Energy-saving flat wire motor air cooling heat dissipation structure optimization method and system

Abstract

The application provides an energy-saving flat wire motor air-cooled heat dissipation structure optimization method and system, relates to the technical field of energy-saving motors, and comprises the following steps: collecting the operation heat load characteristics of the flat wire motor, and obtaining the real-time temperature of the air-cooled heat dissipation structure; generating a heat dissipation data configuration structure optimization strategy of the air-cooled heat dissipation structure based on multi-working condition data records, and obtaining 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, and obtaining 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. The application can solve the technical problems of low heat dissipation efficiency, high energy consumption and serious local temperature rise in the prior art, which affect the operation stability, service life of the flat wire motor under multiple working conditions and the energy efficiency performance of the overall system, achieve the technical goal of air-cooled heat dissipation structure optimization and dynamic control, and achieve the technical effect of improving the motor heat dissipation efficiency and reducing the overall energy consumption.

Description

TECHNICAL FIELD

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

[0002] With the wide application of new energy vehicles, intelligent manufacturing equipment and high-performance electric drive systems, flat wire motors gradually become one of the mainstream drive motors due to their high power density, compact structure and strong heat dissipation capacity. In particular, in high heat load scenarios such as electric vehicles, flat wire motors are tasked with long-term high-efficiency operation, which puts higher requirements on their heat dissipation performance. The current commonly used wind-cooling heat dissipation method has certain forced convection cooling capacity, but still has many limitations and bottlenecks in actual application.

[0003] At present, in the prior art, the fan structure is mostly fixed design, and the blade angle and number are not dynamically matched according to the actual operation status of the motor, resulting in low wind energy utilization efficiency. Secondly, the air guide path layout is unreasonable, and some key heat sources such as stator cores or winding surfaces cannot be fully cooled, forming local heat accumulation. In addition, in some systems, the fan lacks fine control when it is turned on and off, and often adopts a one-size-fits-all approach based on preset thresholds, which cannot accurately adapt to changes in the thermal load of the motor, and is prone to energy waste or heat dissipation lag. Under special working conditions such as congestion and low speed, the cooling air speed is insufficient, and the heat dissipation effect decreases sharply, causing the motor to work at a high temperature for a long time, affecting the service life and efficiency. Furthermore, the prior art lacks a mechanism for real-time monitoring of air flow in the air duct, and cannot determine whether the air duct is blocked and whether the heat dissipation is evenly distributed according to the difference between the inflow and outflow air speeds. Finally, in terms of strategy development, the current heat dissipation optimization is mostly based on experience rules or single-condition testing, lacking dynamic feedback and predictive analysis means for multi-condition data, and cannot form targeted and responsive optimization schemes. Therefore, it is urgent to propose a flat wire motor wind-cooling heat dissipation structure optimization method based on data driving, flexible and adjustable structure, perfect air flow monitoring and energy-saving control capability, to solve the problems of low energy efficiency, slow response and poor adaptability in traditional technology, and to improve the overall operation stability and energy-saving effect of the motor. SUMMARY

[0004] The purpose of the present application is to provide a wind-cooling heat dissipation structure optimization method and system for energy-saving flat wire motors, to solve the technical problems in the prior art that the fan structure is fixed, the air guide path is unreasonable, and there is a lack of real-time air flow monitoring and dynamic control strategy, resulting in low heat dissipation efficiency, high energy consumption and serious local temperature rise, which further affects the operation stability, service life and overall energy efficiency of the flat wire motor under multi-condition.

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

[0006] In a first aspect, the application provides an energy-saving flat wire motor air-cooled heat dissipation structure optimization method, which is realized by an energy-saving flat wire motor air-cooled heat dissipation structure optimization system, comprising: collecting the operating thermal load characteristics of the flat wire motor to obtain the real-time temperature of the air-cooled heat dissipation structure; generating a heat dissipation data configuration of the structure optimization strategy of the air-cooled heat dissipation structure based on the multi-working condition data record 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 a second aspect, the application also provides an energy-saving flat wire motor air-cooled heat dissipation structure optimization system for executing the energy-saving flat wire motor air-cooled heat dissipation structure optimization method of the first aspect, comprising: a temperature obtaining module for collecting the operating thermal load characteristics of the flat wire motor to obtain the real-time temperature of the air-cooled heat dissipation structure; a primary optimization strategy obtaining module for generating a heat dissipation data configuration of the structure optimization strategy of the air-cooled heat dissipation structure based on the multi-working condition data record to obtain a primary optimization strategy; an intermediate optimization strategy obtaining module for 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 a strategy evaluation module for obtaining a heat dissipation optimization result by evaluating the energy-saving effect obtained by the primary optimization strategy and the intermediate optimization strategy.

[0008] The technical solutions provided in the application have at least the following technical effects or advantages: by achieving the technical target 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, prolonging the service life, reducing the overall energy consumption and improving the system operation stability are achieved.

