Air-cooled ducted fan motor controller and installation method thereof

Abstract

The invention discloses an air-cooled ducted fan motor controller and an installation method thereof, the air-cooled ducted fan motor controller is arranged in an air-cooled duct, and the air-cooled ducted fan motor controller comprises: a heat dissipation shell, the interior of which is an accommodating space; a control board; the power main loop module and the control panel are arranged in the heat dissipation shell in the axial direction, and the controlled end of the power main loop module is connected to the output end of the control panel; the power main loop module comprises a plurality of power main loop units, and the heating end of each power main loop unit is welded and fixed to the inner wall of the heat dissipation shell. The heating end of the power main loop unit is directly fixed to the inner wall of the heat dissipation shell through the vacuum reflow soldering technology, efficient heat conduction of a heating component and a heat dissipation structure is achieved, the heat dissipation performance is further enhanced, heat resistance is greatly reduced, stable operation of the controller under the high-load working condition is guaranteed, and the service life of the controller is prolonged. And the heat dissipation requirements of a high-power motor and a controller can be met.

Description

Technical Field

[0001] This invention relates to the field of electric motors, and more specifically to a controller for an air-cooled ducted fan motor and its installation method. Background Technology

[0002] A ducted fan electric propulsion system refers to an electric drive power unit consisting of a ducted fan, a drive motor, and its controller. The drive motor and its controller drive the ducted fan blades to rotate, generating continuous and controllable thrust. Among these components, the drive motor and its controller are key components and power sources of the ducted fan electric propulsion system, and their performance and configuration have a significant impact on the performance of the entire electric drive system.

[0003] However, ducted fan electric drive systems typically have lower power ratings (tens of kilowatts), while higher-power electric drive systems (hundreds of kilowatts) generally employ liquid cooling or a hybrid cooling system to meet the heat dissipation requirements of high-power motors and controllers. Liquid cooling, however, requires a separate liquid cooling circulation system, mainly including pumps, radiators, and connecting pipes. This circulation system occupies a significant amount of space, has complex connections, and carries the risk of coolant leakage, thus posing certain safety hazards for aviation applications. Summary of the Invention

[0004] In view of this, the present invention provides an air-cooled ducted fan motor controller and its installation method to solve the problem that current ducted fan electric drive systems require a separate liquid cooling circulation system, which poses a safety hazard.

[0005] In a first aspect, the present invention provides a controller for a fan motor in an air-cooled duct, disposed in an air-cooled duct, comprising: A heat dissipation housing, the interior of which is an accommodating space; Control panel; A power main circuit module and a control board are arranged axially inside a heat dissipation housing. The controlled end of the power main circuit module is connected to the output end of the control board. The power main circuit module includes multiple power main circuit units, and the heating end of each power main circuit unit is welded and fixed to the inner wall of the heat dissipation housing.

[0006] The beneficial effects of the above-mentioned air-cooled ducted fan motor controller are as follows: the heating end of the main power circuit unit is directly fixed to the inner wall of the heat sink housing, realizing efficient heat conduction between the heating component and the heat dissipation structure, further enhancing the heat dissipation performance, greatly reducing the thermal resistance, ensuring the stable operation of the controller under high load conditions, and meeting the heat dissipation requirements of high-power motors and controllers.

[0007] By using air cooling instead of traditional liquid cooling, there is no need to configure an additional liquid cooling circulation system, which significantly reduces the system size and weight, simplifies the structural layout, and completely eliminates the safety hazard of coolant leakage. It is also more suitable for the stringent safety and lightweight requirements of the aviation industry.

[0008] With its compact and highly integrated structure, it reduces redundant components, improves system reliability and ease of maintenance, and is more suitable for integrated application scenarios of ducted fan electric propulsion systems.

[0009] In one optional embodiment, the heat dissipation housing includes a plurality of heat dissipation housing units, which are detachably connected to each other and arranged in sequence in a cylindrical heat dissipation structure along the circumference. Each power main circuit unit is arranged in the circumference inside the heat dissipation housing, and the heat-generating end of each power main circuit unit is connected to one of the heat dissipation housing units.

