An integrated device comprising a drive unit, a motor, and a planetary gear reducer, and its manufacturing method thereof.

Abstract

This invention discloses an integrated device for drive, motor, and planetary reducer, and its manufacturing method. The technical solution includes a housing, a motor assembly, and a planetary reducer assembly. The housing has independent mounting cavities for the motor assembly and the planetary reducer assembly. An air-cooling structure is provided on the outer circumference of the housing. A driver is installed on the outermost side of the housing, connected to the motor control system. The motor is connected to the planetary reducer. A heat dissipation base plate is provided above the air-cooling channel. The driver, motor, and planetary reducer are integrated, resulting in a compact structure, small size, and light weight. The air-cooling structure of the housing directly cools the driver, motor, and planetary reducer, resulting in low heat generation and good cooling effect. The structure is simple, and the integrated driver, motor, and planetary reducer have high operating efficiency and low energy consumption.

Description

Technical Field

[0001] This invention relates to the field of mechanical technology, and in particular to an integrated device comprising a drive, a motor, and a planetary reducer, and its manufacturing method. Background Technology

[0002] Currently, the traditional method uses a combination of driver, motor, and reducer to drive the operation. Because the driver, motor, and reducer are independent in this traditional method, the main disadvantages are: 1. High heat generation, requiring independent cooling systems for each component; 2. Transmission connection parts are prone to mechanical wear over long-term operation, requiring regular maintenance; 3. The transmission system is large and bulky; 4. Low transmission positioning accuracy; 5. High operating noise and energy consumption; 6. High overall cost. These defects result in existing transmission systems being relatively crude, with low accuracy, high energy consumption, large space occupation, high failure rate, and high requirements for equipment installation and maintenance.

[0003] Currently, patent number CN202022079956.9 discloses a direct connection mechanism for a motor and a reducer. Its main function is to significantly shorten the distance between the motor and the reducer, thereby reducing the overall length of the mechanism. This also reduces the overall size and space occupied, and makes the transmission more reliable and stable. However, it still does not overcome the problems of high heat generation, high operating noise, and transmission positioning accuracy.

[0004] The current patent number CN202110994926.7 discloses an integrated device for motor and planetary reducer and its manufacturing method. Its main function is to reduce the size of the transmission system, improve transmission efficiency, reduce heat generation, reduce operating noise, and significantly improve service life. It has made a breakthrough in liquid cooling structure, but has not overcome the challenge in air cooling structure. In addition, it does not integrate the driver control in the integration process. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an integrated device comprising a drive unit, a motor, and a planetary reducer, as well as a method for manufacturing the same. The integrated drive and control further reduces installation space, resulting in a compact structure, convenient installation, low energy consumption, and significantly reduced heat generation and operating noise.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: an integrated device for drive, motor and planetary reducer, comprising a housing, a motor assembly and a planetary reducer assembly;

[0007] The housing has separate mounting cavities for the motor assembly and the planetary gear reducer assembly; an air-cooling structure is provided on the outer circumference of the housing, and the driver is installed on the outermost side of the housing.

[0008] Preferably, the air-cooled cooling structure includes an air-cooled housing, an air-cooled channel, a heat sink, and an axial fan. The air-cooled channel is located on the outer circumference of the housing and has a first air-cooled air outlet. A second air-cooled air outlet corresponding to the first air-cooled air outlet is located on the outer circumference of the housing. An air outlet and an air-cooled housing are located on the rear side of the housing. An axial fan corresponding to the air outlet is installed inside the air-cooled housing.

[0009] Preferably, a heat dissipation base plate is installed above the air-cooling aisle.

[0010] Preferred configuration: The driver is connected to the motor control unit, and the motor is connected to the planetary reducer. The driver controls a high-speed, low-torque motor, which outputs low-speed, high-torque output via the planetary reducer. The driver mainly consists of an AC-DC rectifier module, a DC filter energy storage capacitor, a DC-AC IGBT inverter module, a power board, a main board, and an LED display.

[0011] Preferably, the motor includes a stator, a rotor, a motor shaft, a rear end cover, and a front end cover. The rear end covers are fixed to the housing. The rotor is installed inside the stator and connected to the motor rotor output shaft. One end of the rotor is connected to the rear end cover and the other end is connected to the front end cover. The stator core is interference-fitted inside the housing and has motor windings.