[0009] The above description is only a summary of the technical solutions of the application. In order to more clearly understand the technical means of the application, the following detailed description can be implemented according to the content of the description, and in order to make the above and other purposes, characteristics and advantages of the application more obvious and easy to understand, the following specific embodiments of the application are described. 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 application, nor is it intended to limit the scope of the application. Other features of the application will become apparent from the following description. BRIEF DESCRIPTION OF DRAWINGS

[0010] In order to more clearly illustrate the technical solutions in the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are only exemplary, and those skilled in the art can obtain other drawings according to the provided drawings without creating any creative labor.

[0011] Figure 1 Flowchart of the air-cooled heat dissipation structure optimization method of the energy-saving flat wire motor of the present application;

[0012] Figure 2 Structure diagram of the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor of the present application.

[0013] Legend: temperature acquisition module 11, primary optimization strategy obtaining module 12, intermediate optimization strategy obtaining module 13, strategy evaluation module 14. DETAILED DESCRIPTION

[0014] The present application provides an air-cooled heat dissipation structure optimization method and system for an energy-saving flat wire motor, which solves the technical problem in the prior art that due to fixed fan structure, unreasonable air guide path, lack of real-time air flow monitoring and dynamic control strategy, the heat dissipation efficiency is low, the energy consumption is high, and the local temperature rise is serious, which further affects the operation stability, service life and energy efficiency performance of the overall system of the flat wire motor under multiple working conditions. The technical goal of intelligent optimization and dynamic control of the air-cooled heat dissipation structure is achieved, and the technical effects of improving the heat dissipation efficiency of the motor, prolonging the service life, reducing the overall energy consumption and improving the system operation stability are achieved.

[0015] Hereinafter, the technical solutions in the present application will be described clearly and completely with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. It should be understood that the present application is not limited by the example embodiments described herein. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application. In addition, it should be noted that, for convenience of description, only parts related to the present application are shown in the drawings, not all.

[0016] Embodiment one, please refer to the accompanying Figure 1 The present application provides an air-cooled heat dissipation structure optimization method for an energy-saving flat wire motor, which is applied to an air-cooled heat dissipation structure optimization system for an energy-saving flat wire motor, and specifically includes the following steps:

[0017] S1: Collect the operating thermal load characteristics of the flat wire motor to obtain the real-time temperature of the air-cooled heat dissipation structure.

[0018] Specifically, collecting the operating thermal load characteristics of the flat wire motor refers to recording the heat generation caused by the current passing through the coil, electromagnetic changes, and mechanical friction during the motor's operation under load. Flat wire motors have more compact windings and higher current density per unit volume, so they generate heat faster. Thermal load is the heat generated and needs to be discharged per unit time, reflecting the heat intensity of the equipment under load. To accurately obtain the thermal load characteristics, multiple temperature, current, and voltage sensors are placed at key heat points inside the motor, such as the stator coil, core, and terminal end, to analyze the temperature rise speed, heat distribution path, and heat source stability by continuously recording data.

[0019] The current temperature of key components in the air cooling system, such as the motor housing, air guide channel, fan outlet, etc. is continuously monitored. The air cooling structure includes multiple parts such as fans, air guide covers, directional air ducts, heat dissipation ribs, and outer shell heat-conducting materials. Real-time temperature data can reflect the actual working effect of the cooling system under different environmental and load conditions.

[0020] S2: Based on the cooling data generated by multi-condition data recording, configure the structure optimization strategy for the air cooling structure, to obtain the primary optimization strategy.

[0021] Specifically, using the motor operating data and corresponding cooling performance collected under different operating conditions, the structural factors affecting cooling efficiency are analyzed, and specific improvement methods are developed. Multi-condition data recording includes current, voltage, temperature, speed, etc. data of the motor under start-up, acceleration, constant speed, high load, low load, etc. conditions, reflecting the thermal load distribution and cooling demand of the motor under various working conditions. After combining and processing the operating data with real-time temperature data, cooling data can be formed. Through cooling data analysis, the influence of different structural parameters (such as fan angle, air duct shape, shell material) on heat conduction and air flow can be determined, and specific solutions to optimize these structures, i.e. structure optimization strategy, can be developed.

[0022] The structure optimization strategy covers multiple aspects, such as adjusting the layout of the air guide channel according to the heat flow path, so that the air flows through the high-temperature area first when flowing through the motor; or optimizing the number and angle of fan blades to increase the air supply under the same power; or adding heat diffusion materials in the high-temperature area of the motor shell to improve heat transfer efficiency, to obtain the primary optimization strategy. The primary optimization strategy emphasizes small-scale but effective adjustments based on the current air cooling structure, without the need for overall structural replacement or significant modification of the assembly method. Instead, it improves cooling performance through increasing ventilation efficiency, optimizing heat conduction path, reducing air resistance, etc.

[0023] S3: Perform cooling optimization on the air cooling structure based on the real-time temperature and the cooling data, to obtain the intermediate optimization strategy.

[0024] Specifically, the current 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 at the current time from each key part of the motor, such as stator winding temperature, core temperature or motor shell surface temperature. Heat dissipation data refers to a database formed based on the relationship between heat release and cooling capacity under multiple past working conditions, including thermal load, air flow, temperature rise speed, cooling efficiency and other parameters, for evaluating the cooling capacity of the air cooling structure under a specific state. 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, so that corresponding fan adjustment, air duct switching or shell auxiliary cooling strategies are executed to improve the overall cooling effect, obtain a medium-level optimization strategy, and form a more intelligent and responsive thermal management scheme than the primary structure optimization.

