Brushless fan

Abstract

The invention provides a brushless fan. The brushless fan comprises a stator assembly, a rotor assembly, a front end cover assembly, a rear end cover assembly, an impeller and a fan cover. The impeller comprises a bottom plate, a cover plate and a plurality of blades; the plurality of blades are arranged between the cover plate and the bottom plate so as to form a flow guide channel between the cover plate and the bottom plate; an opening is formed in the middle of the cover plate, the opening corresponds to the air inlet, and the cover plate is of a structure which is high in the middle and low in the periphery, so that the height of the flow guide channel is gradually reduced from the air inlet to the air outlet; one end of each blade corresponds to the opening, and the other end of each blade extends to the periphery of the bottom plate along a centrifugal track; the blades are rotationally symmetrical to form the flow guide channel; wherein the blade comprises a plurality of flow guide section bodies which are sequentially connected along a centrifugal track, and the plurality of flow guide section bodies are respectively a plurality of sections of tangent arcs. According to the technical scheme, the brushless fan can provide high air pressure and flow.

Description

Technical Field

[0001] The invention relates to a brushless fan. Background Art

[0002] As people pay more and more attention to their health, a portable mobile swimming pool (hereinafter referred to as swimming pool) has quietly entered thousands of households. It has two rigid requirements: large flow and high air pressure. The main body of the swimming pool is made of airtight and watertight plastic leather (PVC, TPU, etc.). The hollow chamber structure has certain elasticity and strength when the chamber is filled with air. It also has a large volume to meet the needs of swimming or bathing. This feature requires the fan to have a large flow rate to inflate quickly. After being filled with air, the contour is formed, and then water is added to form a swimming pool. At this time, the gas with a certain pressure switches to another channel and continues to inflate the pool water, forming waves around the swimming pool. The waves automatically wash, clean, massage, etc. The size of the waves can be adjusted according to needs. In order to prevent the leakage of pool water and gas in the cavity, reverse sealing must be performed. The fan must overcome the reverse sealing resistance to work forward. This feature requires the fan to have a strong air pressure to continuously create waves. Therefore, flow rate and air pressure are two key indicators of fans for swimming pools. These two indicators also fully reflect the efficiency of fans in utilizing air energy. At present, the motors for swimming pools on the market are basically series-excited motors, which have small flow rate and low air pressure and need to be improved. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a brushless blower.

[0004] In order to solve the above technical problems, the present invention provides a brushless fan, including a stator assembly, a rotor assembly, a front cover assembly, a rear cover assembly, an impeller and a wind shield;

[0005] The rotor assembly is rotatably arranged on the stator assembly, the front end cover assembly and the rear end cover assembly are respectively connected to the front and rear ends of the stator assembly, and the two ends of the rotor assembly are rotatably arranged on the front end cover assembly and the rear end cover assembly; the wind cover is arranged outside the front end cover assembly to form a space, the impeller is arranged in the space, one end of the rotor assembly is connected to the impeller to drive the impeller to rotate, the wind cover includes an air inlet, the front end cover assembly includes an air collecting channel connecting the space and the stator assembly, and the rear end cover assembly includes an air outlet connected to the stator assembly;

[0006] Wherein, the impeller includes a base plate, a cover plate and a plurality of blades; the plurality of blades are arranged between the cover plate and the base plate to form a guide channel between the cover plate and the base plate; the middle part of the cover plate includes an opening, the opening corresponds to the air inlet, a gap is formed between the periphery of the cover plate and the base plate, the gap is connected to the space, the cover plate is a structure that is high in the middle and low around, so that the height of the guide channel gradually decreases from the air inlet toward the air outlet; one end of the blade corresponds to the opening, and the other end of the blade extends to the periphery of the base plate along a centrifugal trajectory; the plurality of blades are rotationally symmetrical along the center of the base plate to form the guide channel between two adjacent blades; wherein the blade includes a plurality of guide segment bodies connected in sequence along the centrifugal trajectory, and the plurality of guide segment bodies are respectively a plurality of tangent arcs.

[0007] In a more preferred embodiment, the front end cover assembly includes an air guide wheel, and the air guide wheel includes a plurality of air collecting channels, and the air collecting channels extend from the periphery of the air guide wheel to the center of the air guide wheel.

