Controller with external rectification and axial field motor

Abstract

The application provides a controller with external rectification and an axial magnetic field motor, wherein the controller comprises a controller module, the controller module comprises a control shell and a drive control circuit board arranged in the control shell; a rectification module, the rectification module comprises a rectification shell and a rectification circuit board arranged in the rectification shell; the rectification module is independently arranged outside the controller module, and the two are connected through a flexible cable; the control shell is provided with a motor mounting surface, the controller module is mounted with a motor module as a whole through the motor mounting surface, the drive control circuit board comprises an inverter circuit part, a power supply circuit part and a control circuit part, the inverter circuit part, the power supply circuit part and the control circuit part surround the drive control circuit board in a circular shape, the thickness and the volume of the controller module are effectively reduced, the rectification module is connected to one side of the thickness direction of the controller module in an elongated form, the axial dimension is further reduced, the overall occupied space is reduced, and the application occasions are increased.

Description

[0001] This application is a divisional application of the invention patent filed on November 11, 2021, with application number 2021113321759 and titled "Controller with External Rectifier and Axial Magnetic Field Motor". Technical Field

[0002] This invention relates to the field of axial magnetic field motors, and more particularly to a controller with an external rectifier and an axial magnetic field motor. Background Technology

[0003] Axial field motors, compared to traditional motors, have advantages such as smaller axial volume and higher torque density, making them suitable for installations with limited axial dimensions. The axial field motor is connected to a controller, which controls its operation. Controllers are typically mounted internally or externally to the axial field motor. Internal mounting tends to increase the motor's size, resulting in a larger footprint, while external mounting requires separate wiring to connect the motor and controller, necessitating additional space allocation and also contributing to the larger footprint.

[0004] Furthermore, existing controllers include a housing, and drive circuit boards and control circuit boards housed within the housing. The drive circuit board integrates a rectifier module with a large filtering capacitor. This rectifier module converts AC power into DC power, and the capacitor acts on the rectifier module to filter out unwanted AC components from the DC power supply, smoothing the DC output. Because the controller contains drive and control boards, and the drive board has a large filtering capacitor, its size is relatively large. This means that existing controllers, whether connected internally or externally to the axial field motor, not only increase the overall size but also diminish the advantage of the axial field motor's small size, reducing the applicable scenarios for the axial field motor. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a controller and axial magnetic field motor with external rectification that reduces overall size and expands applicability.

[0006] According to one object of the present invention, the present invention provides a controller with an external rectifier, comprising:

[0007] A controller module, the controller module including a control housing and a drive control circuit board disposed within the control housing;

[0008] A rectifier module, the rectifier module including a rectifier housing and a rectifier circuit board disposed inside the rectifier housing;

[0009] The rectifier module is independently located outside the controller module, and the two are connected by a flexible cable;

[0010] The control housing is provided with a motor mounting surface, and the controller module is installed as an integral unit with the motor module through the motor mounting surface;

[0011] The drive control circuit board includes an inverter circuit section, a power supply circuit section, and a control circuit section. The inverter circuit section, the power supply circuit section, and the control circuit section are all fan-shaped to form a circular drive control circuit board.

[0012] As a preferred technical solution, the control housing has an inner control end face and an outer control end face, and a control periphery extending between the inner control end face and the outer control end face. The thickness of the controller module is defined between the inner control end face and the outer control end face. The rectifier module is located on one side of the thickness direction of the controller module. The flexible cable includes a DC cable. The rectifier module extends and is connected to the outer control end face in such a way that the length direction of the rectifier module is consistent with that of the DC cable. The inner control end face is a motor mounting surface.

[0013] As a preferred technical solution, the control housing is divided into a bottom shell and a cover plate along its thickness direction, and the bottom shell and the cover plate are fixed together by screws or adhesive.

[0014] As a preferred technical solution, heat dissipation fins are also provided on the external control end face.

[0015] According to another objective of the present invention, the present invention also provides an axial magnetic field motor, comprising a controller with an external rectifier as described in the above embodiments, the axial magnetic field motor further comprising:

[0016] A motor module is provided, which is connected to the controller module via a motor cable.

[0017] As a preferred technical solution, the motor module includes a motor housing, the motor housing having an inner motor end face, an outer motor end face, and a motor periphery extending between the inner motor end face and the outer motor end face. The thickness of the motor module is defined between the inner motor end face and the outer motor end face. The controller module is mounted on the motor module with its inner control end face fitting against the inner motor end face, and the motor periphery fits and corresponds to the control periphery portion of the controller module.

[0018] As a preferred technical solution, the motor periphery includes an adjacent motor circular edge and a motor protrusion, and the control periphery includes an adjacent control circular edge and a control protrusion. The motor circular edge and the control circular edge are fitted and correspond to each other. The motor protrusion and the control protrusion face the same direction, and the motor protrusion protrudes beyond the control protrusion, so that a wiring space for accommodating the motor cable is formed between the motor protrusion and the control protrusion, and the wiring space is located within the area enclosed by the motor periphery.

[0019] As a preferred technical solution, a control connection port is provided on the inner motor end face corresponding to the motor protrusion, and a motor connection port is provided on the outer control end face corresponding to the control protrusion. The motor cable is connected in a U-shape between the control connection port and the motor connection port.

[0020] As a preferred technical solution, the external control terminal is also provided with a rectifier connection port and a communication connection port. The rectifier module is detachably connected to the rectifier connection port via a DC cable, and the host computer is detachably connected to the communication connection port via a communication cable.

