A flexible direct-drive fan

Abstract

A flexible direct-drive fan includes a fan casing, an impeller, a direct-drive motor, a fan casing base, a motor bracket, and a collector. Its key technical features are: the fan casing includes a front panel, a rear panel, and a surrounding panel; an inlet-end reinforcing rib and a motor-end reinforcing rib are respectively provided on the inner sides of the front and rear panels; a spiral-shaped surrounding panel is provided between the inlet-end and motor-end reinforcing ribs; an inlet flange and a collector are provided on the front panel; a square motor port and a corresponding square motor port cover are provided on the rear panel and the motor-end reinforcing rib; a motor shaft heat dissipation vent and a connecting pad are provided on the square motor port cover; a motor flange connected to the connecting pad is provided on the motor casing; and elastic damping pads are provided between the various components of the fan. This invention achieves stable operation of direct-drive fans of model 6.3A and above through an elastic connection structure, while also possessing advantages such as structural vibration reduction, small space occupation, material sound insulation, and motor shaft heat dissipation.

Description

Technical Field

[0001] This invention belongs to the field of wind turbines, and specifically relates to a flexible direct-drive wind turbine. Background Technology

[0002] In existing wind turbine technology, most direct-drive wind turbines use rigid connections. Rigid direct-drive connections can only be used for turbine sizes below 6.3A. Wind turbines with rigid direct drives above 6.3A will be damaged due to excessive vibration. Therefore, wind turbines above 6.3A usually use shaft direct-drive or belt drive.

[0003] Compared to direct-drive fans, fans with direct-drive or belt-driven couplings have the following disadvantages: ① When using the same power motor, the mechanical efficiency of fans with direct-drive or belt-driven couplings is lower; ② The transmission components of fans with direct-drive or belt-driven couplings occupy more space; ③ The transmission components of fans with direct-drive or belt-driven couplings are prone to wear, increasing maintenance costs in the later stages. From these disadvantages, it can be seen that direct-drive fans are the optimal fan drive method. How to solve the problem of excessive vibration causing damage to direct-drive fans with a size of 6.3A or higher remains a challenge in the current technology. Summary of the Invention

[0004] The purpose of this invention is to provide a flexible direct-drive fan. Through the flexible connection of the fan structure, the stable operation of direct-drive fans with a size of 6.3A or higher is achieved, solving the problem that direct-drive fans with a size of 6.3A or higher will be damaged due to excessive vibration. At the same time, it has the advantages of structural vibration reduction, small space occupation, sound insulation of materials, and heat dissipation of motor shaft.

[0005] This invention is achieved through the following technical solution: a flexible direct-drive fan, comprising a fan casing, an impeller, a motor directly connected to the impeller, a fan casing base, a motor bracket, and a collector. The key technical points are: the fan casing is cuboid in shape, comprising a front panel, a rear panel, and a surrounding panel; an air inlet reinforcing rib plate connected to the surrounding panel is provided on the inner side near the front panel; a motor end reinforcing rib plate connected to the surrounding panel is provided on the inner side near the rear panel; a volute surrounding panel is provided between the air inlet end reinforcing rib plate and the motor end reinforcing rib plate; symmetrical square air inlets are provided in the middle of the front panel and the air inlet end reinforcing rib plate; square air inlet discs corresponding to the square air inlets are provided on the edges of the two square air inlets; an air inlet flange is provided on the outer side of the square air inlet discs; the collector is located on the inner side of the square air inlet discs; and the rear panel and motor end reinforcing rib plate... The fan housing is provided with symmetrical square motor ports; a square motor port cover plate corresponding to the square motor ports is provided on the reinforcing rib plate at the motor end; a motor shaft heat dissipation vent is provided on the square motor port cover plate; a connecting pad is provided on the outside of the square motor port cover plate; a motor flange connected to the connecting pad is provided on the motor housing; an air outlet corresponding to the outlet end of the volute-shaped enclosure is provided on the enclosure plate, and an air outlet flange is provided at the air outlet of the enclosure plate; the impeller is located inside the volute-shaped enclosure plate, and multiple ventilation fan blades coaxially rotating with the impeller are provided on the side of the impeller near the motor; the fan housing base is located at the bottom of the fan housing; the motor is connected to the fan housing base through a motor bracket; elastic shock-absorbing pads are provided between the motor flange and the connecting pad, between the motor bracket and the motor, between the fan housing and the fan housing base, and between the motor bracket and the fan housing base.