[0008] In a more preferred embodiment, a chamber is provided at the center of the guide wheel, the chamber is used to accommodate a first bearing, one end of the rotor assembly is connected to the first bearing, the chamber is fixedly connected to a support column, and the support column is connected to the stator assembly.

[0009] In a more preferred embodiment, a control panel is arranged on the outer end surface of the wind hood, the air inlet is arranged on the outer end surface of the wind hood, and a plurality of heat dissipation ribs are arranged on the outer end surface of the wind hood, and the heat dissipation ribs form a gap between the outer end surface of the wind hood and the control panel; the power electronic components of the control panel are located in the gap, and the gap is connected to the air inlet.

[0010] In a more preferred embodiment, the air inlet is also provided with sound-absorbing cotton.

[0011] In a more preferred embodiment, the wind shield is made of aluminum alloy.

[0012] In a more preferred embodiment, the stator assembly includes a stator core and a stator coil, the winding type of the stator coil is a fractional slot concentrated winding; the stator core includes a plurality of stator teeth facing inward, and the stator teeth include a plurality of tooth slots extending along the axial direction.

[0013] In a more preferred embodiment, it also includes a crimping terminal; the crimping terminal is connected to the lead wire of the stator coil; wherein the crimping terminal includes a wiring terminal and a crimping terminal, the wiring terminal is used to connect to a power source; the crimping terminal includes a crimping groove, the width of the crimping groove at the entrance gradually increases outward, and the width of the crimping groove gradually decreases in the direction away from the entrance; wherein the crimping terminal includes two layers of plate bodies, and the crimping groove is formed on the two layers of plate bodies correspondingly up and down.

[0014] In a more preferred embodiment, the rotor assembly includes a rotor core and a plurality of permanent magnets, the rotor core includes a plurality of receiving grooves extending through the axial direction, the receiving grooves are arranged inside the rotor core, and the plurality of permanent magnets are respectively installed in the plurality of receiving grooves;

[0015] The rotor assembly also includes two balancing blocks, which are respectively mounted on the two end surfaces of the rotor core.

[0016] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0017] The impeller includes a base plate, a cover plate and a plurality of blades; the plurality of blades are arranged between the cover plate and the base plate to form a guide channel between the cover plate and the base plate; the middle part of the cover plate includes an opening, the opening corresponds to the air inlet, a gap is formed between the periphery of the cover plate and the base plate, the gap is connected to the space, the cover plate is a structure that is high in the middle and low around, so that the height of the guide channel gradually decreases from the air inlet toward the air outlet; one end of the blade corresponds to the opening, and the other end of the blade extends to the periphery of the base plate along a centrifugal trajectory; the plurality of blades are rotationally symmetrical along the center of the base plate to form the guide channel between two adjacent blades; wherein the blade includes a plurality of guide segment bodies connected in sequence along the centrifugal trajectory, and the plurality of guide segment bodies are respectively a plurality of tangent arcs. The blades of the impeller are composed of multiple tangent arcs. The airflow flows in from the center of the impeller and is evenly divided into multiple channels by the blades, and flows into the air guide wheel along the tangent direction of the impeller. This design has low wind resistance, reduces the movement and disturbance of the airflow, and has low noise. At the same time, it ensures that the airflow enters the air guide wheel at a higher linear velocity, thereby obtaining a higher air pressure and flow. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A three-dimensional schematic diagram of a brushless blower in a preferred embodiment of the present invention;

[0019] Figure 2 A cross-sectional view of a brushless blower in a preferred embodiment of the present invention;

[0020] Figure 3 A schematic diagram of a bottom plate in a preferred embodiment of the present invention;

[0021] Figure 4 is a cross-sectional view of an impeller in a preferred embodiment of the present invention;

[0022] Figure 5 A schematic diagram of a wind shield and power electronic components in a preferred embodiment of the present invention;

[0023] Figure 6 A cross-sectional view of a wind shield in a preferred embodiment of the present invention;

[0024] Figure 7 A schematic diagram of a stator assembly in a preferred embodiment of the present invention;

[0025] Figure 8 A schematic diagram of a crimping terminal in a preferred embodiment of the present invention, showing a crimping groove;

[0026] Fig. 9 A three-dimensional schematic diagram of a crimping terminal in a preferred embodiment of the present invention;

[0027] Fig.10 It is a cross-sectional view of a rotor assembly in a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0028] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0029] A brushless fan comprises a stator assembly 1, a rotor assembly 2, a front cover assembly 3, a rear cover assembly 4, an impeller 5 and a wind cover 6.

