Method and system for optimizing air-cooling heat dissipation structure of energy-saving flat wire motor

Abstract

The invention provides an air-cooling heat dissipation structure optimization method and system for an energy-saving flat wire motor, and relates to the technical field of energy-saving motors, and the method comprises the steps: collecting the operation thermal load characteristics of the flat wire motor, and obtaining the real-time temperature of an air-cooling heat dissipation structure; configuring a structure optimization strategy of the air cooling heat dissipation structure based on heat dissipation data generated by the multi-working-condition data record to obtain a primary optimization strategy; performing heat dissipation optimization execution on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data to obtain an intermediate optimization strategy; and obtaining a heat dissipation optimization result through the energy-saving effect obtained through the primary optimization strategy and the intermediate optimization strategy. The technical problems that in the prior art, the heat dissipation efficiency is low, the energy consumption is high, the local temperature rise is serious, and the operation stability and the service life of the flat wire motor under multiple working conditions and the energy efficiency performance of the whole system are affected can be solved, and the technical purposes of air cooling heat dissipation structure optimization and dynamic regulation and control are achieved; the technical effects of improving the heat dissipation efficiency of the motor and reducing the overall energy consumption are achieved.

Description

Technical Field

[0001] The present application relates to the technical field of energy-saving motors, and in particular to a method and system for optimizing the air-cooling heat dissipation structure of energy-saving flat wire motors. Background Art

[0002] With the widespread adoption of new energy vehicles, intelligent manufacturing equipment, and high-efficiency electric drive systems, flat wire motors are becoming a mainstream choice for drive motors due to their high power density, compact structure, and strong heat dissipation capabilities. In high-heat-load scenarios like electric vehicles, flat wire motors are required to operate efficiently and for extended periods, placing higher demands on their heat dissipation performance. While the currently widely used air cooling method offers some cooling capabilities through forced convection, it still faces numerous limitations and bottlenecks in practical applications.

[0003] Currently, existing technologies often use fixed fan structures, with blade angles and numbers not dynamically adjusted to the motor's actual operating conditions, resulting in low wind energy utilization efficiency. Furthermore, the airflow path layout is irrational, preventing some key heat sources, such as the stator core or winding surface, from being adequately cooled, leading to localized heat accumulation. Furthermore, some systems lack precise control over fan on and off, often adopting a one-size-fits-all approach based on preset thresholds. This fails to accurately adapt to changes in the motor's thermal load, easily leading to energy waste or delayed heat dissipation. Furthermore, under special operating conditions such as congestion and low-speed operation, insufficient cooling air speeds can dramatically reduce heat dissipation, causing the motor to operate at continuously high temperatures, impacting its lifespan and efficiency. Furthermore, existing technologies lack a mechanism for real-time monitoring of air flow within the duct, making it impossible to determine whether the duct is blocked or whether heat dissipation is evenly distributed based on differences in inflow and outflow wind speeds. Finally, at the policy development level, current heat dissipation optimization is mostly based on empirical rules or single-condition testing, lacking dynamic feedback and predictive analysis of multi-condition data, making it impossible to develop a targeted and responsive optimization solution. Therefore, it is urgent to propose a flat wire motor air cooling structure optimization method that is data-driven, flexible and adjustable in structure, has perfect airflow monitoring and energy-saving control capabilities, so as to solve the problems of low energy efficiency, slow response and poor adaptability existing in traditional technologies, thereby improving the overall operating stability and energy-saving effect of the motor. Summary of the Invention

[0004] The purpose of this application is to provide a method and system for optimizing the air-cooled heat dissipation structure of an energy-saving flat wire motor, so as to solve the technical problems in the prior art such as low heat dissipation efficiency, high energy consumption and severe local temperature rise due to the fixed fan structure, unreasonable air guide path, and lack of real-time air flow monitoring and dynamic control strategy, which further affect the operating stability, service life and energy efficiency performance of the overall system of the flat wire motor under multiple working conditions.

[0005] In view of the above problems, the present application provides a method and system for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor.

[0006] In the first aspect, the present application provides an air-cooled heat dissipation structure optimization method for an energy-saving flat wire motor, which is implemented through an air-cooled heat dissipation structure optimization system for an energy-saving flat wire motor, including: collecting the operating thermal load characteristics of the flat wire motor to obtain the real-time temperature of the air-cooled heat dissipation structure; configuring the structural optimization strategy of the air-cooled heat dissipation structure based on the heat dissipation data generated by multi-working condition data records to obtain a primary optimization strategy; performing heat dissipation optimization on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data to obtain an intermediate optimization strategy; and obtaining a heat dissipation optimization result by evaluating the energy-saving effect obtained by the primary optimization strategy and the intermediate optimization strategy.

