Electric ducted fan

Abstract

The invention provides an electric ducted fan. The electric ducted fan comprises a duct body, a static blade supporting assembly, an inner rotor motor, a movable blade assembly, a fan controller and a flow guide cover. A shell of the inner rotor motor is fixedly connected with the stationary blade supporting assembly. The movable blade assembly comprises a middle rotating disc and a plurality of movable blades arranged on the middle rotating disc at intervals in the circumferential direction, and the middle rotating disc is connected to a rotating shaft of the inner rotor motor in an anti-torque mode. The fan controller comprises a controller shell, a control board, a power driving board, a capacitor filtering board and a plurality of supporting column assemblies, wherein the control board, the power driving board and the capacitor filtering board are sequentially stacked in the axial direction, and the control board, the power driving board and the capacitor filtering board are sequentially and fixedly connected through the supporting column assemblies. The flow guide cover comprises a front flow guide cover body and a rear flow guide cover body, the front flow guide cover body is fixed to one axial side of the movable blade assembly, and the rear flow guide cover body is fixed to the other axial side of the fan controller. Through the integrated design of parts, redundant parts are reduced, the structural compactness of the ducted fan is improved, and then the design of small size and light weight of the ducted fan is achieved.

Description

Technical Field

[0001] This application relates to the technical field of ducted fans, and more particularly to electric ducted fans. Background Art

[0002] In the design of propulsion systems for electric aircraft (such as flying cars, drones, etc.), ducted fans have become the core power components of lightweight electric vertical takeoff and landing aircraft (EVTOL) due to their high propulsion efficiency, low noise characteristics, and safety protection advantages. The main working principle of a ducted fan is to suck in air and accelerate the airflow by rotating the fan blades, thereby generating thrust for the aircraft to take off and land. Its structure usually consists of fan blades, a motor, an electronic control system, and other parts.

[0003] In traditional ducted fan designs, the fan blades, motor, and electronic control system are usually designed and manufactured separately and finally assembled into a complete system. This design has certain limitations.

[0004] (1) Low component integration: Since the fan blades, motor, and electronic control system are designed separately, each component can only perform a single function and cannot achieve a high degree of functional integration. This leads to an increase in the number of components, the complexity of assembly and debugging, and thus affects the overall efficiency of the system.

[0005] (2) Volume and weight redundancy: In traditional designs, the fan blades, motor, and electronic control system each independently occupy space, resulting in a relatively large overall volume and weight of the fan. For electric aircraft, especially applications such as flying cars that are extremely sensitive to volume and weight, the redundant volume and weight will directly affect the performance and endurance of the aircraft.

[0006] (3) Insufficient power density: The power density of traditional ducted fans is relatively low and cannot provide sufficient thrust to meet the requirements of high-performance electric aircraft.

[0007] (4) Heat dissipation problem: When operating at high power, the motor and electronic control system generate a large amount of heat. In traditional designs, the heat dissipation system is usually set up independently, resulting in low thermal management efficiency.

[0008] Therefore, in order to meet the requirements of modern electric aircraft, especially flying cars, for miniaturization, high power density, lightweight, and efficient heat dissipation, etc., how to integrally design the structure of the ducted fan has become a problem to be solved. Summary of the Invention

[0009] To overcome or mitigate at least one of the deficiencies existing in the above prior art, an object of this application is to provide an electric ducted fan. Through the integrated design of parts, the number of redundant parts is reduced, the structural compactness of the ducted fan is improved, and thus the design of small volume and light weight is achieved.

[0010] To achieve the above-mentioned invention object, the present application adopts the following technical solutions.

[0011] The present application provides an electric ducted fan, which includes:

[0012] A duct body, the inner wall of which forms an air flow channel;

[0013] A stator blade support assembly, which includes a plurality of stator blades evenly distributed in the circumferential direction, and the plurality of stator blades are integrally formed with the inner wall of the duct body;

[0014] An inner rotor motor, the outer shell of which is fixedly connected to the stator blade support assembly;

[0015] A rotor blade assembly, which includes an intermediate turntable and a plurality of rotor blades, the plurality of rotor blades are arranged at intervals in the circumferential direction on the intermediate turntable, and the intermediate turntable is torsionally connected to the rotating shaft of the inner rotor motor;

[0016] A fan controller, which includes a controller housing, a control board, a power drive board and a capacitor filter board stacked in sequence along the axial direction, and a plurality of support column assemblies, and the control board, the power drive board and the capacitor filter board are fixedly connected in sequence through the support column assemblies; and

[0017] A fairing, which includes a front fairing and a rear fairing, the front fairing is fixed to one axial side of the rotor blade assembly, and the rear fairing is fixed to the other axial side of the fan controller.

