Efficient heat dissipation brushless motor and control method thereof

Abstract

The invention relates to the technical field of motors, in particular to an efficient heat dissipation brushless motor and a control method thereof. The technical scheme comprises a motor structure, a cooling structure and a regeneration structure. The motor structure comprises a shell, a stator, a front cover, a rear cover, a rotor, a filter screen and fan blades I; the cooling structure comprises a first pump shell, a first impeller, an annular pipe, a conveying pipe, a first backflow pipe, a cooling box and a second backflow pipe. The linkage structure comprises a ring seat, a supporting shaft and a rotating ring; and the cleaning structure comprises a mounting plate, a brush plate and a brush. Through cooperation of the motor, the cooling structure, the regeneration structure, the linkage structure and the cleaning structure, the linkage structure transmits power to the cleaning structure through rotor power, and the cleaning structure brushes clean a filter screen; a rotor of the cooling structure drives cooling liquid to circulate, the regeneration structure assists cooling of the cooling liquid, diversion driving fan blades strengthen heat dissipation, the functions of efficient heat dissipation, filter screen self-cleaning and cooling liquid regeneration are achieved, and the problems of high temperature of a motor, filter screen blockage and high heat dissipation energy consumption are solved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a high-efficiency heat-dissipating brushless motor and its control method. Background Technology

[0002] Electric vehicles are being used more and more widely in daily life. Due to their advantages such as high efficiency, low noise, and long lifespan, brushless motors are widely used in electric vehicles.

[0003] However, when a brushless motor is running, the stator coil generates heat due to power and the eddy current loss of the rotor permanent magnet will generate a lot of heat. If the heat cannot be dissipated in time, the internal temperature of the motor will rise, which will lead to problems such as aging of the stator coil insulation layer, magnetism decay of the permanent magnet, and increased rotor rotation resistance. This will seriously affect the stability and service life of the motor, and may even cause equipment failure.

[0004] Existing brushless motor cooling solutions mainly rely on single-airflow cooling, which involves the motor's own fan blades driving airflow through the cooling holes to remove heat. However, this method has limited cooling efficiency and is difficult to meet the motor's cooling requirements under high load and long-term operation conditions. Although some motors have added liquid cooling structures, they still require additional coolant pumps and drive motors, which not only increases energy consumption and equipment size but also increases system complexity and failure risk.

[0005] Meanwhile, motor cooling vents are often equipped with filters to prevent dust and impurities from entering the housing. However, these filters are prone to clogging with dust over time, obstructing airflow and further reducing heat dissipation efficiency. Manually cleaning the filters requires periodic shutdowns, increasing maintenance costs and affecting production or equipment continuity. Furthermore, in existing liquid cooling systems, the coolant's cooling and regeneration after absorbing heat is ineffective, relying heavily on natural cooling. This leads to problems such as rapid coolant temperature rise and reduced circulating cooling capacity, failing to provide consistently efficient heat dissipation for the motor.

[0006] In summary, current brushless motors suffer from technical challenges such as low heat dissipation efficiency, easy filter clogging and difficult maintenance, high energy consumption of liquid cooling systems, and poor coolant regeneration. There is an urgent need for a solution integrating efficient heat dissipation, automatic cleaning, and energy-saving regeneration functions to improve the reliability and applicability of brushless motors. Therefore, those skilled in the art have provided a high-efficiency heat-dissipating brushless motor and its control method to address the problems mentioned in the background. Summary of the Invention

[0007] The purpose of this invention is to address the problems existing in the background art by proposing an energy-saving, high-efficiency heat dissipation brushless motor and its control method.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a high-efficiency heat-dissipating brushless motor and its control method, comprising a motor structure, a cooling structure, a regeneration structure, a linkage structure, and a cleaning structure.

[0009] The motor structure includes a housing, a stator located inside the housing, a front cover and a rear cover located at both ends of the housing, a rotor rotatably mounted inside the front cover and the rear cover and located inside the stator, a filter screen located at one end of the rear cover, and a fan blade sleeved on the rotor and located on one side of the filter screen.

[0010] The cooling structure includes a pump casing I located on one side of the upper end of the base and rotatably mounted with the rotor, an impeller I sleeved on the outer wall of the rotor I and rotatably mounted inside the pump casing I, a spiral annular tube sleeved on the outer wall of the casing, a delivery pipe located at the output end of the pump casing I and connected to one end of the annular tube, a return pipe I located at one end of the annular tube, a cooling box located at one end of the return pipe I, and a return pipe II connected to the cooling box and the suction end of the pump casing II.

[0011] The linkage structure includes a ring seat located on one side of the upper end of the base and sleeved on the outside of the rotor, a support shaft rotatably installed at one end of the ring seat, and a rotating ring rotatably installed inside the ring seat.

[0012] The cleaning structure includes a mounting plate located at one end of the rotating ring, a brush plate located on one side of the mounting plate, and a brush located at one end of the brush plate and attached to the filter screen.

[0013] Preferably, the rear cover has equidistantly distributed heat dissipation holes inside, and the heat dissipation holes are located inside the filter screen.

[0014] Preferably, a regeneration structure is provided on one side of the upper end of the base. The regeneration structure includes a partition located inside the cooling box. A flow channel is provided between the partition and the lower end of the cooling box. An expansion valve is provided at one end of the return pipe that passes through the cooling box.

[0015] Preferably, the cooling box is provided with fins inside, the fins extending through the front and rear ends of the cooling box, and the fins are wavy.

[0016] Preferably, the cooling box is provided with bearing brackets at both the front and rear ends, and a mounting shaft is rotatably installed inside the bearing bracket, and a fan blade is sleeved on the outer wall of the mounting shaft.

[0017] Preferably, a pump casing 2 is provided on both the front and rear sides of the cooling box, the mounting shaft is rotatably mounted inside the pump casing 2, and an impeller 2, which is rotatably mounted inside the pump casing 2, is sleeved on the outer wall of the mounting shaft.

[0018] Preferably, one end of the return pipe is provided with a diversion pipe connected to the pump housing, and one end of the pump housing is provided with a diversion pipe connected to the suction end of the pump housing.

