Highly integrated high-efficiency industrial permanent magnet synchronous motor electric control all-in-one machine

Abstract

The application relates to the technical field of industrial motors, and particularly discloses a highly integrated high-efficiency industrial permanent magnet synchronous motor electric control integrated machine, which comprises a machine shell, a front end cover, a motor shaft, a rotor assembly and a stator assembly, and the technical core lies in that an integrated rear end assembly is connected to the rear end of the machine shell, the integrated rear end assembly integrates a rear cover assembly and an electric control shell, and forms a closed cavity together with the front end cover and the machine shell; an electric control system, which comprises a driving board, a control board and a power supply board, is directly integrated in the electric control shell; and a monitoring unit is connected with the electric control system in signal mode. The structure deeply fuses the electric control system and the motor body in physics and electricity, eliminates external controllers and complex cables, greatly shortens the power and signal transmission path, directly reduces line loss and electromagnetic interference, improves system energy efficiency and operation stability, and simultaneously provides a basis for real-time state monitoring and intelligent control of the motor through the built-in monitoring unit.

Description

Technical Field

[0001] This invention relates to the field of industrial motor technology, and in particular to a highly integrated, high-efficiency industrial permanent magnet synchronous motor control unit. Background Technology

[0002] In the field of industrial drives, motors and their controllers, as core power drive components, are still widely used in systems with a predominantly separate layout, meaning the motor body and the frequency converter are installed independently. Even in some systems that use permanent magnet synchronous motors, the motor and the electronic control system are mostly designed separately, and have not yet achieved substantial mechatronics integration.

[0003] Split-type industrial motor drive systems exhibit several limitations in practical applications: Overall system efficiency is low, primarily due to significant iron and copper losses in the motor itself, as well as additional transmission losses from the split layout; their large size and weight, requiring independent controllers, external wiring harnesses, and mounting brackets, result in low power density and poor adaptability in space-constrained environments; furthermore, the system relies on external frequency converters for starting and speed regulation, increasing equipment costs and complicating debugging due to poor matching between the motor and controller, leading to decreased drive efficiency. Structurally, the motor, electrical control, and cooling systems are typically independent modules with low integration, cumbersome assembly, and susceptibility to signal interference, affecting operational stability. Simultaneously, existing products generally lack adequate protection levels, and their sealing designs are insufficient to effectively resist common industrial environments such as dust, oil, and moisture, leading to increased failure rates. In terms of reliability, the stator often employs a single-winding design, lacking fault-tolerant control capabilities, making partial failures prone to causing complete machine shutdown. In addition, components such as the casing often rely on customized die-casting processes, which result in high mold costs and long cycles. Furthermore, the system typically lacks intelligent monitoring functions, leading to high costs for mass production and subsequent maintenance.

[0004] In summary, existing split-type industrial motor drive systems have significant shortcomings in terms of efficiency, size, cost, reliability, and environmental adaptability, making it difficult to meet the growing demands of modern industrial applications for high performance, high integration, and high reliability. Summary of the Invention

[0005] The purpose of this invention is to provide a highly integrated and efficient industrial permanent magnet synchronous motor control unit to solve the aforementioned technical problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution: a highly integrated, high-efficiency industrial permanent magnet synchronous motor and its integrated control unit, comprising: a housing, with a front cover connected to the front end of the housing; a motor shaft passing through the center of the front cover; a rotor assembly fixed to the motor shaft; a stator assembly fixedly installed inside the housing, with an air gap between it and the rotor assembly; an integrated rear-end assembly connected to the rear end of the housing, forming a closed cavity together with the front cover and the housing; the integrated rear-end assembly includes a rear cover assembly and an electrical control housing; an electrical control system including a drive board, a control board, and a power board integrated within the electrical control housing; and a monitoring unit connected to the electrical control system, including a temperature sensor, a current sensor, and a speed sensor.

[0007] Optionally, the rear cover assembly is integrally die-cast with the electronic control housing.

[0008] Optionally, the drive board, control board, and power board are fixed to a pre-set standardized mounting structure inside the electrical control housing using standardized clips and high-strength bolts.