[0021] As a preferred technical solution, the motor connection port, the rectifier connection port, and the communication connection port are arranged side by side on the outer control end face corresponding to the control protrusion.

[0022] Compared with existing technologies, this technical solution has the following advantages:

[0023] The controller module carries the drive control circuit, and the rectifier module carries the rectifier circuit. By independently placing the rectifier module externally within the controller module, the thickness and volume of the controller module are effectively reduced. Furthermore, the rectifier module is located on one side of the controller module's thickness direction, reducing the overall radial dimension. Additionally, the controller module is integrated with the motor module via a motor mounting surface, further reducing the axial dimension, thus minimizing the overall space occupied and increasing applicability. Moreover, the rectifier module can be arranged along the axis of the controller module or at any position, depending on installation requirements, allowing for flexible and diverse combination methods.

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the axial magnetic field motor described in this invention;

[0026] Figure 2 This is a schematic diagram of the combination of the motor module and the controller module described in this invention;

[0027] Figure 3 This is a schematic diagram of the controller module described in this invention;

[0028] Figure 4 This is a schematic diagram of the drive control circuit board described in this invention;

[0029] Figure 5 This is a schematic diagram of the rectifier circuit board described in this invention;

[0030] Figure 6 This is a schematic diagram of the structure of the motor module described in this invention;

[0031] Figure 7 This is a front view of the motor module described in this invention;

[0032] Figure 8 for Figure 7 Sectional view along the AA direction. Detailed Implementation

[0033] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0034] First Embodiment

[0035] like Figure 1 , Figure 4 and Figure 5 As shown, the controller with external rectification includes:

[0036] A controller module 100, the controller module 100 including a control housing 110 and a drive control circuit board 120 disposed in the control housing 110;

[0037] A rectifier module 200, the rectifier module 200 includes a rectifier housing 210 and a rectifier circuit board 220 disposed in the rectifier housing 210, the rectifier module 200 is located on one side of the controller module 100 in the thickness direction;

[0038] The rectifier module 200 is independently disposed outside the controller module 100, and the two are connected by a flexible cable;

[0039] The control housing 110 is provided with a motor mounting surface, and the controller module 100 is installed as a whole with the motor module 300 through the motor mounting surface.

[0040] The controller module 100 carries the drive control circuit, and the rectifier module 200 carries the rectifier circuit. That is, by independently placing the rectifier module 200 outside the controller module 100, the thickness and volume of the controller module 100 are effectively reduced. In addition, the rectifier module 200 is located on one side of the thickness direction of the controller module 100, which reduces the overall radial dimension. Furthermore, the controller module 100 is installed as an integral part of the motor module 300 through the motor mounting surface, which further reduces the axial dimension, thereby reducing the overall space occupied and increasing the applicable occasions.

[0041] like Figure 1 As shown, the control housing 110 has an inner control end face 1101 and an outer control end face 1102, and a control periphery 1103 extending between the inner control end face 1101 and the outer control end face 1102. The thickness of the controller module 100 is defined between the inner control end face 1101 and the outer control end face 1102. The flexible cable includes a DC cable 410. The rectifier module 200 extends and is connected to the outer control end face 1102 in such a way that the length direction of the rectifier module 200 is consistent with that of the DC cable 410. The inner control end face 1101 is a motor mounting surface.

[0042] Specifically, the rectifier module 200 extends along the length of the DC cable 410, forming an elongated shape. The DC cable 410 has a circular cross-section, while the rectifier module 200 has a rectangular cross-section. Furthermore, the cross-sectional area of ​​the rectifier module 200 is slightly larger than that of the DC cable 410, thus reducing the overall size of the rectifier module 200 and improving its applicability.

[0043] More specifically, the DC cable 410 is a flexible DC cable, thus allowing for various assembly methods for the rectifier module 200 and the controller module 100. In one embodiment, the axis of the rectifier module 200 is arranged parallel to the axis of the controller module 100, resulting in a compact and aesthetically pleasing structure while reducing the overall radial dimension. In another embodiment, the rectifier module 200 and the controller module 100 are distributed separately, for example, by using individual mounting brackets, making the assembly method flexible and adaptable to different application scenarios.

[0044] Continue to refer to Figure 1 The external control end face 1102 is also provided with heat dissipation fins. These fins improve the heat dissipation performance of the controller module 100. The shape of the heat dissipation fins is varied and not limited here.

[0045] like Figure 1As shown, the control housing 110 is divided into a bottom shell 111 and a cover plate 112 along its thickness direction. The bottom shell 111 and the cover plate 112 are fixed together by screws or adhesive. That is, the control housing 110 has a split structure, which facilitates the installation and removal of the drive control circuit board 120 into the control housing 110 and facilitates maintenance.

[0046] The inner control end face 1101 corresponds to the end face of the cover plate 112 that is away from the bottom shell 111, while the outer control end face 1102 corresponds to the end face of the bottom shell 111 that is away from the cover plate 112. That is, the rectifier module 200 is connected to the end face of the bottom shell 111 that is away from the cover plate 112.

[0047] Specifically, the dimension of the bottom shell 111 along the thickness direction of the control housing 110 is larger than the dimension of the cover plate 112 along the thickness direction of the control housing 110. The bottom shell 111 and the cover plate 112 are fixed by screws or adhesives to form a cavity between the bottom shell 111 and the cover plate 112 to accommodate the drive control circuit board 120.

