Insulating end cover assembly for preventing bearing electrocorrosion and new energy driving motor thereof

Abstract

The invention discloses an insulating end cover assembly for preventing electric corrosion of a bearing and a new energy driving motor. The insulating end cover assembly comprises a front insulating end cover assembly, a rear insulating end cover assembly and a conductive assembly. The front insulation end cover assembly blocks shaft current from flowing through a front bearing through a front insulation bearing sleeve and an insulation gasket. The rear insulation end cover assembly realizes insulation and axial positioning of a rear bearing through a rear insulation bearing sleeve and a wave spring; the conductive assembly comprises a conductive ring cover plate and a conductive ring with a built-in conductive fiber bundle, the conductive ring is in contact with a cylindrical bulge at the rear end of the rotating shaft, and shaft current is guided to the rear insulation end cover base body and is guided to the ground; starting from the two aspects of insulation and diversion, bearing electrocorrosion is effectively eradicated, the reliability of the motor is improved, and the motor has the advantages of being compact in structure, convenient to assemble and disassemble and low in cost and is suitable for a new energy automobile driving motor.

Description

Technical Field

[0001] This invention relates to the field of insulating end cap assembly technology, and more specifically to an insulating end cap assembly for preventing bearing electro-corrosion and its new energy drive motor. Background Technology

[0002] Permanent magnet synchronous motors are characterized by high torque density, high efficiency, and high reliability, and are widely used in the drive systems of new energy electric vehicles. However, due to factors such as motor flux asymmetry, static electricity accumulation, and shaft currents caused by controller common-mode and differential-mode voltages, high-frequency partial discharges can occur in the bearing roller conveyor, leading to electrolytic corrosion. Furthermore, the higher the motor's power and rated voltage, the greater the risk of bearing overcurrent.

[0003] Common solutions to this problem include using conductive carbon brushes, allowing shaft current to preferentially pass through the brushes instead of the bearing. However, conductive carbon brushes are prone to wear and require periodic replacement, which is difficult. Existing technology also employs ceramic ball bearings for insulation to prevent shaft current from being generated by discharge between the inner and outer rings. However, ceramic bearings are expensive and cannot be widely adopted. Furthermore, ceramic ball bearings have poor load capacity, making them prone to damage under high-load conditions.

[0004] Therefore, an effective solution to prevent bearing electro-corrosion during the warranty period remains an unresolved issue. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an insulating end cap assembly for preventing bearing electro-corrosion. This insulating end cap assembly and its associated new energy drive motor effectively prevent and control bearing electro-corrosion.

[0006] To achieve the above objectives, the present invention provides the following technical solution: An insulating end cap assembly for preventing bearing electro-corrosion includes: A front insulating end cap assembly includes a front insulating end cap base, a front transition steel sleeve, a front insulating bearing sleeve, a front bearing, an insulating washer, and a bearing pressure plate. The front insulating end cap assembly is provided with a front mounting groove. The front transition steel sleeve is installed in the front mounting groove. The front insulating bearing sleeve is fitted onto the front bearing, and both are installed inside the front transition steel sleeve. The bearing pressure plate is installed on the front transition steel sleeve and abuts against the end face of the front bearing through the insulating washer. A rear insulating end cap assembly includes a rear insulating end cap base, a rear transition steel sleeve, a rear edge bearing sleeve, a rear bearing, and a wave spring. The rear insulating end cap base is provided with a rear mounting groove. The rear transition steel sleeve is installed in the rear mounting groove. The wave spring is installed in the rear mounting groove and contacts the end face of the rear bearing. The rear insulating bearing sleeve is installed on the rear bearing, and both are installed in the rear transition steel sleeve. A conductive component includes a conductive ring cover plate and a conductive ring. The conductive ring cover plate has an inner mounting hole, and a plurality of conductive fiber bundles are disposed in the inner hole of the conductive ring. The conductive ring cover plate is detachably mounted on a rear insulating end cap base, and the conductive ring is interference-fitted into the inner mounting hole of the conductive ring cover plate.