[0009] Optionally, the power board integrates a high-efficiency vector control algorithm module optimized for motor body parameters, as well as a power supply module and overload, overcurrent, and overtemperature protection circuits.

[0010] Optionally, the stator assembly is made of ultra-thin silicon steel sheets stacked together, and its stator windings are wound using a flat wire process.

[0011] Optionally, the rotor assembly includes a rotor core made of ultra-thin silicon steel sheets and a high-density rare-earth permanent magnet fixed in the rotor core by an embedded process.

[0012] Optionally, the motor shaft is a high-strength alloy steel shaft with a hardened surface.

[0013] Optionally, the highly integrated and efficient industrial permanent magnet synchronous motor control unit also includes a fan assembly, which is installed at the rear of the housing and powered by an independent power supply; the control board performs stepless speed regulation control on the fan assembly based on the temperature signal fed back by the monitoring unit.

[0014] Optionally, the outer wall of the housing is integrally formed with axially extending heat dissipation fins, and the rear is equipped with an air guide shroud that cooperates with the fan assembly to form an axial forced air cooling channel.

[0015] Optionally, the highly integrated and efficient industrial permanent magnet synchronous motor and electrical control unit further includes a seal disposed between the front cover, the housing, the rear cover assembly and the electrical control housing, and at the position where the motor shaft protrudes.

[0016] Compared with the prior art, the present invention discloses at least the following beneficial effects: This invention achieves a tight integration of the motor body and the electronic control system within a single enclosed cavity. An integrated rear-end component combines the rear cover assembly with the electronic control housing, and houses the drive board, control board, power board, and monitoring unit. This results in a significantly shortened signal transmission path and a more integrated electromechanical structure. This structure effectively reduces the number of external wiring harnesses and interfaces, lowers transmission losses and signal interference, and improves overall system efficiency and operational stability. Simultaneously, the integrated enclosed design enhances the overall machine's protection capabilities, effectively resisting the intrusion of dust, oil, and moisture, making it suitable for complex industrial environments. The monitoring unit collects temperature, current, and speed signals in real time and links them with the electronic control system, providing a reliable data foundation for precise control of motor operation, fault warning, and intelligent heat dissipation. This improves energy efficiency and reliability while also achieving a compact and modular structure, facilitating installation and maintenance, and reducing the system's total lifecycle cost. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Fig. 1 This is an axial sectional view of the motor assembly of the present invention; Fig. 2 This is a cross-sectional view of the motor of the present invention; Fig. 3 This is a schematic diagram of the structure of the motor heat dissipation assembly of the present invention; Reference numerals: 1. Front cover; 2. Front bearing; 3. Rotor assembly; 4. Stator assembly; 5. Rear cover assembly; 6. Resolver assembly; 7. Drive board; 8. Control board; 9. Power board; 10. Fan assembly; 11. Motor shaft; 12. Seal; 13. Monitoring unit; 14. Housing; 20. Fan cover; 21. Fan cover mounting hole. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0021] Reference Figs. 1 to 3 As shown, this embodiment provides a highly integrated, high-efficiency industrial permanent magnet synchronous motor and its control unit, including a front cover 1, a front bearing 2, a rotor assembly 3, a stator assembly 4, a rear cover assembly 5, a resolver assembly 6, a drive board 7, a control board 8, a power supply board 9, a fan assembly 10, a motor shaft 11, a seal 12, and a monitoring unit 13. The motor shaft 11 passes through the center of the front cover 1 and the rear cover assembly 5. The front bearing 2 and the rear bearing are respectively installed in the bearing chambers of the front cover 1 and the rear cover assembly 5 to support the rotation of the motor shaft 11. The rotor assembly 3 is fixed to the motor shaft 11, and the stator assembly 4 is fixedly installed inside the housing 14, maintaining a certain air gap with the rotor assembly 3.