[0007] In the second aspect, the present application also provides an air-cooling heat dissipation structure optimization system for an energy-saving flat wire motor, which is used to execute the air-cooling heat dissipation structure optimization method for an energy-saving flat wire motor as in the first aspect, including: a temperature acquisition module, used to collect the operating thermal load characteristics of the flat wire motor and obtain the real-time temperature of the air-cooling heat dissipation structure; a primary optimization strategy acquisition module, used to configure the structural optimization strategy of the air-cooling heat dissipation structure based on the heat dissipation data generated by multi-working condition data records, and obtain the primary optimization strategy; an intermediate optimization strategy acquisition module, used to perform heat dissipation optimization on the air-cooling heat dissipation structure according to the real-time temperature and the heat dissipation data, and obtain the intermediate optimization strategy; a strategy evaluation module, used to obtain the heat dissipation optimization result through the energy-saving effect evaluated by the primary optimization strategy and the intermediate optimization strategy.

[0008] The technical solution provided in this application has at least the following technical effects or advantages: by achieving the technical goal of intelligent optimization and dynamic regulation of the air-cooled heat dissipation structure, the technical effects of improving the heat dissipation efficiency of the motor, extending the service life, reducing overall energy consumption and improving the stability of system operation are achieved.

[0009] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, which can be implemented in accordance with the contents of the description, and to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are specifically listed below. It should be understood that the content described in this section is not intended to identify the key or important features of the embodiments of the present application, nor is it intended to limit the scope of the present application. Other features of the present application will become easy to understand through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to more clearly illustrate the technical solutions in this application or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely exemplary, and a person of ordinary skill in the art can obtain other drawings based on the provided drawings without creative work.

[0011] Figure 1 This is a flow chart of the method for optimizing the air-cooling heat dissipation structure of the energy-saving flat wire motor of this application; Figure 2 This is a structural diagram of the air-cooling heat dissipation structure optimization system for the energy-saving flat wire motor of this application.

[0012] Explanation of the reference numerals: temperature acquisition module 11 , primary optimization strategy acquisition module 12 , intermediate optimization strategy acquisition module 13 , strategy evaluation module 14 . DETAILED DESCRIPTION

[0013] This application provides a method and system for optimizing the air-cooling heat dissipation structure of energy-saving flat-wire motors. This method addresses the existing technical issues of low heat dissipation efficiency, high energy consumption, and severe local temperature rise caused by fixed fan structures, unreasonable air flow paths, and a lack of real-time air flow monitoring and dynamic control strategies. These issues further impact the flat-wire motor's operational stability, service life, and overall system energy efficiency under various operating conditions. This method achieves the technical goal of intelligently optimizing and dynamically controlling the air-cooling heat dissipation structure, achieving the technical effects of improving motor heat dissipation efficiency, extending service life, reducing overall energy consumption, and enhancing system operational stability.

[0014] Below, the technical solutions in this application will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of this application, rather than all the embodiments of this application. It should be understood that this application is not limited to the example embodiments described herein. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application. It should also be noted that, for the convenience of description, only the parts related to this application, rather than all of them, are shown in the accompanying drawings.

[0015] For example, see the attached Figure 1 The present application provides an air-cooling heat dissipation structure optimization method for an energy-saving flat wire motor, which is applied to an air-cooling heat dissipation structure optimization system for an energy-saving flat wire motor, and specifically includes the following steps: S1: Collect the operating thermal load characteristics of the flat wire motor and obtain the real-time temperature of the air-cooling heat dissipation structure.

[0016] Specifically, collecting the operating thermal load characteristics of a flat-wire motor involves recording the heat generated by current flowing through the coils, electromagnetic fluctuations, and mechanical friction while the motor is powered and running under load. Flat-wire motors, due to their more compact windings and higher current density per unit volume, heat up more quickly. Thermal load is the amount of heat generated and required to be dissipated per unit time, reflecting the intensity of heat generated by the device under load. To accurately capture thermal load characteristics, multiple temperature, current, and voltage sensors are deployed at key heat-generating points within the motor, such as the stator coils, core, and terminal blocks. This continuous data recording allows analysis of temperature rise rates, heat distribution paths, and heat source stability.

[0017] Continuously monitor the current temperature of key components in the air cooling system, such as the motor housing, air ducts, and fan outlets. The air cooling structure includes the fan, air duct, directional air ducts, heat dissipation ribs, and the thermally conductive material of the housing. Real-time temperature data can reflect the actual performance of the cooling system under different environmental and load conditions.

[0018] S2: configuring a structural optimization strategy of the air-cooled heat dissipation structure based on the heat dissipation data generated by multi-operating condition data records to obtain a primary optimization strategy.

[0019] Specifically, the motor operating data and corresponding heat dissipation performance collected under different operating conditions are used to analyze the structural factors that affect heat dissipation efficiency and develop specific improvement methods. Multi-operating condition data records include data such as current, voltage, temperature, and speed of the motor under operating conditions such as startup, acceleration, constant speed, high load, and low load, reflecting the heat load distribution and cooling requirements of the motor under various operating conditions. After combining the operating data with the real-time temperature data, heat dissipation data can be generated. Through heat dissipation data analysis, the impact of different structural parameters (such as fan angle, duct shape, and casing material) on heat conduction and air flow can be clarified, and then specific plans to optimize these structures, namely structural optimization strategies, can be formulated.

