Motor heat dissipation system with bearing type radiator

Abstract

The invention relates to a motor heat dissipation system with a bearing type radiator, belongs to the technical field of motor heat dissipation, and solves the problem that the heat dissipation efficiency and the power density of a high-power motor cannot be obtained at the same time in the prior art. The motor cooling system with the bearing type radiator comprises the radiator, a cooling airflow channel, a permanent magnet synchronous motor, a motor rack, an electronic component, an air inlet valve and a rotating shaft. According to the invention, the heat dissipation system of the motor is optimally designed, so that the heat dissipation efficiency of the system is improved; the radiator serves as a bearing structure and a radiating structure, so that the mass of a motor radiating system is reduced and the power density of the system is improved on the premise of ensuring the structural rigidity and the radiating efficiency of the motor. The circulation path of cooling airflow is optimized, the long air inlet channel with the variable surface roughness is adopted, and the cooling efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motor heat dissipation, and relates to a motor heat dissipation system with a load-bearing radiator, and particularly to a motor heat dissipation system for a high-power motor with a load-bearing radiator. Background Art

[0002] The development of new energy vehicles has put forward higher requirements for performance indicators such as the efficiency and power density of motors, bringing problems such as a sharp increase in the internal heat generation of motors and insufficient effective heat dissipation space. Therefore, the heat dissipation problem has become a bottleneck for the further development of the motor system in the direction of high power density.

[0003] The common motor efficiency can be as high as 90%-95%. Although the heat generation of the motor accounts for a small proportion, the total amount is still huge for high-power motors. If it is not discharged in time, it will not only shorten the life of the internal insulation material of the motor, but also reduce the operating efficiency of the motor, resulting in an increase in heat generation and a further rise in the motor temperature, forming a vicious cycle, seriously affecting the life and operating safety of the motor.

[0004] Air cooling and liquid cooling are common motor heat dissipation systems. The air-cooled heat dissipation system, with advantages such as low cost, high reliability, and convenient installation, is mainly applied to small-power motors, while the liquid-cooled heat dissipation system has higher heat dissipation efficiency and is suitable for occasions where the motor has a large amount of heat generation and a high heat flux density. However, liquid cooling requires additional circulating liquid paths and sealing systems, increasing the cost and complexity of the motor system.

[0005] In the structural design of motors, radiators are often used as separate components to achieve heat exchange in the system, and additional support structures are required for the fixation of the motors, which increases the mass of the motor system and reduces the power density of the system. Summary of the Invention

[0006] In view of the above problems, the present invention provides a motor heat dissipation system with a load-bearing radiator, and particularly a motor heat dissipation system for a high-power (megawatt level, 1MW) motor with a load-bearing radiator, which solves the problem that the heat dissipation efficiency and power density of high-power motors cannot be achieved simultaneously in the prior art.

[0007] The present invention provides a motor heat dissipation system with a load-bearing radiator, including a radiator 11, a cooling air flow channel, a permanent magnet synchronous motor, a motor frame 21, electronic components 22, an intake valve 23, and a rotating shaft 24;

[0008] The permanent magnet synchronous motor includes a stator 14, a rotor 15, and an outer hub 16 arranged from the inside out; the radiator 11 is arranged between the stator 14 and the cooling air flow channel;

[0009] The radiator 11, stator 14, rotor 15, outer hub 16, motor frame 21 and electronic components 22 are sleeved on the cooling air flow channel;

[0010] The motor frame 21 includes a first chamber and a second chamber;

[0011] The first chamber and the second chamber are arranged side by side along the axial direction of the cooling air flow channel;

[0012] An exhaust channel is provided at the top of one end of the second chamber close to the first chamber;

[0013] The electronic components 22 are arranged in the first chamber of the motor frame 21;

[0014] The radiator 11, stator 14, rotor 15, outer hub 16 and rotating shaft 24 are arranged in the second chamber of the motor frame 21;

[0015] The intake valve 23 and the rotating shaft 24 are respectively arranged at both ends of the cooling air flow channel;

[0016] The first chamber is arranged at one end close to the intake valve 23.