[0019] Preferably, a spring is provided between the brush plate and the mounting plate, and a guide rod is provided at one end of the brush plate, which is slidably installed inside the mounting plate and located inside the spring.

[0020] Preferably, the outer wall of the rotating ring is rotatably mounted with balls arranged in a ring array and rolling inside the ring seat. One end of the rotating ring is provided with a toothed ring, and one end of the support shaft is provided with a gear that meshes with the toothed ring. Both the support shaft and the outer wall of the rotor are fitted with synchronous pulleys, and the outer walls of the synchronous pulleys are fitted with belts.

[0021] A control method for a high-efficiency heat-dissipating brushless motor, the steps of which are as follows:

[0022] S1: The stator is made of stacked silicon steel sheets with multiple coils wound around its surface. When DC power is applied, the controller distributes the current to generate a rotatable magnetic field. The rotor, as the rotating part, is mainly composed of permanent magnets. The magnets are arranged with alternating N and S poles. Under the magnetic force of the stator magnetic field, the rotor rotates in the direction of the magnetic field. The controller detects the rotor position in real time through Hall sensors and sequentially energizes the coils of different phases of the stator. The energized stator coils generate a magnetic field, which forms a force of like poles repelling and unlike poles attracting with the magnetic field of the rotor permanent magnets, driving the rotor to rotate. As the rotor rotates, the controller continuously switches the energizing phase of the stator coils so that the stator magnetic field always leads the rotor magnetic field by an angle, continuously generating driving force to keep the rotor rotating at a constant or variable speed. The rotor drives the fan blades to rotate, and the airflow enters the casing through the heat dissipation holes. The airflow enters the casing and effectively removes the heat generated during the operation of the motor, thereby improving the heat dissipation efficiency.

[0023] Meanwhile, the pump casing and impeller in the cooling structure work together to introduce external coolant into the annular pipe. The coolant circulates through the delivery pipe and return pipe. The fins inside the cooling tank further enhance the heat exchange effect, allowing the coolant to cool down quickly and re-enter the circulation. In addition, the baffle and flow channel design in the regeneration structure optimizes the flow path of the coolant, while the expansion valve precisely controls the pressure and flow rate of the coolant to ensure the efficient and stable operation of the entire system.

[0024] S2: During the rotation of the rotor, the impeller generates suction force inside the pump casing, drawing in the regenerated and cooled coolant from the cooling tank and circulating it. The liquid quickly carries away the heat from the motor. At the same time, the rotor transmits the rotational power to the support shaft through the linkage of the synchronous pulley and belt. The support shaft drives the gear to push the gear ring, thereby driving the gear ring to rotate. The rotating ring and the gear ring rotate synchronously, causing the mounting plate on the outer wall to rotate. The mounting plate drives the brush to scrape the outer wall of the filter screen in a decelerating manner. The brush moves slowly on the outer wall of the filter screen through the deceleration cooperation of the gear and the gear ring, scraping and peeling off the dust adhering to the outer wall of the filter screen, thus achieving real-time cleaning of the filter screen.

[0025] S3: In the linkage structure, the cooperation between the support shaft and the rotating ring enables the automatic cleaning function of the brush. When the rotor rotates, the synchronous pulley and belt transmit power to the support shaft, driving the gear to mesh with the gear ring, thereby causing the rotating ring and the mounting plate to move synchronously. The design of the spring and guide rod ensures a constant contact pressure between the brush and the filter screen, ensuring that dust and impurities on the filter screen surface can be removed in time, avoiding blockage that affects heat dissipation performance. This not only improves the reliability of the motor but also significantly reduces maintenance costs. At the same time, the coolant returning through the return pipe will be partially diverted into the pump casing through the distribution pipe. Under the impact of the recirculating coolant, impeller two rotates, driving fan blade two to rotate simultaneously. This pushes the recirculating coolant into the interior of distributor pipe two, and together with return pipe one, it enters the suction end of pump casing one, thus distributing the recirculating coolant. Through the distribution of the recirculating coolant, the rotation of fan blade two is aided, and the airflow around fan blade two increases the heat dissipation effect of the fins, assisting in the cooling and regeneration of the recirculating coolant inside the cooling box. The motor is efficiently cooled through airflow cooling and water cooling. During the cooling process, the coolant is automatically cooled and regenerated without the need for additional electrical equipment, reducing energy consumption.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0027] From the perspective of motor operation and heat dissipation efficiency, this invention enables the stator and rotor of the brushless motor to achieve stable rotation under the control of the controller through precise electromagnetic coordination. At the same time, the rotor drives the fan blades to introduce airflow, which, combined with the coolant circulation driven by the pump casing and impeller, enhances heat exchange through the annular pipe and cooling box fins, forming a dual heat dissipation of airflow and water cooling. This quickly removes heat from the motor, effectively improving heat dissipation efficiency, ensuring long-term stable operation of the motor, and avoiding the impact of high temperature on performance.

[0028] In terms of filter maintenance and cost control, the rotor supports the shaft through synchronous pulleys and belts, which drives the gears and gear rings to drive the brush to decelerate and scrape the filter. The spring and guide rod design ensures constant contact pressure between the brush and the filter, realizing real-time automatic cleaning of the filter, avoiding dust blockage and heat dissipation, greatly reducing the need for manual maintenance and lowering maintenance costs.