[0025] S4: Obtain a heat dissipation optimization result based on the energy saving effect evaluated by the primary optimization strategy and the medium-level optimization strategy.

[0026] Specifically, the energy consumption reduction amplitude generated by the heat dissipation system after optimization at different levels is measured and compared to determine the actual effect of each strategy. The primary optimization strategy is derived from structural design improvements, such as fan blade shape optimization, air duct guide path improvement and motor shell air guide structure enhancement. The medium-level optimization strategy dynamically adjusts the heat dissipation behavior based on real-time operation data, such as real-time control of fan speed, air volume adjustment corresponding to temperature change, and whether to enable a standby air guide channel. The energy consumption sensor and data acquisition module record the operation energy consumption before and after optimization, and combine temperature rise efficiency, fan start-stop frequency and motor surface temperature drop rate to perform comprehensive analysis.

[0027] Further, the present application also includes: based on the heat dissipation data, performing structural optimization on the blade angle, blade number and blade spacing of the fan blades in the air-cooled heat dissipation structure to obtain a fan blade structure optimization strategy; based on the heat dissipation data, setting a directional air duct in the air guide duct of the air-cooled heat dissipation structure to obtain a directional air duct structure optimization strategy; based on the heat dissipation data, forming an air-cooled linkage structure between the motor shell and the directional air duct in the air-cooled heat dissipation structure to obtain a motor shell structure optimization strategy; combining the fan blade structure optimization strategy, the directional air duct structure optimization strategy and the motor shell structure optimization strategy to obtain a primary optimization strategy.

[0028] Specifically, the temperature and airflow distribution data collected by the motor under different operating conditions are used to adjust the geometric parameters of the fan blades to improve the air supply efficiency of the fan under a specific power. The blade angle affects the angle of air cutting, thereby determining the speed and flow 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 air disturbance and the smoothness of the exhaust air. 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 millimeter, the air volume can be increased by about 15% under the same power input, while reducing noise and energy consumption, thereby forming a fan blade structure optimization strategy.

[0029] According to the temperature variation trend and airflow distribution data of different parts of the motor, a special airflow channel is designed in the air duct system to make the wind flow through the area with the largest heat generation first. The directional air duct is a path through which the wind is artificially guided to the key heat dissipation parts, such as the end of the motor coil, the core, and the controller module, which can be achieved by built-in baffles, air duct corners, or air deflectors. For example, installing a 45-degree curved air direction guide piece in the motor end cover area can refocus the air flow that was originally diffused in the motor housing onto the coil above, increasing the cooling rate of this area by 30%, thereby forming a wind guide air duct structure optimization strategy.

[0030] By analyzing the temperature and airflow matching, the shape or material of the motor housing is redesigned so that it not only serves as a mechanical protection but also participates in the cooling process and works in coordination with the air duct. The air cooling linkage structure includes surface cooling ribs, embedded heat-conducting materials (such as graphite sheets or aluminum alloy inner layers), and heat-conducting glue, which form a convection path in structure in cooperation with the directional air duct. For example, changing the smooth housing to a corrugated surface with 10-millimeter-high cooling ribs and adding a heat-conducting sheet in the area contacting the air duct can make the heat transfer from the motor interior to the surface faster, and the airflow can carry away the heat, ultimately forming a motor housing structure optimization strategy.

[0031] Combining the fan blade structure optimization strategy, the wind guide air duct structure optimization strategy, and the motor housing structure optimization strategy, a unified and coordinated cooling system is constructed, which is the primary optimization strategy.

[0032] Further, the application also includes monitoring the inflow and outflow of the directional air duct, and if the inflow is lower than the inflow threshold, a wind import structure is set at the directional air duct, and if the outflow is lower than the outflow threshold, a wind export structure is set at the directional air duct.

[0033] Specifically, the air flow at the inlet and outlet of the air duct is detected in real time by devices such as wind speed sensors, differential pressure gauges, or hot film airflow monitors. Air flow represents the volume of gas passing through a certain cross section per unit time, which is used to evaluate whether the airflow is smooth and the air duct is effectively ventilated. The directional air duct is a pre-set air passage for guiding air to the high heat source area inside the motor, making the cooling process more efficient. Monitoring air flow helps determine whether the air duct is blocked, the air pressure is too low, and the airflow is uniform, so as to decide whether structural intervention is needed.

[0034] When the speed or total amount of air entering the air duct from the outside is detected to be less than the set minimum standard value, auxiliary structures need to be designed at the inlet of the air duct to enhance the air intake capacity. The inflow air flow threshold is a control baseline, for example, set at 80 liters per minute, if the actual value is only 60 liters per minute, it means that the air intake is blocked or the fan capacity is insufficient. The air inlet structure can adopt designs such as external air inlet, air guide cone, air inlet expansion section, etc. to guide more external air into the air duct, thereby supplementing the insufficient cooling air volume. For example, when the electric vehicle is running at low speed, the wind pressure caused by the vehicle speed is low, an air collection groove can be added at the lower part of the vehicle head to increase the air intake flow to 90 liters per minute.

