Method for designing using amount of heat conduction material of motor winding

Abstract

The invention discloses a heat conduction material consumption design method for a motor winding. The method comprises the following steps: simplifying a motor model to obtain a geometric model; arranging a heat conduction material with a first preset height at the end part of the motor winding of the geometric model through finite element analysis software; performing grid discretization processing on the geometric model and setting boundary conditions; simulating the geometric model to calculate the highest temperature of the motor winding and the use amount of the heat conducting material; when the first preset height is smaller than the second preset height, increasing the first preset height based on the preset increment, and returning to execute the step of setting the heat conduction material until the first preset height is not smaller than the second preset height; and constructing a first fitting curve of the first preset height and the highest temperature and a second fitting curve of the first preset height and the amount of the heat conduction material, and obtaining the optimal amount of the heat conduction material according to the first fitting curve and the second fitting curve. According to the invention, the problem that the optimal glue pouring amount is difficult to seek between low cost and high performance in the glue pouring process of the motor winding is solved.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing technology, and more specifically, to a method for designing the amount of heat-conducting material used in motor windings. Background Technology

[0002] Currently, the motor industry is primarily developing towards high precision, high power density, and miniaturization. This leads to a surge in internal heat generation within the motor, coupled with insufficient heat dissipation space, resulting in excessive temperature rise and performance degradation. Current motors mainly dissipate heat by constructing a winding-casing-flow channel or air thermal path between the motor windings and the housing using insulating materials such as thermally conductive resins and adhesives. However, in actual potting processes, the amount of adhesive used often relies on experience for control. Insufficient adhesive leads to inadequate heat dissipation and high-temperature motor failure, while excessive adhesive increases the cost of the thermally conductive material and the overall weight of the motor, reducing the utilization rate of the thermally conductive material. It is difficult to find the optimal potting amount between low cost and high performance. Summary of the Invention

[0003] The main objective of this invention is to provide a method for designing the amount of thermally conductive material used in motor windings, so as to at least solve the problem that the amount of adhesive used in the potting process of motor windings often depends on experience and it is difficult to find the optimal amount of adhesive between low cost and high performance.

[0004] According to one aspect of the present invention, a method for designing the amount of thermally conductive material used in motor windings is provided, comprising:

[0005] Step S1: Simplify the motor model to obtain the geometric model of the motor;

[0006] Step S2: Using finite element analysis software, heat-conducting material of a first preset height is placed at the motor winding end of the geometric model;

[0007] Step S3: Discretize the geometric model into a mesh and set the boundary conditions of the geometric model;

[0008] Step S4: Simulate the geometric model using the finite element analysis software, and obtain the highest temperature of the motor winding and the amount of thermally conductive material used based on the simulation results;

[0009] Step S5: Determine whether the first preset height is less than the second preset height. If so, increase the first preset height based on the preset increment, and repeat steps S2 to S5 until the first preset height is greater than or equal to the second preset height.

[0010] Step S6: Construct a first fitting curve between the first preset height and the highest temperature, and a second fitting curve between the first preset height and the amount of thermally conductive material used. Obtain the optimal amount of thermally conductive material based on the first fitting curve and the second fitting curve.

[0011] Further, step S1 includes:

[0012] Step S11: Perform a 3D scan on the motor to obtain the corresponding 3D model, and import the 3D model into 3D modeling software;

[0013] Step S12: Determine the geometric features of the motor based on the three-dimensional model, and determine non-critical features based on the geometric features;

[0014] Step S13: The non-critical features are simplified using the 3D modeling software to obtain the geometric model corresponding to the motor.

[0015] Further, step S2 includes:

[0016] Step S21: Import the geometric model into the finite element analysis software;

[0017] Step S22: Mark the thermally conductive material region in the geometric model using the finite element analysis software;

[0018] Step S23: Set a first preset height of thermally conductive material in the thermally conductive material area using the finite element analysis software, and associate the first preset height with the parameter list of the finite element analysis software;

[0019] The first preset height is configured as the axial height of the heat-conducting material along the motor.

[0020] Further, step S3 includes:

[0021] Step S31: Select the mesh generation element of the geometric model in the finite element analysis software;

[0022] Step S32: Set the mesh division region and division density based on the geometric model;

[0023] Step S33: Based on the mesh division region and the division density, the geometric model is meshed using the mesh division unit;

[0024] Step S34: Perform mesh optimization on the geometric model after mesh generation based on size optimization technology;

[0025] Step S35: Set the boundary condition parameters of the mesh-optimized geometric model.