[0017] Optionally, the exhaust channel and the rotating shaft 24 are respectively arranged at both ends of the second chamber.

[0018] Optionally, the intake air volume is jointly controlled by the compressor power and the opening degree of the intake valve 23, and the expression of the intake air volume of the cooling air flow is:

[0019] m = β * p / k * t

[0020] Wherein, m represents the intake air volume; β is the opening degree of the intake valve; t is the time;

[0021] The expression of the compressor power p is:

[0022] p = k * v

[0023] Wherein, v is the gas flow velocity; k is the proportionality coefficient.

[0024] Optionally, the surface roughness of the cooling air flow channel increases continuously from the air inlet to the air outlet.

[0025] Optionally, the radiator 11 includes an inner wall 32, a channel grid 33 and an outer wall 34 from the inside to the outside.

[0026] Optionally, the channel grid 33 is a fin type a, a channel type structure b or a lattice type c.

[0027] Optionally, the channel type structure b includes clockwise fins and counterclockwise fins arranged in an alternating manner to form a grid air flow channel.

[0028] Optionally, multiple clockwise fins are arranged between the inner wall 32 and the outer wall 34 in the clockwise direction at the same first inclination angle, and multiple counterclockwise fins are arranged between the inner wall 32 and the outer wall 34 in the counterclockwise direction at the same second inclination angle.

[0029] Optionally, the angular values of the first inclination angle and the second inclination angle are the same.

[0030] Optionally, the radiator 11 further includes an inner wall limiting groove 31 and an outer wall limiting groove 35; the inner wall 32 of the radiator is fixed to the motor frame 21 through the inner wall limiting groove 31, and the outer wall 34 is fixed to the iron core 12 through the outer wall limiting groove 35.

[0031] Compared with the prior art, the present invention has at least the following beneficial effects:

[0032] The heat dissipation system of the motor is optimized, improving the heat dissipation efficiency of the system; the radiator serves as both a load-bearing structure and a heat dissipation structure, reducing the mass of the motor heat dissipation system and increasing the power density of the system while ensuring the structural stiffness and heat dissipation efficiency of the motor.

[0033] The flow path of the cooling air flow is optimized, and a longer cooling air flow channel with variable surface roughness is adopted to improve the cooling efficiency. Description of the Drawings

[0034] Figure 1 It is a schematic diagram of the cooling air flow path of the motor heat dissipation system of the present invention.

[0035] Figure 2 It is a curve of the change in the surface roughness of the air inlet channel of the motor heat dissipation system of the present invention.

[0036] Figure 3 (a)-(b) are the axonometric view and the front view of the motor of the motor heat dissipation system of the present invention.

[0037] Figure 4 It is a diagram of the rotor 90° halbach array and the magnetic induction line distribution of the motor heat dissipation system of the present invention.

[0038] Figure 5 It is the fin-type radiator structure, the channel-type radiator structure, and the lattice-type radiator structure of the motor heat dissipation system of the present invention in (a)-(c).

[0039] Figure 6 It is a schematic diagram of the load-bearing radiator of the motor heat dissipation system of the present invention.

[0040] Figure 7 It is a schematic diagram of the grid air flow channel of the channel-type radiator structure of the present invention.

[0041] Figure 8Schematic diagram of the intake channel, cooling air flow channel, and exhaust channel of the motor cooling system of the present invention.