[0012] Preferably, the planetary reducer includes a planetary reducer assembly gear ring housing, a planetary reducer sun gear, planetary gears, a planet carrier, and an output shaft. The planetary reducer sun gear is mounted on the motor shaft and directly inserted into the planetary reducer planetary gears. The planetary reducer sun gear output from the motor shaft and directly inserted into the planetary reducer planetary gears results in a compact structure, high rotational accuracy, and low noise.

[0013] Preferably, the output end face of the housing is provided with a reducer output end cover and an output shaft, and the inside of the housing is provided with a motor front end cover mounting plate.

[0014] Preferably, the front end cover of the housing is provided with a planetary gear oil inlet and a planetary gear oil outlet on the top and bottom, respectively, and is also provided with an oil level observation port.

[0015] A method for manufacturing an integrated device comprising a drive unit, a motor, and a planetary gear reducer, characterized by the following steps:

[0016] S1. Machining of the housing: The housing is made of aluminum extrusion and stretching process to complete the aluminum blank. First, the aluminum blank housing is shaped internally and externally, precision turned internally, and drilled in the machining center. The planetary gear oil inlet, planetary gear oil outlet and oil level observation port are machined. The surface is rust-proofed and blackened or electrophoresed.

[0017] S2. Pressing the motor front end cover: Press the processed motor front end cover into the housing by heat fitting or cold pressing, and drive the 8 anti-torque pins on the outside of the housing into the end cover.

[0018] S3. Stator core installation on the housing: First, heat the housing to a high temperature to make it expand thermally. Then, insert or press the stator core into the housing. Place the stator core and housing in the room to cool. After the temperature drops to room temperature, proceed to the next step.

[0019] S4. The rear end cover of the motor is fixed on the housing; the rotor of the motor is first installed on the front end cover of the motor, and then pressed into the stator. The front end cover of the motor is fixed on the front end cover mounting plate, and the front end cover of the motor is protected against oil and water by a sealing ring.

[0020] S5. The sun gear of the planetary reducer is mounted on the motor shaft. The motor shaft is connected to the sun gear by a spline and pressed with a gland.

[0021] S6. Apply a ring of high-temperature sealant to the inside of the output end cover of the reducer. After aligning the planetary gears of the planetary reducer with the sun gear of the planetary reducer on the motor shaft, install it into the housing. There are two positioning stops inside the housing. The inner positioning stop controls the accuracy of the input end of the reducer, and the outer positioning stop controls the accuracy of the output end of the reducer. The output end cover of the reducer is fixed on the housing and directly serves as the output end of the integrated machine.

[0022] S7. Add gear lubricating oil or grease through the planetary gear oil inlet on the housing. Add the oil until it exceeds the oil level observation port or when it is full. Then, fix the oil inlet with a vent cap.

[0023] S8. Install motor encoder: There is a position on the motor shaft at the rear end cover of the housing for installing the encoder required by the equipment.

[0024] S9. Driver Installation: The air-cooled housing has a heat dissipation base plate for installing the driver, which facilitates quick installation of the driver. After the driver is embedded, the air-cooling air duct can be directly connected to the power components of the driver for heat dissipation.

[0025] Preferred method: Before installing the motor front cover in step S2, heat the entire housing to 150-180℃ and maintain the temperature for 50-80 minutes; after removing the housing, install the motor front cover, and if necessary, increase the pressing force by 1-2T.

[0026] Preferred: The entire casing is heated to 160°C and maintained for 70 minutes.

[0027] Preferred method: In step S3, the housing is heated to 180-220℃ and kept at that temperature for 1-2 hours to allow the housing to expand thermally. The fitted stator core and housing are then placed indoors for natural cooling or cooled by a fan.

[0028] Preferred step: In step S3, the housing is heated to 220°C and maintained for 1 hour to allow the housing to expand thermally. The fitted stator core and housing are then cooled by a fan.

[0029] Preferably, in step S9, the air-cooled duct of the housing is introduced into the driver, and the air intake temperature is less than 40°C. The air is drawn into the air-cooled duct to directly cool the driver.