[0026] Further, step S4 includes:

[0027] Step S41: Set the convergence parameter conditions for the simulation of the geometric model, and select the corresponding solver;

[0028] Step S42: Perform thermal steady-state analysis on the geometric model using the finite element analysis software, and obtain the calculation results of the solver when the convergence parameter conditions are met;

[0029] Step S43: Extract the highest temperature of the motor winding based on the calculation results of the solver, and obtain the amount of heat-conducting material used at this time.

[0030] Further, the convergence parameter conditions include an energy residual threshold and an iteration number threshold, and step S42 includes:

[0031] Step S421: Start the solver in the finite element analysis software and monitor the change curve of energy residual with the number of iterations in real time;

[0032] Step S422: When the energy residual is less than the energy residual threshold and the number of iterations reaches the maximum number of iterations, output the calculation result of the solver at this time.

[0033] Further, step S5 includes:

[0034] Step S51: Configure the second preset height as the distance Lmax from the end of the stator core of the motor to the end cover;

[0035] Step S52: Determine whether the first preset height L and the second preset height Lmax satisfy L < Lmax;

[0036] If so, calculate L = L + ΔLn, and repeat steps S2 to S5 until L ≥ Lmax; where ΔLn represents the preset increment for the nth iteration.

[0037] Furthermore, the first preset height L satisfies the following relationship: L = (1 / 10)Lmax.

[0038] Furthermore, the preset increment ΔLn satisfies the following relationship: ΔLn=(1\20)Lmax.

[0039] Further, step S6 includes:

[0040] Step S61: Set the first preset height as the horizontal axis, and set the highest temperature and the amount of thermally conductive material as the vertical axis, respectively, to construct a first fitting curve between the first preset height and the highest temperature, and a second fitting curve between the first preset height and the amount of thermally conductive material.

[0041] Step S62: Obtain the intersection point of the first fitting curve and the second fitting curve, obtain the amount of thermally conductive material corresponding to the intersection point and take it as the optimal amount of thermally conductive material.

[0042] In this invention, finite element analysis software is used to simulate and analyze the thermal conductive material at different preset heights, constructing fitting curves for "preset height - maximum temperature" and "preset height - amount of thermal conductive material." This allows for a direct identification of the optimal solution that satisfies the motor's heat dissipation requirements while minimizing the amount of thermal conductive material used. This avoids increased cost and weight due to excessive thermal conductive material usage, or heat dissipation failure due to insufficient thermal conductive material usage, thereby improving the utilization rate of the thermal conductive material and achieving a precise balance between low cost and high performance. Precise control of the amount of thermal conductive material through simulation analysis allows for the creation of a more reasonable thermal path between the motor windings and the casing, effectively reducing the temperature rise caused by a surge in internal heat generation and preventing performance degradation due to excessive temperature, thus improving the stability and reliability of motor operation. Compared to the traditional method of repeatedly adjusting the amount of adhesive used in potting, this invention uses simulation technology to predict the heat dissipation effect under different amounts of material in advance, reducing the number of iterations of physical prototypes, shortening the development cycle, and reducing material waste and time costs caused by experimental trial and error. This application allows for flexible adjustment of simulation models and boundary conditions based on the structural parameters and heat dissipation requirements of different motors, enabling personalized design of thermal conductive material usage, and producing high-performance motor products at a lower cost, thereby enhancing market competitiveness. Attached Figure Description

[0043] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings:

[0044] Figure 1 This is a flowchart illustrating the method for designing the amount of thermally conductive material used in motor windings according to an embodiment of the present invention.

[0045] Figure 2 This is a partial cross-sectional view of the motor disclosed in an embodiment of the present invention;

[0046] Figure 3 This is a partial cross-sectional view of the motor disclosed in an embodiment of the present invention;

[0047] Figure 4 This is a schematic diagram of the temperature field of the motor windings under different potting heights as disclosed in an embodiment of the present invention;

[0048] Figure 5 This is a graph showing the variation trend of the maximum temperature of the motor winding and the amount of thermally conductive material with the potting height, as disclosed in an embodiment of the present invention.