[0035] When the air exhaust speed or volume at the outlet of the air duct is detected to be lower than the standard requirement, structures for guiding air exhaust should be added at the end of the air duct to improve the condition of poor air exhaust. The outflow air flow threshold is also a minimum value, for example, 100 liters per minute, if the actual exhaust is only 70 liters per minute, it means that the internal airflow may be stagnant, causing heat to be unable to be carried away in time. The air outlet structure usually includes conical contraction section, acceleration diffuser, air outlet guide cover, etc. to promote the rapid outflow of air from the system by using fluid guiding effect and outlet diffuser principle. For example, changing the straight pipe at the outlet of the air duct to a conical contraction section can increase the wind speed by 20% without increasing the fan power, helping to exhaust hot air in time.

[0036] Further, the application also includes: collecting the multi-working condition data records and the 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.

[0037] Specifically, when the motor is in different operating states, such as high speed, low speed, acceleration, deceleration, full load or light load, etc., real-time acquisition of relevant operating parameters and temperature data is performed. The multi-working condition data records include current, voltage, speed, power, etc. related to the load of the motor; the thermal data records refer to the temperature information measured under each working condition, such as stator temperature, winding temperature, shell surface temperature, etc. By collecting data in various working conditions, a thermal response database covering all working conditions can be established, thereby providing a rich data source for subsequent analysis and prediction.

[0038] Each piece of temperature data is combined with its corresponding time point to establish a time-temperature relationship, and then to predict the trend of temperature evolution over time. The thermal data time record refers to the time stamp corresponding to each set of temperature data collected, and the thermal prediction is to predict the temperature change of each part of the motor at a future time or in a certain operating phase. The thermal data curve record is a curve drawn with time as the horizontal axis and temperature as the vertical axis, which is used to express the process of heat accumulation or dissipation.

[0039] By analyzing the time-temperature change curve, the heat dissipation capacity and effect of the motor under different working conditions are deduced. The heat dissipation data includes the rate of temperature drop per unit time, the relative contribution of heat dissipation in different parts, the influence of environmental temperature on cooling efficiency, etc. to help judge whether the thermal management performance of the air cooling system under the current structure and operating state meets the standard.

[0040] Further, the present application also includes: identifying the real-time temperature based on the thermal data curve record, judging whether the critical temperature is reached according to the identified thermal data and corresponding identified working condition parameters, obtaining the critical reaching judgment result; according to the critical reaching result and the non-critical reaching result in the critical reaching judgment result, respectively performing positive heat dissipation control and negative heat dissipation control of the air cooling heat dissipation structure, and obtaining the intermediate optimization strategy.

[0041] Specifically, by the trend of temperature change over time in the thermal data curve, the temperature state of the motor in actual operation at the current time is analyzed. The thermal data curve record is the relationship curve between time and temperature generated by the collected data, which reflects the thermal response law of the motor under different working conditions. By comparing the current temperature data with the existing thermal data curve, it is judged whether the current temperature is in abnormal fluctuation or tends to be critical.

[0042] According to the numerical value of the temperature, whether the critical point of thermal risk is reached is judged in combination with the operating state of the motor. The identified thermal data refers to the data that has been measured and identified. The identified working condition parameters include motor speed, load, environmental temperature and other variables. The critical temperature refers to the maximum safe temperature that each component of the motor can withstand under the working condition. For example, in the high-speed heavy-load working condition, the critical temperature of the winding may be 120 degrees Celsius, and in the light-load state, it is 110 degrees Celsius.

[0043] According to whether the critical temperature has been approached, different cooling strategies are adopted. The critical reaching result means that the temperature is about to exceed the bearable range, at which time the positive heat dissipation control is triggered, such as increasing the fan speed, starting the auxiliary air duct, forcibly reducing the load, etc. The non-critical reaching result indicates that the temperature is still within the safe range, at which time the negative heat dissipation control can be performed, such as maintaining the low-speed operation of the fan or suspending the heat dissipation operation to save energy.

[0044] The criticality judgment is combined with the corresponding control strategy to form a dynamically adjusted air cooling control scheme, i.e. the intermediate optimization strategy. Not only is the heat dissipation efficiency improved through structural optimization, but also the thermal variation characteristics of the motor in actual operation are adapted through intelligent judgment and active control means to ensure that the motor operates within the safety zone while minimizing energy consumption.

[0045] Further, the application also includes: if the reaching criticality judgment result is a reaching criticality result, performing positive heat dissipation control of fan operation, wherein the reaching criticality result includes reaching a first criticality and reaching a second criticality; calculating fan operation time based on fan operation of the reaching first criticality and the reaching second criticality; calculating fan operation energy consumption of the reaching first criticality and the reaching second criticality according to the fan operation time; comparing the fan operation energy consumption of the reaching first criticality and the temperature rise efficiency loss energy consumption of the negative heat dissipation control of the reaching first criticality, and the fan operation energy consumption of the reaching second criticality and the temperature rise efficiency loss energy consumption of the negative heat dissipation control of the reaching second criticality, respectively, to obtain a first comparison result and a second comparison result; and performing positive heat dissipation control based on the smaller energy consumption in the first comparison result and the second comparison result, respectively.