[0007] Furthermore, both the front mounting groove of the front insulating end cap base and the rear mounting groove of the rear insulating end cap base are provided with a stop rectangular protrusion ring, and both the outer circumference of the front transition steel sleeve and the rear transition steel sleeve are provided with a stop rectangular ring groove. The stop rectangular protrusion ring can extend into the stop rectangular ring groove for axial positioning.

[0008] Furthermore, the front transition steel sleeve is provided with a plurality of first mounting threaded holes, and the bearing pressure plate is provided with a plurality of first connecting holes. A first bolt is provided in the first connecting hole, and the first bolt passes through the first connecting hole and extends into the first mounting threaded hole.

[0009] Furthermore, the rear insulating end cap base is provided with a plurality of second mounting threaded holes, and the conductive ring cover plate is provided with a plurality of second connecting holes. A second bolt is provided in the second connecting hole, and the second bolt passes through the second connecting hole and extends into the second mounting threaded hole.

[0010] Furthermore, the front and rear insulating bearing sleeves are made of 45# steel and are coated with Teflon.

[0011] Furthermore, the front insulating end cap base, the front transition steel sleeve, the rear insulating end cap base, and the rear transition steel sleeve are all integrally cast.

[0012] Furthermore, the interference fit between the conductive ring and the conductive ring cover plate is 0.02-0.03 mm.

[0013] Furthermore, the insulating gasket is made of epoxy board material and undergoes an aging treatment.

[0014] A new energy drive motor including an insulating end cap assembly for preventing bearing electro-corrosion includes a stator and a rotor. The stator includes a frame and a stator core with windings. The rotor includes a shaft, a rotor core, a rotor pressure plate, a retaining washer, and a round nut. The front insulating end cap assembly is installed at the front end of the shaft, and the rear insulating end cap assembly is installed at the rear end of the shaft. A cylindrical protrusion is provided at the rear end of the shaft. The cylindrical protrusion extends into a conductive ring and contacts and conducts electricity with a plurality of conductive fiber bundles, so that the shaft current is guided to the conductive ring cover plate and then to the ground through the rear insulating end cap substrate.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention employs a design concept combining a front insulating end cap assembly, a rear insulating end cap assembly, and a conductive brush. The front insulating bearing sleeve of the front insulating end cap assembly insulates the front bearing, preventing shaft current from passing through it. Similarly, the rear insulating bearing sleeve of the rear insulating end cap insulates the rear bearing, preventing shaft current from passing through it. The conductive fiber bundles of the conductive ring within the conductive ring cover plate contact the cylindrical protrusion, enabling the shaft to conduct electricity with the conductive ring cover plate. The shaft current is then diverted to ground through the rear insulating end cap substrate, thereby protecting the bearing and preventing electro-corrosion of the bearing by shaft current. This effectively solves the problems of short maintenance cycles and high costs associated with existing motor bearing electro-corrosion prevention solutions.

[0016] 2. This invention uses an interference fit between the inner circle of the conductive ring cover plate and the outer circle of the conductive ring, which realizes the mutual conduction between the cylindrical protrusion of the rotating shaft and the conductive fiber of the conductive ring. When it is necessary to replace the conductive ring of different specifications, only the conductive ring cover plate that matches it needs to be replaced, without replacing the entire rear end cover, thereby effectively simplifying the manufacturing process and reducing production costs.

[0017] 3. The front insulating end cap assembly of the present invention includes a front insulating end cap, an insulating washer, and a bearing pressure plate. The three are provided with a shaft hole mating structure that can achieve axial and radial limiting, ensuring a firm and reliable assembly. The insulating washer and the bearing pressure plate are locked to the front transition steel sleeve of the front insulating end cap base from the outside of the front insulating end cap base by the first bolt, which simplifies the assembly process and facilitates the replacement of parts.