[0048] In summary, the controller module 100 carries the drive control circuit, and the rectifier module 200 carries the rectifier circuit. By independently placing the rectifier module 200 externally within the controller module 100, the thickness and volume of the controller module 100 are effectively reduced. Furthermore, the rectifier module 200 is located on one side of the controller module 100's thickness direction, reducing the overall radial dimension. Additionally, the controller module 100 is integrated with the motor module 300 via a motor mounting surface, further reducing the axial dimension and thus minimizing the overall space required and expanding its applicability. Moreover, the control housing 110 consists of a bottom shell 111 and a cover plate 112, which are fixed together with screws or adhesive to facilitate the disassembly and maintenance of the drive control circuit board 120. Furthermore, the rectifier module 200 can be arranged along the axis of the controller module 100 or at any other location, allowing for flexible and diverse combinations.

[0049] like Figure 1 As shown, the axial magnetic field motor includes a controller with an external rectifier as described in the above embodiment, and the axial magnetic field motor further includes:

[0050] A motor module 300 is connected to the controller module 100 via a motor cable 420.

[0051] Since the axial magnetic field motor adopts the axial magnetic field motor of the above embodiment, the beneficial effects brought by the axial magnetic field motor are as described in the above embodiment.

[0052] In one embodiment, the motor module 300 includes a motor housing 310, the motor housing 310 having an inner motor end face 3101, an outer motor end face 3102, and a motor periphery 3103 extending between the inner motor end face 3101 and the outer motor end face 3102. The thickness of the motor module 300 is defined between the inner motor end face 3101 and the outer motor end face 3102. The controller module 100 is mounted on the motor module 300 such that its inner control end face 1101 is attached to the inner motor end face 3101, and the motor periphery 3103 is partially attached to and corresponds to the control periphery 1103 of the controller module 100.

[0053] Specifically, the motor module 300, the controller module 100, and the rectifier module 200 are arranged axially, with the motor periphery 3103 partially fitting and corresponding to the control periphery 1103 of the controller module 100, and the rectifier module 200 being approximately located within the area enclosed by the control periphery 1103. This effectively reduces the overall radial dimension, decreases the overall space occupied, and increases the range of applicable applications. Furthermore, the close fit between the motor module 300 and the controller module 100 saves on cables.

[0054] In another embodiment, the motor module 300, the controller module 100, and the rectifier module 200 are arranged separately, and can also be installed independently using mounting brackets.

[0055] As can be seen from the above, the axial magnetic field motor has a compact and aesthetically pleasing structure. By changing the structural parameters of the modules, flexible combination or separation can be achieved, making the overall layout more flexible and the overall arrangement more reasonable, thereby enriching the application scenarios of the axial magnetic field motor.

[0056] like Figure 1 As shown, the motor periphery 3103 includes an adjacent motor circular edge portion 31031 and a motor protrusion portion 31032, and the control periphery 1103 includes an adjacent control circular edge portion 11031 and a control protrusion portion 11032. The motor circular edge portion 31031 and the control circular edge portion 11031 are fitted and correspond to each other. The motor protrusion portion 31032 and the control protrusion portion 11032 face the same direction, and the motor protrusion portion 31032 protrudes out of the control protrusion portion 11032, so that a wiring space for accommodating the motor cable 420 is formed between the motor protrusion portion 31032 and the control protrusion portion 11032, and the wiring space is located within the area enclosed by the motor periphery 3103.

[0057] The control edge 11031 is fitted and corresponds to the motor periphery 3103, and the control protrusion 11032, motor cable 420, and wiring space are all located within the area enclosed by the motor periphery 3103. This prevents the motor cable 420 from protruding beyond the control periphery 1103, which would increase the overall size and affect the versatility of the application. Furthermore, the motor protrusion 31032 and the control protrusion 11032 face the same direction, shortening the length of the motor cable 420, reducing costs, and further facilitating heat dissipation from the motor cable 420, thus minimizing the impact on the overall size.

[0058] like Figure 1 As shown, a control connection port 330 is provided on the inner motor end face 3101 corresponding to the motor protrusion 31032, and a motor connection port 131 is provided on the outer control end face 1102 corresponding to the control protrusion 11032. The motor cable 420 is connected in a U-shape between the control connection port 330 and the motor connection port 131.

[0059] To avoid wiring interference, so as to facilitate wiring of the motor cable 420 and subsequent DC cable 410, while ensuring that the motor cable 420 is located within the area enclosed by the perimeter 3103 of the motor, so that the two are arranged compactly.

[0060] like Figure 1 As shown, the external control end face 1102 is also provided with a rectifier connection port 132 and a communication connection port 133. The rectifier module 200 is detachably connected to the rectifier connection port 132 via a DC cable 410, and the host computer is detachably connected to the communication connection port 133 via a communication cable 430.

[0061] Preferably, the motor connection port 131, the rectifier connection port 132, and the communication connection port 133 are arranged side by side on the external control end face 1102 corresponding to the control protrusion 11032. This facilitates centralized appearance and management, thereby improving wiring efficiency.

[0062] In summary, the motor module 300, the controller module 100, and the rectifier module 200 can be arranged axially or distributed, which not only achieves a compact and aesthetically pleasing structure, but also makes them easy to disassemble and maintain. Furthermore, the combination methods are flexible and can meet different usage scenarios.