[0018] In at least one embodiment, the inner rotor motor includes a motor rear end cover, one axial end of which is connected to the outer shell of the inner rotor motor, the other axial end is connected to the controller housing, and the motor rear end cover is installed on the inner wall of the controller housing.

[0019] In at least one embodiment, the ducted fan includes connecting columns and wire ear sheaths, a connection hole is provided on the radial outer part of the motor rear end cover, the wire ear sheaths are installed in the connection hole, the wire ear sheaths are provided with three unconnected connecting column mounting holes, the connecting columns are respectively installed in the connecting column mounting holes, so that one end of the connecting column extends into the inner rotor motor and is threadedly connected to the three-phase terminals of the stator assembly of the inner rotor motor, and the other end of the connecting column extends into the fan controller and is threadedly connected to the three-phase terminals of the control board.

[0020] In at least one embodiment, a plurality of the support post assemblies are arranged at intervals along the circumferential direction, and the support post assembly includes a first support post, a second support post, and a third support post; wherein, the first support post is fixed between the rear end cover of the motor and the control board, the second support post is fixed between the control board and the power drive board, and the third support post is fixed between the power drive board and the capacitor filter board.

[0021] In at least one embodiment, the ducted fan includes MOS transistors, and the inner wall of the controller housing includes a plurality of convex planes evenly distributed along the circumferential direction. The mounting surface of the convex plane is parallel to the axial direction of the fan controller, and the MOS transistors are fixedly mounted on the mounting surface of the convex plane.

[0022] In at least one embodiment, the outer wall of the controller housing includes a plurality of heat dissipation teeth evenly arranged along the circumferential direction. The axial position of the heat dissipation teeth is the same as the axial position of the convex plane, and the distance between adjacent heat dissipation teeth is 1.2 to 1.5 times the height of the heat dissipation teeth.

[0023] In at least one embodiment, the duct body includes two symmetrically arranged mounting seats. The mounting seats are arranged on the outer wall of the duct body and include reinforcing ribs and mounting holes; and / or

[0024] The duct body is provided with a wire harness through hole, and the wire harnesses of the inner rotor motor and the fan controller pass through the wire harness through hole.

[0025] In at least one embodiment, the rear fairing includes two symmetrically distributed support vanes for supporting the ducted fan, and the wire harnesses of the inner rotor motor and the fan controller pass through the support vanes.

[0026] In at least one embodiment, the fan controller includes a controller rear cover. The controller rear cover includes a high-voltage connector and a communication interface. The high-voltage connector is electrically connected to the capacitor filter board, and the communication interface is electrically connected to the inner rotor motor and the fan controller.

[0027] In at least one embodiment, the control board, the power drive board, and the capacitor filter board are all designed in a circular shape.

[0028] By adopting the above technical solution, the present application provides an electric ducted fan. By integrating the duct body, the motor housing, and the stator support assembly into one component, the number of redundant components is reduced, enabling a single component to perform the function of connecting multiple components. This design reduces redundant components and independent designs, while achieving the compactification of the ducted fan, further reducing its volume and weight. At the same time, the circuit board of the fan controller can include three circuit boards with different functions and be stacked axially, thereby reducing the longitudinal dimension of the circuit board to adapt to the size requirements of different fans. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 FIG. 6 is a schematic structural diagram of an electric ducted fan according to an embodiment of the present application;

[0030] Figure 2 is Figure 1 a schematic cross-sectional view of the electric ducted fan taken along the central axis of its motor;

[0031] Figure 3 FIG. 7 is a schematic structural diagram of an electric ducted fan according to an embodiment of the present application, wherein the duct body is not included;

[0032] Figure 4 FIG. 8 is a schematic structural diagram of an electric ducted fan according to an embodiment of the present application from another perspective, wherein the duct body, the fairing, and the stator support assembly are not included;