[0018] 4. The rear insulating end cover assembly of the present invention includes a rear insulating end cover base and a wave spring. The axial positioning of the rear bearing can be achieved by the compression of the wave spring, which prevents the axial movement of the motor rotor and improves the reliability of motor operation.

[0019] 5. The conductive component in this invention includes a conductive ring cover plate and a conductive ring. The conductive ring cover plate has the functions of fixing the conductive ring and protecting the rear end cover of the motor. The conductive fiber bundle inside the conductive ring is reliable and wear-resistant, and can communicate with the cylindrical protrusion at the rear end of the shaft to guide the shaft current to the grounding point of the rear insulating end cover substrate, thereby eliminating the shaft current. When the conductive ring needs to be replaced, only the conductive ring cover plate needs to be removed, so the operation is simpler and more convenient, and the assembly process is simplified. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein: Figure 1 This is a schematic diagram of the structure of a new energy drive motor; Figure 2 This is a schematic diagram of the front insulating end cap assembly; Figure 3 Exploded view of the front insulating end cap assembly; Figure 4 This is a schematic diagram of the structure of the rear insulating end cap assembly; Figure 5 This is a schematic diagram of the rotor structure; Figure 6 This is a schematic diagram of the conductive ring structure; Figure 7 The diagram shows the structure of the structure.

[0021] The markings in the diagram are as follows: 1. Front insulating end cap assembly; 101. Front insulating end cap base; 102. Front transition steel sleeve; 103. Front insulating bearing sleeve; 104. Front bearing; 105. Insulating washer; 106. Bearing pressure plate; 107. First bolt; 108. Front mounting groove; 109. Retaining rectangular convex ring; 110. Retaining rectangular ring groove; 2. Stator; 3. Rotor; 301. Shaft; 302. Retaining washer; 303. Round nut; 304. Rotor core; 305. Rotor pressure plate; 306. Cylindrical protrusion; 4. Rear insulating end cap assembly; 401. Rear insulating end cap base; 402. Rear transition steel sleeve; 403. Rear bearing sleeve; 404. Wave spring; 405. Rear bearing; 5. Conductive ring cover plate; 501. Mounting inner hole; 502. Second connecting hole; 6. Conductive ring; 601. Conductive fiber bundle. Detailed Implementation

[0022] In the description of this invention, it should be noted that the directional terms such as "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this invention.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to define a feature may explicitly or implicitly include one or more of that feature. In the description of this invention, "several" or "a number" means two or more, unless otherwise explicitly specified.

[0024] An insulating end cap assembly for preventing bearing electro-corrosion, such as Figure 1-7 As shown, it includes: The front insulating end cap assembly 1 includes a front insulating end cap base 101, a front transition steel sleeve 102, a front insulating bearing sleeve 103, a front bearing 104, an insulating washer 105, and a bearing pressure plate 106. The front insulating end cap base 101 is provided with a front mounting groove 108. The front transition steel sleeve 102 is installed in the front mounting groove 108. The front insulating bearing sleeve 103 is fitted onto the front bearing 104 and both are installed in the front transition steel sleeve 102. The bearing pressure plate 106 is installed on the front transition steel sleeve 102 and abuts against the end face of the front bearing 104 through the insulating washer 105. The rear insulating end cap assembly 4 includes a rear insulating end cap base 401, a rear transition steel sleeve 402, a rear edge bearing sleeve 403, a rear bearing 405, and a wave spring 404. The rear insulating end cap base 401 is provided with a rear mounting groove. The rear transition steel sleeve 402 is installed in the rear mounting groove. The wave spring 404 is installed in the rear mounting groove and contacts the end face of the rear bearing 405. The rear edge bearing sleeve 403 is installed on the rear bearing 405 and both are installed in the rear transition steel sleeve 402. A conductive component includes a conductive ring cover plate 5 and a conductive ring 6. The conductive ring cover plate 5 is provided with an inner mounting hole 501. A plurality of conductive fiber bundles 601 are provided in the inner hole of the conductive ring 6. The conductive ring cover plate 5 is detachably mounted on the rear insulating end cover base 401. The conductive ring 6 is interference-fitted into the inner mounting hole 501 of the conductive ring cover plate 5.