[0042] 11 - Carrier radiator, 12 - Stator core, 13 - Stator winding, 14 - Stator, 15 - Rotor, 16 - Outer rim, 21 - Frame, 22 - Electronic components, 23 - Intake valve, 24 - Rotating shaft, 25 - Gas compressor, 31 - Inner wall limiting groove, 32 - Inner wall, 33 - Mesh channel, 34 - Outer wall, 35 - Outer wall limiting groove, 36 - Clockwise fins, 37 - Counterclockwise fins. Detailed implementation mode

[0043] In order to more clearly understand the above objects, features, and advantages of the present invention, the present invention will be further described in detail below in conjunction with the drawings and specific implementation modes. It should be noted that, without conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. In addition, the present invention can also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited by the specific embodiments disclosed below.

[0044] A specific embodiment of the present invention, as Figures 1-8 , discloses a motor cooling system with a carrier radiator, including a radiator 11, a cooling air flow channel, a permanent magnet synchronous motor, a motor frame 21, electronic components 22, an intake valve 23, and a rotating shaft 24;

[0045] The permanent magnet synchronous motor includes a stator 14, a rotor 15, and an outer hub 16 arranged from the inside out; the radiator 11 is arranged between the stator 14 and the cooling air flow channel;

[0046] The radiator 11, the stator 14, the rotor 15, the outer hub 16, the motor frame 21, and the electronic components 22 are sleeved on the cooling air flow channel;

[0047] The motor frame 21 includes a first chamber and a second chamber;

[0048] The first chamber and the second chamber are arranged side by side along the axial direction of the cooling air flow channel;

[0049] The first chamber is a sealed chamber; an exhaust channel is arranged at one end of the second chamber close to the first chamber;

[0050] The electronic components 22 are arranged in the first chamber of the motor frame 21;

[0051] The radiator 11, the stator 14, the rotor 15, the outer hub 16, and the rotating shaft 24 are arranged in the second chamber of the motor frame 21;

[0052] The intake valve 23 and the rotating shaft 24 are respectively arranged at both ends of the cooling air flow channel;

[0053] The first chamber is arranged at one end close to the intake valve 23.

[0054] Further, the electronic component 22 supplies power to the stator winding 13, and the electromagnetic induction drives the rotor 15 and the outer rim 16 to rotate. The connected rotating shaft 24 is the output shaft.

[0055] Further, the exhaust passage and the rotating shaft 24 are respectively arranged at both ends of the cooling air flow passage.

[0056] Specifically, as Figure 1 shown, the cooling air flow flows in from the left side of the cooling air flow passage. The intake valve 23 is used to control the intake air volume to cool the electronic component 22 and the inner wall 32 of the carrier radiator. Then, the flow direction is changed at the end cover where the permanent magnet synchronous motor is connected to the rotating shaft 24. The cooling air flow exchanges heat through the grid passage 33 of the radiator 11 and the air gap between the stator 14 and the rotor 15, and then flows upward to the exhaust passage and is sucked out by the downstream gas compressor 25. The mass flow rate of the cooling air flow is jointly controlled by the compressor speed and the intake valve 23, and is adjusted in real time according to the actual operating conditions of the motor to improve the cooling efficiency of the motor.

[0057] Further, the intake air volume is jointly controlled by the power of the gas compressor 25 and the opening degree of the intake valve 23. The expression for the intake air volume of the cooling air flow is:

[0058] m = β * p / k * t

[0059] where m represents the intake air volume; β is the opening degree of the intake valve; t is the time.

[0060] Further, the expression for the compressor power p is:

[0061] p = k * v

[0062] where v is the gas flow velocity; k is the proportionality coefficient.

[0063] As Figure 2 shown, the longer intake passage can increase the contact area and contact time between the air and the cooling air flow passage, and increase the heat dissipation amount. However, as the air continuously flows and exchanges heat, the temperature will gradually rise, the cooling effect will decline, resulting in inconsistent temperatures on both sides of the cooling air flow passage, generating thermal stress and affecting the efficiency and safety of the motor.

[0064] Further, different surface roughnesses are changed at different positions of the cooling air flow passage. As the cooling gas flows, from the inlet to the outlet, the surface roughness of the cooling air flow passage continuously increases, enabling the hotter gas to have a higher heat exchange effect and ensuring the overall heat dissipation uniformity and heat dissipation efficiency.