[0030] The rotor assembly 2 is rotatably arranged on the stator assembly 1, the front end cover assembly 3 and the rear end cover assembly 4 are respectively connected to the front and rear ends of the stator assembly 1, and the two ends of the rotor assembly 2 are rotatably arranged on the front end cover assembly 3 and the rear end cover assembly 4; the wind cover 6 is arranged outside the front end cover assembly 3 to form a space 61, and the impeller 5 is arranged in the space 61. One end of the rotor assembly 2 is connected to the impeller 5 to drive the impeller 5 to rotate, the wind cover 6 includes an air inlet 62, the front end cover assembly 3 includes an air collecting channel 31 connecting the space 61 and the stator assembly 1, and the rear end cover assembly 4 includes an air outlet 41 connected to the stator assembly 1.

[0031] The impeller 5 includes a bottom plate 51, a cover plate 52 and a plurality of blades 53; the plurality of blades 53 are arranged between the cover plate 52 and the bottom plate 51 to form a guide channel 55 between the cover plate 52 and the bottom plate 51; the middle portion of the cover plate 52 includes an opening 521, the opening 521 corresponds to the air inlet 62, a gap 54 is formed between the periphery of the cover plate 52 and the bottom plate 51, the gap 54 is connected to the space 61, and the cover plate 52 is a structure with a high middle and low surroundings, so that the guide channel 55 is formed between the cover plate 52 and the bottom plate 51. The height of the channel 55 gradually decreases from the air inlet 62 toward the air outlet 41; one end of the blade 53 corresponds to the opening 521, and the other end of the blade 53 extends along the centrifugal trajectory to the periphery of the bottom plate 51; the multiple blades 53 are rotationally symmetrical along the center of the bottom plate 51 to form the guide channel 55 between two adjacent blades 53; wherein the blades 53 include multiple guide segments extending and connected in sequence along the centrifugal trajectory, and the multiple guide segments are multiple tangent arcs. The blades 53 of the impeller 5 are multiple tangent arcs. The airflow flows in from the center of the impeller 5, and is evenly divided into multiple channels by the blades 53, and flows into the guide wheel 32 along the tangential direction of the impeller 5. This design has low wind resistance, reduces the turbulence and disturbance of the airflow, and has low noise. At the same time, it ensures that the airflow enters the guide wheel 32 at a higher linear velocity, thereby obtaining a higher air pressure. Figure 3 In the embodiment, rivet points 511 are arranged on the bottom plate 51 at intervals 54 along the centrifugal track, and the blades 53 can be connected to the bottom plate 51 through the rivet points 511, and the rivet points 511 depict the approximate shape of the centrifugal track.

[0032] The front cover assembly 3 includes an air guide wheel 32, and the air guide wheel 32 includes a plurality of air collecting channels 31, and the air collecting channels 31 extend from the periphery of the air guide wheel 32 to the center of the air guide wheel 32. The air guide wheel 32 guides the air flow to between the stator assembly 1 and the rotor assembly 2, and flows from the stator coil 12 to the air outlet 41, taking away most of the heat generated by the control board 7, the stator coil 12 and mechanical friction, cooling and lowering the temperature of the entire electromagnetic circuit. After entering the swimming pool, the heat is transferred to the pool water to heat up the pool water, thereby realizing energy recycling.

[0033] A chamber 321 is provided at the center of the guide wheel 32, and the chamber 321 is used to accommodate the first bearing 33. One end of the rotor assembly 2 is connected to the first bearing 33. The chamber 321 is fixedly connected to a support column, and the support column is connected to the stator assembly 1, so that all parts are connected into a whole.