[0022] In this embodiment, the housing 14 is an axially hollow cylindrical structure. Its front end is connected to the front cover 1 by bolts, and its rear end is connected to the integrated rear end assembly by a flange. The integrated rear end assembly consists of an integrated die-cast rear cover assembly 5 and an electrical control housing. The housing 14, the front cover 1, the rear cover assembly 5, and the electrical control housing together constitute the enclosed cavity of the motor body. The stator assembly 4 is fixed to the inner wall of the housing 14 by heat fitting or interference fit.

[0023] Further optimization of the solution: in terms of the integration of motor and electronic control, the rear cover assembly 5 and the electronic control housing adopt an integrated die-casting structure to form a robust integrated rear-end component.

[0024] Furthermore, the electrical control housing is equipped with a standardized installation structure, and the drive board 7, control board 8 and power board 9 are fixed inside the electrical control housing by standardized clips and high-strength bolts.

[0025] Furthermore, the electronic control housing, the rear cover assembly 5, and the housing 14 are seamlessly connected through the sealing element 12, together forming a fully enclosed protective shell.

[0026] In this embodiment, the electronic control system adopts a highly integrated "three-board-in-one" design, compactly arranging the drive board 7, control board 8, and power supply board 9 within the same electronic control housing. The boards are connected and communicate with each other via an internal bus, resulting in a compact layout and reasonable wiring, reducing external wiring harnesses and connectors, and lowering the risk of signal interference and line loss.

[0027] Further optimizing the solution, power board 9 integrates a highly efficient vector control algorithm specifically optimized for motor parameters, enabling direct motor drive and replacing the traditional independent external frequency converter. Power board 9 integrates a high-efficiency power supply module and overload, overcurrent, and overtemperature protection circuits. Control board 8 integrates bearing housings and various industrial-standard waterproof connector interfaces for easy connection to external devices.

[0028] In one specific embodiment, the vector control algorithm running on the power board 9 is a field-oriented control (FOC) algorithm. The PID parameters of its current loop and speed loop are identified and tuned offline based on parameters such as the stator resistance, direct and quadrature axis inductance, and permanent magnet flux linkage of the motor body, and are then stored in the memory chip of the driver board 7. Specific optimizations include: temperature compensation of the current loop parameters based on a thermal model of the flat wire winding; and adjusting the boundary conditions of the field weakening control strategy according to the changes in magnetic circuit characteristics caused by the optimized air gap.

[0029] Further optimization of the design: In terms of the high-efficiency motor body design, the stator assembly 4 is made of ultra-thin silicon steel sheets with high efficiency and low loss, which significantly reduces iron loss. Its stator windings are further wound using flat wire technology (such as hairpin windings) to improve slot fill factor, reduce copper loss, and improve the thermal conductivity of the windings.

[0030] Furthermore, the core component of rotor assembly 3 employs high-magnetic-density rare-earth permanent magnets (such as high-grade neodymium iron boron magnets), which are fixed in a lightweight rotor core made of ultra-thin silicon steel sheets using an embedded process. Process holes can be added to the rotor core to further reduce rotor weight and mechanical losses while ensuring structural rigidity and load-bearing capacity.

[0031] Furthermore, the motor shaft 11 is made of high-strength alloy steel and undergoes precision machining and surface hardening treatment to improve its wear resistance and torsional strength and reduce shaft wear.

[0032] By optimizing the air gap size between the stator assembly 4 and the rotor assembly 3, and employing precision assembly processes to ensure the uniformity of the air gap, air gap magnetic field losses are effectively reduced. Simultaneously, an insulating protective layer can be installed at the air gap to prevent magnetic field leakage, further reducing losses. This comprehensively improves the energy conversion efficiency of the motor, resulting in a significant increase in the overall rated efficiency.

[0033] To further optimize the technical solution, in terms of efficient heat dissipation and high protection design, the fan assembly 10 is installed at the rear of the casing 14 and is powered by an external power supply independent of the motor speed. Its speed can be automatically adjusted according to the motor operating temperature detected by the monitoring unit 13 to achieve precise heat dissipation and avoid energy waste.

[0034] Furthermore, the fan assembly 10 adopts an IP68 protection rating design, with its outer shell made of waterproof and dustproof alloy material, the fan blades made of corrosion-resistant engineering plastic, and the interface designed to be waterproof and sealed.