[0010] The beneficial effects of the above technical solution are as follows: The detachable design of each heat dissipation housing unit facilitates individual disassembly and maintenance, reducing subsequent maintenance costs and operational complexity. Each main power circuit unit's heating end corresponds one-to-one with an independent heat dissipation housing unit, achieving precise matching between the heating point and the heat dissipation structure, shortening the heat conduction path, and ensuring rapid heat dissipation. The circumferentially enclosed cylindrical structure not only adapts to the overall cylindrical shape of the axially integrated motor and controller system but also fully utilizes the radial space. Combined with the uniform flow of airflow around the cylinder (in the case of an air-cooled system), this further improves heat dissipation efficiency. Simultaneously, the modular heat dissipation housing unit design allows for flexible adjustment of the number or specifications of units according to different power requirements, enhancing the system's adaptability and scalability, effectively ensuring temperature stability during high-power operation, and contributing to the system's long-term reliable operation.

[0011] In one optional implementation, the power main circuit unit includes: Multiple discrete power devices are fixedly mounted on the inner wall of the heat sink housing, and the discrete power devices are the heating ends of the power main circuit unit; A DC multilayer copper busbar is disposed inside the discrete power device and electrically connected to the DC input terminal of the discrete power device; An AC output copper busbar is disposed inside the DC multilayer copper busbar. One end of the AC output copper busbar is electrically connected to the AC output terminal of the discrete power device, and the other end of the AC output copper busbar is electrically connected to the motor cable. A driver board is located inside the AC output copper busbar. The signal input terminal of the driver board is electrically connected to the signal output terminal of the control board, and the signal output terminal of the driver board is electrically connected to the controlled terminal of the discrete power device.

[0012] In one alternative embodiment, the discrete power device is welded and fixed to the inner wall of the heat sink housing.

[0013] The beneficial effects of the above technical solution are as follows: Since the entire process is carried out in a vacuum environment, the influence of harmful substances in the air on the welding quality is avoided, thereby improving the welding quality and reliability. Because the discrete power devices of the main power circuit unit are directly welded to the heat dissipation shell, the thermal resistance of the weld layer is much lower than that of traditional thermally conductive interface materials. Therefore, the total heat dissipation thermal resistance of the module is reduced. At the same time, the welding strength and firmness are also higher than those of traditional bolted connections, improving the vibration resistance and safety of the entire machine.

[0014] The thermal resistance of the solder layer between the discrete power device and the heat sink is lower than that of the thermal interface material, which can effectively reduce the resistance to the transfer of heat generated by the power device to the heat sink during operation, so that the heat can be discharged to the heat sink unit more quickly and efficiently.

[0015] In one optional implementation, the discrete power devices are connected in parallel; the discrete power devices are evenly arranged on the inner wall of the heat sink housing; the number of discrete power devices connected in parallel is adjusted to meet the needs of serialized equipment with different power levels.

[0016] In one alternative implementation, the multiple power main circuit units arranged circumferentially are arranged to form a cylindrical structure. The controller also includes a DC filter for improving electromagnetic compatibility performance. The DC filter is integrated inside the cylindrical structure and includes a filter board. The filter board and the control board are arranged in layers along the axial direction.

[0017] Secondly, the present invention provides an installation method for an air-cooled ducted fan motor controller, comprising the following steps: S1. Determine the number of power main circuit units based on the power level of the target equipment; S2. The heating ends of multiple power main circuit units are welded and fixed to the inner wall of the heat sink housing respectively; S3. Arrange the control board axially inside the heat sink housing; S4. Integrate the heat sink housing onto the motor.

[0018] In one optional implementation, in step S2, the heating, melting, wetting, and cooling processes are performed sequentially in a vacuum environment, specifically including the following steps: The heating system heats the parts of the discrete power devices in the main power circuit unit that are to be soldered to above the melting point of the solder, causing the solder to melt. The molten solder wets the area to be soldered, forming a solder joint through surface tension. The area to be welded is cooled, and during the cooling process, the solder solidifies and forms a strong weld joint.

[0019] In one optional embodiment, the heat dissipation housing is a cylindrical heat dissipation structure formed by splicing multiple heat dissipation housing units, and a power main circuit unit is installed on one heat dissipation housing unit.