[0029] In terms of energy saving and system optimization, the return coolant diversion drives the impeller to rotate, which in turn drives the fan blades to enhance the heat dissipation of the cooling box fins, helping the coolant to automatically cool and regenerate. The entire coolant circulation does not require the participation of additional electrical equipment, which significantly reduces energy consumption and is relatively more energy-efficient. At the same time, the linkage structure integrates cleaning and heat dissipation functions, further improving the overall operating efficiency and reliability of the system. Attached Figure Description

[0030] Figure 1 This is a top-view three-dimensional structural diagram of the present invention; Figure 2 This is a front-view three-dimensional structural schematic diagram of the present invention; Figure 3 This is a front-view three-dimensional structural diagram of the annular tube of the present invention; Figure 4 This is a side view of the three-dimensional structure of the annular tube of the present invention; Figure 5 This is a top-section three-dimensional structural diagram of the pump casing of the present invention; Figure 6 This is a three-dimensional cross-sectional view of one side of the pump casing of the present invention; Figure 7 This is a side sectional perspective view of the cooling box of the present invention. Figure 8 This is a two-view three-dimensional structural diagram of the fan blade of the present invention; Figure 9 This is a side-view perspective three-dimensional structural diagram of the synchronous pulley of the present invention; Figure 10 This is a side-view perspective three-dimensional structural diagram of the ring seat of the present invention; Figure 11 This is a top-section three-dimensional structural diagram of the housing of the present invention; Figure 12 This is a side sectional perspective view of the three-dimensional structure of the housing of the present invention; Figure 13 This is a side view of the three-dimensional structure of the filter screen of the present invention; Figure 14 This is a side-view perspective of the rotating ring structure of the present invention; Figure 15 This is a top-view three-dimensional structural diagram of the rotating ring of the present invention; Figure 16 This is a schematic diagram of the brush plate's three-dimensional structure from the main view.

[0031] Attached reference numerals: 100, Motor structure; 101, Base; 102, Front cover; 103, Housing; 104, Stator; 105, Rear cover; 106, Heat dissipation holes; 107, Rotor; 108, Fan blade 1; 109, Filter screen;

[0032] 200. Cooling structure; 201. Pump casing 1; 202. Delivery pipe; 203. Annular pipe; 204. Return pipe 1; 205. Cooling box; 206. Return pipe 2; 207. Impeller 1;

[0033] 300. Regeneration structure; 301. Baffle plate; 302. Fin; 303. Bearing bracket; 304. Mounting shaft; 305. Fan blade II; 306. Pump casing II; 307. Impeller II; 308. Diverter pipe I; 309. Diverter pipe II;

[0034] 400. Linkage structure; 401. Support shaft; 402. Gear; 403. Rotating ring; 404. Ball bearing; 405. Gear ring; 406. Belt; 407. Synchronous pulley; 408. Ring seat;

[0035] 500. Cleaning structure; 501. Mounting plate; 502. Spring; 503. Brush plate; 504. Brush; 505. Guide rod. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Please see Figures 1 to 16 The present invention provides five embodiments:

[0038] Example 1: A high-efficiency heat-dissipating brushless motor and its control method, comprising a motor structure 100, a cooling structure 200, a regeneration structure 300, a linkage structure 400, and a cleaning structure 500.

[0039] The motor structure 100 includes a housing 103, a stator 104 located inside the housing 103, a front cover 102 and a rear cover 105 located at both ends of the housing 103, a rotor 107 rotatably mounted inside the front cover 102 and the rear cover 105 and located inside the stator 104, a filter screen 109 located at one end of the rear cover 105, and a fan blade 108 sleeved on the rotor 107 and located at one end of the filter screen 109.

[0040] The back cover 105 has equidistantly distributed heat dissipation holes 106 inside, which are located inside the filter screen 109.

[0041] In this embodiment, the core of the motor structure 100 is the electromagnetic interaction between the stator 104 and the rotor 107. The stator 104 is made of stacked silicon steel sheets and has multiple sets of coils wound on its surface. After DC power is applied, the controller will distribute current to the coils of different phases of the stator 104 in sequence according to the position of the rotor 107 detected in real time by the Hall sensor. The coils of the stator 104 after being energized generate a rotatable magnetic field. The rotor 107 is mainly composed of permanent magnets arranged with alternating N and S poles. Under the magnetic force of like poles repelling and unlike poles attracting in the magnetic field of the stator 104, the rotor 107 will rotate in the direction of the magnetic field of the stator 104. At the same time, the controller continuously switches the energizing phase of the coils of the stator 104 so that the magnetic field of the stator 104 always leads the magnetic field of the rotor 107 by a fixed angle, ensuring that the rotor 107 obtains continuous driving force and achieves uniform or variable speed stable rotation, providing core power for the overall operation of the motor.

[0042] When the rotor 107 rotates, it synchronously drives the fan blades 108 fitted on it to rotate. The rotation of the fan blades 108 generates airflow, which passes through the filter 109 located at one end of the rear cover 105. The filter 109 can initially filter dust and impurities in the air to prevent them from entering the housing 103 and causing pollution. Then, it enters the housing 103 through the equidistantly distributed heat dissipation holes 106 inside the rear cover 105. The airflow entering the housing 103 flows through the stator 104, rotor 107 and other core heat-generating components, and exchanges heat with the surface of the components. It carries the heat generated during the operation of the motor out of the housing 103, and finally completes the heat dissipation, forming a complete airflow heat dissipation process of fan blade drive, airflow filtration, perforation into the housing and heat exchange heat dissipation.

[0043] The precise electromagnetic coordination between the stator 104 and the rotor 107, combined with the real-time control of the energizing phase by the controller, enables the rotor 107 to output a stable speed, either at a constant speed or as needed, avoiding speed fluctuations caused by magnetic field misalignment. This provides stable power for the motor to drive the load and reduces equipment malfunctions caused by unstable power. The structure of the fan blade 108, heat dissipation holes 106, and filter 109 creates a targeted airflow heat dissipation channel. The equidistantly distributed heat dissipation holes 106 ensure that airflow enters the housing 103 evenly, fully covering heat-generating components such as the stator 104 and rotor 107, efficiently removing heat and preventing problems such as coil insulation aging and permanent magnet attenuation caused by long-term high-temperature operation, thus extending the service life of the motor's core components.