[0033] Figure 5 FIG. 9 is a schematic structural diagram of a motor according to an embodiment of the present application;

[0034] Figure 6 is Figure 2 a schematic structural diagram of the moving blade assembly and the rotor assembly of the motor in FIG. 9;

[0035] Figure 7 is Figure 2 a schematic structural diagram of the motor rear end cover and the fan controller in FIG. 9;

[0036] Figure 8 is Figure 2 a schematic structural diagram of the motor rear end cover and the fan controller in FIG. 9 from another perspective;

[0037] Figure 9 FIG. 10 is a schematic structural diagram of the fan controller according to an embodiment of the present application from another perspective;

[0038] Figure 10 FIG. 11 is a schematic structural diagram of the circuit board of the fan controller according to an embodiment of the present application.

[0039] DESCRIPTION OF THE REFERENCE NUMERALS

[0040] 10 Duct body; 11 Mounting base;

[0041] 20 Static vane support assembly; 21 Static vane blade;

[0042] 30 Inner rotor motor; 31 Rotating shaft; 32 Stator assembly;

[0043] 33 Rotor assembly; 330 Rotor back iron; 331 Rotor magnet; 332 Rotor sheath; 333 Rotor core;

[0044] 34 Motor front end cover; 35 Motor rear end cover; 36 Hall speed and position sensor;

[0045] 37 Front bearing; 38 Rear bearing;

[0046] 40 Moving vane assembly; 41 Intermediate turntable; 42 Moving vane blade; 43 Moving vane fixing nut

[0047] 50 Fan controller; 51 Controller housing; 510 Raised plane; 520 Heat dissipation teeth;

[0048] 52 Control board; 53 Power drive board; 54 Capacitor filter board; 55 MOS tube;

[0049] 56 Controller rear cover; 560 High voltage connector; 561 Communication interface;

[0050] 57 Support column assembly; 570 Fixing nut; 571 First support column; 572 Second support column; 573 Third support column;

[0051] 60 Deflector; 61 Front deflector; 62 Rear deflector; 620 Support blade;

[0052] 70 Connecting column; 71 Wire ear sheath;

[0053] R Radial;

[0054] A Axial;

[0055] C Circumferential Detailed implementation manners

[0056] The following describes exemplary embodiments of the present application with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, and are not used to exhaust all feasible ways of the present application, nor are they used to limit the scope of the present application.

[0057] Embodiments of the present application provide an electric ducted fan (hereinafter, sometimes simply referred to as "fan"). Among them, unless otherwise specifically stated, "axial", "radial", and "circumferential" respectively refer to the axial, radial, and circumferential directions of the inner rotor motor (hereinafter, sometimes simply referred to as "motor") of the electric ducted fan of the present application.

[0058] Further, "radially outer side" refers to the side along the radial direction away from the central axis of the motor; "axial one side" refers to Figure 2 and Figure 7 the left side in Figure 2 and Figure 7 the right side in

[0059] Further, in this application, two components being "anti-torsionally connected" means that these two components can be connected to transmit torque, including direct connection or indirect connection. For example, these two components can achieve direct anti-torsional connection through splines.

[0060] The following further elaborates on this application in detail in conjunction with the description drawings of the specification and specific embodiments.

[0061] As Figure 1 and Figure 2 shown, an embodiment of this application provides an electric ducted fan, which may include a duct body 10, a stator vane support assembly 20, an inner rotor motor 30, a rotor vane assembly 40, a fan controller 50, and a fairing 60.

[0062] In this embodiment, as Figure 1 shown, the inner wall of the duct body 10 can form an air flow channel, which can be a hollow cylinder, and flanges can be provided on both sides.

[0063] Further, two mounting seats 11 can be symmetrically provided on the outer wall of the duct body 10, and multiple mounting holes can also be provided on each mounting seat 11 to fix the fan to, for example, an external aircraft. In addition, as Figure 1 shown, reinforcing ribs can also be provided on the mounting seats 11 to increase their strength. At the same time, wire harness through holes can also be provided on the barrel wall of the duct body 10 for leading out the wire harnesses of the motor 30 and the fan controller 50.

