Temperature-control-based dustproof motor with adjustable stator and rotor gap and control method thereof

Abstract

The invention discloses a dustproof motor with an adjustable stator and rotor gap based on temperature control and a control method thereof. The motor comprises an outer rotor assembly, an inner stator assembly and a radial working air gap arranged between the outer rotor assembly and the inner stator assembly. The core is that a thermal actuator is arranged in the outer rotor assembly, and the thermal actuator can respond to an instruction of the control assembly and drive a magnetic shoe mounting part of the outer rotor assembly to generate controllable radial elastic deformation through radial size change caused by temperature change of the thermal actuator, so that stepless adjustment of the width of a working air gap is realized. According to the control method, the temperature or the real-time rotating speed of the motor winding is monitored and compared with a preset threshold value, a control instruction is dynamically generated, and the current leading to the thermal actuator is linearly adjusted. The technical problems that a traditional motor is stuck, burnt down and reduced in power due to the fact that dust is easily accumulated in a fixed air gap are solved, the air gap is automatically increased at high temperature or high load to facilitate dust removal and heat dissipation, the small air gap is recovered under normal working conditions to guarantee efficiency, and the reliability and the self-adaptive capacity of the motor in a severe environment are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to a temperature-controlled adjustable stator-rotor gap dustproof motor and its control method. Background Technology

[0002] Existing motors, especially those used in harsh operating conditions, often suffer from dust and sand clogging the gap between the stator and rotor, causing the rotor to seize up due to excessive dust accumulation, which in turn leads to motor burnout and damage.

[0003] Secondly, in order to achieve a higher power conversion rate, the gap between the stator and rotor in existing motors is very small, generally around 0.5 mm. Since this gap is relatively fixed, and the motor itself has a built-in cooling fan to dissipate heat from the stator and rotor, it's easy for dust or sand to be blown into the motor's internal structure by the fan under harsh operating conditions. Over time, this dust accumulation can reduce the gap between the stator and rotor, leading to instantaneous overheating when the motor first starts due to insufficient torque and inertia, causing the motor to seize up or internal coils to burn out. In some cases, dust accumulation also prevents the motor from performing at its full power capacity under excessive load during high-load operation.

[0004] In summary, there is an urgent need for a motor that can automatically adjust the gap between the stator and rotor based on the motor load and its internal temperature, thereby preventing the motor from overheating and seizing due to dust or the coils from burning out. At the same time, it can automatically adjust the gap between the stator and rotor and reduce the motor power to prevent the motor from burning out when the motor is operating under high load and the internal dust accumulation causes insufficient power or internal overheating. Summary of the Invention

[0005] This application provides a temperature-controlled adjustable stator-rotor gap dustproof motor and its control method to solve the technical problems of existing motors that are prone to dust accumulation due to fixed stator-rotor gap, resulting in rotor jamming, motor burnout, and inability to perform normally under high load.

[0006] The following technical solution is adopted: a temperature-controlled adjustable stator-rotor gap dustproof motor, comprising: External rotor assembly; The front cover and the rear cover are respectively located at both ends of the outer rotor assembly and together with the outer rotor assembly form a cavity; The inner stator assembly is fixedly installed in the cavity. The inner stator assembly and the outer rotor assembly are coaxially aligned around a rotating shaft, and a radial working air gap is formed between the outer peripheral surface of the inner stator assembly and the inner peripheral surface of the outer rotor assembly. At least one thermal actuator, disposed within the outer rotor assembly, is configured to generate a radial dimensional change in response to its own temperature change, and to drive the magnetic tile mounting portion of the outer rotor assembly to generate radial elastic deformation via a transmission structure, thereby adjusting the width of the working air gap. And a control component, electrically connected to the thermal actuator, for regulating its temperature by controlling the current flowing to the thermal actuator.

[0007] Furthermore, the outer rotor assembly includes a motor cylinder and multiple magnetic tile assemblies fixed therein. Multiple radial supports are evenly arranged on the inner wall of the motor cylinder. The magnetic tile assemblies and thermal actuators are alternately embedded between two adjacent supports.

[0008] Furthermore, the thermal actuator includes a first thermoelastic body and a second thermoelastic body; the first thermoelastic body is axially disposed between the motor cylinder and the first end face of the magnetic tile assembly; the second thermoelastic body is axially disposed between the bracket and the second end face of the magnetic tile assembly; and heating elements are embedded inside both the first thermoelastic body and the second thermoelastic body.

[0009] Furthermore, each magnetic tile assembly has a first driving groove on the outer side of both ends and a second driving groove on the other side; a first thermoelastic body abuts against the inner wall of the first driving groove, and a second thermoelastic body abuts against the inner wall of the second driving groove.

[0010] In this process, the heating elements corresponding to the first and second thermoelastic bodies are energized to drive the first and second thermoelastic bodies to deform, thereby driving the magnetic tile assembly to move along the radial direction of the motor to adjust the width of the working air gap.

