A fan drive arrangement

Abstract

The application relates to a fan driving device which comprises a side end cover, a PCBA power assembly and a motor assembly; the PCBA power assembly comprises a PCBA board and a filter assembly, a plurality of first limiting holes and second limiting holes are arranged on the PCBA board, and a magnetic decoder is mounted on the PCBA board; the motor assembly comprises a motor body and a motor rear end cover mounted on one side of the motor body, the motor rear end cover is a cavity structure, an alternating current output assembly, three-phase winding terminals, an electric spindle and a plurality of columnar structures are arranged in the cavity, a signal plug and a power plug are mounted on one side of the cavity, the PCBA power assembly is mounted in the cavity of the motor rear end cover, the upper end of the alternating current output assembly is an output copper bar provided with a plurality of protrusions, the protrusions are clamped with the first limiting holes on one side of the PCBA board, the columnar structures are clamped with the second limiting holes on the PCBA board, and the electric spindle is provided with a magnetic block matched with the magnetic decoder. Compared with the prior art, the application realizes fan inverter control and has the advantages of high integration, small equipment and the like.

Description

Technical Field

[0001] This invention relates to the field of cooling fan drives, and more particularly to a fan drive device. Background Technology

[0002] Both traditional gasoline-powered vehicles and modern air conditioning appliances typically have cooling fan assemblies installed inside to dissipate heat from specific components. Conventional cooling fans usually operate in a simple control-driven mode: they work as soon as power is on. In other words, whenever the device is turned on or running, the fan spins at high speed. However, in actual use, such as in a car, when the vehicle is moving at low speed or stopped at a traffic light, the components are not operating, and the heat generated is minimal. If the fan assembly were still running at a high speed, while it might prevent the components from overheating and becoming dangerous, it would also waste energy and cause premature fan aging. When the vehicle resumes normal operation, certain potential risks would arise. This is detrimental to improving the driving range of electric vehicles and hindering energy conservation and emission reduction efforts. Because this traditional fan-driven structure lacks a control inverter, its operation cannot be effectively controlled. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a fan drive device.

[0004] The objective of this invention can be achieved through the following technical solutions:

[0005] A fan drive device includes a side end cover, a PCBA power component, and a motor component; the PCBA power component includes a PCBA board and a filter component, the PCBA board is provided with a plurality of first limiting holes and second limiting holes, and a magnetic decoder is installed on the PCBA board.

[0006] The motor assembly includes a motor body and a rear end cover mounted on one side of the motor body. The rear end cover is a cavity structure, and an AC output component, three-phase winding terminals, an electric spindle, and multiple cylindrical structures are disposed within the cavity. A signal plug and a power plug are mounted on one side of the cavity. The PCBA power component is mounted within the cavity of the rear end cover. The upper end of the AC output component is an output copper busbar with multiple protrusions. The protrusions engage with a first limiting hole on one side of the PCBA board. The cylindrical structures engage with a second limiting hole on the PCBA board. The electric spindle contains a magnetic block that matches the magnetic decoder.

[0007] Further, the filter assembly comprises a base, one side of the base is provided with an integrated film capacitor, and the other side is provided with a first "hui"-shaped mounting hole, the first mounting hole is placed vertically and inclined, and when the PCBA power assembly is mounted on the motor assembly, the first mounting hole is parallel to the power pin; between the integrated film capacitor and the first mounting hole is a raised wall with a plurality of arc-shaped grooves, one side of the raised wall is provided with a second mounting hole, the other side of the second mounting hole is provided with a vertical plate, and the other side of the vertical plate is an H-shaped structure, which comprises a fourth mounting hole and a fifth mounting hole, the fourth mounting hole and the fifth mounting hole communicate with each other, and the base further comprises a third mounting hole closely attached to the H-shaped structure.

[0008] Further, the filter assembly comprises a main filter ring, a secondary filter ring, a main filter capacitor, a secondary filter capacitor and a grounding copper bar, the main filter ring is mounted in the first mounting hole; the main filter capacitor is mounted in the second mounting hole, the secondary filter capacitor is mounted in the third mounting hole, and the secondary filter ring is mounted in the fourth mounting hole and the fifth mounting hole.