[0030] The beneficial effects of this invention are as follows: 1. The driver, motor, and planetary reducer are integrated into one unit, resulting in a compact structure, small size, and light weight; 2. The housing adopts an air-cooled cooling structure, directly cooling the driver, motor, and planetary reducer, resulting in low heat generation, good cooling effect, and simple structure; 3. The integrated driver, motor, and planetary reducer have high operating efficiency and low energy consumption; 4. The stator is directly cooled by the air-cooling structure on the housing, the planetary reducer is lubricated by gear lubricating oil while transferring heat to the motor housing, and then cooled by the motor air-cooling structure. The driver power module is directly cooled by the motor air-cooling structure, simplifying the overall cooling structure, ensuring uniform cooling, rapid temperature reduction, high operating efficiency, and low energy consumption. Attached Figure Description

[0031] Figure 1 This is an internal sectional view of the present invention;

[0032] Figure 2 This is a schematic diagram of the external structure of the present invention;

[0033] Figure 3 This is a schematic diagram of the internal structure of the casing in this invention;

[0034] Figure 4 This is a schematic diagram of the air-cooled housing in this invention;

[0035] Figure 5 This is a side view of the present invention;

[0036] Reference numerals: 1. Driver; 2. Housing; 3. Motor; 31. Stator; 32. Rotor; 33. Motor shaft; 34. Motor rear end cover; 35. Motor front end cover; 4. Planetary reducer; 41. Planetary reducer sun gear; 42. Planetary gear; 5. Air-cooled housing; 6. Air-cooled channel; 7. Heat dissipation base plate; 8. Axial fan; 9. First air-cooled air outlet; 10. Second air-cooled air outlet; 11. Air outlet; 12. Encoder; 13. Planetary gear oil inlet; 14. Planetary gear oil drain port; 15. Oil level observation port. Detailed Implementation

[0037] Combined with appendix Figure 1-5 The preferred embodiments of the present invention will be described in further detail below.

[0038] Example 1: An integrated device for drive, motor and planetary reducer, including housing, motor assembly and planetary reducer assembly, wherein the housing is provided with independent mounting cavities for mounting the motor assembly and planetary reducer assembly respectively.

[0039] A cooling structure is provided on the outer circumference of the casing, and a driver is installed on the outermost side of the casing. The cooling structure includes a cooling casing, a cooling channel, a heat sink, and an axial fan. The cooling channel is located on the outer circumference of the casing and has a first cooling outlet. A second cooling outlet corresponding to the first cooling outlet is located on the outer circumference of the casing. An outlet and a cooling casing are located on the rear side of the casing. An axial fan corresponding to the outlet is installed inside the cooling casing. A heat sink is located above the cooling channel.

[0040] The driver is connected to the motor control unit, and the motor is connected to the planetary reducer. The driver controls a high-speed, low-torque motor, which outputs low-speed, high-torque output through the planetary reducer. The driver mainly consists of an AC-DC rectifier module, a DC filter energy storage capacitor, a DC-ACIGBT inverter module, a power board, a main board, and an LED display.

[0041] The motor assembly includes a stator, a rotor, a motor shaft, a rear end cover, and a front end cover. The front and rear end covers are fixed to the housing. The rotor is installed inside the stator and connected to the motor rotor output shaft. One end of the rotor is connected to the rear end cover and the other end is connected to the front end cover. The stator core is interference-fitted inside the housing and has motor windings.

[0042] The planetary reducer assembly includes a planetary reducer gear ring housing, a planetary reducer sun gear, planetary gears, a planet carrier, and an output shaft. The planetary reducer sun gear is mounted on the motor shaft and directly inserted into the planetary reducer planetary gears. The planetary reducer sun gear output from the motor shaft and directly inserted into the planetary reducer planetary gears results in a compact structure, high rotational accuracy, and low noise. Alternatively, the motor shaft can also be directly constructed as a planetary reducer sun gear structure.

[0043] The output end face of the housing is provided with a reducer output end cover and an output shaft, and the inside of the housing is provided with a motor front end cover mounting plate. The front end cover of the housing is provided with a planetary gear oil inlet and a planetary gear oil outlet on the top and bottom, respectively, and also has an oil level observation port. Gear lubricating oil can be added through the planetary gear oil inlet for lubrication, reducing friction and noise, and the oil level observation port makes it easy to observe the oil level and add oil in time.

[0044] Example 2: A method for manufacturing an integrated drive, motor, and planetary reducer device, comprising the following steps:

[0045] S1. Machining of the housing: The housing is made of aluminum extrusion and stretching process to complete the aluminum blank. First, the aluminum blank housing is shaped internally and externally, precision turned internally, and drilled in the machining center. The planetary gear oil inlet, planetary gear oil outlet and oil level observation port are machined. The surface is rust-proofed and blackened or electrophoresed.

