A motor end portion potting tool and a method of using the same

Abstract

The application discloses a motor end portion potting tool and a use method thereof. The motor end portion potting tool comprises a main body and a separation cylinder. The main body is detachably sleeved on a central shaft of a motor, and an outer wall of the main body abuts against an inner wall of a shell of the motor. The bottom of the separation cylinder is fixedly connected with the main body. A space surrounded by the outer portion of the separation cylinder, the main body, the central shaft, the shell and a stator core of the motor forms a potting cavity. A potting glue is filled in the potting cavity. The potting glue forms a potting body after solidification, so as to conduct heat and seal and protect the end portion of the motor. The potting process is applied to the manufacturing of the permanent magnet motor, and plays a crucial role in improving the heat dissipation performance, sealing protection performance and shock absorption and noise reduction performance of the motor.

Description

Technical Field

[0001] This invention relates to the field of permanent magnet motor manufacturing technology, specifically to a motor end potting tool and its usage method. Background Technology

[0002] Permanent magnet motors are commonly used in new energy vehicles, industrial equipment, and wind power generation. During operation, they are exposed to harmful substances such as water, mud, salt spray, dust, and corrosive gases for extended periods. Furthermore, to improve the power, density, and other performance indicators of permanent magnet motors, it is necessary to increase the motor's thermal load. This necessitates high standards in heat dissipation, sealing and protection, and vibration and noise reduction to meet the operational requirements. Meanwhile, in the field of electronic device manufacturing, liquid composites are often infused into devices containing electronic components. After curing, these components form thermosetting polymer insulating materials—a process known as potting. This improves the overall strength, shock resistance, and insulation of the devices, achieving waterproofing, moisture protection, component protection, and miniaturization. Therefore, applying potting technology to the manufacturing of permanent magnet motors undoubtedly plays a crucial role in improving the motor's heat dissipation, sealing and protection, and vibration and noise reduction performance. Summary of the Invention

[0003] The purpose of this invention is to provide a potting tool for the end of a motor and its method of use, in order to solve the technical problem of how to apply the potting process to the manufacturing process of a permanent magnet motor in order to improve the motor's heat dissipation performance, sealing and protection performance, and vibration and noise reduction performance.

[0004] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a potting fixture for the end of a motor, comprising: The main body is detachably sleeved on the central shaft of the motor, and the outer wall of the main body abuts against the inner wall of the motor housing; The separator is fixedly connected to the main body at its bottom. The space formed by the outside of the separator, the main body, the central shaft, the outer shell, and the stator core of the motor forms a potting cavity. The potting cavity is filled with potting adhesive, which, after curing, forms a potting body to conduct heat and provide sealing protection for the motor end.

[0005] In some embodiments, the main body includes an annular body, a reinforcing body, and a connecting body. The inner diameter of the annular body is adapted to the outer diameter of the central shaft, and the outer diameter of the annular body is adapted to the inner diameter of the outer shell. The annular body has a notch. The reinforcing body is disposed at the notch and its two ends are respectively fixedly connected to the annular body. One end of the connecting body is fixed to the reinforcing body, and the other end of the connecting body abuts against the inner wall of the outer shell. The bottom of the separating cylinder is fixed to the upper surface of the connecting body.

[0006] In some embodiments, the annular body is composed of at least two detachably connected arcuate blocks.

[0007] In some embodiments, the outer casing has a filling port, and the separation cylinder is disposed in the filling port.

[0008] In some embodiments, the gaps connecting the main body and the central shaft, as well as the gaps connecting the separation cylinder and the main body, are filled with sealant.

[0009] Secondly, the present invention also provides a method of using the motor end potting fixture provided in the first aspect of the present invention, comprising the following steps; The separator is fixedly connected to the main body, and the main body is detachably sleeved on the central shaft of the motor. The space enclosed by the outside of the separator, the main body, the central shaft, the outer shell of the motor and the stator core forms a sealed potting cavity. The potting compound is filled into the potting cavity, and after the potting compound cures, it forms a potting body to conduct heat and provide sealing protection for the motor end.

[0010] In some embodiments, the method of use further includes: Sealant is filled into the gaps connecting the main body and the central shaft, as well as the gaps connecting the separation cylinder and the main body.

[0011] In some embodiments, the method of use further includes: The entire motor is placed into a vacuum-sealed potting container for potting.

[0012] In some embodiments, the method of use further includes: After the potting compound has cured into the potting body, the main body and the separation cylinder are removed.

[0013] In some embodiments, a release agent needs to be applied to the inner walls of the body and the separation cylinder before removing them.