[0009] Further, the filter assembly is clamped on the PCBA board through the secondary filter ring, the base comprises an integrated film capacitor, terminals of the main filter capacitor and the integrated film capacitor are both connected to the PCBA board; a terminal on one side of the secondary filter capacitor is connected to the PCBA board, and a terminal on the other end is connected to the motor rear end cover through the grounding copper bar.

[0010] Further, the motor assembly further comprises a water inlet pipe and a water outlet pipe, the motor rear end cover is of a hollow structure, a heat dissipation water channel is integrated therein, a protrusion is provided on a side surface of the motor rear end cover, a water inlet and a water outlet are provided on the protrusion, the water inlet pipe and the water outlet pipe are connected to the water inlet and the water outlet, a first water transfer opening and a second water transfer opening are provided on a lower bottom surface of the motor rear end cover, the water inlet is communicated with the first transfer opening through the heat dissipation water channel, the second transfer opening is directly cross communicated with the water outlet, and the first water transfer opening and the second water transfer opening are respectively mechanically connected with an inlet and an outlet of a heat dissipation water channel on the motor body, forming a heat dissipation cooling path.

[0011] Further, the secondary filter ring is composed of a zinc-manganese and zinc-nickel mixture, and comprises a magnetic plate and a magnetic hook, the magnetic plate is of a rectangular parallelepiped structure, and the magnetic hook is in a "匚" shape.

[0012] . A fan driving device according to the claims, characterized in that the main filter ring is made of nanocrystalline material, has a square shape in appearance, the main filter ring is divided into an upper "U"-shaped structure and a lower "U"-shaped structure, and mating surfaces of the "U"-shaped structural members are mechanically connected through a dovetail groove structure.

[0013] Furthermore, the AC output component includes an output bracket and an output copper busbar. The output copper busbar is Z-shaped and mounted on the output bracket. The output bracket is stepped. The upper surface of the output bracket is provided with multiple first countersunk holes and multiple second countersunk holes. The left side of the output bracket is provided with a notch-shaped wire harness bayonet. The lower surface of the output bracket is provided with multiple notch-shaped terminal bayonet.

[0014] Furthermore, the three-phase winding terminals include a main wire harness and a three-phase magnetic ring, the three-phase magnetic ring being fixed to the main wire harness by a heat-shrink tubing.

[0015] Furthermore, the PCBA power component also includes an IGBT module, which is fixed on the PCBA board.

[0016] Compared with the prior art, the present invention has the following advantages:

[0017] 1. This invention integrates the PCBA power component and motor component into the same device by changing the structure of some components and setting up connectors, thereby reducing the size of the device and reducing the installation difficulty; at the same time, the use of multiple magnetic rings and capacitors in the filter components achieves strong inverter performance, making the entire drive device have better electromagnetic compatibility performance.

[0018] 2. The present invention uses inclined mounting holes and H-shaped structure in the base setting of the filter component, which makes the overall structure of the base more compact. While making the structure compact, it simplifies the layout and enhances the heat dissipation capacity. The protruding wall is set to facilitate the laying of wires, and the upright plate and other structures improve the stability of the base structure.

[0019] 3. The present invention includes a circulating water cooling device in the motor drive unit, which provides cooling during equipment operation and also dissipates heat from the PCBA power components, thereby improving the service life and reliability of the equipment. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention.

[0021] Figure 2 This is a schematic diagram of the PCBA power component in this invention.

[0022] Figure 3 This is a schematic diagram of the PCBA board structure in this invention.

[0023] Figure 4 This is a schematic diagram of the structure of the motor power component in this invention.

[0024] Figure 5 This is a schematic diagram of the AC output component in this invention.

[0025] Figure 6 This is a schematic diagram of the output support of the AC output component in this invention.

[0026] Figure 7 This is a schematic diagram of the base structure in this invention.

[0027] Figure 8 This is a schematic diagram of the base structure in which the relevant circuit devices are installed in this invention.

[0028] Figure 9 This is a schematic diagram of the main filter ring in this invention.