[0046] S2. Pressing the motor front end cover: Before installing the motor front end cover, heat the entire housing to 150℃ and maintain it for 80 minutes; after taking out the housing, press the processed motor front end cover into the housing using a hot-fitting or cold-pressing method, and drive the 8 anti-torque pins on the outside of the housing into the end cover.

[0047] S3. Stator core installation on the housing: First heat the housing to 180°C to make it expand thermally, and keep it for 2 hours to allow the housing to expand thermally. Then, put the stator core into or press it into the housing. Place the stator core and housing in the room for natural cooling or cooling with a fan. After the temperature drops to room temperature, proceed to the next step.

[0048] S4. The rear end cover of the motor is fixed on the housing; the rotor of the motor is first installed on the front end cover of the motor, and then pressed into the stator. The front end cover of the motor is fixed on the front end cover mounting plate, and the front end cover of the motor is protected against oil and water by a sealing ring.

[0049] S5. The sun gear of the planetary reducer is mounted on the motor shaft. The motor shaft is connected to the sun gear by a spline and pressed with a gland.

[0050] S6. Apply a ring of high-temperature sealant to the inside of the output end cover of the reducer. After aligning the planetary gears of the planetary reducer with the sun gear of the planetary reducer on the motor shaft, install it into the housing. There are two positioning stops inside the housing. The inner positioning stop controls the accuracy of the input end of the reducer, and the outer positioning stop controls the accuracy of the output end of the reducer. The output end cover of the reducer is fixed on the housing and directly serves as the output end of the integrated machine.

[0051] S7. Add gear lubricating oil or grease through the planetary gear oil inlet on the housing. Add the oil until it exceeds the oil level observation port or when it is full. Then, fix the oil inlet with a vent cap.

[0052] S8. Install motor encoder: There is a position on the motor shaft at the rear end cover of the housing for installing the encoder required by the equipment.

[0053] S9. Driver Installation: The air-cooled housing has a heat dissipation base plate for installing the driver, which facilitates quick installation of the driver. After the driver is embedded, the air-cooling air duct can be directly connected to the power components of the driver for heat dissipation.

[0054] 1. The drive, motor and planetary reducer are integrated into one unit, which is compact, small in size and light in weight. 2. The housing adopts an air-cooled cooling structure to directly cool the drive, motor and planetary reducer, so that the heat generation is low, the cooling effect is good, and the structure is simple.

[0055] 2. The integrated operation of the driver, motor, and planetary reducer results in high efficiency and low energy consumption. 4. The stator is directly cooled by the air cooling structure on the housing. The planetary reducer is lubricated by gear lubricating oil and the temperature is transferred to the motor housing, where it is cooled by the motor air cooling structure. The driver power module is directly cooled by the motor air cooling structure, which simplifies the overall cooling structure, ensures uniform cooling, rapid temperature reduction, high operating efficiency, and low energy consumption.

[0056] Example 3 is largely the same as Example 2, except that in step S2, before installing the motor front cover, the entire housing is heated to 160°C and held for 70 minutes. After removing the housing, the motor front cover is then installed.

[0057] In Example 4, before installing the motor front cover in step S2, the entire housing is heated to 180°C and maintained for 50 minutes. After removing the housing, the motor front cover is installed. If necessary, an additional pressing force of 1-2T can be applied.

[0058] In Example 5, step S3, the housing is heated to 200°C and maintained for 1.5 hours to allow it to expand thermally. The fitted stator core and housing are then placed indoors to cool naturally. The advantage of interference fit after heating is that the equipment used for installation is simple, the accuracy after fitting is guaranteed, and the assembly effect is good.

[0059] In Example 6, step S9 introduces air-cooling ducts into the drive housing. The air intake temperature is less than 40°C, and the ambient temperature is drawn into the air-cooling ducts to directly cool the drive, resulting in good cooling effect.

[0060] The above embodiments are only used to explain the inventive concept of the present invention, and are not intended to limit the protection of the present invention. Any non-substantial modifications made to the present invention using this concept should fall within the protection scope of the present invention.