[0049] The above figures include the following reference numerals:

[0050] 10. Housing; 11. Heat dissipation channel; 20. Stator core; 30. Motor winding; 40. Heat dissipation space; 41. Initial glue filling space; 42. Unfilled space. Detailed Implementation

[0051] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0052] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0053] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0054] In related technologies, thermally conductive insulating materials are mainly used in motors to dissipate heat from the motor windings. In practical applications, thermally conductive insulating materials are injected into the space between the motor windings and the housing to form a motor winding-housing-flow channel or air thermal path for heat dissipation. However, the amount of injection material depends on experience; too little will result in poor heat dissipation, while too much will increase cost and motor weight. Therefore, this application provides a method for designing the amount of thermally conductive material used in motor windings. This method can simulate the motor structure before injection to analyze the relationship between the injection height, motor winding temperature, and injection amount, thereby obtaining an optimal injection amount (i.e., the amount of thermally conductive material), achieving low cost and high performance for the motor. The shielding device of the present invention will be described in detail below with reference to the accompanying drawings.

[0055] See Figure 1 As shown in the embodiments of this application, a method for designing the amount of thermally conductive material used in motor windings is provided, comprising:

[0056] Step S1: Simplify the motor model to obtain the geometric model of the motor.

[0057] Specifically, step S1 includes:

[0058] Step S11: Perform a 3D scan of the motor to obtain the corresponding 3D model, and import the 3D model into the 3D modeling software;

[0059] Step S12: Determine the geometric features of the motor based on the 3D model, and determine non-critical features based on the geometric features;

[0060] Step S13: Simplify non-critical features using 3D modeling software to obtain the geometric model corresponding to the motor.

[0061] refer to Figure 2 and Figure 3 The diagram shows a partial schematic of the motor in which the method of this embodiment is specifically applied. The motor includes a housing 10, a stator core 20, and a motor winding 30. A heat dissipation channel 11 is provided on the housing 10. A heat dissipation space 40 is formed between the housing 10, the stator core 20, and the motor winding 30. The heat dissipation channel is used to dissipate heat from the motor as a whole through coolant. The heat dissipation space 40 between the housing 10, the stator core 20, and the motor winding 30 is used to dissipate heat from the motor winding 30 through a thermally conductive material. The heat dissipation space 40 has an initial glue-filling space 41 and an un-glue-filled space 42. The initial glue-filling space 41 is the space occupied by the thermally conductive material after glue is filled into the heat dissipation space 40, and the un-glue-filled space 42 is the space where glue may be filled in later.

[0062] In this embodiment, when performing a 3D scan to obtain a 3D model of the motor, a 3D scanning instrument can be used, such as a 3D laser scanner. A specific scanning precision can be set during the scan to ensure accurate acquisition of the motor's geometric features. The motor's geometric features include the specific structure of the housing 10, stator core 20, motor windings 30, and heat dissipation space 40, such as shape, size, and winding distribution. After scanning, corresponding 3D point cloud data is obtained and imported into 3D modeling software. The point cloud processing function of the 3D modeling software is used to convert the 3D point cloud data into a 3D model. SolidWorks is preferred in this embodiment because it has powerful point cloud processing and modeling capabilities, efficiently converting the scanned 3D point cloud data into a complete 3D model that presents the motor's external shape, the position of each component, and the structure of the heat dissipation space 40. Furthermore, by analyzing the 3D model of the motor, the geometric features of the motor are determined. Since this embodiment analyzes the heat dissipation structure of the motor winding 30, structures with less impact on the heat dissipation performance of the motor winding 30, i.e., non-critical features, such as decorative structures and bolt holes on the housing 10, can be optimized using 3D software. Specific structural features that significantly impact the heat dissipation performance of the motor winding 30, including the housing 10, stator core 20, motor winding 30, and the heat dissipation space 40 between them, are retained to obtain the corresponding geometric model of the motor, thereby reducing the computational load of subsequent finite element analysis. During the optimization of non-critical features using the 3D model, for example, decorative grooves on the housing 10 can be directly removed, and bolt holes can be simplified to through-hole structures through extrusion cutting operations.

[0063] In this embodiment, by ensuring that the acquired motor model accurately reproduces the actual structure of the motor and identifying and simplifying non-critical features, the complexity of the geometric model can be significantly reduced, lowering the difficulty of mesh generation and calculation during finite element analysis, shortening simulation calculation time, and improving design efficiency. During the simplification process, key geometric features are retained, ensuring that the simplified geometric model accurately reflects the physical laws of heat conduction within the motor. This makes subsequent simulation analysis results based on the model reliable and provides accurate basic data support for the design of thermal conductive material usage.

[0064] Step S2: Using finite element analysis software, heat-conducting material of a first preset height is placed at the end of the motor winding 30 of the geometric model.

[0065] Specifically, step S2 includes:

[0066] Step S21: Import the geometric model into the finite element analysis software;

[0067] Step S22: Label the thermally conductive material region in the geometric model using finite element analysis software;

[0068] Step S23: Set the thermally conductive material at a first preset height in the thermally conductive material area using finite element analysis software, and associate the first preset height with the parameter list of the finite element analysis software;

[0069] The first preset height is configured as the axial height of the heat-conducting material along the motor.