[0029] Figure 10 This is a schematic diagram of the secondary filter loop in this invention.

[0030] Figure 11 This is a schematic diagram of the heat dissipation and cooling path of the motor rear end cover in this invention.

[0031] Figure 12 This is a schematic diagram of the structure of the three-phase winding terminals in this invention.

[0032] Reference numerals: 1-Side end cap, 2-PCBA power assembly, 21-PCBA board, 211-Magnetic decoder, 212-First limiting hole, 213-Second limiting hole, 22-Filter assembly, 221-Base, 2211-First mounting hole, 2212-Second mounting hole, 2213-Third mounting hole, 2214-Fourth mounting hole, 2215-Fifth mounting hole, 2216-Integrated film capacitor, 2217-Raised wall, 2218-Upright plate, 222-Main filter ring, 223-Secondary filter ring, 2231-Magnetic plate, 2232-Magnetic hook, 224-Main filter capacitor, 225-Secondary filter capacitor 226-Grounding copper busbar, 23-IGBT module, 3-Motor assembly, 31-Motor body, 32-Motor rear end cover, 321-Water inlet, 322-Water outlet, 323-First adapter water inlet, 324-Second adapter water inlet, 33-AC output assembly, 331-Output support, 3311-First countersunk hole, 3312-Second countersunk hole, 3313-Wire harness bayonet, 3314-Terminal bayonet, 34-Three-phase winding terminal, 341-Main wire harness, 342-Three-phase magnetic ring, 35-Electric spindle, 36-Magnetic block, 37-Signal plug-in, 38-Power plug-in, 39-Inlet and outlet water pipes, 310-Columnar structure. Detailed Implementation

[0033] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0034] This embodiment provides a fan drive device, such as... Figure 1 As shown, it includes a side end cover 1, a PCBA power assembly 2, and a motor assembly 3. The PCBA power assembly 2 is as follows: Figure 2 As shown, the system includes a PCBA board 21, a filter assembly 22, and an IGBT module 23. The PCBA board 21 and the IGBT module 23 are fastened together. The PCBA board 21 has multiple circular first limiting holes 212 and second limiting holes 213. A magnetic decoder 211 is also mounted on the PCBA board. Figure 3 As shown.

[0035] In this embodiment, the motor assembly 3 is as follows: Figure 4 As shown, the device includes a motor body 31 and a motor rear end cover 32, which is mechanically connected to the motor body 31. The motor rear end cover 32 is a cylindrical cavity structure, within which an AC output component 33, three-phase winding terminals 34, an electric spindle 35, and multiple cylindrical structures 310 are housed. A signal plug-in 37 and a power plug-in 38 are mounted on one side of the cavity. The PCBA power component 2 is installed within the cavity of the motor rear end cover 32, with its side end fixed to the motor rear end cover 32. The AC output component 33 includes an output support 331 and an output copper busbar 332, as shown... Figure 5 As shown, the output copper busbar 332 is Z-shaped and mounted on the output support 331; the output support 331 is stepped, and its upper surface has multiple first countersunk holes 3311 and multiple second countersunk holes 3312, through which the AC output assembly 33 is fixed to the cavity of the motor rear end cover 32; the left side of the output support 331 has a notch-shaped wire harness bayonet 3313, and the lower surface of the output support 331 has multiple notch-shaped terminal bayonet 3314, such as... Figure 6 As shown. The output copper busbar 332 has multiple circular protrusions that engage with the first limiting hole 212 on one side of the PCBA board 21; the columnar structure 310 engages with the second limiting hole 213 on the PCBA board 21. Through the above engagement, the PCBA board is precisely installed in the rear end cover cavity of the motor; the electric spindle is equipped with a magnetic block 36 that matches the magnetic decoder 211. After the magnetic decoder 211 and the magnetic block 36 work together, they precisely control the speed and torque of the fan.