[0020] Structural optimization strategies encompass multiple aspects, such as adjusting the layout of air ducts based on heat flow paths to prioritize high-heat zones as they flow through the motor; optimizing the number and angle of fan blades to increase airflow while maintaining the same power; and adding thermal diffusion material to high-temperature areas of the motor housing to improve heat transfer efficiency, resulting in a primary optimization strategy. This primary optimization strategy emphasizes making small but effective adjustments to the existing air-cooling structure. It doesn't require a complete structural replacement or significant assembly modifications. Instead, it aims to improve cooling performance by increasing ventilation efficiency, optimizing heat conduction paths, and reducing airflow resistance.

[0021] S3: performing heat dissipation optimization on the air-cooling heat dissipation structure according to the real-time temperature and the heat dissipation data to obtain an intermediate optimization strategy.

[0022] Specifically, the currently collected temperature information and historical heat dissipation performance data are used to jointly drive the dynamic adjustment of the heat dissipation system. Real-time temperature refers to the actual temperature value collected from various key parts of the motor at the current moment, such as the stator winding temperature, the core temperature or the surface temperature of the motor housing. Heat dissipation data refers to a database formed based on the relationship between heat release and cooling capacity under various working conditions in the past, including parameters such as heat load, air flow, temperature rise rate, cooling efficiency, etc., which are used to evaluate the cooling capacity of the air-cooled structure under specific conditions. By comparing whether the current temperature is in a high temperature zone or changes too quickly, a matching relationship is established with past experience data, and corresponding fan adjustment, air duct switching or shell auxiliary heat dissipation strategies are executed to improve the overall cooling effect, and an intermediate optimization strategy is obtained to form a thermal management solution that is smarter and more responsive than primary structural optimization.

[0023] S4: Obtain a heat dissipation optimization result by evaluating the energy-saving effect obtained through the primary optimization strategy and the intermediate optimization strategy.

[0024] Specifically, the energy consumption reduction generated by the optimization of the cooling system at different levels is measured and compared to determine the actual effect of each strategy. The primary optimization strategy comes from structural design improvements, such as optimizing the shape of fan blades, improving the guide path of the air duct, and strengthening the air guide structure of the motor housing. The intermediate optimization strategy dynamically adjusts the cooling behavior based on real-time operating data, such as real-time control of fan speed, adjustment of air volume corresponding to temperature changes, and whether to enable backup air guide channels. The operating energy consumption before and after optimization is recorded by energy consumption sensors and data acquisition modules, and a comprehensive analysis is performed based on indicators such as temperature rise efficiency, fan start and stop frequency, and motor surface temperature drop rate.

[0025] Furthermore, the present application also includes: structurally optimizing the blade angle, blade number and blade spacing of the fan blades in the air-cooled heat dissipation structure based on the heat dissipation data to obtain a fan blade structure optimization strategy; setting a directional air duct in the air-guide duct in the air-cooled heat dissipation structure based on the heat dissipation data to obtain an air-guide duct structure optimization strategy; forming an air-cooled linkage structure with the motor housing and the directional air duct in the air-cooled heat dissipation structure based on the heat dissipation data to obtain a motor housing structure optimization strategy; combining the fan blade structure optimization strategy, the air-guide duct structure optimization strategy and the motor housing structure optimization strategy to obtain a primary optimization strategy.

[0026] Specifically, the cooling effect data such as temperature and airflow distribution collected from the motor under different operating conditions are used to adjust the geometric parameters of the fan blades to improve the fan's air supply efficiency at a specific power. The blade angle affects the angle of air cutting, which in turn determines the speed and direction of the wind; the number of blades affects the continuity and stability of the air volume per unit time; and the blade spacing determines the degree of airflow disturbance and the smoothness of exhaust. By optimizing multiple parameters of the fan blades, such as adjusting the blade angle from 30 degrees to 35 degrees, increasing the number of blades from 5 to 7, and reducing the spacing by 1 mm, the air volume can be increased by about 15% at the same power input, while reducing noise and energy consumption, thus forming a fan blade structure optimization strategy.

[0027] Based on the temperature change trends and wind flow distribution data of different parts of the motor, special wind flow channels are designed in the air duct system to allow wind energy to flow preferentially through the areas with the highest heat generation. Directional air ducts are winds that are artificially guided through specific paths to key heat dissipation areas, such as the ends of the motor coils, the iron core, and the controller module. This can be achieved through built-in baffles, air duct corners, or air guides. For example, if a wind direction guide with a 45-degree bending angle is installed in the motor end cover area, the air flow originally diffused in the motor casing can be refocused above the coil, increasing the cooling rate in this area by 30%, thereby forming an optimization strategy for the air duct structure.

[0028] By analyzing the matching of temperature and airflow, the shape or material of the motor housing is redesigned so that it not only plays a mechanical protection role, but also participates in the heat dissipation process and works in conjunction with the air duct. The air-cooling linkage structure includes surface heat dissipation ribs, embedded thermal conductive materials (such as graphite sheets or aluminum alloy inner layers), thermal conductive adhesive, etc., which structurally cooperate with the directional air duct to form a convection path. For example, the original smooth shell is changed to a corrugated surface with 10 mm high heat dissipation ribs, and thermal conductive sheets are added to the area in contact with the air duct. This can make the heat transfer from the inside of the motor to the surface more quickly, while using the airflow to carry away the heat, ultimately forming a motor housing structure optimization strategy.