[0011] Furthermore, the width of the working air gap is between 0.3mm and 1.3mm.

[0012] Furthermore, the control components include: a controller, which is fixedly mounted on one side of the outer rotor assembly and electrically connected to the heating element; and a power supply support, which is fixedly connected to one end of the inner stator assembly and electrically connected to the controller.

[0013] Furthermore, the controller includes an outer power supply ring and an inner power supply ring; the outer power supply ring is electrically connected to the heating element in each of the first thermoelastic bodies; the inner power supply ring is electrically connected to the heating element in each of the second thermoelastic bodies; the controller also includes a temperature sensor and a control chip; the temperature sensor is disposed on the outer power supply ring and / or the inner power supply ring and is used to detect the temperature of the power supply ring; the control chip is signal-connected to the temperature sensor and is used to control the current output to the heating element according to the feedback of the temperature sensor.

[0014] Furthermore, the power supply support is equipped with at least two electrical contacts; the electrical contacts slide in contact with the outer power supply coil and the inner power supply coil respectively, and are connected to an external power source through a communication line.

[0015] Furthermore, the electrical contact includes a conductive ball and a compression spring; the conductive ball is slidably embedded in the power supply support; the compression spring is disposed between the conductive ball and the power supply support to provide a preload force to the conductive ball toward the power supply coil.

[0016] Furthermore, the two ends of the rotating shaft are fixed by motor mounting brackets; the inner stator assembly is coaxially fixedly connected to the rotating shaft; the middle of the front cover and the rear cover is hollowed out and is rotatably connected to the rotating shaft through bearings; fan blades are integrated on the front cover.

[0017] This application also discloses the following technical solutions: A control method for a temperature-controlled, adjustable stator-rotor gap dustproof motor includes the following steps: Monitoring steps: Obtain the real-time temperature of the motor windings or the real-time speed of the motor as operating parameters; Decision-making steps: Compare the operating parameters with preset thresholds and generate corresponding temperature control commands based on the comparison results; Specifically, when the operating parameter is real-time temperature, if the temperature is higher than the first temperature threshold, an instruction to increase the working air gap is generated; if the temperature is lower than the second temperature threshold, an instruction to decrease the working air gap is generated. When the operating parameter is real-time speed, if the speed is higher than the first speed threshold, an instruction to decrease the working air gap is generated; if the speed is lower than the second speed threshold, an instruction to increase the working air gap is generated. Execution steps: The temperature control command is output to the control component, and the temperature of the thermal actuator is changed by linearly adjusting the current to the thermal actuator, thereby driving the magnetic tile mounting part of the outer rotor assembly to produce radial elastic deformation, and then steplessly adjusting the width of the working air gap to the target range.

[0018] The beneficial effects of this invention are as follows: This application utilizes a thermal actuator to respond to changes in temperature or rotational speed, driving the magnetic tile mounting section to move radially, thus achieving online and dynamic adjustment of the working air gap. When the motor overheats or operates at abnormal speed (due to dust accumulation resistance), the system automatically increases the air gap to provide a channel for dust discharge; under normal operating conditions, it restores a smaller air gap to ensure efficiency. This adaptive mechanism fundamentally solves the persistent problems of rotor jamming, starting failure, and winding burnout caused by dust accumulation in traditional fixed-gap motors, significantly improving the reliability and lifespan of the motor in harsh dusty environments.

[0019] Secondly, this application employs first and second thermoelastic bodies applied to different positions of the magnetic tile assembly. By controlling the heating current linearly through a control chip, bidirectional, stepless, and precise control of the air gap increase and decrease is achieved. This not only avoids mechanical shocks caused by sudden changes in the air gap but also precisely maintains the air gap within the target range based on real-time operating conditions. Thus, a small air gap is maintained when high torque and efficiency are required, while the air gap is appropriately increased when heat dissipation and dust removal are needed. This dynamically finds the optimal balance between the conflicting demands of efficient motor operation and dust removal, optimizing overall performance.

[0020] Meanwhile, the interlocking design of the drive slot and thermoelastic body on the magnetic tile assembly, the alternating layout of the support in the motor cylinder, and the sliding contact between the conductive ball and the power supply coil, together constitute an efficient and reliable force and electricity transmission path. This structure not only concentrates and uniformly converts thermal expansion force into radial displacement, reducing energy loss, but also ensures the continuity of power supply and control under high-speed rotation and vibration environments. The overall structure has good rigidity and strong fatigue resistance, achieving long-life stable operation of the air gap adjustment function.

[0021] Furthermore, this application integrates control components centered on temperature sensors and control chips, forming a closed-loop feedback control system based on motor winding temperature or real-time speed. This system can proactively predict risks (such as early signs of overheating) and trigger air gap adjustment and enhanced cooling by the integrated fan. It not only assists in dust removal and cooling by increasing the air gap but also effectively prevents cascading failures caused by dust accumulation and overheating of the motor through enhanced direct air cooling, thus achieving intelligent operation and maintenance. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings of the embodiments will be briefly introduced below. Obviously, the drawings described below only involve some embodiments of this application and are not intended to limit this application.