[0036] In this embodiment, the filter component 22 includes a base 221, such as Figure 7As shown in the figure, one side of the base 221 is an integrated film capacitor 2216 with a rectangular parallelepiped structure, and the other side is a first mounting hole 2211 in a "square-annular" shape. The first mounting hole 2211 is arranged vertically and obliquely, and when the PCBA power assembly 2 is mounted on the motor assembly 3, the first mounting hole 2211 is parallel to the power insert 38; between the integrated film capacitor 2216 and the first mounting hole 2211 is a raised wall 2217 with a plurality of arc-shaped grooves, and one side of the raised wall 2217 is provided with a second mounting hole 2212. A vertical plate 2218 is arranged on the other side of the second mounting hole, an H-shaped structure is arranged on the other side of the vertical plate 2218, which comprises a fourth mounting hole 2214 and a fifth mounting hole 2215, and the fourth mounting hole 2214 is communicated with the fifth mounting hole 2215. The base 221 further comprises a third mounting hole 2213 closely attached to the H-shaped structure.

[0037] In addition, in this embodiment, the filter assembly 22 further comprises a main filter ring 222, a secondary filter ring 223, a main filter capacitor 224, a secondary filter capacitor 225 and a grounding copper bar 226, as Figure 8 shown in the figure. The main filter ring 222 is made of nanocrystalline material and has a square shape in appearance. The main filter ring 222 is divided into upper and lower "U"-shaped structures, as Figure 9 shown in the figure, the mating surfaces of the "U"-shaped structural members are mechanically connected through a dovetail groove structure. The main filter ring 222 is mounted in the first mounting hole 2211 by epoxy potting; the second mounting hole 2212, the third mounting hole 2213 and the fourth mounting hole 2214 are all rectangular counterbores, the main filter capacitor 224 is mounted in the second mounting hole 2212, and the secondary filter capacitor 225 is mounted in the third mounting hole 2213; the secondary filter ring 223 is composed of a mixture of zinc-manganese and zinc-nickel, and comprises a magnetic plate 2231 and a magnetic hook 2232, as Figure 10 shown in the figure, the magnetic plate 2231 has a rectangular parallelepiped structure, the magnetic hook 2232 is in a "匚"-shaped (open-top rectangular) shape, the magnetic plate 2231 is placed in the fourth mounting hole 2214, and the magnetic hook 2232 passes through the fifth mounting hole 2215 and abuts against the magnetic plate 2231. Meanwhile, the filter assembly is clamped on the PCBA board 21 through the secondary filter ring 223, the base 221 comprises the integrated film capacitor 2216, and the terminals of the main filter capacitor 224 and the integrated film capacitor 2216 are both connected to the PCBA board 21 by welding; the terminal on one side of the secondary filter capacitor 225 is welded to the PCBA board 21, and the terminal on the other end is electrically connected to the motor rear end cover 32 through the grounding copper bar 226.

[0038] Furthermore, in this embodiment, the motor assembly 3 also includes inlet and outlet water pipes 39. The rear end cover 32 of the motor has a hollow structure and integrates heat dissipation channels formed by friction stir welding. A rectangular boss is provided on the side of the rear end cover of the motor, with an inlet 321 and an outlet 322 provided on the boss. The inlet and outlet water pipes 39 are connected to the inlet 321 and the outlet 322. The bottom surface of the rear end cover of the motor has a first transition water port 323 and a second transition water port 324, such as... Figure 11 As shown, the inlet 321 is interconnected with the first adapter 323 through the heat dissipation water channel, and the second adapter 324 is directly interconnected with the outlet 322. The first adapter 323 and the second adapter 324 are mechanically connected to the inlet and outlet of the heat dissipation water channel on the motor body 31, respectively, to form a heat dissipation and cooling passage.

[0039] Finally, in this embodiment, as Figure 12 As shown, the three-phase winding terminal 34 includes a main wire harness 341 and a three-phase magnetic ring 342, which is fixed to the main wire harness 341 by a heat shrink tubing.

[0040] In this embodiment, a capacitor-inductor-capacitor filtering structure is adopted in the inverter section of the filtering component. The entire input terminal uses multi-stage capacitors. First, the main filter ring 222 filters out low-frequency interference. Then, the second main filter capacitor 224 filters out differential-mode signals. Next, the secondary filter capacitor 225 filters out common-mode signals. Then, the secondary filter magnetic ring 222 filters out high-frequency interference. Finally, the integrated thin-film capacitor 2216 filters out interference, making the signal cleaner and achieving an EMC level of five.