[0065] Further, the expression of the surface roughness c(x) of the cooling air flow channel at the corresponding position of the first chamber is:

[0066]

[0067] where x is the flow distance of the gas in the cooling air flow channel starting from the intake valve; c1 and c2 are the surface roughnesses of the pipes at the starting position and the ending position of the first chamber respectively, and c1 < c2; a and b are the starting position of the first chamber and the ending position of the second chamber respectively. The surface roughness of the pipes in the first chamber varies linearly. Preferably, the surface roughness is 0.01 - 0.3.

[0068] As Figure 3 and 4 shown, the structure of the permanent magnet synchronous motor is an outer rotor type. The rotor 15 adopts a halbach array arranged circumferentially, and the magnets are magnetized in a 90° arrangement, generating a stronger magnetic field on one side of the stator and almost no magnetic field on the other side, which can reduce eddy current losses and improve the power density and efficiency of the motor.

[0069] Further, the stator 14 includes an iron core 12 and a stator winding 13;

[0070] The stator winding 13 adopts a Litz coil, which divides the conductor into multiple fine wires with the same diameter, wraps them with insulating materials, and then weaves and winds these fine wires in a specific way (such as twisting, winding or stranding), reducing the energy loss generated by the surface effect and proximity effect of the conductor under high-frequency response (such as when the motor speed increases, the magnetic field change frequency increases or the heat loss increases), and improving the power density and efficiency of the motor.

[0071] Further, the radiator 11 is provided with an inner wall limiting groove 31, an inner wall 32, a channel grid 33 and an outer wall 34 from the inside to the outside.

[0072] The inner wall 32 of the load-bearing radiator is fixed to the motor frame 21 through the inner wall limiting groove 31, and the outer wall 34 is fixed to the iron core 12 through the outer wall limiting groove 35. The torque is transmitted from the stator to the motor frame 21 through the radiator 11, and at the same time, the heat generated during the operation of the stator winding 13 is dissipated.

[0073] Optionally, as Figure 5 shown, the channel grid 33 of the radiator 11 is of fin type a, channel structure b or lattice type c.

[0074] Among them, the channel structure b includes clockwise fins 36 and counterclockwise fins 37 arranged alternately, forming a grid air flow channel; a plurality of clockwise fins are arranged between the inner wall 32 and the outer wall 34 in the clockwise direction at the same first inclination angle, and a plurality of counterclockwise fins are arranged between the inner wall 32 and the outer wall 34 in the counterclockwise direction at the same second inclination angle;

[0075] Preferably, the angular values of the first inclination angle and the second inclination angle are the same.

[0076] In the convective heat transfer in the channel architecture of the present invention, the heat transfer mainly occurs through pipe flow. It is expected that the channel heat transfer retains most of the overall heat transfer capacity of the fin type. The rounded corners at the intersections of the curved fins minimize the reduction of the fin cross-sectional area, avoiding the loss of fin heat dissipation efficiency observed in the lattice type, while retaining most of the load-bearing capacity.

[0077] Furthermore, referring to Figure 6 and 7 , the arcs of the clockwise fins and the counterclockwise fins are the same as the arc of the outer wall circle. The fin thickness h1 at the outer wall is greater than the fin thickness h2 at the inner wall, effectively improving the structural stiffness of the radiator; the adjacent clockwise fins and counterclockwise fins intersect at the outer wall and the inner wall, and the intersection points are located on the outer wall and the inner wall respectively. Appropriate chamfers are made at the intersections to ensure the structural stiffness of the radiator;

[0078] In the polar coordinate system, the fin thickness h varies with the polar angle θ, and the expression is:

[0079]

[0080] In the formula, R is the radius of the outer wall circle; r is the radius of the inner wall circle; d is the center distance; the value range of θ is [0, π / 2].