[0025] Preferably, both the front mounting groove 108 of the front insulating end cap base 101 and the rear mounting groove of the rear insulating end cap base 401 are provided with a stop rectangular protrusion ring 109, and both the outer circumference of the front transition steel sleeve 102 and the rear transition steel sleeve 402 are provided with a stop rectangular ring groove 110, and the stop rectangular protrusion ring 109 can extend into the stop rectangular ring groove 110 for axial limiting; Specifically, by setting stop rectangular ring grooves 110 in the mounting grooves of the front and rear insulating end cover bases 101 and 401, and setting corresponding stop rectangular convex rings 109 on the outer circles of the front and rear transition steel sleeves 102 and 402, axial limiting is achieved by using a mechanical interlocking structure; thereby effectively preventing the transition steel sleeves 102 and 402 from displacing due to vibration or axial force during motor operation, ensuring the positioning accuracy of bearings 104 and 405 and insulating sleeves 103 and 403, improving the overall rigidity and stability of the components, and extending their service life.

[0026] Preferably, the front transition steel sleeve 102 is provided with a plurality of first mounting threaded holes, and the bearing pressure plate 106 is provided with a plurality of first connecting holes. A first bolt 107 is provided in the first connecting hole, and the first bolt 107 passes through the first connecting hole and extends into the first mounting threaded hole. Specifically, by setting a first mounting threaded hole on the front transition steel sleeve 102 and a first connecting hole on the bearing pressure plate 106, and fastening it with a first bolt 107, a detachable rigid connection is formed; thereby achieving simple assembly, uniform locking force, and effective compression of the insulating washer 105 and the front bearing 104 to prevent the bearing 104 from moving, while facilitating later maintenance and parts replacement.

[0027] Preferably, the rear insulating end cap base 401 is provided with a plurality of second mounting threaded holes, and the conductive ring cover plate 5 is provided with a plurality of second connecting holes 502. A second bolt is provided in the second connecting hole 502, and the second bolt passes through the second connecting hole 502 and extends into the second mounting threaded hole. Specifically, a second mounting threaded hole is provided on the rear insulating end cover base 401, and a second connecting hole 502 is provided on the conductive ring cover plate 5. The second bolt enables detachable installation. This modular design makes the conductive ring cover plate 5 easy to disassemble and assemble, facilitating the replacement of the conductive ring 6 or maintenance without replacing the entire rear end cover, significantly reducing maintenance costs and time.

[0028] Preferably, the front insulating bearing sleeve 103 and the rear edge bearing sleeve 403 are made of 45# steel and coated with Teflon. Specifically, the front and rear insulating bearing sleeves 103 and 403 use 45# steel as the base to ensure structural strength; the Teflon coating on the surface utilizes its excellent high insulation, wear resistance and low coefficient of friction to meet the mechanical performance requirements of the bearing sleeves 103 and 403, effectively block shaft current from passing through the bearings 104 and 405, prevent electro-corrosion, and reduce wear between the bearings 104 and 405 and the sleeves 103 and 403.

[0029] Preferably, the front insulating end cap base 101, the front transition steel sleeve 102, the rear insulating end cap base 401, and the rear transition steel sleeve 402 are all integrally cast and then machined to assemble the front insulating end cap base 101 and the front transition steel sleeve 102, and the rear insulating end cap base 401 and the rear transition steel sleeve 402. Specifically, the front and rear insulating end cap bases 101 and 401 and the transition steel sleeves 102 and 402 are integrally cast and then machined to ensure fitting accuracy.