[0064] Preferably, two symmetrically distributed through holes are provided on the duct body 10, and the positions of the through holes are not limited herein. In addition, the duct body 10 can be made of aluminum alloy material by machining.

[0065] In this embodiment, as Figure 2 and Figure 3 shown, the stator vane support assembly 20 can include a plurality of stator vane blades 21 evenly distributed along the circumferential direction C, and the cross-section thereof can be in a blade shape. In addition, the stator vane support assembly 20 can be made of aluminum alloy material. After the plurality of stator vane blades 21 are individually processed, they can be welded to the outer shells of the duct body 10 and the motor 30 to form an integral component.

[0066] It can be understood that the stator vane support assembly 20 can provide support for the motor 30 within the duct body 10 and transfer the thrust generated by the stator vanes 21 to the duct body 10. In addition, it can also promote the flow of air within the duct body 10, increase the air volume, and meet the required air pressure of the system.

[0067] In this embodiment, as Figure 4 shown, the rotor blade assembly 40 can include an intermediate turntable 41 and a plurality of rotor blades 42. Among them, the intermediate turntable 41 is torsionally connected to the rotating shaft 31, and the plurality of rotor blades 42 are circumferentially spaced apart on the intermediate turntable 41 at intervals of C. Further, the intermediate turntable 41 can be fixedly connected to the rotating shaft 31 through a rotor fixing nut 43. In this way, when the motor 30 drives the rotating shaft 31 to rotate, it can drive the plurality of rotor blades 42 to rotate, thereby generating an air flow and realizing the flow and circulation of air.

[0068] Specifically, the rotor blade assembly 40 can generate wind power by rotating, sucking air into one side of the fan, and discharging it to the other side of the fan through the pushing action of the fan blades, thereby forming a continuous air flow. Further, the rotation direction of the rotor blades 42 can be adjusted by adjusting the rotation direction of the rotating shaft 31, thereby realizing the adjustment of the air flow direction of the fan.

[0069] In this embodiment, as Figure 2 shown, the fairing 60 can reduce the air flow resistance, making the air flow smoother, thereby improving the working efficiency of the fan. Specifically, the fairing 60 can include a front fairing 61 and a rear fairing 62. Among them, the front fairing 61 can be fixedly connected to the axial side of the rotor blade assembly 40, and the rear fairing 62 can be fixedly connected to the axial other side of the fan controller 50.

[0070] Preferably, the front fairing 61 can be fixedly connected to the intermediate turntable 41 by bolts, and the rear fairing 62 can be fixedly connected to the controller rear cover 56 of the fan controller 50 by bolts.

[0071] Referring to Figure 3 , the rear fairing 62 can also be provided with a plurality of support blades 620. The support blades 620 are of a hollow structure, that is, they have a hollow channel. In this embodiment, the rear fairing 62 can be provided with 2 symmetrically distributed support blades 620.

[0072] It can be understood that the support blades 620 can increase the support for the fan controller 50, reduce the axial swing, thereby improving the stability of the fan. In addition, the hollow structure of the support blades 620 can further reduce the weight, and the wire harnesses of the motor 30 and the controller can respectively pass through the interiors of the respective support blades 620, avoiding the wire harnesses from swinging due to gas flow and reducing the gas resistance of the fan. The through holes on the duct body 10 can be connected to or aligned with the hollow channels of the support blades 620.

[0073] Furthermore, when the motor 30 is cooled using a water-cooling structure, its water-cooling pipeline can also pass through the inside of the support blade 620 and be connected to the cooling water jacket of the motor 30. Alternatively, at least one hollow channel of the support blade 620 can be used as a cooling water channel.

[0074] As Figure 2 and Figure 5 shown, the motor 30 can include a rotating shaft 31, a stator assembly 32, a rotor assembly 33, a motor front end cover 34, and a motor rear end cover 35. Among them, the motor front end cover 34, the rotor assembly 33, and the motor rear end cover 35 are sequentially installed on the rotating shaft 31 along the axial direction A. Among them, the rotor assembly 33 is torsionally connected to the rotating shaft 31, and the stator assembly 32 is installed on the outer side of the rotor assembly 33 in the radial direction R and fixed to the housing of the motor 30.