[0034] A control panel 7 is arranged on the outer end surface of the wind hood 6, the air inlet 62 is arranged on the outer end surface of the wind hood 6, and a plurality of heat dissipation ribs 63 are arranged on the outer end surface of the wind hood 6. The heat dissipation ribs 63 form a gap 64 between the outer end surface of the wind hood 6 and the control panel 7; the power electronic component 71 of the control panel 7 is located in the gap 64, and the gap 64 is connected to the air inlet 62. The actuator of the power switch circuit in the control board 7 is the power electronic component 71 (MOS tube, IGBT or intelligent module IPM), which is turned on and off in a certain order and frequency according to the rotor position, and the excitation current flowing through the rotating magnetic field will generate a lot of heat. It is the component with the highest temperature in the brushless fan. Excessive temperature will cause it to be damaged or burned. In order to control its temperature below the allowable value, it is necessary to force it to dissipate heat. Most traditional products are composed of a radiator and a cooling fan. The present invention sets the air inlet 62 of the brushless fan on the outer end face of the wind cover 6, where the cooling effect is best. At the same time, the power electronic component 71 is set on the wind cover 6, and no special radiator and cooling fan are required, which greatly reduces the volume of the control board 7 and greatly reduces the cost. The material of the wind cover 6 is made of aluminum alloy with large thermal conductivity and specific heat capacity, which guarantees the heat dissipation requirements of the electronic components to the greatest extent and improves the power and quality reliability of the control board 7. In this embodiment, the air inlet 62 is also provided with a silencer.

[0035] The stator assembly 1 includes a stator core 11 and a stator coil 12, and the winding type of the stator coil 12 is a fractional slot concentrated winding; the stator core 11 includes a plurality of stator tooth poles 11 facing inward, and the stator tooth poles 11 include a plurality of tooth slots 12 extending along the axial direction. The stator assembly 1 is a hub for generating a rotating magnetic field, and the winding type is a fractional slot concentrated winding, which has a simple process, is stable and efficient, and obtains relatively ideal electromagnetic parameters by calculating and optimizing the air gap length, magnetic flux density, and line load, and reduces copper loss; the stator core 11 is made of thin silicon steel sheets with low hysteresis loss and low eddy current loss, which further reduces the iron loss, and 4 tooth slots 12 are set on each stator tooth pole 11, which effectively reduces the torque fluctuation caused by the tooth slot 12 effect, reduces the vibration and electromagnetic noise during operation, and makes the brushless fan run efficiently and quietly.

[0036] The brushless fan also includes a crimping terminal 8; the crimping terminal 8 is connected to the lead wire of the stator coil 12; wherein the crimping terminal 8 includes a terminal 81 and a crimping terminal 82, wherein the terminal 81 is used to connect the power supply; the crimping terminal 82 includes a crimping groove 821, wherein the width of the entrance of the crimping groove 821 gradually increases outward, and the width of the crimping groove 821 gradually decreases in the direction away from the entrance; wherein the crimping terminal 82 includes two layers of plate bodies 822, wherein the crimping groove 821 is formed on the two layers of plate bodies 822 correspondingly from top to bottom. The pressing depth is adjusted according to different wire diameters, and the two layers of plate bodies 822 have a total of four surfaces in contact with the lead wire of the stator coil 12, thereby ensuring the reliability of the electrical and mechanical connection between the crimping terminal 8 and the lead wire of the stator coil 12.

[0037] The rotor assembly 2 includes a rotor core 21 and a plurality of permanent magnets. The rotor core 21 includes a plurality of accommodating grooves 211 extending through the axial direction. The accommodating grooves 211 are arranged inside the rotor core 21. The plurality of permanent magnets are respectively installed in the plurality of accommodating grooves 211. The rotor assembly 2 also includes two balancing blocks 22, which are respectively installed on the two end surfaces of the rotor core 21. The rotor core 21 is provided with grooves corresponding to the number of poles, and the grooves are used to accommodate the permanent magnets. In order to achieve higher power density and reduce the size of the motor, the permanent magnets used in this patent are neodymium iron boron magnets with high magnetic density and high coercive force. Since the speed of the brushless fan is relatively high, the rotor is subjected to a large centrifugal force. In order to eliminate the hidden danger of the permanent magnet loosening and flying out during high-speed rotation, the permanent magnet is pressed into the slot of the rotor core 21, and a balancing block 22 is pressed into each end of the rotor core 21. When performing dynamic balancing of the rotor, a part of the aluminum block can be removed to achieve the purpose of uniform mass distribution and reduce the vibration and noise of the motor. The balancing block 22, the rotor core 21 and the NdFeB magnet are coated with glue to form a whole.