[0063] Second Embodiment

[0064] like Figure 2 and Figure 3 As shown, the axial magnetic field motor includes:

[0065] A motor module 300 includes a motor housing 310, which includes a rear motor housing 312, a front motor housing 311, and a plurality of motor connection groups 313. The plurality of motor connection groups 313 are located at the motor periphery 3103 of the motor housing 310 to connect the rear motor housing 312 and the front motor housing 311.

[0066] A controller module 100 includes a control housing 110, which includes a bottom shell 111, a cover plate 112, and a plurality of control connection groups 113. The number of control connection groups 113 is less than the number of motor connection groups 313. The plurality of control connection groups 113 are located on the control periphery 1103 of the control housing 110, and each control connection group 113 connects the bottom shell 111 and the cover plate 112 while simultaneously connecting to the motor connection group 313, so that the controller module 100 is mounted on the motor module 300 with the cover plate 112 fitting against the motor rear shell 312, and the control periphery 1103 fits and corresponds to the motor periphery 3103.

[0067] In addition to connecting the bottom shell 111 and the cover plate 112, the control connection group 113 also connects to the motor connection group 313. Therefore, there is no need to add an additional connection structure between the motor module 300 and the controller module 100, which not only simplifies the overall size but also reduces the axial size, thereby reducing the overall space occupied and increasing the applicable occasions.

[0068] like Figure 2 and Figure 3 As shown, the control connection group 113 includes a bottom shell connecting ear 1131, a cover plate connecting ear 1132, and an external fastener. The bottom shell connecting ear 1131 extends outward and protrudes from the periphery of the bottom shell 111, and the cover plate connecting ear 1132 extends outward and protrudes from the periphery of the cover plate 112. The external fastener connects the bottom shell connecting ear 1131 and the cover plate connecting ear 1132 and locks them onto the motor connection group 313.

[0069] The external fastener can be a screw, which passes through the bottom shell connecting lug 1131 and the cover plate connecting lug 1132 in sequence until it is threadedly connected to the motor connecting assembly 313, so as to fix the bottom shell 111 and the cover plate 112, and at the same time fix the controller module 100 to the motor module 300.

[0070] Specifically, the cover plate connecting ear 1132 and the cover plate 112 have the same thickness, both being relatively thin. The thickness of the bottom shell connecting ear 1131 is less than the thickness of the bottom shell 111. When the cover plate 112 and the bottom shell 111 abut, the cover plate connecting ear 1132 and the bottom shell connecting ear 1131 abut, preventing the external fasteners passing through the bottom shell connecting ear 1131 and the cover plate connecting ear 1132 from being exposed, thus affecting the connection strength and service life.

[0071] More specifically, the bottom housing connecting lug 1131 has a countersunk hole 11311 through which the external fastener passes, so that the external fastener is hidden inside the control connection group 113 and the motor connection group 313, see reference. Figure 3 This not only improves aesthetics and connection strength, but also prevents the external fasteners from being exposed and affecting service life.

[0072] like Figure 3 As shown, the control periphery 1103 includes an adjacent control circular edge portion 11031 and a control protrusion 11032, wherein the control circular edge portion 11031 is fitted and corresponds to the motor periphery 3103. A plurality of control connection groups 113 are spaced apart on the control circular edge portion 11031.

[0073] The control protrusion 11032 is used for wiring and is located within the area enclosed by the motor periphery 3103. The control round edge 11031 is fitted and corresponds to the motor periphery 3103, thereby enabling the control connection group 113 provided on the control round edge 11031 to correspond to the motor connection group 313 on the motor periphery 3103.

[0074] Continue to refer to Figure 2 There is at least one motor connection group 313 between two adjacent control connection groups 113. It can be seen that the number of control connection groups 113 is less than the number of motor connection groups 313, which further simplifies the structure of the controller module 100, while ensuring the connection performance between the controller module 100 and the motor module 300.

[0075] like Figure 2 and Figure 3 As shown, the bottom shell 112 and the cover plate 111 are sealed by a sealing groove, a sealing gasket, or a sealant. Taking sealant as an example, the mating surfaces of the bottom shell 112 and the cover plate 111 are coated with sealant to improve the sealing performance of the connection between the two, thereby achieving a higher waterproof rating.

[0076] like Figure 2 and Figure 3As shown, heat dissipation fins are provided on the motor housing 310 and / or the control housing 110 to improve heat dissipation performance. For example, heat dissipation fins are provided on the outer control end face 1102 and the motor periphery 3103.

[0077] Preferably, a drive control circuit board 120 is installed inside the control housing 110, and a thermally conductive material is filled between the drive control circuit board 120 and the inner wall of the control housing 110. The thermally conductive material includes thermally conductive silicone grease, which is encapsulated inside the control housing 110 to further improve heat dissipation performance.

[0078] like Figure 2 and Figure 3 As shown, the end face of the bottom shell 111 away from the motor housing 310 is the external control end face 1102. The external control end face 1102 has multiple port portions 11021 for accommodating ports. These ports include a motor connection port 131, a rectifier connection port 132, a communication connection port 133, etc., and they are arranged side-by-side on the external control end face 1102 corresponding to the control protrusion 11032. This arrangement facilitates centralized display and management, thereby improving wiring efficiency.

[0079] In summary, the control connection group 113, in addition to connecting the bottom shell 111 and the cover plate 112, also connects to the motor connection group 313. Therefore, there is no need to add an additional connection structure between the motor module 300 and the controller module 100, which not only simplifies the overall size but also reduces the axial dimension, thereby reducing the overall space occupied and increasing the range of applicable applications. Furthermore, heat dissipation performance is improved through heat dissipation fins and potting thermally conductive material. And sealing performance is further improved by providing a sealing groove, sealing gasket, or sealant between the bottom shell 111 and the cover plate 112.