[0075] As Figure 2 shown, the rotating shaft 31 is connected to the motor front end cover 34 through a front bearing 37. At the same time, the rotating shaft 31 is connected to the motor rear end cover 35 through a rear bearing 38.

[0076] Referring to Figure 2 and Figure 5 , the moving blade assembly 40 can be torsionally connected to one side of the motor front end cover 34. Specifically, the middle turntable 41 of the moving blade assembly 40 can be connected to the rotating shaft 31 through a key and a keyway. It can be understood that a keyway can be provided on the rotating shaft 31 to achieve the quick installation of the moving blade assembly 40 and the rotating shaft 31 and the transmission of torque. In addition, the rotating shaft 31 can be a hollow structure to reduce weight and rotational inertia.

[0077] Furthermore, an end portion on the other side of the rotating shaft 31 ( Figure 2 the right side in

[0078] Referring to Figure 2 , the stator assembly 32 can include a stator core and a stator winding. The stator winding is wound around the stator core, and the stator core is fixedly connected to the housing of the motor 30.

[0079] In this embodiment, as Figure 2 and Figure 3 shown, the stationary blade support assembly 20 is fixedly connected to the housing of the motor 30 by welding, that is, a plurality of stationary blade vanes 21 are fixedly arranged on the housing of the motor 30 at intervals. Therefore, during the operation of the fan, the heat generated by the motor 30 can be transferred to each stationary blade vane 21, thereby realizing the heat dissipation of the motor 30 (especially the stator winding).

[0080] In this embodiment, as Figure 6As shown, the rotor assembly 33 may include rotor permanent magnets 331, a rotor back iron 330, a rotor sheath 332, and a rotor core 333. Among them, the rotor permanent magnets 331 may be installed on the rotor core 333 and are evenly spaced along the circumferential direction C. Further, the rotor permanent magnets 331 may adopt designs such as Halbach magnet arrays or concentrated magnet tangential magnet arrays to increase the air-gap magnetic field intensity of the motor 30. Among them, the rotor permanent magnets 331 may be directly attached to the surface of the rotor core 333 by bonding.

[0081] The rotor sheath 332 may cover the radial outside of the rotor permanent magnets 331 and is used to protect the rotor permanent magnets 331 from the centrifugal force during high-speed rotation. The rotor sheath 332 may be machined from a metal material or manufactured by winding a carbon fiber composite material. In addition, a plurality of threaded holes may be provided on the surface of the rotor back iron 330 along the circumferential direction C to facilitate the installation and fixation with the rotating shaft 31.

[0082] In this embodiment, as Figure 2 shown, one end ( Figure 2 the left side) of the motor rear end cover 35 may be fixedly connected to the housing of the motor 30, and the other end ( Figure 2 the right side) may be fixedly connected to the housing of the fan controller 50. In this way, the motor rear end cover 35 can simultaneously achieve the sealing and fixation of the motor 30 and the fan controller 50, thereby reducing the number of fan components.

[0083] Further, the motor rear end cover 35 may also be used to fix and support the circuit board (such as the control board 52) of the fan controller 50.

[0084] In this embodiment, as Figure 7 and Figure 8 shown, a connection hole may also be provided on the radial outer part of the axial mounting hole for mounting the rotating shaft 31 of the motor rear end cover 35. The wire ear sheath 71 may be installed in this connection hole and may be fixedly connected to the motor rear end cover 35 by bolts. The wire ear sheath 71 is made of an insulating material (such as plastic), and its main function is to achieve insulation.

[0085] Further, referring to Figure 8 , three unconnected connection post mounting holes may be provided inside the wire ear sheath 71, and a connection post 70 may be installed in each connection post mounting hole. The connection post 70 has conductivity, so that one end of the connection post 70 extends into the interior of the motor 30, and the other end extends into the interior of the fan controller 50. Among them, threads may be provided at both ends of the connection post 70, respectively for connecting the three-phase terminals of the stator assembly 32 and the control board 52. In this way, the high-voltage lines in the motor 30 and the fan controller 50 can be directly connected inside the fan through the connection post 70.