[0006] Furthermore, the air inlet end reinforcing rib plate is mainly composed of a left air inlet end reinforcing rib plate, a right air inlet end reinforcing rib plate, an upper air inlet end reinforcing rib plate, and a lower air inlet end reinforcing rib plate welded together; L-shaped folded edges are provided at the edges of the square air inlet of the air inlet end reinforcing rib plate and at the welding positions between the left air inlet end reinforcing rib plate, the right air inlet end reinforcing rib plate, the upper air inlet end reinforcing rib plate, and the lower air inlet end reinforcing rib plate; C-shaped folded edges are provided around the edges of the air inlet end reinforcing rib plate; the motor end reinforcing rib plate is mainly composed of a left motor end reinforcing rib plate, a right motor end reinforcing rib plate, an upper motor end reinforcing rib plate, and a lower motor end reinforcing rib plate welded together; L-shaped folded edges are provided at the edges of the square motor inlet of the motor end reinforcing rib plate and at the welding positions between the left motor end reinforcing rib plate, the right motor end reinforcing rib plate, the upper motor end reinforcing rib plate, and the lower motor end reinforcing rib plate; C-shaped folded edges are provided around the edges of the motor end reinforcing rib plate.

[0007] Furthermore, the square air inlet plate, air inlet flange, and collector are integrated into one structure.

[0008] Furthermore, a sound insulation material layer is provided between the front panel and the air inlet reinforcing plate, between the rear panel and the motor end reinforcing plate, and on the outside of the volute enclosure.

[0009] Furthermore, a flow-stabilizing sealing plate corresponding to the square air inlet is provided on the reinforcing rib plate at the air inlet end.

[0010] Furthermore, the rear disc of the impeller is an inwardly concave cone.

[0011] The beneficial effects and features of this invention are as follows:

[0012] This invention increases the strength of the fan casing through a welded combination structure of the air inlet reinforcing plate, the motor end reinforcing plate, and the volute-shaped enclosure plate within the fan casing. Elastic damping pads are added between the motor flange and connecting gasket, between the motor bracket and the motor, between the fan casing and the fan casing base, and between the motor bracket and the fan casing base, achieving overall vibration reduction and stable operation for direct-drive fans of model 6.3A and above. Compared to fans using direct-drive couplings or belt drives, this invention saves space and avoids subsequent maintenance of transmission parts. The combination of the fan casing structure and sound insulation material layers reduces overall fan noise. The motor-driven fan blades accelerate airflow at the motor shaft location, solving the heat dissipation problem of the motor output shaft and preventing damage to the fan caused by lubricating oil dilution or leakage due to overheating of the motor output shaft, thus protecting the motor structure. Attached Figure Description

[0013] Figure 1 This is a simplified cross-sectional view of the overall structure of the present invention from the side.

[0014] Figure 2 for Figure 1 A simplified enlarged diagram of part A in the middle;

[0015] Figure 3 for Figure 1 A simplified enlarged diagram of part B;

[0016] Figure 4 This is a simplified cross-sectional view of the overall structure of the present invention from the front.

[0017] The main components in the diagram are numbered as follows: 1. Fan casing; 101. Front panel; 102. Rear panel; 103. Enclosure; 104. Inlet end reinforcing rib; 105. Motor end reinforcing rib; 106. Volute enclosure; 107. Outlet flange; 2. Square inlet plate; 201. Inlet flange; 202. Collector; 3. Square motor port cover; 301. Connecting pad; 4. Motor; 401. Motor flange; 5. Impeller; 501. Ventilation fan blade; 6. Fan casing base; 7. Motor bracket; 8. Elastic shock-absorbing pad; 9. Sound insulation material layer; 10. Flow stabilizing sealing plate.

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Implementation

[0019] The following combination Figure 1-4 The present invention will be described in detail through specific embodiments. Example