[0023] Figure 1 This is a schematic diagram of the appearance of the dustproof motor of this application; Figure 2 This is a schematic diagram of the dustproof motor of this application from another angle; Figure 3 This is an exploded view of the dustproof motor of this application; Figure 4 This is a horizontal sectional view of the dustproof motor of this application; Figure 5 This is an exploded view of the outer rotor assembly, magnetic tile assembly, and thermal actuator of the dustproof motor of this application; Figure 6 This is a schematic diagram of the appearance of the control component in this application; Figure 7 This is an exploded view of the inner stator assembly, power supply support, and electrical contacts in this application; Figure 8 This application Figure 2 Sectional view of AA; Figure 9 This is an assembly diagram of the outer rotor assembly and magnet assembly of the dustproof motor of this application; Figure 10 This is a structural cross-sectional view of the power supply support and controller of the dustproof motor of this application; Figure 11 This is a flowchart of the control method of this application.

[0024] Explanation of reference numerals in the attached figures: 100. External rotor assembly; 110. Motor cylinder body; 111. Bracket; 120. Magnet assembly; 121. First drive slot; 122. Second drive slot; 210. Front cover; 211. Fan blades; 220. Rear cover; 230. Bearing; 300. Inner stator assembly; 400. Rotary shaft; 410. Motor mounting bracket; 510. Thermal actuator; 511. First thermoelastic body; 512. Second thermoelastic body; 513. Heating element; 600. Control component; 610. Controller; 611. External power supply coil; 612. Internal power supply coil; 613. Temperature sensor; 614. Control chip; 620. Power supply bracket; 621. Electrical contact; 621a. Conductive ball; 621b. Compression spring; 630. Communication line. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the application will be further described in detail below with reference to the accompanying drawings. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0026] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0027] Unless otherwise defined, the technical or scientific terms used in this patent document shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms “first,” “second,” and similar terms used in this patent specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an,” “a,” or “the,” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising,” “including,” and similar terms mean that the element or object preceding “comprising” or “including” encompasses the element or object listed following “comprising” or “including” and its equivalents, and do not exclude other elements or objects. Terms such as “center,” “upper,” “lower,” “left,” “right,” “vertical,” “horizontal,” “inner,” and “outer” are used only to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly. These terms are only for the convenience of describing this application 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, and therefore should not be construed as a limitation of this application.

[0028] This application provides a temperature-controlled adjustable stator-rotor gap dustproof motor and its control method, aiming to solve the technical problem that existing motors are prone to dust accumulation under harsh operating conditions due to a fixed stator-rotor gap, leading to rotor jamming, motor burnout, and inability to achieve normal power output under high loads. The core of this invention lies in using a thermal actuator to respond to temperature changes, driving the magnetic tile mounting portion of the outer rotor assembly to produce radial elastic deformation, thereby dynamically adjusting the width of the working air gap. This design allows the motor to automatically increase the air gap under high temperature or high load conditions to facilitate dust removal, while reverting to a smaller air gap under normal conditions to ensure motor efficiency, fundamentally avoiding performance degradation and malfunctions caused by dust accumulation.

[0029] Example 1: Basic Structure and Working Principle refer to Figures 1 to 4 This embodiment provides a basic structure for a temperature-controlled, adjustable stator-rotor gap dustproof motor. The motor includes an outer rotor assembly 100, a front end cover 210, a rear end cover 220, an inner stator assembly 300, a rotating shaft 400, a thermal actuator 510, and a control assembly 600.

[0030] The outer rotor assembly 100 constitutes the rotating part of the motor, and multiple magnet assemblies 120 are fixed inside it. A front end cover 210 and a rear end cover 220 are respectively disposed at both ends of the outer rotor assembly 100, forming a cavity together with the outer rotor assembly 100. The inner stator assembly 300 is fixedly disposed within this cavity and is coaxially aligned with the outer rotor assembly 100 around the rotating shaft 400. A radial working air gap is formed between the outer peripheral surface of the inner stator assembly 300 and the inner peripheral surface of the outer rotor assembly 100. The width of this air gap is typically designed to be approximately 0.5 mm to achieve higher power conversion efficiency.

[0031] A thermal actuator 510 is disposed within the outer rotor assembly 100 and is configured to produce radial dimensional changes in response to its own temperature variations. The thermal actuator 510 drives radial elastic deformation of the magnetic tile mounting portion of the outer rotor assembly 100, thereby adjusting the width of the working air gap. A control assembly 600 is electrically connected to the thermal actuator 510 and is used to regulate its temperature by controlling the current flowing through the thermal actuator 510.