[0086] Specifically, asFigure 7 As shown, one axial end of the connecting column 70 can be connected to the three-phase terminals of the stator winding, and the other axial end can be connected to the three-phase terminals of the fan controller 50. In this way, the connection of two high-voltage lines is realized through the connecting column 70, effectively reducing the connecting components between the motor 30 and the fan controller 50, simplifying the connection structure, and thus helping to further reduce the weight of the fan.

[0087] Furthermore, referring to Figure 8 , the connecting column mounting holes can be arranged side by side, and the connecting column 70 can be a hexagon head bolt or a countersunk head bolt, etc. Preferably, in this embodiment, considering that the power supply of the motor 30 is a three-phase power supply, that is, 3 groups of internal thread hexagon head bolts can be provided on the rear end cover 35 of the motor.

[0088] As Figure 9 and Figure 10 shown, the fan controller 50 can include a controller housing 51, a control board 52, a power drive board 53, a capacitor filter board 54 stacked in sequence along the axis A, and a support column assembly 57. Among them, the controller housing 51 is fixedly connected to the rear end cover 35 of the motor and the controller rear cover 56.

[0089] The circuit board of the traditional fan controller 50 usually integrates the control, power drive, and capacitor filtering functions on one board, and this design has requirements for the size of the circuit board. Although it is applicable to the traditional motor drive field with low size requirements, in the applications of miniaturization and high integration, this single-board design is not applicable.

[0090] In order to enable the fan controller 50 to better adapt to the external dimension of the motor 30, in this embodiment, the circuit board of the traditional controller is designed as three circuit boards: the control board 52, the power drive board 53, and the capacitor filter board 54 to distinguish different functions, and the shape of its circuit board can be circular (including approximately circular).

[0091] Specifically, the control board 52 can control and monitor the operating state of the fan, including signal transmission, power management, device monitoring, and fault diagnosis, etc.; the power drive board 53 is the drive circuit of the power module, mainly performing operations such as signal amplification, isolation, adjustment, and inversion; the function of the capacitor filter board 54 is to remove the noise and interference in the power supply and provide a stable DC voltage to ensure the normal operation of other components. In addition, the capacitor filter board 54 is also connected to the high-voltage connector 560 (refer to Figure 2 ) for connecting to the external high-voltage power supply circuit.

[0092] In this embodiment, as Figure 9 , Figure 10As shown, the control board 52, the power drive board 53, and the capacitor filter board 54 can be fixed in the cavity of the fan controller 50 through the support post assembly 57. Specifically, the fan controller 50 can include three groups of support post assemblies 57 arranged at intervals along the circumferential direction C to ensure stable support of the circuit board. The support post assembly can include a first support post 571, a second support post 572, and a third support post 573.

[0093] See Figure 10 , the first support post 571 can be fixed on the rear end cover 35 of the motor, and the control board 52 can be fixed between the second support post 572 and the first support post 571; then, the power drive board 53 can be fixed between the second support post 572 and the third support post 573; finally, the capacitor filter board 54 can be fixed between the third support post 573 and the fixing nut 570 of the capacitor filter board 54, and finally tightened by the fixing nut 570.

[0094] It can be understood that in this embodiment, by stacking the three circuit boards axially in the controller housing 51, this design not only reduces the lateral space of the controller, but also reduces the longitudinal dimension through the optimization of the space layout, so as to better meet the size requirements of the ducted fan.

[0095] From the above, it can be seen that the power drive board 53 can control the on and off of devices such as the IGBT (Insulated Gate Bipolar Transistor) or MOS transistor 55 (Metal Oxide Semiconductor Field Effect Transistor) of the power chip. Among them, the MOS transistor 55 is generally fixed on the power drive board 53.

[0096] In this embodiment, as Figure 9 and Figure 10 shown, the MOS transistor 55 can be fixed on the inner wall of the controller housing 51 and dissipated heat through the heat dissipation teeth 520 on the inner and outer walls of the controller housing 51.

[0097] Specifically, see Figure 9 , a plurality of convex planes 510 evenly distributed along the circumferential direction C and protruding radially inward can be provided on the inner wall of the controller housing 51. The mounting surface of the convex plane 510 is parallel to the axial direction A of the fan controller 50, and the MOS transistor 55 can be mounted on the mounting surface of the convex plane 510.

[0098] Preferably, in this embodiment, three groups of convex planes 510 can be provided on the inner wall of the controller housing 51, and the MOS transistor 55 can be directly attached to these convex planes 510 by bonding.