Claims

1. A method for manufacturing an integrated device comprising a drive unit, a motor, and a planetary gear reducer, the device comprising a drive unit, a housing, a motor, and a planetary gear reducer; the housing having separate mounting cavities for mounting the motor and the planetary gear reducer respectively; Its features are: An air-cooling structure is provided on the outer circumference of the casing, and the driver is installed on the casing; The air-cooled cooling structure includes an air-cooled housing, an air-cooled channel, a heat sink, and an axial fan. The air-cooled channel is located on the outer circumference of the housing and has a first air-cooled air outlet. A second air-cooled air outlet corresponding to the first air-cooled air outlet is located on the outer circumference of the housing. An air outlet and an air-cooled housing are located on the rear side of the housing. An axial fan corresponding to the air outlet is installed inside the air-cooled housing. The manufacturing method for an integrated drive, motor, and planetary gear reducer includes the following steps: S1. Machining of the housing: The housing is made of aluminum blanks using aluminum extrusion and stretching process. First, the aluminum blank housing is shaped internally and externally, precision turned internally, and drilled in the machining center. The planetary gear oil inlet, planetary gear oil outlet and oil level observation port are machined. The surface is treated with blackening or electrophoresis for rust prevention. S2. Pressing the motor front end cover: Press the processed motor front end cover into the housing by heat fitting or cold pressing, and drive the 8 anti-torque pins on the outside of the housing into the end cover. S3. Stator core installation on the housing: First, heat the housing to a high temperature to make it expand thermally. Then, insert or press the stator core into the housing. Place the stator core and housing in the room to cool. After the temperature drops to room temperature, proceed to the next step. S4. The rear end cover of the motor is fixed on the housing; the rotor of the motor is first installed on the front end cover of the motor, and then pressed into the stator. The front end cover of the motor is fixed on the front end cover mounting plate, and the front end cover of the motor is protected against oil and water by a sealing ring. S5. The sun gear of the planetary reducer is mounted on the motor shaft. The motor shaft is connected to the sun gear by a spline and pressed with a gland. S6. Apply a ring of high-temperature sealant to the inside of the output end cover of the reducer. After aligning the planetary gears of the planetary reducer with the sun gear of the planetary reducer on the motor shaft, install it into the housing. There are two positioning stops inside the housing. The inner positioning stop controls the accuracy of the input end of the reducer, and the outer positioning stop controls the accuracy of the output end of the reducer. The output end cover of the reducer is fixed on the housing and directly serves as the output end of the integrated machine. S7. Add gear lubricating oil or grease through the planetary gear oil inlet on the housing. Add the oil until it exceeds the oil level observation port or when it is full. Then, fix the oil inlet with a vent cap. S8. Install motor encoder: There is a position on the motor shaft at the rear end cover of the housing for installing the encoder required by the equipment. S9. Driver Installation: The air-cooled housing has a heat dissipation base plate for installing the driver, which facilitates quick installation of the driver. After the driver is embedded, the air-cooling air duct is directly connected to the power component of the driver for heat dissipation.

2. The method for manufacturing an integrated device comprising a drive unit, a motor, and a planetary reducer according to claim 1, characterized in that: A heat dissipation base plate is installed above the air-cooling aisle.

3. The method for manufacturing an integrated device comprising a drive unit, a motor, and a planetary reducer according to claim 1, characterized in that: The driver is connected to the motor control unit, and the motor is connected to the star reducer.

4. The method for manufacturing an integrated drive, motor, and planetary reducer device according to claim 1, characterized in that: Before installing the motor front cover in step S2, heat the entire housing to 150-180℃ and maintain the temperature for 50-80 minutes; then remove the housing and install the motor front cover.

5. A method for manufacturing an integrated drive, motor, and planetary reducer device according to claim 1, characterized in that: Before installing the motor front cover in step S2, the entire housing is heated to 160°C and maintained for 70 minutes.

6. A method for manufacturing an integrated drive, motor, and planetary reducer device according to claim 4, characterized in that: In step S3, the housing is heated to 180-220℃ and kept at that temperature for 1-2 hours to allow the housing to expand thermally. The fitted stator core and housing are then placed indoors to cool naturally or with a fan.

7. A method for manufacturing an integrated drive, motor, and planetary reducer device according to claim 6, characterized in that: In step S3, the housing is heated to 220°C and kept at that temperature for 1 hour to allow it to expand thermally. The fitted stator core and housing are then cooled by a fan.

8. A method for manufacturing an integrated drive, motor, and planetary reducer device according to claim 1, characterized in that: In step S9, the air-cooled duct of the housing is introduced into the driver. The air intake temperature is less than 40°C, which is the ambient temperature. The air is drawn into the air-cooled duct to directly cool the driver.

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