[0080] Third Embodiment

[0081] like Figures 1 to 3 As shown, the controller module 100 includes a control housing 110, which has an inner control end face 1101 and an outer control end face 1102, and a control periphery 1103 extending between the inner control end face 1101 and the outer control end face 1102. The control periphery 1103 includes an adjacent control circular edge portion 11031 and a control protrusion 11032. The outer control end face 1102 corresponding to the control protrusion 11032 is provided with a plurality of port portions 11021, and the side of the control protrusion 11032 away from the control circular edge portion 11031 forms a wiring space for accommodating the cable connected to the port portion 11021.

[0082] The cable includes a motor cable 420 connecting the motor module 300 and the controller module 100, so that the cable is wired from the wiring space near the port portion 11021, which not only saves cable but also prevents wiring interference. It also prevents the cable wiring from becoming messy, thus avoiding the defect of increasing the overall size of the controller module 100 and affecting the installation scenario.

[0083] like Figure 3 As shown, the arc of the control circle 11031 is greater than 200°, so that the control periphery 1103 is approximately circular. This allows the control circle 11031 of the controller module 100 to fit snugly against the motor periphery 3103 of the motor module 300, reducing the overall size and making it suitable for installation spaces with shorter axial dimensions. (Refer to...) Figure 2 .

[0084] like Figure 3 As shown, the circumferential dimension of the control protrusion 11032 along the control circular edge 11031 is four times or more the radial dimension of the control protrusion 11032 along the control circular edge 11031, so that the control protrusion 11032 is rectangular, and so that the plurality of port portions 11021 are arranged along the length direction of the rectangle of the control protrusion 11032, so that the distance between the port portion 11021 and the wiring space is shorter, saving cables and facilitating wiring.

[0085] Furthermore, the radial dimension of the control protrusion 11032 along the control circular edge 11031 is less than twice the diameter of the port portion 11021. This ensures that the radial dimension of the control protrusion 11032 along the control circular edge 11031 is small, preventing the control protrusion 11032 from extending beyond the area enclosed by the motor periphery 3103, thus increasing the overall size and affecting the suitability for the installation environment. (Refer to...) Figure 2 .

[0086] Furthermore, the port portion 11021 is located at the midpoint of the radial dimension of the control protrusion 11032 along the control circular edge portion 11031. This efficient use of space ensures that the distance between each port portion 11021 and the wiring space is consistent and short, saving cable and improving wiring efficiency.

[0087] Continue to refer to Figure 3 The side of the control protrusion 11032 away from the control circular edge 11031 is horizontal to prevent it from being irregular and affecting the cable wiring.

[0088] like Figure 3As shown, the thickness of the controller module 100 is defined between the inner control end face 1101 and the outer control end face 1102. The thickness of the controller module 100 is smaller than the radius of the control circle edge 11031, so that the controller module 100 is flat. This reduces the axial dimension of the controller module 100 and aligns it axially with the motor module 300, reducing the overall size and expanding its application scenarios.

[0089] like Figure 3 As shown, heat dissipation fins are provided on the outer control end face 1102 corresponding to the control circular edge 11031 to improve heat dissipation performance.

[0090] In summary, the cable includes a motor cable 420 connecting the motor module 300 and the controller module 100, allowing the cable to be wired from the wiring space near the port portion 11021. This not only saves cable but also prevents wiring interference. Furthermore, it prevents the cable wiring from becoming messy, which would increase the overall size of the controller module 100 and thus affect the installation scenario.

[0091] Fourth embodiment

[0092] like Figure 8 As shown, the universal motor connection assembly 313 includes a front shell connector 3131, a rear shell connector 3132, a motor fastener, and an external fastener. The front shell connector 3131 and the rear shell connector 3132 abut against each other, forming a multi-level connection channel 3133 that passes through the front shell connector 3131 and the rear shell connector 3132 respectively. The motor fastener is connected to and hidden in the middle of the multi-level connection channel 3133 to connect the front shell connector 3131 and the rear shell connector 3132. The external fastener is screwed to both sides of the multi-level connection channel 3133 to fix the external device to the front shell connector 3131 or the rear shell connector 3132.

[0093] As can be seen, the motor connection assembly 313 not only connects the front housing connector 3131 and the rear housing connector 3132, but also connects to external devices, including controller modules, etc. This prevents the two connection structures from separating, which would result in redundant overall structure, wasted materials, and ultimately increased costs. This application integrates two connection structures, reducing the overall size, achieving versatility, and meeting the needs of various installation methods in different usage scenarios.

[0094] like Figure 8 As shown, the front shell connector 3131 has a front shell inner end face 31311 and a front shell outer end face 31312, and a front shell channel 31313 penetrating the front shell inner end face 31311 and the front shell outer end face 31312.

[0095] The rear shell connector 3132 has an inner rear shell end face 31321 and an outer rear shell end face 31322, and a rear shell channel 31323 penetrating the inner rear shell end face 31321 and the outer rear shell end face 31322. The front shell connector 3131 is connected to the rear shell connector 3132 by the inner front shell end face 31311 abutting against the inner rear shell end face 31321, and the front shell channel 31313 and the rear shell channel 31323 form the multi-level connection channel 3133.