[0038] The above is only a preferred specific implementation of the present invention, but the design concept of the present invention is not limited to this. Any technician familiar with the technical field who uses this concept to make non-substantial changes to the present invention within the technical scope disclosed by the present invention shall be deemed to infringe the protection scope of the present invention.

Claims

1. A brushless fan, characterized in that: It includes a stator assembly, a rotor assembly, a front cover assembly, a rear cover assembly, an impeller and a wind shield; The rotor assembly is rotatably arranged on the stator assembly, the front end cover assembly and the rear end cover assembly are respectively connected to the front and rear ends of the stator assembly, and the two ends of the rotor assembly are rotatably arranged on the front end cover assembly and the rear end cover assembly; the wind cover is arranged outside the front end cover assembly to form a space, the impeller is arranged in the space, one end of the rotor assembly is connected to the impeller to drive the impeller to rotate, the wind cover includes an air inlet, the front end cover assembly includes an air collecting channel connecting the space and the stator assembly, and the rear end cover assembly includes an air outlet connected to the stator assembly; Wherein, the impeller includes a base plate, a cover plate and a plurality of blades; the plurality of blades are arranged between the cover plate and the base plate to form a guide channel between the cover plate and the base plate; the middle part of the cover plate includes an opening, the opening corresponds to the air inlet, a gap is formed between the periphery of the cover plate and the base plate, the gap is connected to the space, the cover plate is a structure that is high in the middle and low around, so that the height of the guide channel gradually decreases from the air inlet toward the air outlet; one end of the blade corresponds to the opening, and the other end of the blade extends to the periphery of the base plate along a centrifugal trajectory; the plurality of blades are rotationally symmetrical along the center of the base plate to form the guide channel between two adjacent blades; wherein the blade includes a plurality of guide segment bodies connected in sequence along the centrifugal trajectory, and the plurality of guide segment bodies are respectively a plurality of tangent arcs.

2. A brushless fan according to claim 1, characterized in that: The front end cover assembly includes an air guide wheel, and the air guide wheel includes a plurality of air collecting channels, and the air collecting channels extend from the periphery of the air guide wheel to the center of the air guide wheel.

3. A brushless fan according to claim 2, characterized in that: A chamber is provided at the center of the guide wheel, and the chamber is used to accommodate a first bearing. One end of the rotor assembly is connected to the first bearing. The chamber is fixedly connected to a support column, and the support column is connected to the stator assembly.

4. A brushless fan according to claim 1, characterized in that: A control panel is arranged on the outer end surface of the wind hood, the air inlet is arranged on the outer end surface of the wind hood, and a plurality of heat dissipation ribs are arranged on the outer end surface of the wind hood, and the heat dissipation ribs form a gap between the outer end surface of the wind hood and the control panel; the power electronic components of the control panel are located in the gap, and the gap is connected to the air inlet.

5. A brushless fan as claimed in claim 4, characterized in that: The air inlet is also provided with sound-absorbing cotton.

6. A brushless fan according to claim 4, characterized in that: The wind shield is made of aluminum alloy.

7. A brushless fan according to claim 1, characterized in that: The stator assembly includes a stator core and a stator coil, wherein the winding type of the stator coil is a fractional slot concentrated winding; the stator core includes a plurality of stator tooth poles facing inward, and the stator tooth poles include a plurality of tooth slots extending along the axial direction.

8. A brushless fan according to claim 7, characterized in that: It also includes a crimping terminal; the crimping terminal is connected to the lead wire of the stator coil; wherein the crimping terminal includes a wiring terminal and a crimping terminal, the wiring terminal is used to connect a power supply; the crimping terminal includes a crimping groove, the width of the crimping groove at the entrance gradually increases outward, and the width of the crimping groove gradually decreases in the direction away from the entrance; wherein the crimping terminal includes two layers of plate bodies, and the crimping groove is formed on the two layers of plate bodies correspondingly up and down.

9. A brushless fan according to claim 1, characterized in that: The rotor assembly comprises a rotor core and a plurality of permanent magnets, wherein the rotor core comprises a plurality of receiving grooves extending through the rotor core in an axial direction, wherein the receiving grooves are arranged inside the rotor core, and the plurality of permanent magnets are respectively arranged in the plurality of receiving grooves; The rotor assembly also includes two balancing blocks, which are respectively mounted on the two end surfaces of the rotor core.

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