[0044] The filter 109 at one end of the rear cover 105 can filter out dust, lint and other impurities in the air before the airflow enters the housing 103, preventing impurities from adhering to the surface of the stator 104 coil or entering the rotation gap between the rotor 107 and the front cover 102 and the rear cover 105. This not only avoids impurities affecting the coil heat dissipation efficiency, but also reduces the wear of rotating parts, lowers the probability of motor failure due to impurity contamination, and further improves the reliability of motor operation. The motor drive and basic airflow heat dissipation do not have complex multi-circuit or linkage components, the number of parts is relatively small, and the assembly difficulty is low. During subsequent maintenance, it is only necessary to clean the filter 109 regularly to prevent the filter 109 from being blocked and affecting the airflow, and check whether the fan blade 108 is intact, so as to ensure the normal operation of the structure and reduce the complexity and cost of maintenance operations.

[0045] Example 2:

[0046] The linkage structure 400 includes a ring seat 408 located on one side of the upper end of the base 101 and sleeved on the outside of the rotor 107, a rotating ring 403 rotatably installed inside the ring seat 408, and a support shaft 401 rotatably installed at one end of the ring seat 408.

[0047] A spring 502 is provided between the brush plate 503 and the mounting plate 501. A guide rod 505 is provided at one end of the brush plate 503, which is slidably installed inside the mounting plate 501 and located inside the spring 502.

[0048] The cleaning structure 500 includes a mounting plate 501 located at one end of the rotating ring 403, a brush plate 503 located on one side of the mounting plate 501, and a brush 504 located at one end of the brush plate 503 and attached to the filter screen 109.

[0049] The outer wall of the rotating ring 403 is rotatably mounted with balls 404 arranged in a ring array and rolling inside the ring seat 408. One end of the rotating ring 403 is provided with a gear ring 405, and one end of the support shaft 401 is provided with a gear 402 that meshes with the gear ring 405. Both the support shaft 401 and the outer wall of the rotor 107 are fitted with synchronous pulleys 407, and the outer walls of the synchronous pulleys 407 are fitted with belts 406.

[0050] In this embodiment, when the motor is running, the rotation of the rotor 107 will drive the synchronous pulley 407 sleeved on its outer wall to rotate. Since the outer wall of the support shaft 401 is also sleeved with a synchronous pulley 407, and the two synchronous pulleys 407 are connected by a belt 406, the rotational force of the rotor 107 will be transmitted to the support shaft 401 through the path of the rotor 107 synchronous pulley 407, the belt 406, and the support shaft 401 synchronous pulley 407, driving the support shaft 401 to rotate synchronously at one end of the ring seat 408. A gear 402 is provided at one end of the support shaft 401, and a gear ring 405 that meshes with the gear 402 is provided at one end of the rotating ring 403. When the support shaft 401 rotates, the meshing action of the gear 402 and the gear ring 405 will drive the rotating ring 403 to rotate inside the ring seat 408. The annular array of ball bearings 404 on the outer wall of the rotating ring 403 can reduce its friction with the inner wall of the ring seat 408, ensuring smooth rotation.

[0051] When the rotating ring 403 rotates, the mounting plate 501 connected to one end of it will move synchronously with the rotating ring 403. The brush plate 503 on one side of the mounting plate 501 and the brush 504 at one end of the brush plate 503 will also rotate. Since the brush 504 is always in contact with the filter screen 109 of the motor back cover 105, the brush 504 will scrape the outer wall of the filter screen 109 during the rotation. At the same time, the spring 502 between the brush plate 503 and the mounting plate 501 will generate continuous elastic force. With the help of the guide rod 505 that is slidably installed inside the mounting plate 501 at one end of the brush plate 503, it is ensured that the brush plate 503 only moves in a direction perpendicular to the filter screen 109 to avoid deviation. This ensures that the brush 504 always adheres to the surface of the filter screen 109 with constant pressure. Even if the filter screen 109 has slight deformation or uneven surface, the scraping and cleaning effect can be guaranteed. Finally, the dust and impurities on the surface of the filter screen 109 are removed in real time.

[0052] Without an additional power source, the brush 504 is driven by the rotation of the rotor 107 to scrape the dust and impurities on the outer wall of the filter screen 109 in real time, preventing the filter screen 109 from becoming clogged due to long-term use. This ensures that the airflow driven by the fan blade 108 passes smoothly through the filter screen 109 and the heat dissipation hole 106 into the housing 103, maintaining the unobstructed airflow heat dissipation channel, preventing heat accumulation inside the motor due to the clogging of the filter screen 109, ensuring overall heat dissipation efficiency, realizing automatic cleaning of the filter screen 109, and ensuring unobstructed heat dissipation channel.

[0053] The combined design of spring 502 and guide rod 505 serves two purposes. First, the spring 502 provides constant contact pressure to brush 504, preventing dust residue due to insufficient pressure or wear on filter 109 due to excessive pressure. Second, the guide rod 505 restricts the movement direction of brush plate 503, preventing brush 504 from shifting during cleaning and ensuring that all areas of filter 109 are evenly scraped, thus improving the stability and reliability of cleaning effect. Constant cleaning pressure enhances cleaning reliability. The annular array of balls 404 on the outer wall of rotating ring 403 rolls with the inside of ring seat 408, converting the sliding friction between rotating ring 403 and ring seat 408 into rolling friction, significantly reducing wear on both. Meanwhile, the meshing transmission of gear 402 and gear ring 405, and the linkage of synchronous pulley 407 and belt 406 are mature low-loss transmission methods, reducing energy loss and component wear during power transmission, extending the overall service life of linkage structure 400 and cleaning structure 500. Low-friction design extends the service life of the structure.

[0054] The linkage structure 400 and the cleaning structure 500 directly obtain power from the motor rotor 107, without the need for additional drive components such as motors and cylinders. This simplifies the overall structural layout, reduces potential failure points, and only requires periodic checks of the belt tension 406, the meshing status of the gear 402 and the gear ring 405, and the wear of the brush 504. The maintenance operation is simple, which can significantly reduce the maintenance cost and downtime of the equipment. The high degree of structural integration further reduces maintenance costs.