[0099] Further, in the corresponding area of the outer wall of the convex plane 510, a plurality of heat dissipation teeth 520 can be evenly arranged along the circumferential direction C, that is, the axial height of these heat dissipation teeth 520 is equal to the axial height of the convex plane 510, and the axial position of the heat dissipation teeth 520 is the same as the axial position of the convex plane 510. In this way, the heat generated by the MOS transistor 55 can be effectively transferred to the heat dissipation teeth 520 and the controller housing 51, thereby achieving rapid heat dissipation.

[0100] Preferably, the distance between adjacent heat dissipation teeth 520 is 1.2 to 1.5 times the height of the heat dissipation teeth 520, and the plurality of heat dissipation teeth 520 can be integrally formed with the controller housing 51.

[0101] See Figure 2 , the controller rear cover 56 can be used to seal the other end of the fan controller 50 ( Figure 2 the right side), and is respectively connected to the controller housing 51 and the rear deflector 62. Specifically, the controller rear cover 56 can also be provided with a high-voltage connector 560 and a communication interface 561. Among them, the high-voltage connector 560 can be used to supply power to the fan controller 50 and the motor 30, and the communication interface 561 can be used to transmit control signals and communicate.

[0102] See Figure 2 and Figure 10 , the connection method of the high-voltage lines of the fan controller 50 and the motor 30 can be: the external power line can enter the fan cavity through the hollow channel of the support blade of the rear deflector 62 and be connected to the high-voltage connector 560; the high-voltage connector 560 can connect the high-voltage wire to the capacitor filter board 54 for filtering, and then connect to the power drive board 53 through the capacitor filter board 54, and then connect to the control board 52 through the power drive board 53. The three-phase terminals on the control board 52 are connected to the three-phase terminals of the stator assembly 32 through the connecting posts 70, thereby realizing the connection of the entire high-voltage circuit of the fan.

[0103] Further, the heat dissipation structure of the fan provided by the embodiments of the present application makes full use of the gas flow of the fan and improves the heat transfer coefficient of the motor 30 heat dissipation (i.e., stator heat dissipation). Specifically, the fan air flow flows through the stator blade 21 and the outer shell of the motor 30, thereby reducing the temperature rise of the motor 30 and improving the heat dissipation capacity and power density of the motor 30. In addition, the stator heat dissipation utilizes the traditional stator blade support structure to realize the reuse of the functions of the stator blade support and stator heat dissipation, effectively improving the utilization rate of components. At the same time, by fixing the MOS transistor 55 on the controller housing 51 with heat dissipation teeth 520, heat dissipation can be carried out by using the gas flow of the fan.

[0104] It can be understood that for the ducted fan provided by the present application, by integrating the duct body 10, the motor housing and the stator vane support assembly 20 into one component, the number of redundant components is reduced. At the same time, the motor 30 and the fan controller 50 share the same end cover (i.e., the rear end cover 35 of the motor), achieving simultaneous sealing of the motor 30 and the fan controller 50 and providing support for the internal components. This integrated design can effectively combine the fan blades, the motor 30 and the fan controller 50 to form a compact and lightweight whole.

[0105] For the ducted fan provided by the present application, since a single component has the function of connecting multiple components, a compact design of the ducted fan is achieved, further reducing the volume and weight. At the same time, the circuit board of the fan controller 50 can include three circuit boards with different functions and be stacked axially, thereby reducing the longitudinal dimension of the circuit board to adapt to the size requirements of different fans.

[0106] It should be understood that the above embodiments, examples or illustrations are exemplary only and do not limit the present application. Those skilled in the art can make various variations and changes to the above embodiments, examples or illustrations under the teaching of the present application without departing from the scope of the present application.