[0020] In one optional implementation, before step S3, the following step is further included: The DC filter is placed inside the cylindrical heat dissipation structure, and the filter board and control board are arranged in an axially layered layout. The filter board is fixed and its electrical wiring with the power main circuit unit is completed. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 Exploded view of the air-cooled ducted fan motor controller provided by the present invention; Figure 2 A schematic diagram of the structure of a single power main circuit unit in the air-cooled ducted fan motor controller provided by the present invention; Figure 3 A side view of a single power main circuit unit in the air-cooled ducted fan motor controller provided by the present invention; Figure 4 For the present invention Figure 3 A magnified view of a portion of the image; Figure 5 A schematic diagram of the structure of the air-cooled ducted fan motor controller and the motor integrated according to the present invention; Figure 6 A partial cross-sectional view of the motor when the air-cooled ducted fan motor controller and the motor are integrated, as provided by the present invention. Figure 7 An exploded view of the air-cooled ducted fan motor controller and motor integration provided by the present invention; Figure 8 This is a schematic diagram of the integrated electric drive system for pure air-cooled forced convection heat dissipation applied to ducted fans, provided by the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Controller; 11. Power main circuit unit; 111. Discrete power devices; 112. DC multilayer copper busbar; 113. AC output copper busbar; 114. Driver board; 115. Current sensor; 116. Solder layer; 12. Control board; 13. First shielding support plate; 14. Motor end cover; 15. DC filter; 151. Filter board; 152. Magnetic ring; 16. Second shielding support plate; 17. Connecting plate; 18. Positive interface; 19. Negative interface; 120. Low voltage interface; 2. Motor; 21. Motor housing; 211. Heat pipe groove; 22. Motor rotor assembly; 23. Stationary blades; 24. L-shaped heat pipe; 25. Ceramic block; 26. Motor winding. 3. Heat sink housing; 31. Heat sink housing unit; 32. Connecting boss. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0025] According to an embodiment of the present invention, in a first aspect, a controller for an air-cooled ducted fan motor is provided, disposed in an air-cooled duct 4, and combined with... Figures 1 to 4 As shown, the system includes a heat sink housing 3, a power main circuit module, and a control board 12. The power main circuit module and the control board 12 are arranged axially, and the controlled end of the power main circuit module is connected to the output end of the control board 12. The power main circuit module is the hardware foundation for the controller to realize DC / AC power conversion. The power main circuit module includes multiple power main circuit units 11 arranged circumferentially. Each power main circuit unit 11 is used to provide power to one phase of the motor 2. The heating end of each power main circuit unit 11 is fixed to the inner wall of the heat sink housing 3 by vacuum reflow soldering technology.

[0026] The aforementioned air-cooled ducted fan motor controller has its main power circuit unit's heating end directly fixed to the inner wall of the heat sink housing 3 using vacuum reflow soldering technology. This achieves efficient heat conduction between the heating components and the heat dissipation structure, further enhancing heat dissipation performance, significantly reducing thermal resistance, ensuring stable operation of the controller under high load conditions, and meeting the heat dissipation requirements of high-power motors and controllers.

[0027] By using air cooling instead of traditional liquid cooling, there is no need to configure an additional liquid cooling circulation system, which significantly reduces the system size and weight, simplifies the structural layout, and completely eliminates the safety hazard of coolant leakage. It is also more suitable for the stringent safety and lightweight requirements of the aviation industry.

[0028] With its compact and highly integrated structure, it reduces redundant components, improves system reliability and ease of maintenance, and is more suitable for integrated application scenarios of ducted fan electric propulsion systems.

[0029] In some embodiments, the controller 1 adopts a novel layout with modular power main circuit as its core feature, enhancing interchangeability. The heat dissipation housing 3 includes multiple heat dissipation housing units 31, which are detachably connected and arranged in sequence in a cylindrical heat dissipation structure along the circumference. The heat-generating end of each power main circuit unit 11 is connected to one heat dissipation housing unit 31.