[0070] In this embodiment, ANSYS Workbench software is used as an example for finite element analysis. When analyzing the geometric model of the motor, the geometric model obtained after processing by the 3D software is exported in STEP format and then imported into the ANSYS Workbench software. In ANSYS Workbench, the selection tool is used to select the heat dissipation space 40 between the housing 10, stator core 20, and motor winding 30 in the geometric model as the heat-conducting material area. The heat-conducting material area is labeled using the annotation function of ANSYS Workbench. The thermal management material category is found in the material library list of ANSYS Workbench, and a suitable thermal conductive material is selected, such as a specific model of thermal grease or thermal silicone. If the required material is not in the material library of ANSYS Workbench, a custom thermal conductive material is created by manually entering the material name, thermal conductivity, density, specific heat capacity, and other attribute parameters through the custom option. After selecting or creating the material, it is added to the current project. Then switch to the "Model" module. In the previously marked thermal conductive material area, select "Assign Material," then select the newly added thermal conductive material and assign it to the thermal conductive material area. In the size settings of the properties window, set the height of the thermal conductive material along the motor axis to the first preset height L. Enter the specific value of the first preset height L in the corresponding axial height input box, for example, "10mm." Finally, associate the first preset height L with the parameter list of the ANSYS Workbench software. At this point, the "L" parameter will appear in the window. You can then adjust the height of the thermal conductive material by modifying the value of this parameter.

[0071] By locating the application area of ​​the thermally conductive material (the end of motor winding 30) in the geometric model, the spatial range in which the thermally conductive material functions is clearly defined, providing a clear boundary for subsequent simulation analysis of the electrode winding temperature. Associating the first preset height with the parameter list enables parametric design, facilitating automatic and rapid adjustment of the potting height during subsequent iterative optimization, and conducting simulation analysis at different heights, thus improving the automation and efficiency of the design process.

[0072] Preferably, the first preset height L of the thermally conductive material in this embodiment satisfies the relationship L = (1 / 10)Lmax, where Lmax is the distance from the end of the stator core 20 to the end cover. For example, when the distance Lmax from the end of the stator core 20 to the end cover is 50mm, the first preset height is 5mm. That is, the initial height of the thermally conductive material is one-tenth of the distance between the end of the stator core 20 and the end cover, which ensures accurate subsequent fitting relationship analysis with relatively small calculations and improved design efficiency. Optionally, the first preset height L can also be set to L = (1 / 5)Lmax, L = (1 / 20)Lmax, or L = (1 / 30)Lmax, that is, the first preset height L can be set to one-fifth, one-twentieth, or one-thirtieth of the distance Lmax from the end of the stator core 20 to the end cover. Without considering the amount of calculation, the smaller the initial value of the first preset height L, the more accurate the combination result.

[0073] Step S3: Discretize the geometric model into a mesh and set the boundary conditions for the geometric model.

[0074] Specifically, step S3 includes:

[0075] Step S31: Select the mesh generation element for the geometric model in the finite element analysis software;

[0076] Step S32: Set the mesh division region and mesh density based on the geometric model;

[0077] Step S33: Based on the mesh division region and mesh density, perform mesh division on the geometric model using mesh division units;

[0078] Step S34: Perform mesh optimization on the geometric model after mesh generation based on size optimization technology;

[0079] Step S35: Set the boundary condition parameters for the mesh-optimized geometric model.

[0080] In this embodiment, after setting the thermally conductive material, tetrahedral meshing elements are selected in the meshing module of ANSYS Workbench software. Tetrahedral meshing elements are suitable for model meshing with complex geometries and can better fit the structure of the motor geometric model. Based on the structural characteristics of the geometric model, meshing regions are set. In this embodiment, the geometric model is divided into critical and non-critical regions, with different meshing methods used for each. For critical regions such as the motor winding 30, stator core 20, and housing 10, which have a significant impact on heat dissipation performance, the meshing is refined, for example, the mesh density can be set to 20 meshes per millimeter. For non-critical regions such as the housing 10, which have a relatively small impact on heat dissipation, the mesh density is set to 10 meshes per millimeter. Based on the set meshing regions and mesh density, the selected tetrahedral meshing elements are used to mesh the geometric model. During the meshing process, ANSYS Workbench software automatically generates a mesh based on the geometric shape and set parameters of the geometric model, forming a mesh model composed of multiple tetrahedral elements. Based on size optimization technology, the geometric model after mesh generation is optimized. In ANSYS Workbench software, the mesh optimization function is enabled. The software adjusts the size and shape of the mesh to remove poor-quality mesh elements, improving the overall quality of the mesh model and ensuring the accuracy and stability of the calculation results. Boundary condition parameters of the optimized geometric model are set according to the actual operating conditions of the motor. For example, the outer surface of the motor housing 10 is set as a convective heat transfer boundary condition, and the corresponding convective heat transfer coefficient and ambient temperature are set; the motor winding 30 is set as a heat source, and the heat generation rate of the motor winding 30 is calculated based on the motor's rated power and efficiency.