[0046] Specifically, when it is identified that the current temperature has approached or exceeded the thermal limit allowed for motor operation, a high-efficiency operation mode of the fan is immediately started to enhance the heat dissipation capacity. The reaching criticality result means that the temperature curve has broken through the set warning threshold, and in order to prevent further temperature rise from causing damage to the winding insulation, magnetic material or other key components, the heat dissipation device needs to be actively turned on. Positive heat dissipation control refers to actively taking measures to increase the heat dissipation effect, such as increasing the fan speed, turning on the standby air duct, increasing the radiator power, etc. The criticality is further subdivided into two levels, i.e. reaching a first criticality and reaching a second criticality, the first criticality being a lower-risk early warning temperature point, such as 100 degrees Celsius, and the second criticality being a temperature point closer to the upper limit of the material safety, such as 115 degrees Celsius, representing a higher risk level.

[0047] Under the two different criticality levels, the time interval of the fan from starting to shutting down is recorded respectively. The operation time, usually measured in seconds or minutes, is an important basic data for evaluating the load degree of the fan. For example, the fan operation under the first criticality may last for 300 seconds, while the operation under the second criticality may last for 600 seconds to ensure that the heat is effectively taken away. Through the operation time, the required energy consumption can be further estimated and the economy of the control strategy can be evaluated.

[0048] The operation time is multiplied by the power of the fan to obtain the energy consumption. The fan operation energy consumption is measured in watt-hours or kilowatt-hours, reflecting the cost of this control behavior in terms of power consumption. For example, if the fan power is 50 watts, the first criticality operation lasts for 300 seconds, i.e. 4.17 watt-hours, and the second criticality operation lasts for 600 seconds, i.e. 8.33 watt-hours, which can be used for comparison with the energy efficiency of other control methods.

[0049] The economic benefits of the two control modes are quantitatively analyzed. The energy consumption of fan operation to reach the first critical point and the energy consumption of passive heat dissipation control to reach the first critical point are compared, and the energy consumption of fan operation to reach the second critical point and the energy consumption of passive heat dissipation control to reach the second critical point are compared, to obtain first and second comparison results. Passive heat dissipation control generally means running the fan at a low speed or not running the fan to reduce energy consumption, but the heat of passive heat dissipation control cannot be discharged in time, resulting in temperature rise, thereby making the entire system need more energy to cool down or maintain performance in the future. The energy consumption of temperature rise efficiency loss refers to the energy consumption expenditure indirectly caused by the temperature rise, such as the motor efficiency decrease causing the same output to need more input power. Assuming that passive control causes an additional power consumption of 6 watts at the first critical point, and active control only causes a power consumption of 4.17 watts, the first comparison result shows that active control is more energy-saving; if passive control costs 10 watts and active control costs 8.33 watts at the second critical point, a similar conclusion is drawn.

[0050] If the energy consumption of active control is lower than the energy consumption loss caused by passive control at the first critical point, the fan speed is increased to cool down quickly; if passive control is found to be more advantageous at a certain critical point, the fan operation is suppressed to save power. The final control logic is based on the comparison of actual energy consumption effects, avoiding resource waste caused by blind overcooling or overheating. Table 1 is a data record of the heat dissipation control strategy in the last time under different critical conditions, comparing the energy consumption of fan operation and passive control, and selecting the scheme with smaller energy consumption to perform active heat dissipation control.

[0051] Table 1: Data record of the heat dissipation control strategy in the last time

[0052]

[0053] Further, the application also includes: performing active heat dissipation control of fan low-speed operation according to the reaching of the first critical point; performing active heat dissipation control of fan high-speed operation according to the reaching of the second critical point; calculating a temperature rise trend based on the identified heat data; identifying the temperature rise trend through a temperature rise threshold, and performing active heat dissipation control of fan accelerated operation if the identified heat data is within the reaching critical result and the temperature rise trend is within the temperature rise threshold.

[0054] Specifically, when the temperature of the motor reaches the first stage critical temperature set by the system, the fan is actively controlled to run at a low speed, thereby starting active heat dissipation. The first critical point is a critical point in the initial stage of temperature rise, which is usually triggered when the motor has not yet overheated but has a temperature rise trend. Low-speed operation means that the fan power output is small, for example, the speed is controlled at about 1000 revolutions per minute, and the main purpose is to save energy while preventing the temperature from continuing to rise rapidly.

[0055] When the motor temperature further rises to the second critical temperature, the fan speed is immediately increased to accelerate the cooling process. The second criticality indicates that it enters the high-temperature risk zone, and if it is not quickly cooled, it may cause performance degradation or damage. High-speed operation generally refers to the fan speed being increased to 3000 revolutions per minute or higher, and the corresponding air volume is larger, which can quickly take away heat and inhibit further temperature rise.

[0056] Based on the identification of thermal data, the temperature rise trend is calculated, which represents the rate of change of the current temperature over time from the collected temperature data, i.e. the trend of temperature rise per unit time. The temperature rise trend helps to judge the possibility of thermal runaway in advance.