[0032] When the motor operates in harsh environments (such as deserts or mines), dust can easily intrude into the working air gap. Dust accumulation reduces the effective width of the air gap, increasing rotor rotation resistance. In this situation, the control component 600 monitors the temperature of the motor windings or the motor speed to determine if air gap adjustment is necessary. If the temperature is too high or the speed is abnormal, the control component 600 outputs current to the thermal actuator 510, raising its temperature. One side of the thermal actuator 510 expands due to heat, pushing the magnet mounting portion outward radially, thereby increasing the working air gap. The increased air gap allows accumulated dust to be thrown out during rotor rotation or discharged through airflow, restoring normal motor operation. When the temperature decreases or the speed returns to normal, the control component 600 controls the thermal actuator 510 on the other side to heat up, forcing the magnet mounting portion to move in the opposite direction, restoring the air gap to its smaller width and ensuring motor efficiency.

[0033] This embodiment effectively solves the problems of rotor jamming and motor burnout caused by dust accumulation by dynamically adjusting the working air gap. Traditional motors have a fixed air gap, making it impossible to automatically remove accumulated dust. This design, however, allows the air gap to increase when needed, promoting dust removal and thus preventing malfunctions. Furthermore, the air gap adjustment is based on temperature or speed feedback, achieving adaptive control and ensuring the motor's reliability and lifespan under various operating conditions.

[0034] Example 2:

[0035] refer to Figure 5 and Figure 9This embodiment optimizes the outer rotor assembly 100 based on embodiment 1. The outer rotor assembly 100 includes a motor cylinder 110 and a plurality of magnetic tile assemblies 120 fixed therein. A plurality of radial supports 111 are uniformly arranged circumferentially on the inner wall of the motor cylinder 110, and the magnetic tile assemblies 120 and the thermal actuator 510 are alternately embedded between two adjacent supports 111.

[0036] Specifically, the bracket 111 extends radially inward from the inner wall of the motor cylinder 110, forming multiple mounting slots. The magnetic tile assembly 120 and the thermal actuator 510 are alternately embedded in these mounting slots to ensure uniform circumferential distribution. This arrangement not only improves the structural stability of the outer rotor assembly 100 but also provides an efficient transmission path for the thermal actuator 510.

[0037] Because the magnetic tile assembly 120 and the thermal actuator 510 are alternately arranged, the temperature change of the thermal actuator 510 can directly affect the adjacent magnetic tile assembly 120. When the thermal actuator 510 expands due to heat, its radial dimension increases, pushing the magnetic tile assembly 120 towards the inner wall of the motor cylinder 110, thereby changing the air gap width between it and the inner stator assembly 300, ensuring the uniformity and consistency of air gap adjustment, and avoiding local stress concentration.

[0038] Furthermore, since thermal actuators 510 are respectively provided on both sides of the magnetic tile assembly 120, the magnetic tile assembly 120 can be moved in the motor cylinder 110 by controlling the operation of the thermal actuators 510 at both ends, thereby adjusting the width of the air gap in an adaptive manner.

[0039] This embodiment achieves precise control of the air gap adjustment by optimizing the structure of the outer rotor assembly. The alternating layout allows the thermal actuator 510 to directly drive the magnetic tile assembly 120, reducing transmission losses and improving response speed. At the same time, the bracket 111 enhances the rigidity of the motor cylinder 110, preventing fatigue damage under repeated deformation.

[0040] Example 3: Detailed Implementation of Thermal Actuator refer to Figure 5 , Figure 8 and Figure 9 This embodiment describes the structure of the thermal actuator 510 in detail. The thermal actuator 510 includes a first thermoelastic body 511 and a second thermoelastic body 512. The first thermoelastic body 511 is axially disposed between the motor cylinder 110 and the first end face of the magnetic tile assembly 120; the second thermoelastic body 512 is axially disposed between the bracket 111 and the second end face of the magnetic tile assembly 120. Heating elements 513 are embedded inside both the first thermoelastic body 511 and the second thermoelastic body 512.

[0041] The thermoelastic is made of a material with a high coefficient of thermal expansion, such as shape memory alloy or thermoplastic polymer. The heating element 513 is a resistance wire or similar structure that generates heat when energized, causing the thermoelastic to expand. The first thermoelastic 511 and the second thermoelastic 512 are located at opposite ends of the magnetic tile assembly 120 to ensure uniform transmission of deformation force.

[0042] Furthermore, each magnetic tile assembly 120 has a first drive groove 121 on one side and a second drive groove 122 on the other side. A first thermoelastic body 511 abuts against the inner wall of the first drive groove 121, and a second thermoelastic body 512 abuts against the inner wall of the second drive groove 122. The first drive groove 121 and the second drive groove 122 are groove structures, located at the end and middle of the magnetic tile assembly 120 respectively, for accommodating the expansion portion of the thermal actuator. This design ensures effective contact between the thermal actuator 510 and the magnetic tile assembly 120 and converts the expansion force into radial displacement. By providing the first drive groove 121 and the second drive groove 122, this design concentrates the expansion force of the thermal actuator 510 onto the critical position of the magnetic tile assembly 120. The first drive groove 121 is located at the end and receives the thrust of the first thermoelastic body 511; the second drive groove 122 is located in the middle and receives the thrust of the second thermoelastic body 512. This distribution ensures that the magnetic tile assembly 120 deforms uniformly along its length, preventing distortion caused by localized stress. When the thermal actuator 510 expands, the portion embedded in the drive groove directly pushes the groove wall, causing the magnetic tile assembly 120 to undergo radial elastic deformation, thereby adjusting the air gap.