[0081] When discretizing the geometric model, selective mesh elements are chosen, and different mesh densities are set for different partitions. This ensures the accuracy of heat conduction analysis in key areas while controlling the overall computational scale, balancing the accuracy and efficiency of the simulation calculations. This results in simulations that are both accurate and obtainable within a reasonable timeframe. Mesh quality is optimized using size optimization techniques to reduce computational errors caused by distorted meshes, thus improving the reliability of the simulation analysis. Precisely setting boundary condition parameters accurately reproduces the actual heat exchange environment during motor operation, making the simulation results closer to reality. This provides a reliable basis for accurately obtaining the maximum temperature of the motor windings at 30°C and the amount of thermally conductive material required.

[0082] Step S4: Simulate the geometric model using finite element analysis software, and obtain the highest temperature of motor winding 30 and the amount of heat-conducting material used based on the simulation results.

[0083] Specifically, step S4 includes:

[0084] Step S41: Set the convergence parameter conditions for the simulation of the geometric model, and select the corresponding solver;

[0085] Step S42: Perform thermal steady-state analysis on the geometric model using finite element analysis software, and obtain the calculation results of the solver when the convergence parameter conditions are met;

[0086] Step S43: Extract the highest temperature of the motor winding 30 based on the solver's calculation results, and obtain the amount of heat-conducting material used at this time.

[0087] Specifically, the convergence parameter conditions include an energy residual threshold and an iteration number threshold, and step S42 includes:

[0088] Step S421: Start the solver in the finite element analysis software and monitor the change curve of energy residual with the number of iterations in real time;

[0089] Step S422: When the energy residual is less than the energy residual threshold and the number of iterations reaches the maximum number of iterations, output the calculation result of the solver at this time.

[0090] In this embodiment, the convergence parameters for the geometric model simulation are set in the solver settings module of the ANSYS Workbench software. The simulation convergence parameters include the energy residual and the number of iterations; for example, the energy residual threshold is set to 1×102. -5 The iteration threshold was set to 100, and the built-in steady-state thermal analysis solver in ANSYS Workbench was selected. The steady-state thermal analysis solver was launched in ANSYS Workbench to begin thermal steady-state analysis of the geometric model. ANSYS Workbench monitored the energy residual as a function of iteration number in real time. When the energy residual was less than the energy residual threshold of 1×10⁻⁶, the iteration was stopped. -5 When the number of iterations reaches the maximum of 100, the calculation results of the steady-state thermal analysis solver are output. Based on the calculation results of the steady-state thermal analysis solver, the highest temperature T0 of the motor winding 30 is extracted using the temperature extraction tool in the post-processing module of ANSYS Workbench software, and the temperature value at this time is recorded. At the same time, based on the set heat-conducting material area and the current first preset height of the heat-conducting material, the amount of heat-conducting material Q0 at this time is calculated, and the relevant data is recorded.

[0091] In this embodiment, reasonable setting of convergence parameters, including energy residual threshold and iteration number threshold, and selection of a suitable solver, ensures the stability and convergence of the finite element simulation calculation process, avoiding inaccurate results due to non-convergence or insufficient accuracy. Thermal steady-state analysis focuses on heat conduction under stable motor operation, consistent with the actual long-term heat dissipation scenario of the motor. Real-time monitoring of the energy residual curve intuitively reflects the convergence trend of the simulation calculation, facilitating timely detection of anomalies during the calculation process, allowing for early adjustment of simulation parameters, avoiding prolonged ineffective calculations, and improving design efficiency. Using "energy residual less than the threshold and iteration number reaching the maximum iteration number" as the result output condition provides dual protection for the accuracy of the simulation calculation results. This prevents inaccurate results due to insufficient iteration number while avoiding excessive iteration that wastes computational resources, ensuring reliable output calculation results and providing high-quality data for subsequent extraction of the highest winding temperature and thermal conductive material usage, as well as iterative optimization.