[0029] The fan blade structure optimization strategy, the air duct structure optimization strategy and the motor housing structure optimization strategy are combined to build a unified and coordinated cooling system, which is the primary optimization strategy.

[0030] Furthermore, the present application also includes: monitoring the inflow wind flow and outflow wind flow of the directional air duct, if the inflow wind flow is lower than the inflow wind flow threshold, setting an inlet wind structure at the directional air duct, if the outflow wind flow is lower than the outflow wind flow threshold, setting an outlet wind structure at the directional air duct.

[0031] Specifically, wind speed sensors, differential pressure gauges, or hot-film airflow monitors are used to monitor the air volume at the duct inlet and outlet in real time. Air flow represents the volume of gas passing through a certain cross-section per unit time and is used to assess whether the airflow is smooth and the duct is effectively ventilated. Directional ducts are pre-set air passages used to direct air to high-heat source areas within the motor, making the cooling process more efficient. Monitoring air flow helps determine whether the duct is blocked, whether the air pressure is too low, or whether the airflow is uniform, thereby determining whether structural intervention is needed.

[0032] When it is detected that the speed or total amount of wind entering the air duct from the outside is less than the set minimum standard value, an auxiliary structure needs to be designed at the entrance of the air duct to enhance the air intake capacity. The inflow air flow threshold is a control baseline. For example, if it is set to 80 liters per minute, if it is actually only 60 liters per minute, it means that the air intake is blocked or the fan capacity is insufficient. The wind introduction structure can adopt designs such as external air inlets, air guide cones, and air outlet expansion sections to guide more external air into the air duct, thereby supplementing the insufficient cooling air volume. For example, when an electric vehicle is driving at a low speed, due to the low headwind pressure caused by the vehicle speed, an air collection trough can be added to the lower part of the front of the vehicle to increase the air intake flow to 90 liters per minute.

[0033] When it is detected that the air discharge speed or volume at the air duct outlet is lower than the standard requirements, a structure for guiding exhaust should be added at the end of the air duct to improve the condition of poor exhaust. The outflow air flow threshold is also a set minimum value, for example, 100 liters per minute. If the actual discharge is only 70 liters per minute, it means that the internal air flow may be stagnant, resulting in heat not being taken away in time. The outflow air structure usually includes a contraction-type air duct outlet, an accelerating diffuser, an air outlet guide cover and other forms, which use the fluid guiding effect and the outlet diffusion principle to promote the rapid outflow of wind from the system. For example, changing the air duct outlet from a straight pipe to a tapered contraction section can increase the wind speed by 20% without increasing the fan power, helping to discharge hot air in time.

[0034] Furthermore, the present application also includes: collecting the multi-operating condition data records and thermal data records; performing thermal prediction based on the thermal data records and corresponding thermal data time records to obtain thermal data curve records; and obtaining the heat dissipation data according to the thermal data curve records.

[0035] Specifically, the system acquires relevant operating parameters and temperature data in real time under various motor operating conditions, including high speed, low speed, acceleration, deceleration, full load, and light load. Multi-condition data logging includes information related to motor load, such as current, voltage, speed, and power. Thermal data logging refers to temperature information measured under each operating condition, such as stator temperature, winding temperature, and housing surface temperature. By collecting data under various operating conditions, a thermal response database covering all operating conditions can be established, providing a rich data source for subsequent analysis and prediction.

[0036] By combining each temperature data point with its corresponding time point, a time-temperature relationship is established, allowing predictions of temperature trends over time. A thermal data time record refers to the timestamp associated with each set of temperature data. Thermal prediction involves predicting the temperature changes of various motor components at a specific moment or stage in the future. A thermal data curve record is a graph plotted with time on the horizontal axis and temperature on the vertical axis, depicting the process of heat accumulation or dissipation.

[0037] By analyzing the time-temperature curve, we can infer the motor's heat dissipation capacity and effectiveness under different operating conditions. This heat dissipation data includes indicators such as the rate of temperature drop per unit time, the relative contribution of different components to heat dissipation, and the impact of ambient temperature on cooling efficiency. This helps determine whether the air-cooling system's thermal management performance meets standards under its current structure and operating conditions.

[0038] Furthermore, the present application also includes: identifying the real-time temperature based on the thermal data curve record, judging whether the critical temperature has been reached based on the identified thermal data and the corresponding identified operating condition parameters, and obtaining a critical temperature judgment result; and performing active heat dissipation control and passive heat dissipation control of the air-cooled heat dissipation structure according to the critical temperature reaching result and the non-critical temperature reaching result in the critical temperature reaching judgment result, respectively, to obtain the intermediate optimization strategy.

[0039] Specifically, the temperature change over time in the thermal data curve is used to analyze the actual temperature status of the motor at the current moment in operation. The thermal data curve records the relationship between time and temperature generated from the collected data, reflecting the thermal response of the motor under different operating conditions. By comparing the current temperature data with the existing thermal data curve in real time, it is determined whether the current temperature is experiencing abnormal fluctuations or approaching a critical point.