[0096] Specifically, the rear shell channel 31323 is divided into a primary threaded hole 313a, a secondary countersunk hole 313b, and a tertiary threaded hole 313c in sequence from the inner end face 31321 of the rear shell to the outer end face 31322 of the rear shell.

[0097] The front shell channel 31313 is divided into a primary countersunk hole 313d and a secondary threaded hole 313e in the direction from the inner end face 31311 of the front shell to the outer end face 31312 of the front shell.

[0098] In one embodiment, the head of the motor fastener is located in the primary countersunk hole 313d, and the tail of the motor fastener is threadedly connected to the primary threaded hole 313a, so that the motor fastener connects the front shell connector 3131 and the rear shell connector 3132.

[0099] In another embodiment, the external fastener is screwed into the secondary threaded hole 313e to move the external device away from the rear shell connector 3132 and fix it to the front shell connector 3131.

[0100] In another embodiment, the external fastener passes through the third-level threaded hole 313c and is screwed into the first-level threaded hole 313a, so that the external device is away from the front shell connector 3131 and fixed to the rear shell connector 3132.

[0101] In another embodiment, the external fastener is screwed into the three-stage threaded hole 313c to move the external device away from the front housing connector 3131 and fix it to the rear housing connector 3132.

[0102] As described above, the external device can be installed on the front shell connector 3131 using the secondary threaded hole 313e, specifically abutting and fixing to the outer end face 31312 of the front shell. The external device can also be installed on the rear shell connector 3132 using the tertiary threaded hole 313c or the primary threaded hole 313a, specifically abutting and fixing to the outer end face 31322 of the rear shell. Furthermore, the external fasteners screwed into the secondary threaded hole 313e, the tertiary threaded hole 313c, and the primary threaded hole 313a are located on one side of the axial direction of the motor fastener. That is, the external fasteners and the motor fasteners are simultaneously located within the multi-level connection channel 3133 to achieve the connection between the front shell connector 3131 and the rear shell connector 3132, as well as the connection between the motor connection group 313 and the external device. The external device can be installed on the front shell connector 3131 or the rear shell connector 3132 to meet the needs of various installation methods in different usage scenarios.

[0103] Continue to refer to Figure 8 The diameters of the secondary threaded hole 313e and the tertiary threaded hole 313c are larger than the diameter of the primary threaded hole 313a, so that the multi-level connecting channel 3133 forms multiple stepped holes of different sizes to meet the installation requirements of the motor fastener and the external fastener, thereby achieving universal installation.

[0104] In summary, the motor connection assembly 313 not only connects the front housing connector 3131 and the rear housing connector 3132, but also connects to external devices, including controller modules. This prevents the two connection structures from separating, which would result in redundant overall structure, wasted materials, and ultimately increased costs. This application integrates two connection structures, reducing the overall size, achieving versatility, and meeting the diverse installation requirements of different usage scenarios.

[0105] like Figures 6 to 8 As shown, the motor module 100 further includes a motor housing 110, which includes a plurality of motor connection groups 313 as described in the above embodiments, as well as a rear motor housing 312 and a front motor housing 311. The plurality of motor connection groups 313 are located at the motor periphery 3103 of the motor housing 110 to connect the rear motor housing 312 and the front motor housing 311.

[0106] Since the motor module 100 adopts the motor connection group 313 of the above embodiment, the beneficial effects of the motor module 100 brought by the motor connection group 313 are as described in the above embodiment.

[0107] refer to Figure 6The motor housing 100 has at least one rotor and at least one stator installed inside. The rotor is fixed on the rotating shaft 320, the stator is sleeved on the rotating shaft 320, and the rotating shaft 320 extends out from the front housing 311 of the motor.

[0108] Continue to refer to Figure 6 The front housing connector 3131 is connected to the periphery of the motor front housing 311, and both are flush and have the same dimensions along the thickness direction of the motor module 100. The rear housing connector 3132 is connected to the periphery of the motor rear housing 312, and both are flush and have the same dimensions along the thickness direction of the motor module 100, so that the motor front housing 311 and the motor rear housing 312 are fixed by the motor connection assembly 313, and external equipment is fixed to the rear housing 312 or the motor front housing 311 by the motor connection assembly 313.

[0109] Fifth Embodiment

[0110] like Figure 4 and Figure 5 As shown, the discrete circuit board includes a drive control circuit board 120 and a rectifier circuit board 220 that are separated from each other, so that the rectifier circuit board 220 is set independently relative to the drive control circuit board 120, and the drive control circuit board 120 and the rectifier circuit board 220 are connected by a cable.

[0111] The drive control circuit board 120 corresponds to the controller module 100, and the rectifier circuit board 220 corresponds to the rectifier module 200. (Ref) Figure 1 Compared to existing technologies, the rectifier circuit board 220 is set independently from the drive control circuit board 120, so that the overall size of the drive control circuit board 120 is smaller, thereby reducing the thickness of the controller module 100, reducing the controller's connection harness, and facilitating disassembly and installation.

[0112] like Figure 4 As shown, the drive control circuit board 120 includes an inverter circuit section 121, a power supply circuit section 122, and a control circuit section 123.