[0030] In this embodiment, the detachable design of each heat dissipation housing unit 31 facilitates individual disassembly and maintenance, reducing subsequent maintenance costs and operational complexity. Each power main circuit unit's heating end corresponds one-to-one with an independent heat dissipation housing unit 31, achieving precise matching between the heating point and the heat dissipation structure, shortening the heat conduction path, and ensuring rapid heat dissipation. The circumferentially enclosed cylindrical structure not only fits the overall cylindrical shape of the axially integrated motor and controller system but also fully utilizes the radial space. Combined with the uniform flow of airflow around the cylinder (in the case of an air-cooled system), this further enhances heat dissipation efficiency. Simultaneously, the modular design of the heat dissipation housing unit 31 allows for flexible adjustment of the number or specifications of units according to different power requirements, enhancing the system's adaptability and scalability, effectively ensuring temperature stability during high-power operation, and contributing to the system's long-term reliable operation.

[0031] In some embodiments, six power main circuit units 11 are provided, each power main circuit unit 11 corresponding to one phase of the motor winding 26. The six power main circuit units 11 form the entire controller power main circuit along the circumference. The modular design of the power main circuit improves the fault tolerance and safety of the electric drive system. When any power main circuit unit 11 or the corresponding motor winding 26 fails, the controller 1 switches to the single three-phase winding operating mode to continue outputting power.

[0032] Specifically, the built-in fault diagnosis module of controller 1 monitors the current, voltage, and temperature signals of each power main circuit unit 11 in real time. When an abnormality is detected in a power main circuit unit 11 or its corresponding motor winding, the power supply to the faulty branch is quickly cut off, and any three phases of the remaining five-phase windings are combined into a three-phase working system to maintain the basic power output capability of the electric drive system. This fault-tolerant design works in deep synergy with the modular structure of the heat sink 3: the heat sink unit 31 corresponding to the faulty unit can be independently disassembled and repaired without stopping the operation of the entire system, greatly shortening the fault handling time.

[0033] In some embodiments, the power main circuit unit 11 includes discrete power devices 111, DC multilayer copper busbars 112, AC output copper busbars 113, and a driver board 114. Multiple discrete power devices 111 are provided and fixedly mounted on the inner wall of the heat sink housing 3. Each discrete power device 111 serves as the heating element of the power main circuit unit 11. The DC multilayer copper busbar 112 is disposed inside the discrete power devices 111 and electrically connected to the DC input terminal of the discrete power devices 111. The terminals of the DC multilayer copper busbar 112 are electrically connected and fixed to the terminals of the discrete power devices by soldering. The other end of the DC multilayer copper busbar 112 is connected to a busbar, and then to a DC input and a supporting capacitor. The AC output copper busbar 113 is located inside the DC multilayer copper busbar 112. One end of the AC output copper busbar 113 is electrically connected to the AC output terminal of the discrete power device 111, that is, the terminals of the AC output copper busbar 113 are soldered to the AC terminals of the discrete power device. The other end of the AC output copper busbar 113 is electrically connected to the three-phase cable of the motor. Furthermore, a current sensor 115 is installed at the output terminal of the AC output copper busbar 113 to measure the phase current, and an AC cable connection hole is provided.

[0034] The drive board 114 is located inside the AC output copper busbar 113, with the discrete power device pins soldered on it. It is also reinforced with adhesive to enhance vibration resistance. The signal input terminal of the drive board 114 is electrically connected to the signal output terminal of the control board 12, and the signal output terminal of the drive board 114 is electrically connected to the controlled terminal of the discrete power device 111. The drive board 114 receives the control signal from the control board 12 and outputs a drive signal to the control terminal of the discrete power device, controlling the on / off state of the discrete power device, thereby regulating the main power circuit current.

[0035] Furthermore, the discrete power devices 111 are fixed to the inner wall of the heat sink housing 3 using vacuum reflow soldering technology. Vacuum reflow soldering is a welding process that utilizes heating and reflow in a vacuum environment. Its working principle mainly involves four processes: heating, melting, wetting, and cooling. First, the area to be soldered is heated above the melting point of the solder by the heating system, causing the solder to melt. Next, the molten solder wets the area to be soldered, forming a solder joint through surface tension. Finally, during the cooling process, the solder solidifies and forms a strong solder joint. Because the entire process is carried out in a vacuum environment, the influence of harmful substances in the air on the welding quality is avoided, thereby improving the welding quality and reliability. Since the discrete power devices 111 of the power main circuit unit 11 are directly soldered to the heat sink housing 3, the thermal resistance of the solder layer is much lower than that of traditional thermally conductive interface materials. Therefore, the total heat dissipation thermal resistance of the module is reduced, and the welding strength and firmness are also higher than those of traditional bolted connections, improving the vibration resistance and safety of the entire device.