[0055] Example 3:

[0056] The cooling structure 200 includes a pump casing 201 located on one side of the upper end of the base 101 and rotatably mounted with the rotor 107, an impeller 207 sleeved on the outer wall of the rotor 107 and rotatably mounted inside the pump casing 201, a spiral annular tube 203 sleeved on the outer wall of the housing 103, a delivery tube 202 located at the output end of the pump casing 201 and connected to one end of the annular tube 203, a return pipe 204 located at one end of the annular tube 203, a cooling box 205 located at one end of the return pipe 204, and a return pipe 206 connected to the cooling box 205 and the suction end of the pump casing 306.

[0057] In this embodiment, when the motor is running, the rotation of the rotor 107 synchronously drives the impeller 207, which is sleeved on its outer wall, to rotate. The impeller 207 is rotatably installed inside the pump casing 201, and the pump casing 201 and the rotor 107 maintain a rotational engagement. When the impeller 207 rotates at high speed inside the pump casing 201, it generates a negative pressure suction effect, drawing the cooled coolant from the cooling tank 205 through the return pipe 204. At the same time, the rotational power of the impeller 207 pressurizes the coolant, causing it to flow out from the output end of the pump casing 201 and be precisely delivered to the spiral sleeved on the outer wall of the housing 103 via the delivery pipe 202. The annular tube 203, which is used for heat exchange between the housing 103 and the coolant, adopts a spiral design and fits tightly against the outer wall of the housing 103, maximizing the contact area with the housing 103. When the coolant flows continuously in the annular tube 203, the heat generated by the operation of the stator 104 and rotor 107 inside the housing 103 is transferred to the wall of the annular tube 203 through heat conduction, and then quickly absorbed by the coolant flowing inside the tube. Due to its high specific heat capacity, the coolant can efficiently carry the heat transferred by the housing 103, achieving a rapid drop in the temperature of the housing 103, and indirectly assisting in cooling the core components inside the motor.

[0058] After absorbing heat, the coolant flows along the spiral annular pipe 203 to the end and is then returned to the cooling tank 205 via the return pipe 204, completing one cycle of heat absorption, transportation, and heat dissipation preparation. At the same time, the cooling tank 205 is connected to the suction end of the pump housing 306 via the return pipe 206, which can further transport the cooled coolant to the pump housing 306 according to subsequent heat dissipation needs, providing a reserve and diversion support for the coolant circulation of the entire heat dissipation system, ensuring that the coolant can be recycled and reused throughout the system.

[0059] Enhanced heat dissipation capacity and compensation for the inadequacy of single heat dissipation: The large-area contact design between the spiral annular tube 203 and the housing 103, compared to the traditional local heat dissipation structure, can fully cover the surface of the housing 103, avoiding heat dissipation dead zones. Moreover, the specific heat capacity of liquid is much higher than that of air, and the efficiency of heat absorption by coolant is several times that of airflow heat dissipation. It can quickly reduce the temperature of housing 103, thereby indirectly removing the heat from the stator 104 and rotor 107 inside the motor. This effectively compensates for the efficiency shortcomings of single airflow heat dissipation under high load conditions and ensures the temperature stability of the motor when running at high power.

[0060] With no additional power consumption, the system structure is simplified. The core power of the cooling structure 200 comes directly from the rotation of the motor rotor 107. There is no need to configure an independent coolant pump or drive motor. This power-driven design reduces the system's additional energy consumption, meets energy-saving requirements, and saves the installation space and connection structure of independent power components, simplifies the overall layout, and reduces the system risk caused by the failure of multiple power sources.

[0061] The system features stable and reliable circulation, adapting to a closed-loop pipeline consisting of the delivery pipe 202, return pipe 1 204, and cooling tank 205 for long-term operation. This ensures orderly circulation of coolant, preventing leakage or stagnation. The rotational fit between pump housing 1 201 and rotor 107, and the sealing design between impeller 1 207 and pump housing 1 201, further guarantee the stability of coolant delivery. This meets the heat dissipation requirements of the motor during long-term continuous operation, avoiding heat dissipation failure due to interruption of coolant circulation. The system boasts strong structural compatibility, facilitating system integration. The annular pipe 203 of the cooling structure 200 is directly sleeved on the outer wall of the housing 103, and the pump housing 1 201 is installed on the upper end of the base 101 and linked with the rotor 107. No modification to the internal structure of the motor housing 103 is required, allowing easy adaptation to the existing motor body. Furthermore, the connection design between return pipe 2 206 and pump housing 2 306 provides an interface for subsequent expansion of diversion heat dissipation and auxiliary heat dissipation functions, enhancing the system's scalability and integration.

[0062] Example 4:

[0063] A regeneration structure 300 is provided on one side of the upper end of the base 101. The regeneration structure 300 includes a partition 301 located inside the cooling box 205. The partition 301 and the lower end of the cooling box 205 are provided with flow channels. A return pipe 204 passes through the cooling box 205 and an expansion valve is provided at one end.

[0064] The cooling box 205 is equipped with fins 302 inside, which extend through the front and rear ends of the cooling box 205 and are wavy.

[0065] The front and rear ends of the cooling box 205 are equipped with bearing brackets 303. The bearing brackets 303 have a mounting shaft 304 rotatably installed inside the bearing brackets 303. The outer wall of the mounting shaft 304 is fitted with a fan blade 305.

[0066] Pump casings 306 are provided on both the front and rear sides of the cooling box 205. The mounting shaft 304 is rotatably mounted inside the pump casing 306. An impeller 307, which is rotatably mounted inside the pump casing 306, is sleeved on the outer wall of the mounting shaft 304.

[0067] One end of the return pipe 204 is provided with a diversion pipe 308 that is connected to the pump housing 306, and one end of the pump housing 306 is provided with a diversion pipe 309 that is connected to the suction end of the pump housing 201.

[0068] In this embodiment, the coolant flowing out of the annular pipe 203 and having absorbed the heat of the casing 103 is transported to the cooling tank 205 via the return pipe 204. It first passes through the expansion valve at one end of the return pipe 204 that penetrates the cooling tank 205. The expansion valve can precisely adjust the pressure and flow rate of the coolant according to the actual temperature and circulation requirements of the coolant in the cooling tank 205. This avoids the coolant from staying in the cooling tank 205 for too short a time due to excessive flow and insufficient heat dissipation, or the coolant from being too small and affecting the overall circulation efficiency. This ensures that the coolant enters the cooling tank 205 in a suitable state.