[0092] Step S5: Determine whether the first preset height is less than the second preset height. If so, increase the first preset height based on the preset increment, and repeat steps S2 to S5 until the first preset height is greater than or equal to the second preset height.

[0093] Specifically, step S5 includes:

[0094] Step S51: Configure the second preset height as the distance Lmax from the end of the stator core 20 of the motor to the end cover;

[0095] Step S52: Determine whether the first preset height L and the second preset height Lmax satisfy L < Lmax;

[0096] If so, calculate L = L + ΔLn, and repeat steps S2 to S5 until L ≥ Lmax; where ΔLn represents the preset increment for the nth iteration.

[0097] Specifically, the preset increment ΔLn satisfies the following relationship: ΔLn=(1\20)Lmax.

[0098] In this embodiment, the second preset height Lmax is configured as the distance from the end of the stator core 20 of the motor to the end cover, for example, Lmax = 50mm. It is determined whether the first preset height L and the second preset height Lmax satisfy L < Lmax. In this case, L = 5mm, satisfying the condition L < Lmax, then L = L + ΔLn is calculated, where the preset increment ΔLn = (1 / 20), as referenced. Figure 3As shown, the total increment of the nth iteration relative to the first iteration is ΔL1 + ΔL2 + ΔL3 + ... + ΔLn, i.e., L = L + ΔL1 + ΔL2 + ΔL3 + ... + ΔLn, Lmax = 2.5mm, so L = 10 + 2.5 = 12.5mm. Then, repeat steps S2 to S5, i.e., modify the first preset height of the thermally conductive material in the thermally conductive material region to 12.5mm in the ANSYS Workbench software. This only requires mesh generation, setting boundary conditions, and simulation calculations in the ANSYS Workbench software. Record the highest temperature T1 of the motor winding 30 and the amount of thermally conductive material Q1 at the end of the simulation.

[0099] Following the above method, continuously increase the height of the heat-conducting material, and calculate L = 12.5 + 2.5 = 15 mm, L = 15 + 2.5 = 17.5 mm, ... until L ≥ 100 mm, at which point the calculation ends. Record the highest temperatures of the motor winding 30 T2, T3, T4, ... Tn obtained in each calculation, and the corresponding amounts of heat-conducting material Q2, Q3, Q4, ... Qn.

[0100] Optionally, the preset increment ΔLn can also be set to L = (1 / 10)Lmax, L = (1 / 30)Lmax or L = (1 / 40)Lmax, that is, the preset increment ΔLn can be set to one-tenth, one-twentieth or one-thirtieth of the distance Lmax between the end of the stator core 20 and the end cover. Without considering the amount of calculation, the smaller the value of Lmax, the more accurate the simulation result.

[0101] By setting a second preset height Lmax (the distance from the end of the stator core 20 to the end cover) as the maximum space limit for the pouring of thermal conductive material, the iterative optimization process is made to fit the actual physical structure constraints of the motor, ensuring that the final designed potting height is within the achievable manufacturing range of the motor and guaranteeing the feasibility of the design scheme. By iteratively increasing the potting height and repeating the simulation analysis process, from the minimum potting height (the initial value of the first preset height) to the maximum potting height (Lmax), data on the highest winding temperature and thermal conductive material usage at different potting heights are obtained. This provides a complete data sample for subsequent construction of fitting curves and finding the optimal usage, ensuring the scientific nature and comprehensiveness of the optimal solution. The preset increment adopts a small step increment relative to Lmax (1 / 20Lmax), which allows for fine adjustment of the potting height during the iterative optimization process, capturing the subtle patterns of the influence of potting height changes on winding temperature and material usage. This avoids skipping possible "optimal usage ranges" due to excessively large step sizes, ensuring the accuracy of the subsequently constructed fitting curves and thus improving the accuracy of finding the optimal thermal conductive material usage. Simultaneously, it prevents excessive simulation calculations from increasing computational load and complexity, thus improving simulation efficiency. Setting a preset flow rate increment associated with Lmax provides good versatility, adapting to motors of different sizes. Regardless of motor size, it allows for uniform iterative potting height adjustments, enabling the design method of this embodiment to be effectively applied in the heat dissipation design of different motor models.

[0102] Step S6: Construct a first fitting curve between the first preset height and the highest temperature, and a second fitting curve between the first preset height and the amount of heat-conducting material. Obtain the optimal amount of heat-conducting material based on the first fitting curve and the second fitting curve.