[0036] like Figure 3 and Figure 4 As shown, the thermal resistance of the solder layer 116 between the discrete power device 111 and the heat sink 3 is lower than that of the thermally conductive interface material. This effectively reduces the resistance to heat transfer from the power device during operation to the heat sink, allowing heat to be dissipated more quickly and efficiently to the heat sink unit 31. The heat sink unit 31 further dissipates heat to the external environment through its surface heat dissipation structure, thereby significantly reducing the operating temperature of the discrete power device 111 and preventing performance degradation or damage due to overheating. Simultaneously, the tight connection of the solder layer 116, combined with the high welding strength of the vacuum reflow soldering process, further enhances the fixation between the discrete power device 111 and the heat sink 3, improving the system's vibration resistance and long-term operational stability, providing crucial support for the reliable operation of the air-cooled ducted fan motor controller.

[0037] In some embodiments, each power main circuit unit 11 employs a parallel configuration of multiple discrete power devices 111. The function of the discrete power devices 111 is to achieve AC-DC conversion. Increasing the number of discrete power devices 111 connected in parallel increases the output current capability and the output power level. Therefore, adjusting the number of discrete power devices connected in parallel can support a series of devices with different power ratings.

[0038] Each discrete power device 111 is evenly arranged on the inner wall of the heat sink 3, which makes the heat load distribution on the inner wall of the heat sink 3 more balanced, avoids the occurrence of local overheating, and further optimizes the heat dissipation efficiency.

[0039] In some embodiments, a plurality of circumferentially arranged power main circuit units 11 are arranged to form a cylindrical structure. The controller 1 also includes a DC filter 15 for improving electromagnetic compatibility performance. The DC filter 15 is integrated inside the cylindrical structure, eliminating the need for additional external installation space, which helps optimize the overall size of the controller, adapts to the compact design requirements of axial integration of the motor and controller, and improves the system's integration and space utilization.

[0040] The DC filter 15 includes a filter board 151, a magnetic ring 152, and several filter capacitors. The filter board 151, the magnetic ring 152, and the filter capacitors are all arranged within the cylindrical structure formed by the power main circuit units 11. The filter board 151 and the control board 12 are arranged in layers along the axial direction, which can make full use of the axial space inside the controller, avoid additional radial space occupation, further enhance the compactness of the cylindrical structure, and adapt to the space constraints of axial integration of the motor and the controller. At the same time, the layered layout can effectively reduce electromagnetic coupling interference between the filter board and the control board, improve the signal filtering accuracy of the DC filter, and enhance the overall electromagnetic compatibility performance of the system.

[0041] In some embodiments, after each power main circuit unit 11 is connected to the heat dissipation housing unit 31, one side is sealed by a first shielding support plate 13. The first shielding support plate 13 is provided with multiple connecting plates 17, and the inner wall of the heat dissipation housing unit 31 is provided with connecting bosses 32. The connecting bosses 32 are arranged axially, with support positions at both ends. Connecting holes are respectively provided on the connecting plates 17 and the connecting bosses 32. When connecting the first shielding support plate 13, the connecting bosses 32 are placed in the position of the connecting plates 17 and the two are connected by screws, so that the first shielding support plate 13 faces the side of each power main circuit unit 11.

[0042] A second shielding support plate 16 is provided between the control board 12 and each power main circuit unit 11. Multiple ear plates are provided on the second shielding support plate 16. The ear plates are fastened to the lateral extension of the connecting boss 32 by bolts, forming a rigid isolation layer between the control board 12 and the power main circuit unit 11. The weak current control circuit is isolated by the second shielding support plate 16, which improves the anti-electromagnetic interference capability and also improves the space utilization.

[0043] In some embodiments, the controller 1 further includes a positive interface 18, a negative interface 19, and a low-voltage interface 120. The positive interface 18 and the negative interface 19 are directly connected to the DC bus of the internal power main circuit unit 11 to realize the input and output of high-voltage power. The low-voltage interface 120 is located on the side wall of the heat dissipation housing unit 31 corresponding to the second shielding support plate 16, and is connected to the control board 12 through an internal wiring harness to transmit control signals, status monitoring data, and debugging instructions.