[0113] The main component of the inverter circuit section 121 is a power module (IPM), an advanced power switching device that combines the advantages of high current density, low saturation voltage, and high voltage withstand capability of GTRs (high-power transistors), with the advantages of high input impedance, high switching frequency, and low drive power of MOSFETs (field-effect transistors). Furthermore, the IPM integrates logic, control, detection, and protection circuits, making it convenient to use, reducing system size and development time, and significantly enhancing system reliability. The main component of the power supply circuit section 122 is a DC-DC module, a power supply unit that can be directly mounted on a printed circuit board. Its characteristics include the ability to provide power to application-specific integrated circuits (ASICs), digital signal processors (DSPs), microprocessors, memories, field-programmable gate arrays (FPGAs), and other digital or analog loads. The control circuit section 123 mainly includes an MCU and its peripheral circuits, a motor current signal acquisition circuit, a motor speed signal acquisition circuit, and a communication circuit. Its main components are the main control chip (MCU) and other logic chips required by various circuits.

[0114] Furthermore, the inverter circuit section 121, the power supply circuit section 122, and the control circuit section 123 are all fan-shaped to form a circular drive control circuit board 120, in order to fit the approximately circular control housing 110. (Refer to...) Figure 3 This reduces the thickness of the control housing 110.

[0115] Furthermore, the inverter circuit section 121 and the power supply circuit section 122 have an arc of 90°, and the control circuit section 123 has an arc of 180°. This reasonable layout improves the compactness of the drive control circuit board 120, makes the controller module 100 thinner, and thus increases its applicable environment.

[0116] Furthermore, the edge of the inverter circuit section 121 away from the edge of the control circuit section 123 forms a rectangular drive wiring section 124 opposite to the edge of the power supply circuit section 122 away from the edge of the control circuit section 123. The drive wiring section 124 is provided with a plurality of port sections 11021 corresponding to the control protrusion 11032 to realize wiring.

[0117] like Figure 5 As shown, the rectifier circuit board includes an AC input section 221, a filter circuit section 222, an EMC circuit section 223, and a DC output section 224.

[0118] The main components of the AC input section 221 are rectifier bridges, relays, etc. The main components of the filter circuit section 222 are filter capacitors, etc. The main components of the EMC circuit section 223 are common-mode inductors, film capacitors, etc. The main components of the DC output section 224 are terminals, etc.

[0119] Furthermore, the AC input section 221, the EMC circuit section 223, and the DC output section 224 surround the filter circuit section 222 to form a rectangular rectifier circuit board 220 to fit into the cuboid rectifier housing 210.

[0120] Furthermore, the AC input section 221 and the DC output section 224 are respectively located on both sides of the filter circuit section 222, wherein the AC input section 221 is L-shaped, and the DC output section 224 and the EMC circuit section 223 are both in a straight line shape, with the EMC circuit section 223 located between the AC input section 221 and the DC output section 224. This compact arrangement reduces the size of the rectifier circuit board, thereby improving its applicability to various installation environments.

[0121] Specifically, the AC input section 221 and the DC output section 224 are located on the left and right sides of the filter circuit section 222, and the EMC circuit section 223 is located on the front side of the filter circuit section 222, so that the AC input section 221, the EMC circuit section 223 and the DC output section 224 surround the filter circuit section 222, thereby forming the rectangular rectifier circuit board 220.

[0122] More specifically, the AC input section 221 includes an AC wiring section 2211, and the DC output section 224 includes a DC wiring section 2241. The AC wiring section 2211 and the DC wiring section 2241 are arranged diagonally to allow for independent wiring and prevent interference.

[0123] like Figure 1 , Figure 4 and Figure 5 As shown, the DC wiring portion 2241 of the rectifier circuit board 220 is opposite to the drive wiring portion 124 and is connected by a cable.

[0124] In summary, the rectifier circuit board 220 is independently configured relative to the drive control circuit board 120, resulting in a smaller overall size of the drive control circuit board 120 and consequently a reduced thickness of the controller module 100, thereby expanding the application scenarios of the controller module. Compared to the existing two-layer stacked circuit board structure, this reduces the number of connection harnesses for the controller. Furthermore, the rectifier circuit board 220 and the drive control circuit board 120 can be arranged arbitrarily for easy disassembly and installation.

[0125] Sixth Embodiment

[0126] like Figures 3 to 5 As shown, the controller module 100 includes a control housing 110 and a drive control circuit board 120 disposed within the control housing 110. The control housing 110 has an inner control end face 1101 and an outer control end face 1102. The drive control circuit board 120 includes an inverter circuit section 121, a power supply circuit section 122, and a control circuit section 123. The inverter circuit section 121, the power supply circuit section 122, and the control circuit section 123 are located in the same plane to integrate the drive control circuit board 120 into a single piece. The drive control circuit board 120 is accommodated between the inner control end face 1101 and the outer control end face 1102 in a tightly stacked manner.

[0127] The drive control circuit board 120 removes the rectifier section to form a one-piece drive control circuit board 120. Compared with the existing structure of stacked circuit boards on both sides, this further reduces the thickness of the controller module 100, thereby meeting different usage scenarios.

[0128] Preferably, the drive control circuit board 120 is parallel to the inner control end face 1101 and the outer control end face 1102, so that the drive control circuit board 120 is tightly stacked between the inner control end face 1101 and the outer control end face 1102, thereby achieving the purpose of a thinner controller module 100.

[0129] like Figure 3 As shown, the control housing 110 also has a control periphery 1103 extending between the inner control end face 1101 and the outer control end face 1102 to encapsulate the drive control circuit board 120 within the control housing 110.

[0130] Specifically, the control periphery 1103 includes an adjacent control circular edge portion 11031 and a control protrusion 11032, and the drive wiring portion 124 is opposite to the control protrusion 11032 to form a port portion 11021 on the outer control end face 1102 corresponding to the control protrusion 11032.