[0103] Specifically, step S6 includes:

[0104] Step S61: Set the first preset height as the horizontal axis, and set the maximum temperature and the amount of heat-conducting material as the vertical axis, respectively, to construct the first fitting curve between the first preset height and the maximum temperature, and the second fitting curve between the first preset height and the amount of heat-conducting material.

[0105] Step S62: Obtain the intersection point of the first fitting curve and the second fitting curve, obtain the amount of thermally conductive material corresponding to the intersection point and take it as the optimal amount of thermally conductive material.

[0106] In this embodiment, thermal grease is used as the thermally conductive material. After obtaining the corresponding data through simulation using ANSYS Workbench software, the recorded first preset height L (L1, L2, L3, L4, ... Ln) is used as the abscissa, and the corresponding maximum temperature T (T0, T2, T3, T4, ... Tn) and the amount of thermal grease Q (Q1, Q2, Q3, Q4, ... Qn) are used as the ordinates. Using data processing software, a first fitting curve between the first preset height L and the maximum temperature T, and a second fitting curve between the first preset height L and the amount of thermal grease Q are constructed. This embodiment uses Origin software. In Origin software, a suitable curve fitting function (such as a polynomial fitting function) is selected so that the fitting curve can better reflect the changing trend of the data. In Origin software, the intersection point of the first fitting curve and the second fitting curve is obtained through the curve analysis function. The amount of thermal grease used at this intersection point represents the optimal amount that balances low cost and high performance while meeting heat dissipation requirements. This amount should be recorded as the final design result. (Reference) Figure 4 The diagram shows a simulation of the temperature field of the motor winding 30 under different potting heights (0, 5mm, 10mm, 15mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 55mm) under the same heat dissipation conditions in this embodiment. This embodiment analyzes half of a gear. Different colors in the diagram represent different temperatures (deeper red indicates higher temperature, deeper blue indicates lower temperature). It can be seen that the temperature is lower the further away from the motor winding 30, and higher the temperature the closer to the motor winding 30. The motor winding 30 itself has the highest temperature. (Reference) Figure 5 The figure shows the trend of the first and second fitting curves under different thermal grease heights in this embodiment. In the figure, as the thermal grease height (real-time first preset height) gradually increases, the first fitting curve shows a decreasing trend, and the second fitting curve shows an increasing trend. The first fitting curve shows that when the thermal grease height increases from 0mm to approximately 25-30mm, the maximum temperature of the motor winding 30 shows a significant decreasing trend. For example, at 0mm, the temperature exceeds 160℃, while at 25mm it drops below 140℃, indicating that increasing the thermal grease filling enhances heat conduction and effectively reduces the maximum temperature of the motor winding 30. When the thermal grease height exceeds the critical value of 25-30mm, the decreasing trend of the maximum temperature of the motor winding 30 begins to gradually decrease, until it approaches a plateau at approximately 50mm. The second fitting curve shows that as the thermal grease height L increases, the amount of thermal grease used continuously increases. At 0mm, the amount is 0, while at 50mm it reaches 16000mm. 3The relationship between volume and height is consistent with the logical positive correlation between volume and height. Combining the first and second fitted curves, it can be seen that the 25-30mm area represents a balance between cooling and thermal grease usage. For example, in the figure, a 25mm height of thermal grease corresponds to a maximum electrode winding temperature of 142.5℃, and a corresponding thermal grease usage of 4000mm. 3 At this time, the highest temperature of the motor winding 30 is relatively low and the amount of thermal grease used is relatively small, which can achieve the optimal balance between heat dissipation and thermal grease usage. Under the premise of ensuring the heat dissipation performance of the motor winding 30, the cost of using thermal grease is controlled.

[0107] By constructing fitted curves, discrete simulation data (temperature and dosage at different potting heights) are transformed into continuous and intuitive curves showing the changing trends. The influence of potting height on winding temperature can be clearly observed through these curves, providing a visual and intuitive basis for design decisions regarding the amount of thermal conductive material used. The intersection of the first and second fitted curves is used as the criterion for determining the optimal amount of thermal conductive material, i.e., the balance point where "the cooling effect per unit of thermal conductive material is optimal." Before the intersection point, increasing the potting height significantly reduces winding temperature (high material cost-effectiveness); after the intersection point, increasing the potting height has little effect on cooling (low material cost-effectiveness). The optimal dosage determined in this way minimizes the amount of thermal conductive material used while meeting the 30°C heat dissipation performance requirements of the motor windings, achieving the design goals of low cost and high performance.