[0044] According to an embodiment of the present invention, in a second aspect, an integrated electric drive system for pure air-cooled forced convection heat dissipation of ducted fans is provided, with an output power of 200kW or more, combined with... Figures 1 to 8 As shown, the device includes an air-cooled ducted fan motor controller, a motor 2, and stationary blades 23. Multiple stationary blades 23 are provided, spaced apart on the side wall of the motor housing 21 and fixedly connected to the motor housing 21. A connecting plate is provided at the end of each stationary blade 23, and the connecting plate is connected to the inner wall of the ducted fan nacelle, thereby enabling the air-cooled ducted fan motor controller to be installed inside the ducted fan nacelle.

[0045] The controller 1 is axially integrated with the motor 2, and the controller 1 is housed inside the heat sink 3. The motor 2 includes a motor housing 21, a motor rotor assembly 22, and a motor stator assembly, the motor stator assembly including motor windings 26. The heat sink 3 is connected to the motor housing 21, specifically to the motor end cover 14.

[0046] The aforementioned integrated electric drive system for pure air-cooled forced convection cooling of ducted fans, through the axial integration design of motor 2 and controller 1, not only eliminates the long-distance cable and cooling pipe connections between traditional independent devices, significantly improving system integration to adapt to the layout requirements of compact scenarios such as ducted fan nacelles, but also achieves efficient heat conduction through the structure where the heat-generating end of the power main circuit unit 11 is directly connected to the heat sink 3 and distributed circumferentially, ensuring temperature stability during high-power operation. Simultaneously, the design of the power main circuit module and control board arranged axially in layers within controller 1, and the power main circuit units distributed circumferentially, fully utilizes radial and axial space, further optimizing space utilization.

[0047] In addition, this embodiment reduces external electrical connection points and cooling pipes, which reduces cable loss and electromagnetic interference risks, and avoids the risk of coolant leakage (if an air-cooled solution is used), significantly improving the reliability of system operation.

[0048] In some embodiments, a plurality of heat pipe grooves 211 are provided on the outer wall of the motor housing 21. A plurality of L-shaped heat pipes 24 are built into the ends (hot spot locations) of the motor windings 26. One end of each L-shaped heat pipe 24 is located inside the motor windings 26, and the other end is inserted into the heat pipe grooves 211 on the outer wall of the motor housing 21. Utilizing the heat transfer characteristics of the L-shaped heat pipes 24, the heat accumulated at the ends of the motor windings 26 can be quickly conducted from the built-in ends to the motor housing 21. The heat pipe grooves 211 on the outer wall of the motor housing 21 can cooperate with cooling structures (such as heat sink fin arrays or cooling airflow channels) to further diffuse heat to the overall heat dissipation surface of the motor housing 21. The heat is then quickly removed by the airflow circulation in the air-cooled ducted fan electric drive system, significantly reducing the hot spot temperature of the motor windings 26. This effectively prevents insulation aging or performance degradation caused by overheating of the windings, thereby improving the motor's continuous operating capability and long-term reliability. In addition, the arrangement of the L-shaped heat pipe 24 does not occupy too much space in the motor axial direction, which is in line with the compact design concept of the air-cooled ducted fan motor controller. While ensuring heat dissipation efficiency, it maintains the system's integration and structural compactness.

[0049] There is a receiving gap between the end of the motor winding 26 and the inner wall of the motor housing 21. The receiving gap is filled with a ceramic block 25. The ceramic block 25 abuts against the L-shaped heat pipe 24 and supports the L-shaped heat pipe 24, ensuring that the L-shaped heat pipe always keeps in close contact with the hot spot area at the end of the motor winding. This prevents the L-shaped heat pipe 24 from shifting or leaving the heat transfer path due to vibration during motor operation, thus maintaining stable and efficient heat conduction. At the same time, the ceramic block has excellent thermal conductivity and insulation properties. Its filling can eliminate the air insulation layer in the receiving gap and use its own insulation properties to isolate the electrical path between the L-shaped heat pipe and the motor housing and winding, preventing the risk of leakage or short circuit.