[0040] Based on the temperature value and the motor's operating state, it is determined whether the critical thermal risk point has been reached. Identified thermal data refers to the measured and identified operating parameters, including variables such as motor speed, load, and ambient temperature. The critical temperature refers to the maximum safe temperature that the motor components can withstand under these operating conditions. For example, under high-speed and heavy-load conditions, the critical temperature of the winding may be 120 degrees Celsius, while under light load conditions it may be 110 degrees Celsius.

[0041] Different cooling strategies are implemented depending on whether the temperature is approaching a critical level. Reaching a critical level indicates that the temperature is about to exceed the acceptable range, triggering proactive cooling controls such as increasing fan speed, activating auxiliary airflow, and forcibly reducing the load. A non-critical level indicates that the temperature is still within a safe range, and reactive cooling controls can be implemented, such as maintaining a low fan speed or suspending cooling operations to save energy.

[0042] Combining criticality judgment with corresponding control strategies creates a dynamically adjusted air cooling control solution, known as the intermediate optimization strategy. This not only improves heat dissipation efficiency through structural optimization, but also adapts to the motor's thermal characteristics during actual operation through intelligent judgment and proactive control, ensuring operation within the safe zone while minimizing energy consumption.

[0043] Furthermore, the present application also includes: if the critical judgment result is a critical result, active heat dissipation control of the fan operation is performed, wherein the critical result includes reaching the first critical and reaching the second critical; based on the fan operation reaching the first critical and reaching the second critical, the fan operation time is calculated; based on the fan operation time, the fan operation energy consumption reaching the first critical and reaching the second critical is calculated; the fan operation energy consumption reaching the first critical and reaching the second critical is compared with the energy consumption of the temperature rise efficiency loss of the passive heat dissipation control reaching the first critical, and the fan operation energy consumption reaching the second critical and the energy consumption of the temperature rise efficiency loss of the passive heat dissipation control reaching the second critical, respectively, to obtain a first comparison result and a second comparison result; active heat dissipation control is performed based on the smaller energy consumption of the first comparison result and the second comparison result.

[0044] Specifically, when it is identified that the current temperature is close to or exceeds the thermal limit allowed for motor operation, the fan's high-efficiency operation mode is immediately started to enhance heat dissipation capacity. Reaching the critical result means that the temperature curve has exceeded the set warning threshold. In order to prevent further temperature rise from damaging the winding insulation, magnetic materials or other key components, the heat dissipation device must be actively turned on. Active heat dissipation control refers to taking proactive measures to increase the heat dissipation effect, such as increasing the fan speed, opening the backup air duct, increasing the radiator power, etc. Criticality is further subdivided into two levels, namely reaching the first criticality and reaching the second criticality. The first criticality is a lower-risk warning temperature point, such as 100 degrees Celsius, and the second criticality is a temperature point closer to the material's safety upper limit, such as 115 degrees Celsius, representing a higher risk level.

[0045] Record the time interval from fan startup to fan shutdown at two different criticality levels. Run time, typically measured in seconds or minutes, is an important baseline for assessing fan load levels. For example, at the first criticality, a fan might run for 300 seconds, while at the second criticality, it might run for 600 seconds to ensure effective heat removal. Run time can be used to further estimate energy consumption and evaluate the economic viability of control strategies.

[0046] Multiply the run time by the fan's power to calculate energy consumption. Fan operation energy consumption, measured in watt-hours or kilowatt-hours, reflects the power consumption of the control behavior. For example, if the fan power is 50 watts, running for 300 seconds at the first critical threshold consumes 4.17 watt-hours, while running for 600 seconds at the second critical threshold consumes 8.33 watt-hours. This is used for energy efficiency comparison with other control methods.

[0047] The economic benefits of the two control methods were quantitatively analyzed. The fan operating energy consumption at the first critical threshold was compared with the energy consumption due to the temperature rise efficiency loss of passive cooling control at the first critical threshold, and the fan operating energy consumption at the second critical threshold was compared with the energy consumption due to the temperature rise efficiency loss of passive cooling control at the second critical threshold, resulting in the first and second comparison results. Passive cooling control typically involves running the fan at a low speed or not running it to reduce energy consumption. However, heat generated by passive cooling control cannot be dissipated in a timely manner, resulting in a temperature rise, which in turn requires more energy to cool the entire system or maintain performance. Energy consumption due to temperature rise efficiency loss refers to the energy expenditure indirectly caused by this temperature rise, such as decreased motor efficiency requiring more input power for the same output. Assuming that passive control results in an additional power consumption of 6 watt-hours at the first critical threshold, while active control only results in 4.17 watt-hours, the first comparison result indicates that active control is more energy-efficient. A similar conclusion is drawn if the cost of passive control is 10 watt-hours at the second critical threshold, while active control costs 8.33 watt-hours.

[0048] If the energy consumption of active control is lower than the energy loss caused by passive control at the first critical threshold, the fan speed is increased to achieve faster cooling. If passive control is found to be more advantageous at a certain critical threshold, fan operation is suppressed to save power. The final control logic is based on a comparison of actual energy consumption results, avoiding the waste of resources caused by blindly overcooling or overheating. Table 1 shows the most recent data record of the cooling control strategy, comparing the energy consumption of fan operation and passive control under different critical conditions, and selecting the less energy-consuming option for active cooling control.