[0035] Furthermore, the fan assembly 10 is mounted on the housing 14 via a shock-absorbing mount to reduce the impact of industrial vibrations on its operation and extend its service life.

[0036] Furthermore, a fan cover 20 is installed on the outside of the fan assembly 10. The fan cover 20 is detachably connected to the housing 14 or the air guide cover through the fan cover fixing holes 21. The fan cover 20 adopts a protective grille structure to prevent external foreign objects from contacting the fan blades during operation, while ensuring smooth cooling airflow and improving safety during use.

[0037] Furthermore, the housing 14 is manufactured from standard-sized stretched aluminum profiles, and its outer wall is integrally formed with axially extending trapezoidal heat dissipation fins to increase the heat dissipation area. An air guide shroud is installed at the rear of the housing 14. This shroud, in conjunction with the fan assembly 10, guides the cooling airflow along the heat dissipation fins on the outer wall of the housing 14, forming a highly efficient axial forced air cooling channel. The heat generated inside the motor is transferred to the housing 14 through heat conduction, and then quickly dissipated through this air cooling channel, forming a highly efficient heat dissipation closed loop of "internal heat conduction + external forced air cooling".

[0038] The technical solution has been further optimized. In terms of standardization and modular design, the whole machine adopts a modular and standardized design concept. The length of the housing 14 can be flexibly adjusted by cutting standard aluminum profiles according to the motor power specifications, eliminating the need for separate die casting for different models, which greatly reduces the development cost and cycle of the housing 14.

[0039] Furthermore, the inner wall of the housing 14 has a standardized mounting groove for easy heat-fitting of the stator assembly 4. The front cover 1 and the rear cover assembly 5 adopt a standardized flange structure and uniform connection hole positions to ensure versatility with housings 14 of different lengths.

[0040] Furthermore, the drive board 7, control board 8, and power board 9 of the electronic control system also adopt a standardized design, which can be quickly replaced and adapted according to different power specifications or industrial application scenarios.

[0041] Furthermore, components such as the fan assembly 10 and seals 12 all adopt standardized specifications, facilitating bulk procurement and subsequent maintenance. This design greatly enhances the flexibility of product modification and shortens the development cycle.

[0042] In one specific embodiment, the seal 12 is a fluororubber seal 12, and its material is FKM (fluororubber).

[0043] Further optimizing the technical solution, in terms of the fully enclosed high-protection structure design, this integrated electronic control unit adopts a fully enclosed structure to withstand harsh industrial environments. All connecting surfaces between the front cover 1, the housing 14, the rear cover assembly 5, and the electronic control housing are equipped with sealing grooves and fitted with high-temperature resistant and oil-resistant fluororubber seals 12 to achieve reliable static sealing.

[0044] Furthermore, at the position where the motor shaft 11 passes through the front cover 1 and the rear cover assembly 5, a dual dynamic sealing structure combining a labyrinth seal and a skeleton oil seal is adopted, which not only ensures the smooth operation of the shaft system, but also effectively prevents impurities such as dust and moisture from entering.

[0045] Furthermore, the connection surface between the fan assembly 10 and the housing 14 also employs a double seal of sealant and gasket. The wiring terminals on the control board 8 also utilize a waterproof sealing structure. Through these multiple sealing designs, the entire unit achieves a high protection rating of IP68.

[0046] Based on the above embodiments, the monitoring unit 13 integrates temperature sensors, current sensors, and speed sensors to monitor the motor's operating status in real time and feed the data back to the control board 8, providing a data foundation for intelligent control, fault warning, and precise heat dissipation.

[0047] In one specific embodiment, the control board 8 receives the real-time temperature signal fed back by the monitoring unit 13, and generates a PWM control signal to the fan assembly 10 according to a preset temperature-fan speed mapping table or PID algorithm, so as to realize stepless speed regulation of the fan assembly 10.

[0048] It should be understood that, in practical applications, the technical features of this embodiment can be appropriately combined, replaced, or adjusted. For example, the speed control strategy of the fan assembly 10 can be optimized into multi-speed control according to specific application scenarios; the material of the seal 12 can be replaced with a more targeted material according to different corrosive media; and the control algorithm of the electronic control system can also be deeply customized according to the load characteristics. These variations based on the core concept of this invention should all fall within the protection scope of this invention.