[0050] A high thermal conductivity silicone potting compound is injected between the motor winding 26 and the L-shaped heat pipe 24. The specific injection process is as follows: after one end of the L-shaped heat pipe 24 is located inside the motor winding 26 and the other end of the L-shaped heat pipe 24 is inserted into the heat pipe groove 211 on the outer wall of the motor housing 21, a vacuum is drawn and the high thermal conductivity silicone potting compound is injected to ensure sealing and fit, reduce the thermal resistance of the winding, and thus improve heat dissipation efficiency.

[0051] The cooling medium is the airflow generated by the rotation of the ducted fan blades. Compared to liquid cooling solutions, the integrated electric drive system using pure air-cooled forced convection for ducted fan cooling eliminates the need for additional cooling circulation systems and connecting pipes, saving space. It also completely eliminates coolant leakage issues, improving the reliability and safety of the electric drive system, the entire electric propulsion system, and the whole machine.

[0052] The electric drive system adopts a deeply integrated system configuration of motor 2 and controller 1. Motor 2 and controller 1 are axially integrated and share a common motor end cover 14. From the outside, motor 2 and controller 1 have the same outer contour, which is highly integrated, easy to arrange, and saves space. The system is installed in the ducted fan nacelle through stationary blades, and controller 1 is connected to the motor housing by bolts. The high-voltage AC cable is directly connected inside the system.

[0053] This embodiment improves the power rating of the pure air-cooled ducted fan electric drive system by employing advanced thermal management technology, thereby enhancing the safety and reliability of the ducted fan system. Through deeply integrated configuration design and structural reuse, the size and weight of the electric drive system are reduced, while power density is increased.

[0054] According to an embodiment of the present invention, in a third aspect, a method for installing a wind-cooled ducted fan motor controller is provided, comprising the following steps: S1. Determine the number of power main circuit units 11 according to the power level of the target equipment. Connect multiple heat dissipation housing units detachably in sequence along the circumference to form a heat dissipation housing with a cylindrical heat dissipation structure.

[0055] Fabricate a power main circuit unit 11. Arrange a DC multilayer copper busbar inside the discrete power device and electrically connect the DC multilayer copper busbar to the DC input terminal of the discrete power device. Set an AC output copper busbar inside the DC multilayer copper busbar and electrically connect one end of the AC output copper busbar to the AC output terminal of the discrete power device, and reserve a motor cable connection port at the other end. Install a driver board inside the AC output copper busbar and electrically connect the signal output terminal of the driver board to the controlled terminal of the discrete power device.

[0056] S2. The heating ends of multiple power main circuit units 11 are fixed to the inner wall of the heat sink housing 3 using vacuum reflow soldering technology. Specifically, each discrete power device is fixed to the inner wall of the corresponding heat sink housing unit using vacuum reflow soldering technology, ensuring that the heating ends of the discrete power devices are in close contact with the heat sink housing unit.

[0057] In step S2, the heating, melting, wetting and cooling processes are carried out sequentially in a vacuum environment, specifically including the following steps: the part to be welded of the discrete power device 111 of the power main circuit unit 11 is heated to above the melting point of the solder by the heating system, so that the solder melts; the molten solder wets the part to be welded and forms a solder joint through surface tension; the part to be welded is cooled, and during the cooling process, the solder solidifies and forms a strong solder joint.

[0058] Before step S3, the following steps are also included: placing the DC filter 15 in the internal space of the cylindrical heat dissipation structure, maintaining the filter board and the control board in an axially layered layout, fixing the filter board and completing its electrical wiring with the power main circuit unit.

[0059] S3. Arrange the control board 12 axially inside the heat sink housing 3, connect the control board with the filter board and the signal and power circuit of the main power circuit unit, and fix it after verifying that the wiring is correct.

[0060] Overall testing: Power on and test the installed controller to check whether the heat dissipation efficiency, power output stability and electromagnetic compatibility meet the design requirements. After confirming that all parameters meet the standards, the installation is completed.

[0061] S4. Integrate the heat sink 3 onto the motor 2.