[0043] By dividing the thermal actuator 510 into first and second thermoelastic bodies and axially arranging them on both sides of the magnetic tile assembly 120, this design achieves multi-point drive of the magnetic tile assembly 120. When the heating element 513 in the first thermoelastic body 511 is energized, the first thermoelastic body 511 expands, pushing the first end face of the magnetic tile assembly 120, causing the entire magnetic tile assembly 120 to move inward towards the outer diameter, at which time the width of the air gap decreases.

[0044] When the heating element 513 in the second thermoelastic body 512 is energized, the second thermoelastic body 512 expands, pushing the second end face of the magnetic tile assembly 120, causing the entire magnetic tile assembly 120 to move outward in the direction of its outer diameter. At this time, the width of the air gap increases. This bidirectional driving method avoids tilting or jamming of the magnetic tile assembly 120 during the deformation process, ensuring the linearity and stability of the air gap adjustment.

[0045] Beneficially, the heating element 513 installed inside the motor can also solve the problem of low motor conversion efficiency during cold start. When the motor is in a cold working condition, the electromagnetic conversion efficiency will decrease. When the internal temperature of the motor is detected to be too low, the control component 600 will activate the heating element 513 (heating rod) to preheat the inside of the motor, thereby improving the electromagnetic conversion efficiency of the motor during cold start.

[0046] Example 4: Structural details of the control component refer to Figure 6 , Figure 7 and Figure 10 This embodiment describes the structure of the control component 600 in detail. The control component 600 includes a controller 610 and a power supply support 620. The controller 610 is fixedly disposed on one side of the outer rotor assembly 100 and is electrically connected to the heating element 513. The power supply support 620 is fixedly connected to one end of the inner stator assembly 300 and is electrically connected to the controller 610.

[0047] The controller 610 includes an outer power supply ring 611 and an inner power supply ring 612. The outer power supply ring 611 is electrically connected to the heating element 513 within each of the first thermoelastic bodies 511; the inner power supply ring 612 is electrically connected to the heating element 513 within each of the second thermoelastic bodies 512. The controller 610 also includes a temperature sensor 613 and a control chip 614. The temperature sensor 613 is disposed on the outer power supply ring 611 and / or the inner power supply ring 612 and is used to detect the temperature of the power supply ring. The control chip 614 is signal-connected to the temperature sensor 613 and is used to control the current output to the heating element 513 based on the feedback from the temperature sensor 613.

[0048] The power supply support 620 is provided with at least two electrical contacts 621. The electrical contacts 621 are in sliding contact with the outer power supply coil 611 and the inner power supply coil 612, respectively, and are electrically connected to an external power source through a communication line 630. The communication line 630 contains a wire harness electrically connected to the inner stator assembly 300 to supply power to the inner stator assembly 300; the communication line 630 also contains a lead wire electrically connected to the temperature sensor 613.

[0049] The control component 600 achieves independent control of the thermal actuator 510 through separate power supply coils and electrical contacts. The outer power supply coil 611 and the inner power supply coil 612 correspond to the first and second thermoelastic bodies, respectively, allowing the control chip 614 to adjust the heating level of different parts as needed. A temperature sensor 613 monitors the temperature of the power supply coils in real time to prevent overheating damage. The electrical contacts 621 adopt a sliding contact method to adapt to the rotation of the outer rotor assembly 100 and ensure continuous power supply. The control chip 614 processes temperature or speed signals, generates control commands, and precisely adjusts the heating current.

[0050] The control components in this embodiment provide efficient energy management and protection mechanisms. Independent power supply coils enable zoned control of the thermal actuator 510, optimizing the air gap adjustment effect. The cooperation between the temperature sensor 613 and the control chip 614 ensures the system operates within a safe temperature range, avoiding the risk of overheating.

[0051] refer to Figure 10As a preferred embodiment of this solution, the electrical contact 621 has been optimized. The electrical contact 621 includes a conductive ball 621a and a compression spring 621b. The conductive ball 621a is slidably embedded in the power supply support 620; the compression spring 621b is disposed between the conductive ball 621a and the power supply support 620, providing a preload force to the conductive ball 621a toward the power supply coil.