[0069] The baffle 301 inside the cooling tank 205 together with the lower end forms a specific flow channel. The coolant, after being regulated by the expansion valve, will flow in an orderly manner along the flow channel, avoiding local stagnation or short circuit of the coolant in the cooling tank 205, and ensuring that each part of the coolant can fully contact the heat dissipation components. At the same time, the wavy fins 302 that run through the front and rear ends inside the cooling tank 205 have a wavy design that greatly increases the contact area with the coolant. During the flow of the coolant, heat will be quickly transferred to the fins 302, and the fins 302 will then diffuse the heat to the outside of the cooling tank 205, realizing the initial cooling and regeneration of the coolant, and reserving a low-temperature cooling medium for subsequent circulating heat dissipation.

[0070] The coolant delivered by the return pipe 204 does not all directly enter the main channel of the cooling tank 205. A portion of it is delivered through the branch pipe 308 to the pump casings 306 on both sides of the cooling tank 205. The coolant entering the pump casing 306 impacts the impeller 307, which is fitted onto the mounting shaft 304. The impact force of the liquid flow drives the impeller 307 to rotate. Since the impeller 307 is fixedly connected to the mounting shaft 304, the rotation of the impeller 307 drives the mounting shaft 304 to rotate synchronously within the bearing bracket 303, completing the conversion of the coolant's kinetic energy into mechanical rotational energy.

[0071] The fan blade 305, which is sleeved on the outer wall of the mounting shaft 304, rotates together with the mounting shaft 304. The rotation of the fan blade 305 will accelerate the airflow around the cooling box 205. The airflow can quickly carry away the heat transferred from the fins 302 to the outside of the cooling box 205, further improving the heat exchange efficiency between the fins 302 and the coolant, and helping the coolant to cool down quickly in the cooling box 205. At the same time, the rotation of the impeller 307 will also push the coolant in the pump casing 306 to be transported through the diversion pipe 309 to the suction end of the pump casing 201, and re-enter the main circulation pipeline, realizing the full system recycling of the coolant and avoiding the waste of the diverted part of the coolant.

[0072] The expansion valve precisely regulates the coolant pressure and flow rate, and the baffle 301 and flow channel optimize the coolant flow path, ensuring that the coolant flows through the fin area 302 at a reasonable flow rate in the cooling tank 205 without any heat dissipation dead zones. The large contact area design of the wave-shaped fins 302 significantly enhances the heat exchange effect, which can quickly reduce the coolant temperature to the range suitable for circulating heat dissipation, ensuring that the coolant re-entering the main circulation always has a high heat absorption capacity, avoiding the overall heat dissipation efficiency reduction due to excessively high coolant temperature, and ensuring the long-term stable operation of the entire heat dissipation system.

[0073] By using the coolant diversion pressure of the return pipe 204 to drive the impeller 307 and the fan blade 305 to rotate, the air around the cooling box 205 can be accelerated without the need for additional power equipment such as motors and fans, thus enhancing the heat dissipation effect of the fins 302. This design, which uses the kinetic energy of the coolant itself to drive auxiliary heat dissipation, not only reduces the system's additional energy consumption and meets the requirements of energy-saving design, but also avoids the structural complexity and failure risk brought by additional power equipment, thereby reducing the overall energy consumption and maintenance cost of the system.

[0074] The arrangement of splitter pipe 308 and splitter pipe 309 constructs a dual-path coolant flow system consisting of a main circulation (regeneration in cooling tank 205) and an auxiliary circulation (driving fan blades for heat dissipation). A portion of the coolant undergoes core regeneration in cooling tank 205, while the other portion drives auxiliary heat dissipation and then rejoins the main circulation, eliminating coolant waste. Simultaneously, the cooperation between pump housing 306 and impeller 307 ensures smooth return of the split coolant to pump housing 201, maintaining pressure balance throughout the circulation system and significantly improving overall coolant utilization. The bearing bracket 303 provides stable support to the mounting shaft 304, reducing radial sway during impeller 307 and fan blade 305 rotation and minimizing frictional wear between components. The baffles 301 and fins 302 within cooling tank 205 are fixed structures with no complex moving parts, resulting in a low failure rate. The entire regeneration and splitting system is integrated around cooling tank 205, consistent with the cooling system in Embodiment 3. The structure 200 is seamlessly integrated, requiring no major modifications to the main motor structure. This facilitates assembly and integration, reduces component wear caused by structural conflicts, and extends the lifespan of the entire cooling system. The synergistic effect of fan blade 305 and fins 302 adds forced air cooling assistance to the original coolant regeneration, forming a composite cooling mode of liquid cooling plus air cooling. Even when the motor is under high load and high heat conditions, it can quickly dissipate heat, preventing excessive temperature from affecting motor performance. This redundant cooling design allows the motor to adapt to a wider range of application scenarios and improves its environmental adaptability.

[0075] Example 5:

[0076] The control steps for a high-efficiency heat dissipation brushless motor are as follows:

[0077] S1: The stator 104 is made of laminated silicon steel sheets with multiple sets of coils wound around its surface. When DC power is applied, the controller distributes the current to generate a rotatable magnetic field. The rotor 107, as the rotating part, is mainly composed of permanent magnets. The magnets are arranged with alternating N and S poles. Under the magnetic force of the stator 104's magnetic field, they rotate in the direction of the magnetic field. The controller detects the position of the rotor 107 in real time through Hall sensors and sequentially energizes the coils of different phases of the stator 104. The energized coils of the stator 104 generate a magnetic field, which interacts with the magnetic field of the permanent magnets in the rotor 107. The forces of like poles repulsing and unlike poles attracting drive the rotor 107 to rotate. As the rotor 107 rotates, the controller continuously switches the energizing phase of the stator 104 coil, ensuring that the magnetic field of the stator 104 always leads the magnetic field of the rotor 107 by an angle, continuously generating driving force to keep the rotor 107 rotating at a constant or variable speed. The rotor 107 drives the fan blades to rotate, and the airflow enters the housing 103 through the heat dissipation holes 106. The airflow effectively removes the heat generated during the operation of the motor, thereby improving the heat dissipation efficiency.