[0081] Preferably, R is the radius of the outer wall circle of 63 mm, r is slightly less than R and takes 60 mm, the center distance d takes 2 mm, and θ takes [34°, 54°], that is, the lower and upper limits of θ are [0.19π, 0.3π], corresponding to the fin thickness h2 at the inner wall and the fin thickness h1 at the outer wall respectively.

[0082] Furthermore, the processing and forming method of the channel grid 33 is as follows: draw a circle with the inner diameter at the inner diameter of the outer wall and draw a circle with the outer diameter at the outer diameter of the outer wall, cut out the part between the inner and outer walls, use the connection line between the intersection point of the adjacent clockwise fins and counterclockwise fins on the outer diameter circle and the center of the circle as the center line, make a mirror image of the middle part to generate a grid air flow channel in the shape of a mountain, chamfer the intersections, make a circular array with a density of 6x60, axially stretch the planar graph to be the same as the length of the motor stator, and stretch and cut out the limit grooves of the inner and outer walls, and finally complete the overall modeling of the load-bearing radiator.

[0083] The above is only the preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A motor cooling system with a load-bearing radiator, characterized in that: It includes a radiator, a cooling air flow channel, a permanent magnet synchronous motor, a motor frame, electronic components, an air intake valve and a rotating shaft; The permanent magnet synchronous motor includes a stator, a rotor and an outer hub arranged from the inside to the outside; the radiator is arranged between the stator and the cooling air flow channel; The radiator, stator, rotor, outer hub, motor frame and electronic components are sleeved in the cooling air flow channel; The motor frame includes a first chamber and a second chamber; The first chamber and the second chamber are arranged side by side along the axial direction of the cooling air flow channel; An exhaust passage is arranged at the top of the second chamber near one end of the first chamber; The electronic components are arranged in the first chamber of the motor frame; The radiator, stator, rotor, outer hub and rotating shaft are arranged in the second chamber of the motor frame; The air intake valve and the rotating shaft are respectively arranged at two ends of the cooling air flow channel; The first chamber is arranged at one end close to the intake valve.

2. The motor cooling system according to claim 1, characterized in that: The exhaust channel and the rotating shaft are respectively arranged at two ends of the second chamber.

3. The motor cooling system according to claim 1, characterized in that: The intake volume is controlled by the compressor power and the opening of the intake valve. The expression of the intake volume of the cooling air flow is: m=β*p / k*t Among them, m represents the intake volume; β is the opening of the intake valve; t is the time; The expression of compressor power p is: p=k*v Where v is the gas flow rate and k is the proportionality coefficient.

4. The motor cooling system according to claim 1, characterized in that: The surface roughness increases continuously from the air inlet to the air outlet in the cooling air flow channel.

5. The motor cooling system according to claim 1, characterized in that: The heat sink 11 includes an inner wall, a channel grid and an outer wall from the inside to the outside.

6. The motor heat dissipation system according to claim 5, characterized in that: The channel grid is of fin type a, channel structure b or lattice type c.

7. The motor cooling system according to claim 6, characterized in that: The channel structure b includes clockwise fins and counterclockwise fins that are staggered to form a grid airflow channel.

8. The motor cooling system according to claim 7, characterized in that: A plurality of clockwise fins are arranged between the inner wall and the outer wall in a clockwise direction at the same first inclination angle, and a plurality of counterclockwise fins are arranged between the inner wall and the outer wall in a counterclockwise direction at the same second inclination angle.

9. The motor heat dissipation system according to claim 8, characterized in that: The first inclination angle and the second inclination angle have the same value.

10. The motor cooling system according to claim 8, characterized in that: The radiator also includes an inner wall limiting groove and an outer wall limiting groove; the inner wall of the radiator is fixed to the motor frame through the inner wall limiting groove, and the outer wall is fixed to the iron core through the outer wall limiting groove.

Images