[0052] The conductive ball 621a is made of a highly conductive material (such as copper or silver), and its spherical design allows it to slide on the surface of the power supply coil with reduced friction. A compression spring 621b ensures that the conductive ball 621a remains in contact with the power supply coil at all times, even when the outer rotor assembly 100 rotates or vibrates. Because the outer rotor assembly 100 rotates continuously, the electrical contact 621 needs to adapt to this movement without interrupting the power supply. The spherical surface of the conductive ball 621a forms a point contact with the power supply coil, reducing contact resistance and wear. The compression spring 621b provides constant pressure, compensating for dimensional changes caused by manufacturing tolerances and thermal expansion, ensuring stable transmission of electrical signals under dynamic conditions, providing continuous power to the thermal actuator 510, and improving the system's durability and reliability, making it particularly suitable for high-speed and vibration environments. Example 5: Overall Structural Integration and Heat Dissipation Optimization refer to Figures 1 to 4 This embodiment describes the overall structure integration of the motor. The two ends of the rotating shaft 400 are fixed by the motor mounting bracket 410. The inner stator assembly 300 is coaxially fixedly connected to the rotating shaft 400. The front cover 210 and the rear cover 220 have hollowed-out sections in the middle and are rotatably connected to the rotating shaft 400 via bearings 230. Fan blades 211 are integrated on the front cover 210.

[0053] The motor mounting bracket 410 ensures stable support for the rotating shaft 400 and prevents vibration. The openwork design of the front cover 210 and the rear cover 220 reduces weight and promotes internal airflow. The fan blades 211 rotate with the outer rotor assembly 100, generating airflow to force-cool the motor.

[0054] This design optimizes heat dissipation by integrating fan blades 211 and a perforated end cap. When the motor operates under high load, the winding temperature rises, and the fan blades 211 enhance airflow, carrying away heat and dust from the air gap. Simultaneously, the control component 600 adjusts the air gap according to the temperature, further improving heat dissipation. The fixing method of the shaft 400 ensures concentricity between the stator and rotor, avoiding additional friction and heat generation caused by misalignment, achieving a balance between heat dissipation and dust prevention. The fan blades 211 and the perforated end cap improve cooling efficiency and reduce the risk of overheating.

[0055] Example 6: Detailed flow of the control method refer to Figure 11This embodiment provides a control method for a temperature-controlled, adjustable stator-rotor gap dustproof motor. The method includes the following steps: Monitoring steps: Obtain the real-time temperature of the motor windings or the real-time speed of the motor as operating parameters. Temperature can be detected by sensors embedded in the windings, and speed can be calculated by an encoder or back electromotive force.

[0056] Decision-making steps: The operating parameters are compared with preset thresholds, and corresponding temperature control commands are generated based on the comparison results. When the operating parameter is real-time temperature, if the temperature is higher than the first temperature threshold (e.g., 100°C), a command to increase the working air gap is generated; if it is lower than the second temperature threshold (e.g., 80°C), a command to decrease the working air gap is generated. When the operating parameter is real-time rotational speed, if the rotational speed is higher than the first rotational speed threshold (e.g., 90% of the rated speed), a command to decrease the working air gap is generated (to improve efficiency); if it is lower than the second rotational speed threshold (e.g., 70% of the rated speed), a command to increase the working air gap is generated (to promote dust removal).

[0057] Execution steps: The temperature control command is output to the control component 600, and the temperature of the thermal actuator 510 is changed by linearly adjusting the current to the thermal actuator 510, thereby driving the magnetic tile mounting part of the outer rotor assembly 100 to produce radial elastic deformation, and then steplessly adjusting the width of the working air gap to the target range.

[0058] The control method in this application is based on the feedback principle, monitoring key operating parameters in real time. The temperature threshold is set according to the motor's insulation class and heat dissipation capacity, while the speed threshold is set according to the load characteristics. By linearly adjusting the current, stepless adjustment of the air gap is achieved, avoiding vibration caused by sudden changes. This closed-loop control ensures that the motor always operates under the optimal air gap.

[0059] The control method in this embodiment achieves adaptive optimization of the motor. Compared with motors with a fixed air gap in the prior art, this method dynamically adjusts the air gap according to actual operating conditions, which not only prevents dust accumulation faults but also maintains efficient operation. Stepless adjustment avoids mechanical shock, extends motor life, and the method is simple, reliable, and easy to integrate into existing control systems.

[0060] Example 7: Motor Cold Start Preheating Control Method Based on Heating Element This embodiment, as a supplement and functional extension to the foregoing embodiments, focuses on how to utilize the existing heating element 513 inside the motor to solve the problem of decreased electromagnetic conversion efficiency during cold starts in extremely cold conditions. This solution requires no additional hardware; by reusing the thermal actuator 510 and its heating element 513 designed for adjusting the air gap, it achieves active preheating of the motor's internal space, thereby optimizing cold start performance.