[0078] Meanwhile, the pump casing 201 and impeller 207 in the cooling structure 200 work together to introduce external coolant into the annular pipe 203. The coolant circulates through the delivery pipe 202 and the return pipe 204. The fins 302 inside the cooling tank 205 further enhance the heat exchange effect, enabling the coolant to cool down quickly and re-enter the circulation. In addition, the baffle 301 and flow channel design in the regeneration structure 300 optimize the flow path of the coolant, while the expansion valve precisely controls the pressure and flow rate of the coolant to ensure the efficient and stable operation of the entire system.

[0079] S2: During the rotation of rotor 107, the impeller 207 generates suction force inside pump casing 201, drawing in the regenerated and cooled coolant from cooling tank 205 for circulation. The liquid quickly carries away the heat of the motor. At the same time, rotor 107 transmits rotational power to support shaft 401 through the linkage of synchronous pulley 407 and belt 406. Support shaft 401 drives gear 402 to push gear ring 405, thereby driving gear ring 405 to rotate. Rotating ring 403 rotates synchronously with gear ring 405, driving mounting plate 501 on the outer wall to rotate. Mounting plate 501 drives brush 504 to scrape the outer wall of filter screen 109 in a decelerated manner. Brush 504, through the deceleration cooperation of gear 402 and gear ring 405, slowly moves on the outer wall of filter screen 109, scraping and peeling off the dust adhering to the outer wall of filter screen 109, realizing real-time cleaning of filter screen 109.

[0080] S3: In the linkage structure 400, the cooperation between the support shaft 401 and the rotating ring 403 enables the automatic cleaning function of the brush 504. When the rotor 107 rotates, the synchronous pulley 407 and the belt 406 transmit power to the support shaft 401, driving the gear 402 to mesh with the gear ring 405, thereby causing the rotating ring 403 and the mounting plate 501 to move synchronously. The design of the spring 502 and the guide rod 505 ensures a constant contact pressure between the brush 504 and the filter screen 109, ensuring that dust and impurities on the surface of the filter screen 109 can be removed in time, avoiding blockage that affects heat dissipation performance. This not only improves the reliability of the motor but also significantly reduces maintenance costs. At the same time, the coolant returning through the return pipe will pass through the diversion pipe... Part 308 is diverted into the pump casing 2 306. Under the impact of the returning coolant, the impeller 2 307 rotates, driving the fan blade 2 305 to rotate. At the same time, it pushes the returning coolant into the diversion pipe 2 309 and together with the return pipe 1 204, enters the suction end of the pump casing 1 201, realizing the distribution of the returning coolant. Through the distribution of the returning coolant, the rotation of the fan blade 2 305 is assisted. The air flow around the fan blade 2 305 increases the heat dissipation effect of the fins 302 and assists in the cooling and regeneration of the returning coolant inside the cooling box 205. The motor is efficiently cooled through airflow cooling and water cooling. During the heat dissipation process, the coolant is automatically cooled and regenerated without the need for additional electrical equipment, reducing energy consumption.

[0081] The above specific embodiments are merely several preferred embodiments of the present invention. Based on the technical solutions of the present invention and the relevant teachings of the above embodiments, those skilled in the art can make various alternative improvements and combinations to the above specific embodiments.

[0082] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-efficiency heat-dissipation brushless motor, comprising a motor structure (100), a cooling structure (200), a regeneration structure (300), a linkage structure (400) and a cleaning structure (500), characterized in that: the motor structure (100) comprises a casing (103), a stator (104) located inside the casing (103), a front cover (102) and a rear cover (105) located at both ends of the casing (103), a rotor (107) rotatably installed inside the front cover (102) and the rear cover (105) and located inside the stator (104), a filter screen (109) located at one end of the rear cover (105), and a fan blade I (108) sleeved on the rotor (107) and located at one end of the filter screen (109); the cooling structure (200) comprises a pump shell I (201) located at one side of the upper end of the base (101) and rotatably installed with the rotor (107), an impeller I (207) sleeved on an outer wall of the rotor (107) and rotatably installed inside the pump shell I (201), an annular pipe (203) spirally sleeved on an outer wall of the casing (103), a delivery pipe (202) located at an output end of the pump shell I (201) and in communication with one end of the annular pipe (203), a backflow pipe I (204) located at one end of the annular pipe (203), a cooling box (205) located at one end of the backflow pipe I (204), and a backflow pipe II (206) in communication with the cooling box (205) and a suction end of the pump shell II (306); the linkage structure (400) comprises a ring seat (408) located at one side of the upper end of the base (101) and sleeved on the outer side of the rotor (107), a support shaft (401) rotatably installed at one end of the ring seat (408), and a rotating ring (403) rotatably installed inside the ring seat (408); the cleaning structure (500) comprises a mounting plate (501) located at one end of the rotating ring (403), a brush plate (503) located at one side of the mounting plate (501), and a brush (504) located at one end of the brush plate (503) and abutting against the filter screen (109).

2. The high efficient heat dissipation brushless motor according to claim 1, characterized in that: The rear cover (105) is internally provided with equidistantly distributed heat dissipation holes (106), and the heat dissipation holes (106) are located inside the filter screen (109).

3. The high efficient heat dissipation brushless motor according to claim 1, characterized in that: A regeneration structure (300) is arranged at one side of the upper end of the base (101), and the regeneration structure (300) comprises a partition plate (301) located inside the cooling box (205), a flow channel is arranged inside the partition plate (301) and the lower end of the cooling box (205), and an expansion valve is arranged at one end of the cooling box (205) through the backflow pipe I (204).

4. The high efficiency heat dissipation brushless motor of claim 1, wherein: The cooling box (205) is internally provided with fins (302), the fins (302) penetrate through the front and rear ends of the cooling box (205), and the fins (302) are in a wave shape.