[0057] The temperature rise trend is identified by comparing the actual temperature rise trend with the set threshold to determine whether it enters a dangerous temperature rise state. If the identification of thermal data is within the critical result and the temperature rise trend is within the temperature rise threshold, the fan is accelerated to run actively to control the heat dissipation, which means that the current temperature has reached the critical level but the temperature rise speed has not exceeded the warning value. Therefore, a compromise can be adopted, such as increasing the fan speed to 2000 revolutions per minute to speed up the heat dissipation pace while keeping the energy consumption control within a reasonable range.

[0058] Further, the present application also includes: extracting the same working condition according to the multi-working condition data record; fitting the thermal data of the intermediate optimization strategy and the corresponding thermal data time under the same working condition to obtain a thermal data curve; and performing energy efficiency evaluation on the thermal data curve based on the thermal data curve record to obtain an intermediate energy saving effect.

[0059] Specifically, in a large number of recorded flat wire motor operation data, data sets with similar operating conditions are selected. For example, in the operation records under different speeds, loads, currents and other working conditions of the vehicle, by setting a judgment standard, records under certain fixed speed such as 60 kilometers per hour, same load such as 500 kilograms, and motor current stable at 40 amperes are extracted, which are called the same working condition. The extracted data is used to exclude interference variables to make subsequent analysis more accurate.

[0060] Under the same operating conditions, the temperature rise trend of the motor over time is calculated. Thermal data refers to a data sequence of temperature change over time, and thermal data time is obtained by collecting specific time points of temperature, and a smooth curve is generated by mathematical fitting, such as polynomial fitting or spline curve, to describe the thermal response characteristics of the motor under the intermediate optimization strategy.

[0061] Based on the fitted curve, the relationship between the heat dissipation resources used in the thermal response process and the temperature rise control ability is analyzed. Energy efficiency evaluation includes calculating the energy consumption required to reduce the temperature by one unit, or the heat that can be taken away by the fan for every 1 watt of electricity used.

[0062] Further, the application also includes: extracting equivalent working conditions based on the multi-working condition data record; and evaluating the energy efficiency of the primary optimization strategy under the equivalent working conditions in terms of fan working time, motor operating power, and real-time temperature to obtain a primary energy-saving effect.

[0063] Specifically, part of the historical data covering multiple operating conditions is screened out, which has consistent characteristics, such as working conditions with close parameters such as rotating speed, current, load, or external environment temperature, so as to compare and analyze different heat dissipation strategies under similar conditions.

[0064] Under the equivalent working conditions, the energy efficiency of the primary optimization strategy is evaluated in terms of fan working time, motor operating power, and real-time temperature to measure the energy-saving effect of the primary optimization strategy. The fan working time refers to the total length of time that the fan actually operates under the strategy, such as the time required for the temperature to drop to the target value from the start of operation. The motor operating power measures the load intensity of the motor itself under this working condition, and the real-time temperature indicates whether the system heat dissipation meets the standard. The combination of the three can calculate the efficiency of temperature change per unit time under the condition of unit power, and then evaluate the energy efficiency of the heat dissipation strategy. For example, the fan is continuously operated for 60 seconds, the motor maintains a power output of 20 kilowatts, and the temperature is stable below 65 degrees Celsius. Compared with the original scheme, 10 seconds of fan operation time is saved, and the temperature is reduced by 5 degrees Celsius.

[0065] In summary, the wind-cooled heat dissipation structure optimization method for the energy-saving flat wire motor provided by the application has the following technical effects: by achieving the technical target of intelligent optimization and dynamic regulation of the wind-cooled heat dissipation structure, the technical effects of improving the heat dissipation efficiency of the motor, prolonging the service life, reducing the overall energy consumption, and improving the system operation stability are achieved.

[0066] Embodiment two, based on the same inventive concept as the wind-cooled heat dissipation structure optimization method for the energy-saving flat wire motor in the foregoing embodiments, the application also provides a wind-cooled heat dissipation structure optimization system for the energy-saving flat wire motor, please refer to the accompanying Figure 2 , including: a temperature acquisition module 11 for collecting the operating thermal load characteristics of the flat wire motor and acquiring the real-time temperature of the wind-cooled heat dissipation structure; a primary optimization strategy obtaining module 12 for generating a structure optimization strategy of the wind-cooled heat dissipation structure based on the heat dissipation data recorded in multiple working conditions to obtain a primary optimization strategy; a middle-level optimization strategy obtaining module 13 for performing heat dissipation optimization on the wind-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data to obtain a middle-level optimization strategy; and a strategy evaluation module 14 for obtaining a heat dissipation optimization result by evaluating the energy-saving effects obtained by the primary optimization strategy and the middle-level optimization strategy.

[0067] Further, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: based on the heat dissipation data, performing structural optimization on the blade angle, the number of blades and the blade spacing of the fan blade in the air-cooled heat dissipation structure to obtain a fan blade structural optimization strategy; based on the heat dissipation data, setting a directional air duct in the air guide duct of the air-cooled heat dissipation structure to obtain a directional air duct structural optimization strategy; based on the heat dissipation data, forming an air-cooled linkage structure of the motor shell and the directional air duct in the air-cooled heat dissipation structure to obtain a motor shell structural optimization strategy; and combining the fan blade structural optimization strategy, the directional air duct structural optimization strategy and the motor shell structural optimization strategy to obtain a primary optimization strategy.