[0049] In summary, the highly integrated and efficient industrial permanent magnet synchronous motor control unit provided by this invention brings about significant and comprehensive benefits through the implementation of the above-mentioned technical solutions: First, energy efficiency is significantly improved. Through the high-efficiency motor body design and integrated design, iron loss, copper loss, mechanical loss, and line loss are greatly reduced, resulting in a significant improvement in overall efficiency compared to traditional products and outstanding energy-saving effects. Second, structure and cost are optimized. The highly integrated design eliminates external frequency converters and redundant wiring harnesses, resulting in a significant reduction in the overall size and weight of the unit, an increase in power density, and a reduction in the overall costs of procurement, installation, and operation and maintenance. Third, environmental adaptability is extremely strong. The IP68-level forced air cooling and fully enclosed multi-seal design ensure the heat dissipation performance and operational reliability of the equipment in extremely harsh industrial environments, significantly reducing the failure rate. Fourth, production and iteration are highly efficient. The standardized and modular design eliminates the need for customized molds for the casing 14 and core components, greatly shortening the product development cycle, reducing mass production costs, and enabling rapid adaptation to diverse market demands. This invention effectively solves many pain points of existing industrial motor drive systems in terms of efficiency, integration, reliability and economy, and has extremely high industrial promotion value.

[0050] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to 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 invention.

[0051] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine, characterized in that, include: The housing (14) has a front cover (1) connected to its front end. The motor shaft (11) passes through the center of the front end cover (1); The rotor assembly (3) is fixed to the motor shaft (11); The stator assembly (4) is fixedly installed inside the housing (14) and has an air gap with the rotor assembly (3); An integrated rear-end assembly is connected to the rear end of the housing (14) and together with the front cover (1) and the housing (14) forms a closed cavity; the integrated rear-end assembly includes a rear cover assembly (5) and an electronic control housing; The electronic control system includes a drive board (7), a control board (8), and a power supply board (9) integrated within the electronic control housing. The monitoring unit (13) is connected to the electronic control system and includes a temperature sensor, a current sensor and a speed sensor.

2. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 1, characterized in that, The rear cover assembly (5) is integrally die-cast with the electronic control housing.

3. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 1, characterized in that, The drive board (7), control board (8) and power board (9) are fixed to the pre-set standardized installation structure inside the electrical control housing by standardized buckles and high-strength bolts.

4. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 1 or 3, characterized in that, The power board (9) integrates a high-efficiency vector control algorithm module for optimizing the parameters of the motor body, as well as a power supply module and overload, overcurrent and overtemperature protection circuits.

5. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control unit according to claim 1, characterized in that, The stator assembly (4) is made of ultra-thin silicon steel sheets stacked together, and its stator winding is wound using a flat wire process.

6. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 5, characterized in that, The rotor assembly (3) includes a rotor core made of ultra-thin silicon steel sheets and a high magnetic density rare earth permanent magnet fixed in the rotor core by an embedded process.

7. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 1, characterized in that, The motor shaft (11) is a high-strength alloy steel shaft with a hardened surface.

8. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control unit according to claim 1, characterized in that, It also includes a fan assembly (10), which is installed at the rear of the housing (14) and is powered by an independent power supply; the control board (8) performs stepless speed regulation control on the fan assembly (10) based on the temperature signal fed back by the monitoring unit (13).

9. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control integrated machine according to claim 8, characterized in that, The outer wall of the casing (14) is integrally formed with axially extending heat dissipation fins, and the tail is equipped with an air guide shroud that cooperates with the fan assembly (10) to form an axial forced air cooling channel.

10. The highly integrated, high-efficiency industrial permanent magnet synchronous motor and electrical control unit according to claim 1, characterized in that, It also includes a seal (12) disposed between the front cover (1), the housing (14), the rear cover assembly (5) and the electrical control housing, and at the point where the motor shaft (11) protrudes.

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