hub (11) of the fan (1) has a first annular shell (111), a second annular shell (112) surrounding the first annular shell (111), and an upper end shell (113) disposed on the upper ends of the first annular shell (111) and the second annular shell (112); the upper end of the shaft (4) is embedded in the first annular shell (111) and is injection molded integrally with the first annular shell (111); the upper end face of the shaft (4) is in contact with the lower surface of the upper end shell (113); the magnetic yoke (31) of the rotor (3) is embedded in the second annular shell (112) and is injection molded integrally with the second annular shell (112); The motor also includes a base (2), which has a third annular shell (21), a fourth annular shell (22) surrounding the third annular shell (21), and a lower end shell (23) closing the bottom of the third annular shell (21) and the fourth annular shell (22); the third annular shell (21), the fourth annular shell (22), and the lower end shell (23) together form an annular groove (a); the motor includes a PCB board (6) fixed to the lower end of the stator (5) and an electrical control component (7) fixed to the PCB board (6); the stator (5) is fixedly sleeved on the outer periphery of the third annular shell (21), and the PCB board (6) and the electrical control component (7) are both located in the annular groove (a); the annular groove (a) is filled with potting compound (a1) to seal the PCB board (6) and the electrical control component (7); The motor also includes a wire (8); the fourth annular shell (22) is provided with a wire outlet (221); one end of the wire (8) is electrically connected to the electronic control assembly (7), and the other end extends out from the wire outlet (221).

2. The motor according to claim 1, characterized in that, The third annular shell (21) surrounds the shaft hole (b), and the lower end of the rotating shaft (4) extends into the shaft hole (b); the lower end of the rotating shaft (4) is magnetic, and a magnetic sheet (b2) is installed in the shaft hole (b). The magnetic sheet (b2) is located directly below the rotating shaft (4) to attract the rotating shaft (4) along the axial direction.

3. The motor according to claim 2, characterized in that, The outer periphery of the rotating shaft (4) is provided with a limiting groove (41), and an elastic limiting member (b4) is installed in the shaft hole (b). The elastic limiting member (b4) has a through hole (b41). The rotating shaft (4) passes through the through hole (b41), and the inner edge of the elastic limiting member (b4) extends into the limiting groove (41).

4. The motor according to claim 1, characterized in that, The electronic control component (7) includes a chip (71), which integrates Hall position sensor function, PWM speed regulation function and active soft switching function.

5. The motor according to claim 4, characterized in that, The electronic control component (7) also includes peripheral functional circuits (72) that implement the functions of the chip (71).

6. The motor according to claim 1, characterized in that, The potting compound (a1) is a two-component electronic heat dissipation silicone.

7. The method for potting a motor according to any one of claims 1-6, characterized in that, The potting method is as follows: First, configure a wire sheath that is compatible with the shape of the outlet (221) and the hole shape with the wire (8), and then put the wire sheath over the wire (8). Then, the stator (5) is assembled into place so that the PCB board (6) and the electrical control component (7) are both located in the annular groove (a); Then, the cable sleeve is installed at the cable outlet (221). Then, the potting compound (a1) is poured in.

8. A refrigeration system, the refrigeration system comprising a motor, characterized in that, The motor is the motor described in any one of claims 1-6.

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