[0049] Table 1: Data record of the most recent thermal control strategy

[0050] Furthermore, the present application also includes: performing active heat dissipation control for the fan to run at low speed based on the reaching of the first critical value; performing active heat dissipation control for the fan to run at high speed based on the reaching of the second critical value; calculating the temperature rise trend based on the identified thermal data; identifying the temperature rise trend through a temperature rise threshold, and if the identified thermal data is within the reaching critical result and the temperature rise trend is within the temperature rise threshold, performing active heat dissipation control for the fan to run at accelerated speed.

[0051] Specifically, when the motor temperature reaches the system's first critical temperature, the fan is actively controlled to run at a lower speed, thereby initiating active heat dissipation. The first critical temperature is the initial point of temperature rise, typically triggered when the motor is not yet overheating but is showing signs of heating up. Low-speed operation means the fan output is low, for example, controlling the speed to around 1000 rpm. The main purpose is to save energy while preventing the temperature from rising further.

[0052] If the motor temperature continues to rise and reaches the second critical temperature, the fan speed is immediately increased to accelerate the cooling process. This second critical temperature indicates the high-temperature risk zone. If heat is not quickly dissipated, performance degradation or damage may occur. High-speed operation generally refers to increasing the fan speed to 3000 rpm or higher, which increases the corresponding air volume and quickly removes heat, suppressing further temperature increases.

[0053] Calculating temperature rise trends based on identified thermal data means analyzing the rate of temperature change over time from collected temperature data, i.e., the temperature rise trend per unit time. This temperature rise trend helps to identify the possibility of thermal runaway in advance.

[0054] Identifying temperature rise trends using temperature rise thresholds involves comparing the actual temperature rise trend with the set threshold to determine whether a dangerous temperature rise has occurred. If the identified thermal data falls within the critical range and the temperature rise trend is within the threshold, active cooling control, such as fan acceleration, is implemented. This indicates that the current temperature has reached a critical level but the rate of temperature rise has not exceeded the warning value. Therefore, a compromise approach, such as increasing the fan speed to 2000 rpm, can be used to accelerate cooling while keeping energy consumption within a reasonable range.

[0055] Furthermore, the present application also includes: extracting equivalent working conditions based on the multi-working condition data records; under the equivalent working conditions, fitting the thermal data and corresponding thermal data time of the intermediate optimization strategy to obtain a thermal data curve; performing energy efficiency evaluation on the thermal data curve based on the thermal data curve records to obtain an intermediate energy-saving effect.

[0056] Specifically, the system selects datasets with similar operating conditions from a large amount of recorded flat-wire motor operating data. For example, within a vehicle's operating records under different speeds, loads, and currents, a set of criteria is used to extract data under parameters such as a fixed speed of 60 kilometers per hour, a constant load of 500 kilograms, and a stable motor current of 40 amperes. These data are then used to eliminate interfering variables, ensuring more accurate subsequent analysis.

[0057] Under the same operating conditions, calculate the motor's temperature rise trend over time. Thermal data refers to a series of temperature changes over time. Thermal data is obtained by collecting temperature data at specific time points. A smooth curve, such as a polynomial fit or spline curve, is generated through mathematical fitting to describe the motor's thermal response characteristics under intermediate optimization strategies.

[0058] Based on the fitted curve, the relationship between the heat dissipation resources used during the thermal response and the ability to control temperature rise is analyzed. Energy efficiency evaluation involves calculating the energy required for a unit temperature reduction, or the amount of heat removed by a fan per watt of power used.

[0059] Furthermore, the present application also includes: extracting equivalent working conditions based on the multi-working condition data records; under the equivalent working conditions, performing energy efficiency evaluation on the primary optimization strategy based on fan working time, motor operating power, and real-time temperature to obtain primary energy-saving effects.

[0060] Specifically, the historical data covering multiple operating conditions are screened out to identify those with consistent characteristics, such as operating conditions with similar parameters such as speed, current, load, or external ambient temperature, so that different cooling strategies can be compared and analyzed under similar conditions.

[0061] Under the same operating conditions, the energy efficiency of the primary optimization strategy is evaluated using fan operating time, motor operating power, and real-time temperature to measure the energy-saving effect of the primary optimization strategy. Fan operating time refers to the total length of time the fan actually runs under this strategy, such as the time required from the start of operation to the temperature dropping to the target value. Motor operating power measures the load intensity of the motor itself under this operating condition, and real-time temperature indicates whether the system heat dissipation meets the standard. Combining these three factors can calculate the efficiency of temperature change per unit time under unit power conditions, and then evaluate the energy efficiency of the heat dissipation strategy. For example, if the fan runs continuously for 60 seconds, the motor maintains a power output of 20 kilowatts, and the temperature is stabilized below 65 degrees Celsius, compared with the original solution, 10 seconds of fan operating time is saved and the temperature is reduced by 5 degrees Celsius.

[0062] In summary, the air-cooling heat dissipation structure optimization method of the energy-saving flat wire motor provided in this application has the following technical effects: by realizing the technical goals of intelligent optimization and dynamic regulation of the air-cooling heat dissipation structure, the technical effects of improving the heat dissipation efficiency of the motor, extending the service life, reducing overall energy consumption and improving the system operation stability are achieved.