[0041] The assembly process of this fan drive unit is as follows:

[0042] First, assemble the motor structure component 3. Assemble the motor body 31 and the electric spindle 35 containing the rotor into one unit, and fix the magnet 36 to one end of the electric spindle 35. Next, assemble the motor rear end cover 32, screw the inlet and outlet water pipes 39 onto the inlet 321 and outlet 322 respectively, and then install the signal plug 37 and power plug 38 onto the cylindrical surface of the motor rear end cover 32. Then, assemble the AC output component 33, pre-place the three-phase output copper busbar 332 on the output end support 323, and fix the AC output component 33 into the cavity of the motor rear end cover 32 through the second countersunk hole 3312. Next, mechanically connect the motor rear end cover 32 to the motor body 31 with bolts by applying a flat sealant to the bottom, while ensuring that the first adapter 323, the second adapter 324, and the inlet and outlet of the motor body 31 are matched. Finally, electrically connect the motor three-phase winding terminals 34 to the AC output component 33 with bolts.

[0043] Next, assemble the PCBA power assembly. Connect the IGBT module 23 to the PCBA board 21 using self-tapping screws. Then, assemble the filter assembly 22. The main filter ring 222 is encapsulated in the first mounting hole 2211 with epoxy resin. The main filter capacitor 224 is fixed in the second mounting hole 2212, the secondary filter capacitor 225 is fixed in the third mounting hole 2213, and the magnetic plate 2231 is placed in the fourth mounting hole 2214. Next, pre-position the PCBA board 21 above the base 221. The magnetic hook 2232 is inserted into the fifth mounting hole 2214 to abut against the magnetic plate 2231. Simultaneously, part of the PCBA board 21 is enclosed by the secondary filter ring 223 formed by the magnetic hook 2232 and the magnetic plate 2231. Finally, the entire PCBA power assembly 2, consisting of the filter assembly 22, PCBA board 21, and IGBT module 23, is placed inside the motor rear end cover 32, and the PCBA board 21 is fixedly connected to the motor rear end cover 32 using bolts. Next, the secondary filter ring 223 is fixed by using a wedge slider to press against the magnetic hook 2232. Finally, the power plug 38 is electrically connected to the PCBA board 21 by bolts, the signal plug 37 is electrically connected to the PCBA board 21 by plugging it in, and the PCBA board 21 is electrically connected to the output copper busbar 332 of the AC output component 33.

[0044] Finally, assemble the side end cover. Secure the side end cover 1 to the top of the rear end cover 32 of the motor using bolts. The fan drive unit is now assembled.

[0045] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A fan drive device, characterized in that, Comprises a side end cover (1), a PCBA power component (2) and a motor component (3); the PCBA power component comprises a PCBA board (21) and a filter component (22), wherein a plurality of first limiting holes (212) and second limiting holes (213) are arranged on the PCBA board (21), and a magnetic decoder (211) is mounted on the PCBA board; The motor component (3) comprises a motor body (31) and a motor rear end cover (32) mounted on one side of the motor body (31), the motor rear end cover (32) is of a cavity structure, an AC output component (33), a three-phase winding terminal (34), an electric spindle (35) and a plurality of column structures (310) are arranged in the cavity, a signal connector (37) and a power connector (38) are mounted on one side of the cavity, the PCBA power component (2) is mounted in the cavity of the motor rear end cover (32), the upper end of the AC output component (33) is an output copper bar (332) provided with a plurality of convex blocks, and the convex blocks are clamped with the first limiting holes (212) on one side of the PCBA board (21); the column structures are clamped with the second limiting holes (213) on the PCBA board (21); a magnetic block (36) matched with the magnetic decoder (211) is arranged in the electric spindle; The filter component (22) comprises a base (221), one side of the base (221) is provided with an integrated thin film capacitor (2216), and the other side is provided with a first mounting hole (2211) in a shape of a Chinese character 'hui', the first mounting hole (2211) is vertically and obliquely arranged, and when the PCBA power component (2) is mounted on the motor component (3), the first mounting hole (2211) is parallel to the power connector (38); a convex wall (2217) provided with a plurality of arc-shaped grooves is arranged between the integrated thin film capacitor (2216) and the first mounting hole (2211), one side of the convex wall (2217) is provided with a second mounting hole (2212), a vertical plate (2218) is arranged on the other side of the second mounting hole, and the other side of the vertical plate (2218) is an H-shaped structure which comprises a fourth mounting hole (2214) and a fifth mounting hole (2215), the fourth mounting hole (2214) is communicated with the fifth mounting hole (2215), and the base (221) further comprises a third mounting hole (2213) closely attached to the H-shaped structure.