[0062] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A wind tunnel fan motor controller characterized by, Be provided in the wind cooling duct (4), including: The heat dissipation shell (3) is internally provided with a containing space; The control panel (12); The power main loop module and the control panel (12) are arranged in the heat dissipation shell (3) along the axial direction, and the controlled end of the power main loop module is connected to the output end of the control panel (12); The power main loop module includes a plurality of power main loop units (11), and the heating end of each power main loop unit (11) is respectively welded and fixed on the inner wall of the heat dissipation shell (3).

2. The wind tunnel fan motor controller of claim 1, wherein, The heat dissipation shell (3) includes a plurality of heat dissipation shell units (31), and each heat dissipation shell unit (31) is detachably connected and sequentially arranged in a cylindrical heat dissipation structure along the circumferential direction, and each power main loop unit (11) is arranged in the heat dissipation shell (3) along the circumferential direction, and the heating end of each power main loop unit (11) is connected with one heat dissipation shell unit (31).

3. The wind tunnel fan motor controller of claim 1, wherein, The power main loop unit (11) includes: A plurality of discrete power devices (111) are respectively fixedly arranged on the inner wall of the heat dissipation shell (3), and the discrete power device (111) is the heating end of the power main loop unit (11); A direct current laminated copper bar (112) is arranged on the inner side of the discrete power device (111) and is electrically connected to the direct current input end of the discrete power device (111); An alternating current output copper bar (113) is arranged on the inner side of the direct current laminated copper bar (112), one end of the alternating current output copper bar (113) is electrically connected to the alternating current output end of the discrete power device (111), and the other end of the alternating current output copper bar (113) is electrically connected to the motor cable; A drive panel (114) is arranged on the inner side of the alternating current output copper bar (113), the signal input end of the drive panel (114) is electrically connected to the signal output end of the control panel (12), and the signal output end of the drive panel (114) is electrically connected to the controlled end of the discrete power device (111).

4. The wind tunnel fan motor controller of claim 3, wherein, The discrete power device (111) is welded and fixed on the inner wall of the heat dissipation shell (3).

5. The wind tunnel fan motor controller of claim 3, wherein, Each of the discrete power devices (111) is connected in parallel with each other; each of the discrete power devices (111) is uniformly arranged on the inner wall of the heat dissipation shell (3); by adjusting the number of parallel connections of the discrete power devices (111), the series equipment requirements of different power levels can be adapted.

6. The wind tunnel fan motor controller of claim 1, wherein, A plurality of power main loop units (11) arranged along the circumferential direction are arranged to form a cylindrical structure; The controller (1) further includes a direct current filter (15) for improving electromagnetic compatibility, the direct current filter (15) is integrated in the interior of the cylindrical structure, and the direct current filter (15) includes a filter panel (151), and the filter panel (151) and the control panel (12) are arranged in layers along the axial direction.

7. A method of installing a fan motor controller for a fan duct, characterized by, The method is the installation method of the wind cooling duct fan motor controller according to any one of claims 1-6, including the following steps: S1. Determine the number of power main loop units (11) according to the power level of the target equipment; S2. Welding and fixing the heating end of each power main circuit unit (11) to the inner wall of the heat dissipation shell (3) respectively; S3. Arranging the control board (12) inside the heat dissipation shell (3) along the axial direction; S4. Integrating the heat dissipation shell (3) on the motor.

8. The method of mounting a fan ducted fan electric machine controller of claim 7, wherein, In step S2, the heating, melting, wetting and cooling processes are sequentially performed in a vacuum environment, which specifically includes the following steps: Heating the part to be welded of the discrete power device (111) of the power main circuit unit (11) to above the melting point of the solder through the heating system, so that the solder is melted; The melted solder wets the part to be welded, and a welding point is formed by surface tension; Cooling the part to be welded, and in the cooling process, the solder solidifies and forms a firm welding point.

9. The method of mounting a fan ducted fan electric machine controller of claim 7, wherein, The heat dissipation shell (3) is a cylindrical heat dissipation structure formed by splicing a plurality of heat dissipation shell units (31), and one power main circuit unit (11) is arranged on one heat dissipation shell unit (31).

10. The method of mounting a fan ducted fan electric machine controller of claim 9, wherein, Before step S3, it also includes the following steps: Placing the DC filter (15) in the internal space of the cylindrical heat dissipation structure, so that the filter board and the control board maintain an axial layered layout relationship, fixing the filter board and completing the electrical wiring of the power main circuit unit.

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