[0061] Structural basis and working principle: As previously described, the thermal actuator 510 includes a first thermoelastic body 511 and a second thermoelastic body 512, each containing a heating element 513 (such as a resistance wire). These heating elements are originally driven by the control component 600 to generate differential expansion through selective heating to drive the movement of the magnetic tile assembly. In this embodiment, the control chip 614 is further configured to execute a "preheating mode". In this mode, the control chip 614 can control all or some of the heating elements 513 to heat up synchronously and uniformly. The heat generated is no longer primarily for the purpose of creating differential deformation, but rather directly heats the surrounding internal space of the motor cylinder 110, the magnetic tile assembly 120, and the winding ends of the adjacent inner stator assembly 300 through heat conduction and heat radiation.

[0062] The operation process is as follows: 1. Monitoring and Judgment Phase: When the motor is powered on or in standby mode, the control component 600 continuously or periodically monitors the reference temperature T0 inside the motor through its temperature sensor 613 (or a dedicated low-temperature sensor added near the winding).

[0063] The control chip 614 compares T0 with the preset cold start temperature threshold T1 (such as 0°C or 5°C, depending on the motor design and material properties).

[0064] If T0 ≤ T1, the motor is determined to be in a cold operating condition, and the cold start efficiency may be impaired. At this time, the control chip 614 automatically switches from the normal "operating gap adjustment mode" to the "cold start preheating mode".

[0065] 2. Preheating Execution Phase: Upon entering preheating mode, the control chip 614 generates a preheating control command. This command controls the power circuit to apply a calculated constant current or pulsed current, below its deformation trigger threshold, to all or grouped heating elements 513.

[0066] This current value is calibrated to produce a significant thermal effect from the heating element 513, but the heat generated is insufficient to cause sufficient differential expansion between the first thermoelastic body 511 and the second thermoelastic body 512 to drive the magnetic tile assembly. In other words, even if there is slight uniform expansion, the air gap width will not change significantly due to the balanced forces on both sides.

[0067] All activated heating elements 513 work simultaneously like multiple built-in "heating rods," and their heat energy is rapidly transferred to the magnetic tile assembly 120 and motor cylinder 110 in close contact with them through heat conduction. The temperature inside the entire sealed cavity is gradually increased through heat radiation and convection, especially preheating the components that have a direct impact on the magnetic properties of the permanent magnet and the copper loss of the winding.

[0068] 3. Preheating monitoring and termination phase: During the preheating process, temperature sensor 613 continuously monitors the temperature rise.

[0069] When the monitored temperature T0 rises above the cold start temperature threshold T1 and reaches a set preheating completion threshold T' (e.g., 10°C or 15°C), the control chip 614 determines that the preheating has achieved a satisfactory effect.

[0070] The control chip 614 then cuts off or significantly reduces the preheating power supply to the heating element 513, ending the "cold start preheating mode".

[0071] 4. Mode switching and normal startup: After the preheating mode ends, the system automatically switches back to the normal "operation gap adjustment mode".

[0072] At this point, the internal temperature of the motor has increased, the magnetism of the permanent magnet has been restored, the winding resistance has been relatively reduced, and the electromagnetic conversion efficiency has been significantly improved.

[0073] When the user starts the motor, the motor will enter the working state with higher efficiency and lower starting current. At the same time, the control component 600 will intelligently manage the differential heating of the heating element 513 for the thermal actuator 510 according to the logic described in Examples 1-6, based on the real-time monitored winding temperature or speed, so as to dynamically adjust the working air gap.

[0074] In this embodiment, active preheating effectively overcomes the problems of insufficient starting torque and low efficiency caused by the decrease in magnetic flux density of permanent magnets and changes in winding resistance in cold environments. The motor starts more smoothly, the peak starting current is reduced, and the overall energy efficiency is improved, making it particularly suitable for commercial treadmills in garage gyms without heating in winter or in cold outdoor areas.

[0075] This technical solution reuses the thermal actuator 510 and heating element 513, which are necessary for gap adjustment, without the need for an additional independent preheating device (such as a PTC heater). Without increasing hardware costs and structural complexity, it endows the motor with an important environmental adaptability function, thereby enhancing the added value of the product.

[0076] The software logic of the 614 control chip enables intelligent judgment and seamless switching between preheating mode and gap adjustment mode. The two functions do not interfere with each other. They share a single temperature sensing and control system, allowing for smooth cold starts of the motor and reducing stress on the motor bearings and winding insulation caused by high current surges and torque fluctuations, thus extending the overall service life of the motor.

[0077] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A temperature-controlled, adjustable stator-rotor gap dustproof motor, characterized in that, include: External rotor assembly (100); The front cover (210) and the rear cover (220) are respectively disposed at both ends of the outer rotor assembly (100) and together with the outer rotor assembly (100) form a cavity; An inner stator assembly (300) is fixedly disposed in the cavity. The inner stator assembly (300) and the outer rotor assembly (100) are coaxially aligned around a rotating shaft (400), and a radial working air gap is formed between the outer peripheral surface of the inner stator assembly (300) and the inner peripheral surface of the outer rotor assembly (100). At least one thermal actuator (510) is disposed within the outer rotor assembly (100) and is configured to generate a radial dimension change in response to its own temperature change, and to drive the magnetic tile mounting portion of the outer rotor assembly (100) to generate radial elastic deformation via a transmission structure to adjust the width of the working air gap. as well as A control component (600), electrically connected to the thermal actuator (510), is used to regulate the temperature of the thermal actuator (510) by controlling the current flowing to it.