[0108] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0109] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0110] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for designing the amount of heat-conducting material used in motor windings, characterized in that, include: Step S1: Simplify the motor model to obtain the geometric model of the motor; Step S2: Using finite element analysis software, heat-conducting material of a first preset height is placed at the motor winding end of the geometric model; Step S3: Discretize the geometric model into a mesh and set the boundary conditions of the geometric model; Step S4: Simulate the geometric model using the finite element analysis software, and obtain the highest temperature of the motor winding and the amount of thermally conductive material used based on the simulation results; Step S5: Determine whether the first preset height is less than the second preset height. If so, increase the first preset height based on the preset increment, and repeat steps S2 to S5 until the first preset height is greater than or equal to the second preset height. Step S6: Construct a first fitting curve between the first preset height and the highest temperature, and a second fitting curve between the first preset height and the amount of thermally conductive material used. Obtain the optimal amount of thermally conductive material based on the first fitting curve and the second fitting curve.

2. The method for designing the amount of thermally conductive material used in motor windings according to claim 1, characterized in that, Step S1 includes: Step S11: Perform a 3D scan on the motor to obtain the corresponding 3D model, and import the 3D model into 3D modeling software; Step S12: Determine the geometric features of the motor based on the three-dimensional model, and determine non-critical features based on the geometric features; Step S13: The non-critical features are simplified using the 3D modeling software to obtain the geometric model corresponding to the motor.

3. The method for designing the amount of thermally conductive material used in motor windings according to claim 1, characterized in that, Step S2 includes: Step S21: Import the geometric model into the finite element analysis software; Step S22: Mark the thermally conductive material region in the geometric model using the finite element analysis software; Step S23: Set a first preset height of thermally conductive material in the thermally conductive material area using the finite element analysis software, and associate the first preset height with the parameter list of the finite element analysis software; The first preset height is configured as the axial height of the heat-conducting material along the motor.

4. The method for designing the amount of thermally conductive material used in motor windings according to claim 1, characterized in that, Step S3 includes: Step S31: Select the mesh generation element of the geometric model in the finite element analysis software; Step S32: Set the mesh division region and division density based on the geometric model; Step S33: Based on the mesh division region and the division density, the geometric model is meshed using the mesh division unit; Step S34: Perform mesh optimization on the geometric model after mesh generation based on size optimization technology; Step S35: Set the boundary condition parameters of the mesh-optimized geometric model.

5. The method for designing the amount of thermally conductive material used in motor windings according to claim 1, characterized in that, Step S4 includes: Step S41: Set the convergence parameter conditions for the simulation of the geometric model, and select the corresponding solver; Step S42: Perform thermal steady-state analysis on the geometric model using the finite element analysis software, and obtain the calculation results of the solver when the convergence parameter conditions are met; Step S43: Extract the highest temperature of the motor winding based on the calculation results of the solver, and obtain the amount of heat-conducting material used at this time.

6. The method for designing the amount of thermally conductive material used in motor windings according to claim 5, characterized in that, The convergence parameter conditions include an energy residual threshold and an iteration number threshold. Step S42 includes: Step S421: Start the solver in the finite element analysis software and monitor the change curve of energy residual with the number of iterations in real time; Step S422: When the energy residual is less than the energy residual threshold and the number of iterations reaches the maximum number of iterations, output the calculation result of the solver at this time.

7. The method for designing the amount of thermally conductive material used in motor windings according to claim 2, characterized in that, Step S5 includes: Step S51: Configure the second preset height as the distance Lmax from the end of the stator core of the motor to the end cover; Step S52: Determine whether the first preset height L and the second preset height Lmax satisfy L < Lmax; If so, calculate L = L + ΔLn, and repeat steps S2 to S5 until L ≥ Lmax; where ΔLn represents the preset increment for the nth iteration.

8. The method for designing the amount of thermally conductive material used in motor windings according to claim 7, characterized in that, The first preset height L satisfies the following relationship: L=(1\10)Lmax.

9. The method for designing the amount of thermally conductive material used in motor windings according to claim 7, characterized in that, The preset increment ΔLn satisfies the following relationship: ΔLn=(1\20)Lmax.

10. The method for designing the amount of thermally conductive material used in motor windings according to claim 1, characterized in that, Step S6 includes: Step S61: Set the first preset height as the horizontal axis, and set the highest temperature and the amount of thermally conductive material as the vertical axis, respectively, to construct a first fitting curve between the first preset height and the highest temperature, and a second fitting curve between the first preset height and the amount of thermally conductive material. Step S62: Obtain the intersection point of the first fitting curve and the second fitting curve, obtain the amount of thermally conductive material corresponding to the intersection point and take it as the optimal amount of thermally conductive material.

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