5. The high efficiency heat dissipation brushless motor of claim 1, wherein: Bearing supports (303) are arranged at the front and rear ends of the front end of the cooling box (205), mounting shafts (304) are rotatably installed inside the bearing supports (303), and fan blades II (305) are sleeved on the outer walls of the mounting shafts (304).

6. A high efficiency heat dissipating brushless motor according to claim 5, characterized in that: The cooling box (205) is provided with pump shell two (306) on both sides, the mounting shaft (304) is rotatably installed in the pump shell two (306), and the mounting shaft (304) is provided with an impeller two (307) rotatably installed in the pump shell two (306).

7. A high efficiency heat dissipating brushless motor according to claim 6, characterized in that: One end of the return pipe one (204) is provided with a shunt pipe one (308) communicated with the pump shell two (306), and one end of the pump shell two (306) is provided with a shunt pipe two (309) communicated with the suction end of the pump shell one (201).

8. The high efficiency heat dissipation brushless motor of claim 1, wherein: The spring (502) is arranged between the brush plate (503) and the mounting plate (501), one end of the brush plate (503) is provided with a guide rod (505) slidably installed in the mounting plate (501) and located in the spring (502).

9. The high efficiency heat dissipation brushless motor of claim 1, wherein: The rotating ring (403) is rotatably installed with the rolling balls (404) arranged in an annular array and rolling in the ring seat (408), one end of the rotating ring (403) is provided with a gear ring (405), one end of the support shaft (401) is provided with a gear (402) engaged with the gear ring (405), the support shaft (401) and the rotor (107) are both provided with the synchronous wheels (407), and the synchronous wheels (407) are both provided with the belts (406).

10. A control method of a high-efficiency heat-dissipation brushless motor, characterized by: The control method of the high-efficiency heat dissipation brushless motor comprises the following steps: S1: the stator (104) is made of silicon steel sheets, and a plurality of coils are wound on the surface; after direct current is input, the controller distributes the current to generate a rotatable magnetic field; the rotor (107) is a rotating part and mainly composed of permanent magnets; the magnetic steel is arranged alternately in N and S poles; under the magnetic force of the stator (104) magnetic field, the rotor (107) rotates along the magnetic field direction; the controller detects the position of the rotor (107) in real time through the Hall sensor, and sequentially electrifies the coils of different phases of the stator (104); the coils of the stator (104) after electrification generate a magnetic field, which forms an attractive force with the magnetic field of the rotor (107) permanent magnet, pushes the rotor (107) to rotate, and the controller continuously switches the electrification phase of the stator (104) coil, so that the stator (104) magnetic field always leads the rotor (107) magnetic field by one angle, continuously generates driving force, and makes the rotor (107) keep uniform or variable speed rotation; the rotor (107) drives the fan blade to rotate, the airflow enters the machine shell (103) through the heat dissipation hole (106), the airflow enters the machine shell (103), effectively takes away the heat generated in the process of motor operation, and improves the heat dissipation efficiency. At the same time, the pump shell one (201) and impeller one (207) in the cooling structure (200) work together to introduce external cooling liquid into the annular pipe (203), realize the circulating flow of the cooling liquid through the delivery pipe (202) and the return pipe one (204), and further enhance the heat exchange effect of the fins (302) inside the cooling box (205), so that the cooling liquid can be quickly cooled and participate in the circulation again. In addition, the partition (301) and flow channel design in the regeneration structure (300) optimize the flow path of the cooling liquid, and the expansion valve precisely controls the pressure and flow of the cooling liquid, ensuring efficient and stable operation of the entire system. S2: In the process of rotating the rotor (107), the impeller one (207) generates suction inside the pump shell one (201) to suck the cooled cooling liquid in the cooling box (205) into circulation, which quickly carries away the heat of the motor through the liquid, and at the same time, the rotor (107) synchronously drives the support shaft (401) through the linkage of the synchronous wheel (407) and the belt (406), the support shaft (401) drives the gear (402) to push the gear ring (405), and then drives the gear ring (405) to rotate, the rotating ring (403) and the gear ring (405) rotate synchronously, and the outer wall of the mounting plate (501) rotates, the mounting plate (501) drives the brush (504) to scrape the outer wall of the filter screen (109) in a deceleration manner, the brush (504) is slowly walking on the outer wall of the filter screen (109) through the deceleration cooperation of the gear (402) and the gear ring (405), and the dust adhered to the outer wall of the filter screen (109) is scraped and peeled off, realizing the real-time cleaning of the filter screen (109). S3: In the linkage structure (400), the cooperation of the support shaft (401) and the rotating ring (403) realizes the automatic cleaning function of the brush (504). When the rotor (107) rotates, the synchronous wheel (407) and the belt (406) transmit power to the support shaft (401), drive the gear (402) to mesh with the gear ring (405), so that the rotating ring (403) and the mounting plate (501) move synchronously. The design of the spring (502) and the guide rod (505) ensures the constant contact pressure between the brush (504) and the filter screen (109), ensures that the dust and impurities on the surface of the filter screen (109) can be removed in time, avoids the blockage affecting the heat dissipation performance, not only improves the reliability of the motor, but also greatly reduces the maintenance cost. At the same time, the cooling liquid flowing back through the shunt pipe one (308) is partially shunted into the pump shell two (306). Under the impact of the backflow cooling liquid, the impeller two (307) rotates, driving the fan blade two (305) to rotate, pushing the backflow cooling liquid into the shunt pipe two (309) and entering the suction end of the pump shell one (201) together with the backflow pipe one (204), realizing the distribution of the backflow cooling liquid. Through the distribution of the backflow cooling liquid, the rotation of the fan blade two (305) is assisted, the gas flow around the fan blade two (305) increases the heat dissipation effect of the fin (302), and the cooling of the cooling box (205) is assisted. The backflow cooling liquid in the internal regeneration, through air cooling and water cooling, the motor is efficiently cooled, and the cooling liquid is automatically cooled and regenerated in the cooling process without the participation of additional power equipment, reducing energy consumption.

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