[0063] In the second embodiment, based on the same inventive concept as the air-cooling heat dissipation structure optimization method of the energy-saving flat wire motor in the above embodiment, the present application also provides an air-cooling heat dissipation structure optimization system for the energy-saving flat wire motor, please refer to the attached Figure 2 , including: a temperature acquisition module 11, used to collect the operating thermal load characteristics of the flat wire motor and obtain the real-time temperature of the air-cooled heat dissipation structure; a primary optimization strategy acquisition module 12, used to configure the structural optimization strategy of the air-cooled heat dissipation structure based on the heat dissipation data generated by multi-working condition data records, and obtain the primary optimization strategy; an intermediate optimization strategy acquisition module 13, used to perform heat dissipation optimization on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data, and obtain the intermediate optimization strategy; a strategy evaluation module 14, used to obtain the heat dissipation optimization result through the energy-saving effect evaluated by the primary optimization strategy and the intermediate optimization strategy.

[0064] Furthermore, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: structurally optimize the blade angle, blade number and blade spacing of the fan blades in the air-cooling heat dissipation structure based on the heat dissipation data to obtain a fan blade structure optimization strategy; set a directional air duct in the air guide duct in the air-cooling heat dissipation structure based on the heat dissipation data to obtain an air guide duct structure optimization strategy; form an air-cooling linkage structure with the motor housing and the directional air duct in the air-cooling heat dissipation structure based on the heat dissipation data to obtain a motor housing structure optimization strategy; combine the fan blade structure optimization strategy, the air guide duct structure optimization strategy and the motor housing structure optimization strategy to obtain a primary optimization strategy.

[0065] Furthermore, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: monitor the inflow air flow and outflow air flow of the directional air duct; if the inflow air flow is lower than the inflow air flow threshold, an inlet air structure is set at the directional air duct; if the outflow air flow is lower than the outflow air flow threshold, an outlet air structure is set at the directional air duct.

[0066] Furthermore, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: collect the multi-working condition data records and thermal data records; perform thermal prediction based on the thermal data records and the corresponding thermal data time records to obtain thermal data curve records; and obtain the heat dissipation data according to the thermal data curve records.

[0067] Furthermore, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: identify the real-time temperature based on the thermal data curve record, judge whether the critical temperature is reached according to the identified thermal data and the corresponding identified operating condition parameters, and obtain a critical judgment result; according to the critical result and the non-critical result in the critical judgment result, perform active heat dissipation control and passive heat dissipation control of the air-cooled heat dissipation structure respectively, and obtain the intermediate optimization strategy.

[0068] Furthermore, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is also used for: if the critical judgment result is a critical result, performing active heat dissipation control of the fan operation, wherein the critical result includes reaching the first critical and reaching the second critical; calculating the fan operation time based on the fan operation reaching the first critical and reaching the second critical; calculating the fan operation energy consumption reaching the first critical and reaching the second critical based on the fan operation time; comparing the fan operation energy consumption reaching the first critical and the energy consumption of the temperature rise efficiency loss of the passive heat dissipation control reaching the first critical, and the fan operation energy consumption reaching the second critical and the energy consumption of the temperature rise efficiency loss of the passive heat dissipation control reaching the second critical, respectively, to obtain a first comparison result and a second comparison result; performing active heat dissipation control based on the smaller energy consumption of the first comparison result and the second comparison result.

[0069] Furthermore, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: perform active heat dissipation control of the fan running at low speed based on the reaching of the first critical point; perform active heat dissipation control of the fan running at high speed based on the reaching of the second critical point; calculate the temperature rise trend based on the identified thermal data; identify the temperature rise trend through a temperature rise threshold, and if the identified thermal data is within the reaching critical result and the temperature rise trend is within the temperature rise threshold, perform active heat dissipation control of the fan accelerating operation.

[0070] Furthermore, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: extract the same working conditions based on the multi-working condition data records; under the same working conditions, fit the thermal data and corresponding thermal data time of the intermediate optimization strategy to obtain a thermal data curve; perform energy efficiency evaluation on the thermal data curve according to the thermal data curve records to obtain an intermediate energy-saving effect.

[0071] Furthermore, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is also used to: extract the same working conditions based on the multi-working condition data records; under the same working conditions, the primary optimization strategy is energy-efficiently evaluated based on the fan working time, motor operating power, and real-time temperature to obtain a primary energy-saving effect.

[0072] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The air-cooling and heat dissipation structure optimization method and specific examples of the energy-saving flat wire motor in the aforementioned embodiment 1 are also applicable to the air-cooling and heat dissipation structure optimization system of the energy-saving flat wire motor in this embodiment. Through the aforementioned detailed description of the air-cooling and heat dissipation structure optimization method of the energy-saving flat wire motor, those skilled in the art can clearly understand the air-cooling and heat dissipation structure optimization system of the energy-saving flat wire motor in this embodiment, so for the sake of brevity of the specification, it will not be described in detail here.

[0073] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

[0074] Obviously, those skilled in the art may make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the present application and its equivalents, the present application is intended to include these modifications and variations.

