Motor and controller integrated device for eVTOL

Abstract

The invention belongs to the field of electric propulsion system motor driving, and particularly relates to a motor and controller integrated device for eVTOL. Comprising an integrated heat dissipation fan assembly, a motor assembly and a controller assembly, a motor and controller integrated heat dissipation scheme is adopted, forced air cooling heat dissipation is conducted on the controller through a motor integrated fan, the design of a cooling system is simplified, and the power-to-weight ratio is effectively increased. And meanwhile, the motor controller and the motor adopt coaxial equal-outer-diameter design, and the characteristics of high power density and high volume density are very suitable for being applied to an eVTOL aircraft electric propulsion system.

Description

Technical Field

[0001] The present invention relates to an aviation electric propulsion system, and belongs to the field of electric propulsion system motor drive, and in particular to an integrated motor and controller device for eVTOL. Background Art

[0002] In recent years, electric vertical take-off and landing aircraft (eVTOL) has attracted widespread attention from aerospace companies, the automotive industry, the military, the transportation industry and academia. The aircraft uses electric propulsion instead of internal combustion engine power, and has many advantages and characteristics, including energy saving and environmental protection, high efficiency and low energy consumption, zero emissions, low vibration and noise levels, etc. These advantages rely on high-efficiency and high-power density electric propulsion systems to be realized. Therefore, the research and development of electric propulsion motor drive systems with high power-to-weight ratio, high power-to-volume ratio and efficient heat dissipation is particularly important.

[0003] Currently in eVTOL, most electric propulsion systems use discrete motors and controllers that are installed in different locations, which leads to disadvantages such as difficult layout, increased weight of wiring harnesses, low power-to-weight ratio, and low system efficiency. Summary of the invention

[0004] Purpose of the invention: To provide an integrated motor and controller device for eVTOL, thereby improving the system power-to-weight ratio and reducing the product size.

[0005] Technical solution:

[0006] A motor and controller integrated device for eVTOL, comprising: an integrated cooling fan assembly, a motor assembly and a controller assembly, wherein a motor shaft 16 is fixed on a cooling fan 1 and serves as a rotating shaft of the cooling fan 1 to form an integrated cooling fan assembly; the motor assembly is an outer rotor and inner stator structure, the motor assembly comprises a rotor component 2, a stator component 3, a bearing 15, and a stator bracket 4, the stator component 3 is fixed on the stator bracket 4, the rotor component 2 is mounted on the cooling fan 1, and the rotor component 2 and the stator component 3 are connected via the bearing 15; the rotor component 2 comprises a rotor housing, a rotor core, and a permanent magnet array, wherein the permanent magnet array is mounted on the rotor core and integrally mounted on the rotor housing; the stator component 3 comprises: a rotor with cooling teeth The stator internal bracket, stator core and stator winding of the sheet; wherein, the stator internal bracket is located at the center of the motor, and the stator internal bracket is expanded outward to install the stator core and stator winding; the controller assembly includes: a connecting frame 5, a capacitor plate 6, a drive plate 7, an adapter plate 8, a heat sink 9, a shell 10, a mounting seat 11, a power board 12, a first control board 13, and a capacitor 14, wherein the capacitor 14 is fixed on the capacitor plate 6, and the capacitor plate 6, the adapter plate 8, the drive plate 7, the power board 12, the first control board 13, and the second control board 19 are fixed on the heat sink 9 to form a heat dissipation structure; the heat dissipation structure is arranged in the shell 10, and the shell 10 is fixed in the connecting frame 5; one end of the connecting frame 5 is connected to the stator bracket 4, and the other end of the connecting frame 5 is connected to the shell 10 and the mounting seat 11.

[0007] Furthermore, the cooling fan 1 not only provides cooling air volume for the motor and controller to dissipate heat, but also provides structural support for the rotor components.

[0008] Furthermore, the heat dissipation duct passes through the stator component 3 and the heat sink 9 to dissipate heat for the controller assembly and the motor assembly.

[0009] Furthermore, the heat sink 9 includes a bottom plate and a side plate, the adapter plate 8 is fixed on the bottom plate, the drive plate 7, the power plate 12, the first control board 13, and the second control board 19 are fixed on the side plates, the capacitor plate 6 is fixed on the top of the heat sink 9, and the capacitor 14 is fixed on the capacitor plate 6.

[0010] Furthermore, the connecting frame 5 is an annular hollow structure.