[0020] The flexible direct-drive fan includes a fan housing 1, an impeller 5, a motor 4 directly connected to the impeller, a fan housing base 6, a motor bracket 7, and a collector 202. The fan housing is cuboid in shape and includes a front panel 101, a rear panel 102, and a surrounding plate 103 welded together. An inlet end reinforcing rib 104, welded to the surrounding plate, is located on the inner side near the front panel. A motor end reinforcing rib 105, welded to the surrounding plate, is located on the inner side near the rear panel. A spiral surrounding plate 106 is welded between the inlet end reinforcing rib and the motor end reinforcing rib. The volute of this fan is formed by welding together the reinforcing ribs and the volute-shaped enclosure. Symmetrical square air inlets (i.e., the air inlets of the volute) are provided in the middle of the front panel and the reinforcing ribs at the air inlet end. Square air inlet plates 2, corresponding to the square air inlets, are provided at the edges of the two square air inlets. An air inlet flange 201 is provided on the outer side of the square air inlet plate, and the collector is located on the inner side of the square air inlet plate. For ease of production, the square air inlet plate, air inlet flange, and collector are welded as a single unit. For ease of installation and maintenance, the square air inlet plate is fastened to the fan casing with self-tapping screws. Symmetrical square motor openings are provided on the rear panel and the motor end reinforcing rib; a square motor opening cover plate 3 corresponding to the square motor openings is provided on the motor end reinforcing rib; a motor shaft heat dissipation vent is provided on the square motor opening cover plate; a connecting pad 301 is welded to the outside of the square motor opening cover plate; a motor flange 401 is provided on the motor housing, which is connected and fixed to the connecting pad by bolts; an air outlet (i.e., the air outlet of the volute) corresponding to the outlet end of the volute housing is provided on the enclosure plate, and an air outlet flange 107 is welded to the air outlet of the enclosure plate; to increase the structural strength of the impeller, the impeller is located inside the volute housing, and the rear plate of the impeller is concave inward. The impeller has a cone-shaped body; multiple ventilation fan blades 501, which rotate coaxially with the impeller, are welded to the side of the impeller near the motor. These ventilation fan blades are circumferentially arranged around the central shaft of the rear disc of the impeller. The ventilation fan blades can cooperate with the motor shaft heat dissipation port to dissipate heat from the motor output shaft during the rotation of the fan. The fan housing base is located at the bottom of the fan housing. The motor is connected to the fan housing base through a motor bracket. Elastic shock-absorbing pads are provided between the motor flange and the connecting pad, between the motor bracket and the motor, between the fan housing and the fan housing base, and between the motor bracket and the fan housing base. All the above structural connections with elastic shock-absorbing pads are bolted connections, which are also elastic connections, for ease of installation and production.

[0021] To increase the strength of the fan casing, the air inlet end reinforcing rib is mainly composed of a left air inlet end reinforcing rib, a right air inlet end reinforcing rib, an upper air inlet end reinforcing rib, and a lower air inlet end reinforcing rib welded together. L-shaped flanges are provided at the edges of the square air inlet of the air inlet end reinforcing rib and at the welding points between the left, right, upper, and lower air inlet end reinforcing ribs. C-shaped flanges are provided around the edges of the air inlet end reinforcing rib. The motor end reinforcing rib is mainly composed of a left motor end reinforcing rib, a right motor end reinforcing rib, an upper motor end reinforcing rib, and a lower motor end reinforcing rib welded together. L-shaped flanges are provided at the edges of the square motor outlet of the motor end reinforcing rib and at the welding points between the left, right, upper, and lower motor end reinforcing ribs. C-shaped flanges are provided around the edges of the motor end reinforcing rib. The L-shaped and C-shaped flanges are formed by bending, and the air inlet end reinforcing rib and the motor end reinforcing rib are formed by bending followed by welding.

[0022] To reduce noise during operation, a sound insulation material layer is provided between the front panel and the air inlet stiffener, between the rear panel and the motor stiffener, and on the outside of the volute enclosure. This sound insulation material layer is a combination of pixel flame-retardant board and sound insulation felt.

[0023] To prevent eddies from forming inside the spiral enclosure due to excessive grooves, which would reduce fan efficiency, a flow-stabilizing sealing plate corresponding to the square air inlet is provided on the reinforcing rib plate at the air inlet end. This flow-stabilizing sealing plate has a circular opening for the collector to pass through. For ease of installation and maintenance, stabilizing corners are welded to the four corners of the square air inlet on the inner side of the reinforcing rib plate at the air inlet end. The flow-stabilizing sealing plate is connected to the stabilizing corners by self-tapping screws.