[0030] Preferably, the interference fit between the conductive ring 6 and the conductive ring cover plate 5 is 0.02-0.03mm, which relies on elastic deformation to achieve a tight fit, ensuring that the conductive ring 6 does not loosen under high-speed rotation, maintaining stable contact with the protrusion of the rotating shaft 301, and ensuring the reliability of the shaft current output path.

[0031] Preferably, the insulating gasket 105 is made of epoxy board material, which has good insulation performance and mechanical strength. Furthermore, the insulating gasket 105 undergoes aging treatment to improve its heat resistance, moisture resistance, and anti-aging ability, thereby maintaining stable insulation performance under harsh working conditions, extending service life, and reducing faults caused by insulation failure.

[0032] Preferably, the front transition steel sleeve 102 and the rear transition steel sleeve 402 are both made of 45# steel. This material has excellent machinability and strength, is easy to precision machine, ensures the dimensional accuracy and surface quality of the sleeve, and improves the fit quality with the bearings 104, 405 and the insulating sleeves 103, 403.

[0033] Preferably, the front insulating end cap base 101 and the rear insulating end cap base 401 are made of ZL101A cast aluminum. This material is lightweight, has good thermal conductivity and is easy to cast, which effectively reduces the overall weight of the motor and facilitates heat dissipation. At the same time, the cast aluminum base facilitates the grounding of conductive components and introduces shaft current into the ground.

[0034] A new energy drive motor including an insulating end cap assembly for preventing bearing electro-corrosion includes a stator 2 and a rotor 3. The stator 2 includes a frame and a stator core with windings. The rotor 3 includes a shaft 301, a rotor core 304, a rotor pressure plate 305, a retaining washer 302, and a round nut 303. The front insulating end cap assembly 1 is installed at the front end of the shaft 301, and the rear insulating end cap assembly 4 is installed at the rear end of the shaft 301. The rear end of the shaft 301 is provided with a cylindrical protrusion 306. The cylindrical protrusion 306 extends into a conductive ring 6 and contacts and conducts with several conductive fiber bundles 601, so that the shaft current is guided to the conductive ring cover plate 5 and then to the ground through the rear insulating end cap base 401.

[0035] advantage: 1. Fundamentally solve the problem of bearing electro-corrosion: Through the structure of insulating bearing sleeves 103 and 403 and insulating washers 105 in the front and rear insulating end cover assemblies 1 and 4, the path of shaft current through bearings 104 and 405 is completely blocked, avoiding electro-corrosion caused by current discharge between bearing raceways, and significantly extending the service life of bearings 104 and 405.

[0036] 2. Highly efficient shaft current extraction mechanism: The conductive ring 6 in the conductive component contacts the cylindrical protrusion 306 at the rear end of the rotating shaft 301 through the conductive fiber bundle 601, forming a low-resistance path, which reliably guides the shaft current to the rear insulating end cover substrate 401 and connects it to the ground, fundamentally eliminating the harm of shaft current.

[0037] 3. Compact structure and convenient assembly: The modular design and detachable connection (such as the bolt-fixed bearing pressure plate 106 and conductive ring cover plate 5) simplify the assembly and maintenance process, reduce the dependence on professional tools, and improve production and maintenance efficiency.

[0038] 4. High reliability and strong adaptability: The retaining ring groove 110, wave spring 404 and other structures ensure the axial positioning of bearings 104, 405 and sleeves 102, 402, preventing axial movement during motor operation; the insulation and conductive parts are all made of wear-resistant and anti-aging materials, which are suitable for the high speed and high load conditions of new energy motors.

[0039] 5. Low manufacturing cost and good processability: The end cap base 101, 401 and the transition steel sleeve 102, 402 are integrally cast, reducing the number of processing steps; the conductive ring 6 and the cover plate 5 are standardized with interference fit, which facilitates mass production and component replacement, and the overall manufacturing cost is effectively controlled.