[0011] Further, the current sensor 20 is a Hall current sensor and is disposed on the capacitor plate 6 .

[0012] Furthermore, a driving board 7 and a power board 12 are arranged in parallel on a side plate of the heat sink 9 .

[0013] Furthermore, the side plates of the heat sink 9 are evenly distributed at an average of 90° along the circumference.

[0014] Beneficial effects:

[0015] The present invention is applicable to the application of an eVTOL electric propulsion system with high space requirements and high power-to-weight ratio. Through the integrated design of the cooling fan, motor, and controller, the spatial structure is effectively utilized to improve the flexibility and adaptability of the eVTOL overall layout, thereby effectively improving the power density. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 An exploded view of an integrated motor controller for eVTOL

[0017] Figure 2 Capacitor plate design and layout diagram

[0018] Figure 3 The three-layer board layout structure diagram

[0019] Figure 4 Controller power distribution board and heat dissipation layout diagram.

[0020] Among them, fan 1, rotor component 2, stator component 3, stator bracket 4, connecting frame 5, capacitor plate 6, drive plate 7, adapter plate 8, heat sink 9, shell 10, mounting seat 11, power board 12, first control board 13, capacitor 14, bearing 15, motor shaft 16, positive terminal 17, negative terminal 18, second control board 19, current sensor 20. DETAILED DESCRIPTION

[0021] In summary, the present application provides an integrated motor and controller device for eVTOL, which adopts an integrated design method to integrate the motor, controller and heat dissipation device into an integrated design, thereby improving the power-to-weight ratio of the system and providing optimized space for host layout.

[0022] like Figure 1-4 , a motor and controller integrated device for eVTOL, comprising: an integrated cooling fan assembly, a motor assembly and a controller assembly, wherein the motor shaft 16 is fixed to the cooling fan 1 and serves as the rotating shaft of the cooling fan 1 to form an integrated cooling fan assembly;

[0023] The motor assembly is an outer rotor and inner stator structure, and the motor assembly includes a rotor component 2, a stator component 3, a bearing 15, and a stator bracket 4. The stator component 3 is fixed on the stator bracket 4, and the rotor component 2 is installed on the cooling fan 1. The rotor component 2 and the stator component 3 are connected through the bearing 15; the rotor component 2 includes a rotor housing, a rotor core, and a permanent magnet array, wherein the permanent magnet array is installed on the rotor core and is integrally installed on the rotor housing;

[0024] The stator component 3 includes: a stator internal bracket with heat dissipation teeth, a stator core and a stator winding; wherein the stator internal bracket is located at the center of the motor, and the stator internal bracket is expanded to install the stator core and the stator winding;

[0025] The controller assembly includes: a connecting frame 5, a capacitor plate 6, a driving plate 7, an adapter plate 8, a heat sink 9, a housing 10, a mounting seat 11, a power plate 12, a first control plate 13, and a capacitor 14, wherein the capacitor 14 is fixed on the capacitor plate 6, and the capacitor plate 6, the adapter plate 8, the driving plate 7, the power plate 12, the first control plate 13, and the second control plate 19 are fixed on the heat sink 9 to form a heat dissipation structure;

[0026] The heat dissipation structure is arranged in the housing 10, and the housing 10 is fixed in the connecting frame 5;

[0027] One end of the connecting frame 5 is connected to the stator support 4 , and the other end of the connecting frame 5 is connected to the housing 10 and the mounting seat 11 .

[0028] The cooling fan 1 not only provides cooling air volume for the motor and controller to dissipate heat, but also provides structural support for the rotor components.

[0029] In a possible embodiment, the heat dissipation duct passes through the stator component 3 and the heat sink 9 to dissipate heat for the controller assembly and the motor assembly.

[0030] In a possible embodiment, the heat sink 9 includes a bottom plate and a side plate, the adapter plate 8 is fixed on the bottom plate, the drive board 7, the power board 12, the first control board 13, and the second control board 19 are fixed on the side plates, the capacitor plate 6 is fixed on the top of the heat sink 9, and the capacitor 14 is fixed on the capacitor plate 6.

[0031] In a possible embodiment, the connecting frame 5 is an annular hollow structure. The motor controller and the motor are coaxial with the same outer diameter design.

[0032] In a possible embodiment, the current sensor 20 is a Hall current sensor and is disposed on the capacitor plate 6 .

[0033] In a possible embodiment, a driving board 7 and a power board 12 are arranged in parallel on a side plate of the heat sink 9 .