[0024] This invention utilizes a welded assembly structure of a reinforcing rib plate at the air inlet end, a reinforcing rib plate at the motor end, and a volute-shaped surround plate within the fan casing. This structure increases the strength of the fan casing while reducing resonance during operation. The combination of the fan casing structure and sound insulation material layers achieves overall fan noise reduction. The addition of a flow-stabilizing sealing plate between the reinforcing rib plate at the air inlet end and the collector prevents eddies from forming inside the fan due to the concave structure of the square air inlet of the reinforcing rib plate, thus avoiding reduced fan efficiency. The square air inlet plate, collector, and air inlet flange are all welded together as a standard component, allowing for pre-production and inventory management, thus improving production efficiency. During installation, the distance between the impeller front plate and the collector can be effectively adjusted by moving the collector and the air inlet flange, facilitating installation and debugging. Elastic damping pads are added between the motor flange and the connecting pad, between the motor bracket and the motor, between the fan casing and the fan casing base, and between the motor bracket and the fan casing base, achieving overall vibration reduction and stable operation of the fan. The motor drives the ventilation fan blades to rotate, accelerating the airflow at the motor shaft position, solving the heat dissipation problem of the motor output shaft, avoiding damage to the fan caused by the dilution or flow of lubricating oil due to overheating of the motor output shaft, and providing protection for the motor structure.

[0025] This invention reduces casing resonance by using a robust fan casing structure with elastic connections and elastic damping pads, thus solving the problem of excessive vibration causing damage to rigid direct-drive fans of size 6.3A and above. Noise is reduced by using sound insulation material integrated into the fan casing. The elastic connection structure between the connecting pad and the motor flange enables bidirectional positioning of the motor and fan casing. Three-terminal air cooling of the motor is achieved using ventilation fan blades.

Claims

1. A flexible direct-drive fan, comprising a fan casing, an impeller, a motor directly connected to the impeller, a fan casing base, a motor bracket, and a collector, characterized in that: The fan casing is cuboid in shape and includes a front panel, a rear panel, and a surrounding panel. An air inlet reinforcing rib connected to the surrounding panel is located on the inner side near the front panel. A motor end reinforcing rib connected to the surrounding panel is located on the inner side near the rear panel. A spiral-shaped surrounding panel is located between the air inlet and motor end reinforcing ribs. Symmetrical square air inlets are located in the center of the front panel and the air inlet reinforcing ribs. Square air inlet discs corresponding to the square air inlets are located at the edges of the two square air inlets. An air inlet flange is located on the outer side of the square air inlet discs, and the collector is located inside the square air inlet discs. Symmetrical square motor openings are located on the rear panel and the motor end reinforcing ribs. A motor end reinforcing rib is located opposite to the square motor openings. A square motor port cover is provided; a motor shaft heat dissipation vent is provided on the square motor port cover; a connecting pad is provided on the outside of the square motor port cover; a motor flange connected to the connecting pad is provided on the motor housing; an air outlet corresponding to the outlet end of the volute-shaped enclosure is provided on the enclosure plate, and an air outlet flange is provided at the air outlet of the enclosure plate; the impeller is located inside the volute-shaped enclosure plate, and multiple ventilation fan blades coaxially rotating with the impeller are provided on the side of the impeller near the motor; the fan housing base is located at the bottom of the fan housing; the motor is connected to the fan housing base through a motor bracket; elastic shock-absorbing pads are provided between the motor flange and the connecting pad, between the motor bracket and the motor, between the fan housing and the fan housing base, and between the motor bracket and the fan housing base; The air inlet reinforcing rib plate is welded together from a left air inlet rib plate, a right air inlet rib plate, an upper air inlet rib plate, and a lower air inlet rib plate. L-shaped flanges are provided at the edges of the square air inlet of the air inlet reinforcing rib plate and at the welding points between the left, right, upper, and lower air inlet rib plates. C-shaped flanges are provided around the perimeter of the air inlet reinforcing rib plate. The motor end reinforcing rib plate is welded together from a left motor end rib plate, a right motor end rib plate, an upper motor end rib plate, and a lower motor end rib plate. The square motor inlet edge of the motor end reinforcing rib plate and the welding points between the left, right, upper, and lower reinforcing rib plates of the motor end are provided with L-shaped folded edges; C-shaped folded edges are provided around the edges of the motor end reinforcing rib plate; sound insulation material layers are provided between the front panel and the air inlet reinforcing rib plate, between the rear panel and the motor end reinforcing rib plate, and on the outer side of the volute enclosure; a flow stabilizing sealing plate corresponding to the square air inlet is provided on the air inlet reinforcing rib plate; the rear disc of the impeller is an inwardly concave cone.

2. The flexible direct-drive fan according to claim 1, characterized in that: The square air inlet plate, air inlet flange, and collector are integrated into one structure.

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