2. The fan drive device according to claim 1, characterized in that, The filter component (22) comprises a main filter ring (222), a secondary filter ring (223), a main filter capacitor (224), a secondary filter capacitor (225) and a grounding copper bar (226), the main filter ring (222) is mounted in the first mounting hole (2211); the main filter capacitor (224) is mounted in the second mounting hole (2212), the secondary filter capacitor (225) is mounted in the third mounting hole (2213), and the secondary filter ring (223) is mounted in the fourth mounting hole (2214) and the fifth mounting hole (2215).

3. A fan drive device according to claim 2, characterized in that, The filter assembly (22) is clamped on the PCBA board (21) by the secondary filter ring (223), the base (221) comprises an integrated thin film capacitor (2216), and the terminals of the main filter capacitor (224) and the integrated thin film capacitor (2216) are both connected to the PCBA board (21); a terminal on one side of the secondary filter capacitor (225) is connected to the PCBA board (21), and a terminal on the other end is connected to the motor rear end cover (32) through a grounding copper bar (226).

4. A fan drive device according to claim 1, characterized in that, The motor assembly (3) further comprises a water inlet and outlet pipe (39), the motor rear end cover (32) is of a hollow structure with a heat dissipation water channel integrated therein, a boss is arranged on a side surface of the motor rear end cover, a water inlet (321) and a water outlet (322) are arranged on the boss, the water inlet and outlet pipe (39) connects the water inlet (321) and the water outlet (322), a first adapter water port (323) and a second adapter water port (324) are arranged on the lower bottom surface of the motor rear end cover, the water inlet (321) communicates with the first adapter water port (323) through the heat dissipation water channel, the second adapter water port (324) directly cross-communicates with the water outlet (322), and the first adapter water port (323) and the second adapter water port (324) are respectively mechanically connected with the inlet and outlet of the heat dissipation water channel on the motor body (31) to form a heat dissipation cooling passage.

5. A fan drive device according to claim 2, characterized in that, The secondary filter ring (223) is composed of a zinc-manganese and zinc-nickel mixture, and comprises a magnetic plate (2231) and a magnetic hook (2232), the magnetic plate (2231) is of a cuboid structure, and the magnetic hook (2232) is in a shape of "匚".

6. A fan drive device according to claim 2, characterized in that, The main filter ring (222) is made of nanocrystalline material and has a square-shaped appearance, the main filter ring (222) is divided into upper and lower U-shaped structures, and the mating surfaces of the U-shaped structural members are mechanically connected through a dovetail groove structure.

7. A fan drive device according to claim 1, characterized in that, The AC output assembly (33) comprises an output support (331) and an output copper bar (332), the output copper bar (332) is Z-shaped and mounted on the output support (331); the output support (331) is stepped, a plurality of first counterbores (3311) and a plurality of second counterbores (3312) are arranged on the upper end face of the output support (331), a notched wire harness bayonet (3313) is arranged on the left side of the output support (331), and a plurality of notched terminal bayonets (3314) are arranged on the lower end face of the output support (331).

8. A fan drive device according to claim 1, characterized in that, The three-phase winding terminal (34) comprises a main wire harness (341) and a three-phase magnetic ring (342), and the three-phase magnetic ring (342) is fixed on the main wire harness (341) through a heat-shrinkable sleeve.

9. A fan drive device according to claim 1, characterized in that, The PCBA power assembly (2) further comprises an IGBT module (23), and the IGBT module (23) is fixed on the PCBA board (21).

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