Claims

1. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor is characterized in that: include: Collect the operating thermal load characteristics of the flat wire motor and obtain the real-time temperature of the air-cooling heat dissipation structure; Based on the heat dissipation data generated by the multi-operating condition data records, a structural optimization strategy of the air-cooled heat dissipation structure is configured to obtain a primary optimization strategy; Performing heat dissipation optimization on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data to obtain an intermediate optimization strategy; The heat dissipation optimization result is obtained by evaluating the energy-saving effect obtained through the primary optimization strategy and the intermediate optimization strategy.

2. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 1, characterized in that: Get the primary optimization strategy, including: Based on the heat dissipation data, the fan blade angle, the number of blades and the blade spacing of the fan blades in the air-cooled heat dissipation structure are structurally optimized to obtain a fan blade structure optimization strategy; Based on the heat dissipation data, a directional air duct is set in the air guide duct of the air cooling heat dissipation structure to obtain an air guide duct structure optimization strategy; Based on the heat dissipation data, an air-cooling linkage structure is formed between the motor housing and the directional air duct in the air-cooling heat dissipation structure, and an optimization strategy for the motor housing structure is obtained; The fan blade structure optimization strategy, the air guide duct structure optimization strategy and the motor housing structure optimization strategy are combined to obtain a primary optimization strategy.

3. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 2, characterized in that: Monitor the inflow and outflow of the directional air duct. If the inflow is lower than the inflow threshold, set an inlet wind structure at the directional air duct. If the outflow is lower than the outflow threshold, set an outlet wind structure at the directional air duct.

4. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 1, wherein: Generate thermal data, including: collecting the multi-operating condition data records and thermal data records; Performing thermal prediction based on the thermal data record and the corresponding thermal data time record to obtain a thermal data curve record; The heat dissipation data is obtained according to the thermal data curve record.

5. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 4, characterized in that: Get intermediate optimization strategies, including: Identifying the real-time temperature based on the thermal data curve record, determining whether the critical temperature has been reached according to the identified thermal data and the corresponding identified operating condition parameters, and obtaining a critical temperature reaching determination result; According to the critical reaching result and the non-critical reaching result in the critical reaching judgment result, active heat dissipation control and passive heat dissipation control of the air-cooling heat dissipation structure are respectively performed to obtain the intermediate optimization strategy.

6. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 5, characterized in that: Active thermal controls, including: If the critical value judgment result is a critical value, active heat dissipation control of the fan operation is performed, wherein the critical value includes a first critical value and a second critical value; Calculating the fan operation time based on the fan operation reaching the first threshold and the fan operation reaching the second threshold; Calculating the fan operation energy consumption reaching the first critical value and the fan operation energy consumption reaching the second critical value according to the fan operation time; Comparing the fan operation energy consumption reaching a first critical value and the energy consumption due to the temperature rise efficiency loss of the passive heat dissipation control reaching the first critical value, and the fan operation energy consumption reaching a second critical value and the energy consumption due to the temperature rise efficiency loss of the passive heat dissipation control reaching the second critical value, respectively, to obtain a first comparison result and a second comparison result; Active heat dissipation control is performed based on the lower energy consumption of the first comparison result and the second comparison result.

7. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 6, characterized in that: Active thermal control also includes: According to the reaching of the first critical value, active heat dissipation control is performed by running the fan at a low speed; According to the reaching of the second critical value, active heat dissipation control is performed by running the fan at a high speed; calculating a temperature rise trend based on the identified thermal data; The temperature rise trend is identified by a temperature rise threshold, and if the identified thermal data is within the critical result and the temperature rise trend is within the temperature rise threshold, active heat dissipation control is performed by accelerating the fan operation.

8. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 4, wherein: Achieve energy-saving effects, including: Extracting the same working conditions according to the multi-working condition data records; Under the same working conditions, fitting the thermal data of the intermediate optimization strategy and the corresponding thermal data time to obtain a thermal data curve; An energy efficiency evaluation is performed on the thermal data curve according to the thermal data curve record to obtain an intermediate energy saving effect.

9. The method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to claim 1, wherein: Energy saving effects also include: Extracting equivalent working conditions based on the multiple working condition data records; Under the same working conditions, the energy efficiency of the primary optimization strategy is evaluated based on the fan working time, motor operating power, and real-time temperature to obtain a primary energy-saving effect.

10. The air cooling and heat dissipation structure optimization system of the energy-saving flat wire motor is characterized by: The steps for implementing the method for optimizing the air-cooling heat dissipation structure of an energy-saving flat wire motor according to any one of claims 1 to 9 include: The temperature acquisition module is used to collect the operating thermal load characteristics of the flat wire motor and obtain the real-time temperature of the air-cooled heat dissipation structure; A primary optimization strategy obtaining module is used to configure the structural optimization strategy of the air-cooled heat dissipation structure based on the heat dissipation data generated by multi-operating condition data records to obtain the primary optimization strategy; An intermediate optimization strategy obtaining module, configured to perform heat dissipation optimization on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data, and obtain an intermediate optimization strategy; The strategy evaluation module is used to obtain the heat dissipation optimization result by evaluating the energy-saving effect obtained by the primary optimization strategy and the intermediate optimization strategy.

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