2. The dustproof motor according to claim 1, characterized in that: The outer rotor assembly (100) includes a motor cylinder (110) and a plurality of magnetic tile assemblies (120) fixed therein. The inner wall of the motor cylinder (110) is uniformly provided with a plurality of radial supports (111). The magnetic tile assemblies (120) and the thermal actuator (510) are alternately embedded between two adjacent supports (111).

3. The dustproof motor according to claim 2, characterized in that: The thermal actuator (510) includes a first thermoelastic (511) and a second thermoelastic (512); The first thermoelastic body (511) is axially disposed between the motor cylinder (110) and the first end face of the magnetic tile assembly (120); the second thermoelastic body (512) is axially disposed between the bracket (111) and the second end face of the magnetic tile assembly (120); heating elements (513) are embedded inside both the first thermoelastic body (511) and the second thermoelastic body (512).

4. The dustproof motor according to claim 3, characterized in that: Each of the magnetic tile assemblies (120) has a first driving groove (121) on one side and a second driving groove (122) on the other side; the first thermoelastic (511) abuts against the inner wall of the first driving groove (121), and the second thermoelastic (512) abuts against the inner wall of the second driving groove (122). The heating element (513) corresponding to the first thermoelastic (511) and the second thermoelastic (512) is energized to drive the first thermoelastic (511) and the second thermoelastic (512) to deform, thereby driving the magnetic tile assembly (120) to move along the radial direction of the motor to adjust the width of the working air gap.

5. The dustproof motor according to claim 4, characterized in that: The width of the working air gap is between 0.3mm and 1.3mm.

6. The dustproof motor according to claim 3, characterized in that: The control component (600) includes: The controller (610) is fixedly mounted on one side of the outer rotor assembly (100) and electrically connected to the heating element (513); and The power supply bracket (620) is fixedly connected to one end of the inner stator assembly (300) and electrically connected to the controller (610).

7. The dustproof motor according to claim 6, characterized in that: The controller (610) includes an outer power supply ring (611) and an inner power supply ring (612). The external power supply ring (611) is electrically connected to the heating element (513) inside each of the first thermoelastic bodies (511); The inner power supply coil (612) is electrically connected to the heating element (513) in each of the second thermoelastic bodies (512); The controller (610) also includes a temperature sensor (613) and a control chip (614). The temperature sensor (613) is disposed on the outer power supply ring (611) and / or the inner power supply ring (612) for detecting the temperature of the power supply ring; the control chip (614) is signal-connected to the temperature sensor (613) for controlling the current output to the heating element (513) according to the feedback of the temperature sensor (613); The power supply support (620) is provided with at least two electrical contacts (621), which slide in contact with the outer power supply ring (611) and the inner power supply ring (612) respectively, and are connected to an external power source through a communication line (630).

8. The dustproof motor according to claim 7, characterized in that: The electrical contact (621) includes a conductive ball (621a) and a compression spring (621b). The conductive ball (621a) is slidably embedded in the power supply support (620); The compression spring (621b) is disposed between the conductive ball (621a) and the power supply support (620) to provide the conductive ball (621a) with a preload force toward the power supply coil.

9. The dustproof motor according to claim 1, characterized in that: The two ends of the rotating shaft (400) are fixed by the motor mounting bracket (410); The inner stator assembly (300) is coaxially and fixedly connected to the rotating shaft (400); The front end cover (210) and the rear end cover (220) are hollow in the middle and are rotatably connected to the rotating shaft (400) through the bearing (230); Fan blades (211) are integrated on the front cover (210).

10. A control method for a temperature-controlled, adjustable stator-rotor gap dustproof motor as described in any one of claims 1-9, characterized in that, Includes the following steps: Monitoring steps: Obtain the real-time temperature of the motor windings or the real-time speed of the motor as operating parameters; Decision-making steps: Compare the operating parameters with preset thresholds, and generate corresponding temperature control commands based on the comparison results; When the operating parameter is real-time temperature, if the temperature is higher than the first temperature threshold, an instruction to increase the working air gap is generated; if the temperature is lower than the second temperature threshold, an instruction to decrease the working air gap is generated. When the operating parameter is the real-time rotational speed, if the rotational speed is higher than the first rotational speed threshold, an instruction to reduce the working air gap is generated; if it is lower than the second rotational speed threshold, an instruction to increase the working air gap is generated. Execution steps: The temperature control command is output to the control component (600), and the temperature of the thermal actuator (510) is changed by linearly adjusting the current to it, thereby driving the magnetic tile mounting part of the outer rotor assembly (100) to produce radial elastic deformation, and then steplessly adjusting the width of the working air gap to the target range.

Images