[0131] More specifically, the dimension of the control protrusion 11032 along the circumferential direction of the control circle 11031 is four times or more the radial dimension of the control protrusion 11032 along the control circle 11031, so that the control protrusion 11032 is rectangular.

[0132] like Figure 4 As shown, the inverter circuit section 121, the power supply circuit section 122, and the control circuit section 123 are all fan-shaped to form the circular drive control circuit board 120, which is adapted to the roughly circular control housing 110.

[0133] The inverter circuit section 121 and the power supply circuit section 122 have an arc of 90°, and the control circuit section 123 has an arc of 180°. The edge of the inverter circuit section 121 away from the edge of the control circuit section 123, and the edge of the power supply circuit section 122 away from the edge of the control circuit section 123, form a rectangular drive wiring portion 124. The drive wiring portion 124 corresponds to the control protrusion 11032 to achieve wiring.

[0134] like Figure 3 As shown, heat dissipation fins are provided on the outer control end face 1102 corresponding to the control circular edge 11031 to improve heat dissipation performance.

[0135] In summary, the drive control circuit board 120 eliminates the rectifier section to form a single piece, which, compared to the existing structure of stacked circuit boards on both sides, further reduces the thickness of the controller module 100, thereby meeting different application scenarios.

[0136] The embodiments described above are only used to illustrate the technical ideas and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. The scope of patent application of the present invention should not be limited by these embodiments. That is, any equivalent changes or modifications made in accordance with the spirit disclosed in the present invention still fall within the patent scope of the present invention.

Claims

1. An axial magnetic field motor, characterized in that, Includes a controller with external rectification and a motor module (300), wherein the controller with external rectification includes: A controller module (100) includes a control housing (110) and a drive control circuit board (120) disposed within the control housing (110). A rectifier module (200) includes a rectifier housing (210) and a rectifier circuit board (220) disposed within the rectifier housing (210). The rectifier module (200) is independently located outside the controller module (100), and the two are connected by a flexible cable; The control housing (110) is provided with a motor mounting surface, and the controller module (100) is installed as a whole with the motor module (300) through the motor mounting surface; The drive control circuit board (120) includes an inverter circuit section (121), a power supply circuit section (122) and a control circuit section (123). The inverter circuit section (121), the power supply circuit section (122) and the control circuit section (123) are all fan-shaped to form a circular drive control circuit board (120). The motor module (300) is connected to the controller module (100) via a motor cable (420). The motor module (300) includes a motor housing (310), which has an inner motor end face (3101), an outer motor end face (3102), and a motor periphery (3103) extending between the inner motor end face (3101) and the outer motor end face (3102). The thickness of the motor module (300) is defined between the inner motor end face (3101) and the outer motor end face (3102). The controller module (100) is mounted on the motor module (300) with its inner control end face (1101) fitting against the inner motor end face (3101). The motor periphery (3103) is partially fitted and corresponds to the control periphery (1103) of the controller module (100). The motor periphery (3103) includes an adjacent motor round edge (31031) and a motor protrusion (31032), and the control periphery (1103) includes an adjacent control round edge (11031) and a control protrusion (11032). The motor round edge (31031) and the control round edge (11031) are fitted and correspond to each other. The motor protrusion (31032) and the control protrusion (11032) face the same direction, and the motor protrusion (31032) protrudes out of the control protrusion (11032) so that a wiring space for accommodating the motor cable (420) is formed between the motor protrusion (31032) and the control protrusion (11032), and the wiring space is located in the area enclosed by the motor periphery (3103).

2. The axial magnetic field motor as described in claim 1, characterized in that, The control housing (110) has an inner control end face (1101) and an outer control end face (1102), and a control periphery (1103) extending between the inner control end face (1101) and the outer control end face (1102). The thickness of the controller module (100) is defined between the inner control end face (1101) and the outer control end face (1102). The rectifier module (200) is located on one side of the thickness direction of the controller module (100). The flexible cable includes a DC cable (410). The rectifier module (200) extends and is connected to the outer control end face (1102) in such a way that the length direction of the rectifier module (200) is consistent with that of the DC cable (410). The inner control end face (1101) is a motor mounting surface.

3. The axial magnetic field motor as described in claim 1, characterized in that, The control housing (110) is divided into a bottom shell (111) and a cover plate (112) along its thickness direction. The bottom shell (111) and the cover plate (112) are fixed together by screws or adhesive.

4. The axial magnetic field motor as described in claim 2, characterized in that, The external control end face (1102) is also provided with heat dissipation fins.

5. The axial magnetic field motor as described in claim 1, characterized in that, A control connection port (330) is provided on the inner motor end face (3101) corresponding to the motor protrusion (31032), and a motor connection port (131) is provided on the outer control end face (1102) corresponding to the control protrusion (11032). The motor cable (420) is connected in a U-shape between the control connection port (330) and the motor connection port (131).

6. The axial magnetic field motor as described in claim 5, characterized in that, The external control end face (1102) is also provided with a rectifier connection port (132) and a communication connection port (133). The rectifier module (200) is detachably connected to the rectifier connection port (132) via a DC cable (410), and the host computer is detachably connected to the communication connection port (133) via a communication cable (430).

7. The axial magnetic field motor as described in claim 6, characterized in that, The motor connection port (131), the rectifier connection port (132), and the communication connection port (133) are arranged side by side on the outer control end face (1102) corresponding to the control protrusion (11032).

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