[0034] In a possible embodiment, the side plates of the heat sink 9 are evenly distributed at an average of 90° along the circumference.

[0035] The motor shaft 16 is fixed on the cooling fan 1 to form a cooling fan assembly, and the cooling fan assembly is fixed to the rotor housing. When the rotor rotates, the cooling fan assembly is driven to form cooling air.

[0036] refer to Figure 2A current sensor, a capacitor 14, a positive terminal 17 and a negative terminal 18 are welded on the capacitor plate 6 of the controller, and the overall design layout is located close to the motor side, wherein the positive and negative terminals are connected to the power board through wires, and the three-phase output line of the controller is led out through the power board terminals and then connected to the motor winding through the current sensor.

[0037] refer to Figure 3 The capacitor plate 9 and the adapter plate 8 form a vertically symmetrical installation structure, and the control board, the drive board 7 and the power board (12) are installed in the middle part to form a three-layer matching structure. The capacitor plate introduces the power DC into the power board through the positive and negative terminals, and the drive board electrical signal is introduced from the control board to the drive board through the adapter board, which reduces the internal wiring harness connection and improves reliability.

[0038] refer to Figure 4 The motor fan, the stator bracket with cooling fins and the controller radiator are extended outward with the motor shaft as the center. The middle of the controller radiator is connected to the rear end cover of the motor to form a dedicated cooling duct to improve the cooling efficiency. The power board is equipped with a power MOS tube, and the back plate is directly installed on the radiator, which is conducive to the heat dissipation of the power board. The drive board is installed on the power board and is evenly distributed with the control board 19 along the circumference at an average of 90°, effectively utilizing the space size.

Claims

1. A motor and controller integrated device for eVTOL, characterized in that: include: An integrated cooling fan assembly, a motor assembly and a controller assembly, wherein a motor shaft (16) is fixed on a cooling fan (1) and serves as a rotating shaft of the cooling fan (1), thereby forming an integrated cooling fan assembly; the motor assembly is an outer rotor and inner stator structure, the motor assembly comprises a rotor component (2), a stator component (3), a bearing (15) and a stator bracket (4), the stator component (3) is fixed on the stator bracket (4), the rotor component (2) is mounted on the cooling fan (1), and the rotor component (2) and the stator component (3) are connected via a bearing (15); the rotor component (2) comprises a rotor housing, a rotor core and a permanent magnet array, wherein the permanent magnet array is mounted on the rotor core and integrally mounted on the rotor housing; the stator component (3) comprises: a stator internal bracket with cooling fins, a stator core and a stator winding; wherein The internal stator bracket is located at the center of the motor, and the internal stator bracket is expanded to install the stator core and the stator winding; the controller assembly comprises: a connecting frame (5), a capacitor plate (6), a drive plate 7, an adapter plate (8), a heat sink (9), a shell (10), a mounting seat (11), a power plate 12, a first control plate (13), and a capacitor (14), wherein the capacitor (14) is fixed on the capacitor plate (6), and the capacitor plate (6), the adapter plate (8), the drive plate (7), the power plate (12), the first control plate (13), and the second control plate (19) are fixed on the heat sink (9) to form a heat dissipation structure; the heat dissipation structure is arranged in the shell (10), and the shell (10) is fixed in the connecting frame (5); one end of the connecting frame (5) is connected to the stator bracket (4), and the other end of the connecting frame (5) is connected to the shell (10) and the mounting seat (11).

2. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The cooling fan (1) not only provides cooling air volume for the motor and controller to dissipate heat, but also provides structural support for the rotor components.

3. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The heat dissipation duct passes through the stator component (3) and the heat dissipation element (9) and is used to dissipate heat for the controller assembly and the motor assembly.

4. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The heat sink (9) comprises a bottom plate and a side plate, the adapter plate (8) is fixed on the bottom plate, the drive plate (7), the power plate (12), the first control plate (13), and the second control plate (19) are fixed on the side plates, the capacitor plate (6) is fixed on the top of the heat sink (9), and the capacitor (14) is fixed on the capacitor plate (6).

5. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The connecting frame (5) is an annular hollow structure.

6. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The current sensor 20 is a Hall current sensor and is arranged on the capacitor plate (6).

7. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: A driving board (7) and a power board (12) are arranged in parallel on a side plate of a heat sink (9).

8. The motor and controller integrated device for eVTOL according to claim 1, characterized in that: The side plates of the heat sink (9) are evenly distributed at an average of 90 degrees along the circumference.

Images