Claims

1. An electric ducted fan, characterized in that, Comprising: A duct body (10), the inner wall of which forms an air flow channel; A stator vane support assembly (20), which includes a plurality of stator vane blades (21) evenly distributed along the circumference (C), and the plurality of stator vane blades (21) are integrally formed with the inner wall of the duct body (10); An inner rotor motor (30), the outer shell of which is fixedly connected to the stator vane support assembly (20); A rotor vane assembly (40), which includes an intermediate turntable (41) and a plurality of rotor vane blades (42), the plurality of rotor vane blades (42) are arranged at intervals along the circumference (C) on the intermediate turntable (41), and the intermediate turntable (41) is torsionally connected to the rotating shaft (31) of the inner rotor motor (30); A fan controller (50), which includes a controller housing (51), a control board (52), a power drive board (53) and a capacitor filter board (54) stacked in sequence along the axial direction, and a plurality of support column assemblies (57), the control board (52), the power drive board (53) and the capacitor filter board (54) are fixedly connected in sequence through the support column assemblies (57); and A fairing (60), which includes a front fairing (61) and a rear fairing (62), the front fairing (61) is fixed to one axial side of the rotor vane assembly (40), and the rear fairing (62) is fixed to the other axial side of the fan controller (50).

2. The electric ducted fan according to claim 1, wherein The inner rotor motor (30) includes a motor rear end cover (35), one axial end of which is connected to the outer shell of the inner rotor motor (30), the other axial end is connected to the controller housing (51), and the motor rear end cover (35) is installed on the inner wall of the controller housing (51).

3. The electric ducted fan according to claim 2, wherein, The ducted fan includes a connecting column (70) and a wire ear sheath (71), a connecting hole is provided on the radial outer part of the motor rear end cover (35), the wire ear sheath (71) is installed in the connecting hole, the wire ear sheath (71) is provided with three unconnected connecting column mounting holes, and the connecting column (70) is respectively installed in the connecting column mounting holes, so that one end of the connecting column (70) extends into the inner rotor motor (30) and is threadedly connected to the three-phase terminals of the stator assembly (32) of the inner rotor motor (30), and the other end of the connecting column (70) extends into the fan controller (50) and is threadedly connected to the three-phase terminals of the control board (52).

4. The electric ducted fan according to claim 2, characterized in that The plurality of support column assemblies (57) are arranged at intervals along the circumference (C), and the support column assembly (57) includes a first support column (571), a second support column (572) and a third support column (573); wherein, the first support column (571) is fixed between the motor rear end cover (35) and the control board (52), the second support column (572) is fixed between the control board (52) and the power drive board (53), and the third support column (573) is fixed between the power drive board (53) and the capacitor filter board (54).

5. The electric ducted fan according to claim 1, wherein, The ducted fan includes a MOS transistor (55). The inner wall of the controller housing (51) includes a plurality of raised planes (510) evenly distributed along the circumferential direction (C). The mounting surface of the raised plane (510) is parallel to the axial direction of the fan controller (50), and the MOS transistor (55) is fixedly mounted on the mounting surface of the raised plane (510).

6. The electric ducted fan according to claim 5, wherein, The outer wall of the controller housing (51) includes a plurality of heat dissipation teeth (520) evenly arranged along the circumferential direction (C). The axial position of the heat dissipation teeth (520) is the same as that of the raised plane (510), and the distance between adjacent heat dissipation teeth (520) is 1.2 to 1.5 times the height of the heat dissipation teeth (520).

7. The electric ducted fan according to claim 1, wherein, The ducted body (10) includes two symmetrically arranged mounting seats (11). The mounting seats (11) are arranged on the outer wall of the ducted body (10), and each mounting seat (11) includes a reinforcing rib and a mounting hole; and / or The ducted body (10) is provided with a wire harness through-hole, and the wire harnesses of the inner rotor motor (30) and the fan controller (50) pass through the wire harness through-hole.

8. The electric ducted fan according to claim 1, wherein The rear fairing (62) includes two symmetrically distributed support vanes (620) for supporting the ducted fan, and the wire harnesses of the inner rotor motor (30) and the fan controller (50) pass through the support vanes (620).

9. The ducted electric fan according to any one of claims 1 to 8, characterized in that, The fan controller (50) includes a controller rear cover (56). The controller rear cover (56) includes a high-voltage connector (560) and a communication interface (561). The high-voltage connector (560) is electrically connected to the capacitor filter board (54), and the communication interface (561) is electrically connected to the inner rotor motor (30) and the fan controller (50).

10. The electric ducted fan according to claim 9, wherein, The control board (52), the power drive board (53), and the capacitor filter board (54) are all designed in a circular shape.

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