[0068] Further, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: monitoring the inflow wind flow and the outflow wind flow of the directional air duct, and if the inflow wind flow is lower than an inflow wind flow threshold, setting an import wind structure at the directional air duct, and if the outflow wind flow is lower than an outflow wind flow threshold, setting an export wind structure at the directional air duct.

[0069] Further, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: collecting the multi-working condition data record and the thermal data record; performing thermal prediction based on the thermal data record and the corresponding thermal data time record to obtain a thermal data curve record; and obtaining the heat dissipation data according to the thermal data curve record.

[0070] Further, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: identifying the real-time temperature based on the thermal data curve record, performing positive heat dissipation control and negative heat dissipation control of the air-cooled heat dissipation structure according to the identified thermal data and the corresponding identified working condition parameters to obtain a critical temperature reaching judgment result, and obtaining a middle-level optimization strategy according to the critical temperature reaching judgment result.

[0071] Further, the air-cooled heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: if the critical temperature reaching judgment result is a critical temperature reaching result, performing positive heat dissipation control of fan operation, wherein the critical temperature reaching result includes reaching a first critical temperature and reaching a second critical temperature; calculating a fan operation time based on the fan operation of the reaching first critical temperature and the reaching second critical temperature; calculating the fan operation energy consumption of the reaching first critical temperature and the reaching second critical temperature according to the fan operation time; comparing the fan operation energy consumption of the reaching first critical temperature and the negative heat dissipation control temperature rise efficiency loss energy consumption of the reaching first critical temperature, and the fan operation energy consumption of the reaching second critical temperature and the negative heat dissipation control temperature rise efficiency loss energy consumption of the reaching second critical temperature, respectively, to obtain a first comparison result and a second comparison result; and performing positive heat dissipation control based on the smaller energy consumption in the first comparison result and the second comparison result, respectively.

[0072] Further, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: according to the reaching of the first critical value, performing positive heat dissipation control of low-speed operation of the fan; according to the reaching of the second critical value, performing positive heat dissipation control of high-speed operation of the fan; calculating a temperature rise trend based on the identified heat data; identifying the temperature rise trend through a temperature rise threshold, and if the identified heat data is within the reaching critical value and the temperature rise trend is within the temperature rise threshold, performing positive heat dissipation control of accelerated operation of the fan.

[0073] Further, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: extracting the same working condition based on the multi-working condition data record; fitting the heat data of the intermediate optimization strategy and the corresponding heat data time under the same working condition to obtain a heat data curve; and performing energy efficiency evaluation on the heat data curve based on the heat data curve record to obtain an intermediate energy-saving effect.

[0074] Further, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor is further used for: extracting the same working condition based on the multi-working condition data record; fitting the heat data of the intermediate optimization strategy and the corresponding heat data time under the same working condition to obtain a heat data curve; and performing energy efficiency evaluation on the heat data curve based on the heat data curve record to obtain an intermediate energy-saving effect.

[0075] The embodiments in the specification are described in a progressive manner, and each embodiment focuses on the difference from other embodiments. The air-cooling heat dissipation structure optimization method and specific example of the energy-saving flat wire motor in the foregoing first embodiment are also applicable to the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor in the present embodiment. Based on the foregoing detailed description of the air-cooling heat dissipation structure optimization method of the energy-saving flat wire motor, those skilled in the art can clearly understand the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor in the present embodiment. Therefore, for the sake of brevity of the specification, the air-cooling heat dissipation structure optimization system of the energy-saving flat wire motor in the present embodiment will not be described in detail.

[0076] The above description of disclosed embodiments enables a person skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

[0077] Obviously, those skilled in the art can make various modifications and variations 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 equivalent technologies, the present application also intends to include these modifications and variations.

Claims

1. An optimization method for air-cooled heat dissipation structure of an energy-saving flat wire motor, characterized in that, The method comprises the following steps: Collecting the operating thermal load characteristics of the flat wire motor to obtain the real-time temperature of the air-cooled heat dissipation structure; Generating a heat dissipation data configuration based on the heat dissipation data recorded under multiple working conditions to obtain a primary optimization strategy for the structure of the air-cooled heat dissipation structure; Performing heat dissipation optimization on the air-cooled heat dissipation structure based on the real-time temperature and the heat dissipation data to obtain an intermediate optimization strategy; Obtaining a heat dissipation optimization result by evaluating the energy-saving effect of the primary optimization strategy and the intermediate optimization strategy; Obtaining the primary optimization strategy comprises the following steps: 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 of the air-cooled heat dissipation structure based on the heat dissipation data to obtain a directional air duct structure optimization strategy; Forming an air-cooled linkage structure between the motor shell and the directional air duct in the air-cooled heat dissipation structure based on the heat dissipation data to obtain a motor shell structure optimization strategy; Combining the fan blade structure optimization strategy, the directional air duct structure optimization strategy and the motor shell structure optimization strategy to obtain the primary optimization strategy; Generating the heat dissipation data comprises the following steps: Collecting the multiple working 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; Obtaining the heat dissipation data based on the thermal data curve records; Obtaining the intermediate optimization strategy comprises the following steps: Identifying the real-time temperature based on the thermal data curve records, judging whether the critical temperature is reached based on the identified thermal data and corresponding identified working condition parameters to obtain a critical judgment result; Performing positive heat dissipation control and negative heat dissipation control on the air-cooled heat dissipation structure based on the reached critical result and the not-reached critical result in the critical judgment result to obtain the intermediate optimization strategy.