[0040] 6. Suitable for high-performance new energy drive motors: The overall structure is lightweight, the insulation performance is reliable, and the conductivity is high, which meets the requirements of electric vehicles, hybrid power and other new energy fields for high efficiency, long life and low maintenance of motors, and has good market application prospects.

[0041] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An insulating end cap assembly for preventing electrical corrosion of a bearing, comprising: The application relates to a front and rear insulation end cover assembly and a conductive assembly. The front insulation end cover assembly comprises a front insulation end cover base, a front transition steel sleeve, a front insulation bearing sleeve, a front bearing, an insulation gasket and a bearing pressing plate, the front insulation end cover base is provided with a front mounting groove, the front transition steel sleeve is mounted in the front mounting groove, the front insulation bearing sleeve is sleeved on the front bearing and both are mounted in the front transition steel sleeve, and the bearing pressing plate is mounted on the front transition steel sleeve and abuts against the end surface of the front bearing through the insulation gasket. The rear insulation end cover assembly comprises a rear insulation end cover base, a rear transition steel sleeve, a rear edge bearing sleeve, a rear bearing and a wave spring, the rear insulation end cover base is provided with a rear mounting groove, the rear transition steel sleeve is mounted in the rear mounting groove, the wave spring is mounted in the rear mounting groove and is in contact with the end surface of the rear bearing, and the rear insulation bearing sleeve is mounted on the rear bearing and both are mounted in the rear transition steel sleeve. The conductive assembly comprises a conductive ring cover plate and a conductive ring, the conductive ring cover plate is provided with a mounting inner hole, a plurality of conductive fiber bundles are arranged at the inner hole of the conductive ring, the conductive ring cover plate is detachably mounted on the rear insulation end cover base, and the conductive ring is mounted in the mounting inner hole of the conductive ring cover plate in an interference fit.

2. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, characterized in that: The front mounting groove of the front insulation end cover base and the rear mounting groove of the rear insulation end cover base are both provided with a stop rectangular convex ring, the outer circle of the front transition steel sleeve and the rear transition steel sleeve is both provided with a stop rectangular ring groove, and the stop rectangular convex ring can extend into the stop rectangular ring groove to limit the axial position.

3. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The front transition steel sleeve is provided with a plurality of first mounting threaded holes, the bearing pressing plate is provided with a plurality of first connecting holes, the first connecting holes are provided with first bolts, and the first bolts extend into the first mounting threaded holes through the first connecting holes.

4. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The rear insulation end cover base is provided with a plurality of second mounting threaded holes, the conductive ring cover plate is provided with a plurality of second connecting holes, the second connecting holes are provided with second bolts, and the second bolts extend into the second mounting threaded holes through the second connecting holes.

5. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The front insulation bearing sleeve and the rear insulation bearing sleeve are made of 45# steel material and are sprayed with a Teflon coating on the surface.

6. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The front insulation end cover base, the front transition steel sleeve, the rear insulation end cover base and the rear transition steel sleeve are integrally formed by casting.

7. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The interference amount of the conductive ring and the conductive ring cover plate is 0.02-0.03 mm.

8. An insulating cap assembly for preventing electric corrosion of a bearing according to claim 1, wherein: The insulation gasket is made of an epoxy plate material and is subjected to aging treatment.

9. A new energy drive motor comprising the insulating end cap assembly for preventing bearing electric corrosion according to any one of claims 1-7. The application further relates to a motor comprising a stator and a rotor, the stator comprises a frame and a stator core with windings, the rotor comprises a rotating shaft, a rotor core, a rotor pressing plate, a stop washer and a round nut, the front insulation end cover assembly is mounted at the front end of the rotating shaft, the rear insulation end cover assembly is mounted at the rear end of the rotating shaft, the rear end of the rotating shaft is provided with a cylindrical protrusion, the cylindrical protrusion extends into the conductive ring and is in contact with the plurality of conductive fiber bundles to guide the shaft current to the conductive ring cover plate and then to the ground through the rear insulation end cover base.

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