2. The method for optimizing the air-cooled heat dissipation structure of the energy-saving flat wire motor according to claim 1, characterized in that, Monitoring the inflow and outflow of the directional air duct, and if the inflow is lower than the inflow threshold, setting an import air structure at the directional air duct, and if the outflow is lower than the outflow threshold, setting an export air structure at the directional air duct.

3. The method for optimizing the air cooling heat dissipation structure of the energy-saving flat wire motor according to claim 1, characterized in that, The positive heat dissipation control comprises the following steps: If the critical judgment result is the reached critical result, performing positive heat dissipation control on the fan operation, wherein the reached critical result includes the first reached critical and the second reached critical; Calculating the fan operation time based on the fan operation of the first reached critical and the second reached critical; Calculating the fan operation energy consumption of the first reached critical and the second reached critical based on the fan operation time; Comparing the fan operation energy consumption of the first reached critical and the second reached critical with the energy consumption of the temperature rise efficiency loss of the negative heat dissipation control of the first reached critical and the second reached critical respectively to obtain a first comparison result and a second comparison result; Performing positive heat dissipation control based on the smaller energy consumption in the first comparison result and the second comparison result respectively.

4. The energy-saving flat wire motor air-cooled heat dissipation structure optimization method according to claim 3, characterized in that, The positive heat dissipation control further comprises the following steps: Performing positive heat dissipation control on the fan low-speed operation based on the first reached critical; According to the reaching second critical, the positive heat dissipation control of fan high-speed operation is carried out; The temperature rise trend is identified based on the identified heat data; The temperature rise trend is identified by a temperature rise threshold, and if the identified heat data is within the reaching critical result and the temperature rise trend is within the temperature rise threshold, the positive heat dissipation control of fan acceleration operation is carried out.

5. The method for optimizing the air cooling heat dissipation structure of the energy-saving flat wire motor according to claim 1, characterized in that, The energy saving effect is obtained, including: According to the same working condition of the multi-working condition data record extraction; Under the same working condition, the heat data of the intermediate optimization strategy and the corresponding heat data time are fitted to obtain the heat data curve; According to the heat data curve record, the heat data curve is evaluated to obtain the intermediate energy saving effect.

6. The method for optimizing the air cooling heat dissipation structure of the energy-saving flat wire motor according to claim 1, characterized in that, The energy saving effect is obtained, and further includes: Based on the multi-working condition data record extraction of the same working condition; Under the same working condition, the fan working time, motor operating power and real-time temperature are used to evaluate the energy efficiency of the primary optimization strategy to obtain the primary energy saving effect.

7. The energy-saving flat wire motor air-cooling heat dissipation structure optimization system is characterized in that, The steps for implementing the optimization method of the air-cooled heat dissipation structure of the energy-saving flat wire motor of any one of claims 1 to 6, comprising: Temperature acquisition module, for collecting the operating thermal load characteristics of the flat wire motor, and acquiring the real-time temperature of the air-cooled heat dissipation structure; Primary optimization strategy obtaining module, for generating the structure optimization strategy of the air-cooled heat dissipation structure based on the heat dissipation data generated by the multi-working condition data record, to obtain the primary optimization strategy; Intermediate optimization strategy obtaining module, for performing heat dissipation optimization on the air-cooled heat dissipation structure according to the real-time temperature and the heat dissipation data, to obtain the intermediate optimization strategy; Strategy evaluation module, for obtaining the heat dissipation optimization result by evaluating the energy saving effect obtained by the primary optimization strategy and the intermediate optimization strategy; The primary optimization strategy is obtained, including: Based on the heat dissipation data, the blade angle, blade number and blade spacing of the fan blade in the air-cooled heat dissipation structure are optimized to obtain the fan blade structure optimization strategy; Based on the heat dissipation data, the directional air duct is set in the air guide duct of the air-cooled heat dissipation structure to obtain the air guide duct structure optimization strategy; Based on the heat dissipation data, the motor shell and the directional air duct form a wind-cooled linkage structure in the air-cooled heat dissipation structure to obtain the motor shell structure optimization strategy; The fan blade structure optimization strategy, the air guide duct structure optimization strategy and the motor shell structure optimization strategy are combined to obtain the primary optimization strategy; Generating heat dissipation data, including: Collecting the multi-working condition data record and heat data record; Based on the heat data record and the corresponding heat data time record, heat prediction is carried out to obtain the heat data curve record; According to the heat data curve record, the heat dissipation data is obtained; The intermediate optimization strategy is obtained, including: Based on the heat data curve record, the real-time temperature is identified, and the reaching critical judgment result is obtained by identifying the heat data and the corresponding identification working condition parameter to judge whether the critical temperature is reached; According to the reaching critical judgment result, the reaching critical result and the non-reaching critical result, the positive heat dissipation control and the negative heat dissipation control of the air-cooled heat dissipation structure are carried out respectively to obtain the intermediate optimization strategy.

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