[0014] Compared with the prior art, the beneficial effects of the present invention mainly include: This invention provides a motor end-filling fixture and its usage method. The main body is detachably fitted onto the central shaft of the motor, and a separator cylinder is fixed to the main body. Thus, the exterior of the separator cylinder, the main body, the central shaft, the stator core, and the motor housing form a sealed filling cavity. Filling this cavity with potting compound, after curing to form a potting body, encapsulates the winding at the motor end on the stator core side. This allows heat generated by the winding to be transferred to the housing, achieving cooling and sealing. After the potting body is formed, the potting body and separator cylinder can be removed from the motor. Therefore, the technical solution of this invention effectively applies the potting process to the manufacturing of permanent magnet motors. It effectively solves the heat dissipation problem at the motor winding end while reducing additional components, simplifying the motor structure, lowering the manufacturing process difficulty, shortening the manufacturing cycle, and reducing manufacturing costs. Simultaneously, the formed potting body also has good sealing and vibration damping properties, improving the heat dissipation performance, sealing protection performance, and vibration and noise reduction performance of the permanent magnet motor. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in this application, the accompanying drawings used in the embodiments will be briefly described below: Figure 1 This is a schematic diagram of the filling tooling described in this invention; Figure 2 This is a schematic diagram of the structure of the potting body formed after potting according to the present invention; Figure 3 This is a schematic diagram showing the usage state of the potting tool described in this invention; Figure 4 This is a schematic diagram of another usage state of the potting tool described in this invention; Figure 5 yes Figure 3 A sectional view; Figure 6 This is a flowchart of the usage method described in this invention.

[0016] As shown in the figure: 100. Filling tool; 110. Main body; 111. Ring body; 112. Reinforcing body; 113. Connecting body; 120. Separating cylinder; 130. Filling body; 200. Motor; 210. Central shaft; 220. Stator core; 230. Housing; 231. Filler. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] Permanent magnet motors are commonly used in new energy vehicles, industrial equipment, and wind power generation. During operation, they are exposed to harmful substances such as water, mud, salt spray, dust, and corrosive gases for extended periods. Furthermore, to improve the power, density, and other performance indicators of permanent magnet motors, it is necessary to increase the motor's thermal load. This necessitates high standards in heat dissipation, sealing and protection, and vibration and noise reduction to meet the operational requirements. Meanwhile, in the field of electronic device manufacturing, liquid composites are often infused into devices containing electronic components. After curing, these components form thermosetting polymer insulating materials—a process known as potting. This improves the overall strength, shock resistance, and insulation of the devices, achieving waterproofing, moisture protection, component protection, and miniaturization. Therefore, applying potting technology to the manufacturing of permanent magnet motors undoubtedly plays a crucial role in improving the motor's heat dissipation, sealing and protection, and vibration and noise reduction performance.

[0019] In view of this, the present invention provides a potting tool for the end of a motor and a method for using it, which can apply the potting process to the manufacturing process of a permanent magnet motor, thereby improving the motor's heat dissipation performance, sealing and protection performance and vibration and noise reduction performance, so that the permanent magnet motor can meet the usage requirements.

[0020] like Figures 1-5 As shown, a first aspect of the present invention provides a motor end potting fixture 100, including a main body 110 and a separation cylinder 120. The main body 110 is detachably sleeved on the central shaft 210 of the motor 200, and the outer wall of the main body 110 abuts against the inner wall of the outer shell 230 of the motor 200. The bottom of the separation cylinder 120 is fixedly connected to the main body 110. The space formed by the outside of the separation cylinder 120, the main body 110, the central shaft 210, the outer shell 230 and the stator core 220 of the motor 200 forms a potting cavity. The potting cavity is filled with potting adhesive, which, after curing, forms a potting body 130 to conduct heat and provide sealing protection for the motor end.

[0021] In the above-described technical solution of the present invention, the main body 110 is detachably sleeved on the central shaft 210 of the motor 200 and the separating cylinder 120 is fixed on the main body 110. Thus, the exterior of the separating cylinder 120, the main body 110, the central shaft 210, the stator core 220, and the outer shell 230 of the motor 200 form a sealed potting cavity. The potting compound is filled into the potting cavity, and after it cures to form the potting body 130, it can wrap the winding of the motor end on one side of the stator core 220. The heat generated by the winding can be transferred to the outer shell, thereby achieving the purpose of cooling and sealing. After the potting body 130 is formed, the main body 110 and the separating cylinder 120 can be removed from the motor 200. Therefore, the technical solution of the present invention effectively applies the potting process to the manufacturing of permanent magnet motors. It can effectively solve the heat dissipation problem at the end of the motor windings, while reducing additional components, simplifying the motor structure, reducing the difficulty of motor manufacturing, shortening the manufacturing cycle, and reducing manufacturing costs. At the same time, the formed potting body also has good sealing and shock absorption properties, improving the heat dissipation performance, sealing protection performance, and vibration and noise reduction performance of the permanent magnet motor.

[0022] It is understood that the motor 200 mentioned in the above technical solution of the present invention is a common permanent magnet motor in the prior art. Its structure mainly includes a central shaft 210, a stator core 220 and a housing 230. The central shaft 210 is disposed in the central hole of the stator core 220 and the housing 230 is disposed outside the stator core 220. The motor 200 also includes a rotor core and a permanent magnet. The permanent magnet is embedded in the rotor core. The rotor core is disposed between the stator core 220 and the central shaft 210. The stator core 220 is wound with windings. The potting fixture 100 provided by the present invention is disposed at the end of the central shaft 210 and encloses the windings on the stator core 220 therein. It is used to transfer the heat generated by the windings to the housing 230, thereby achieving the purpose of cooling and sealing protection.

[0023] The design principle of this invention is based on potting technology, which is widely used in the manufacture of electronic devices. The main materials for potting compounds include epoxy resin, silicone resin, and polyurethane potting compounds. These materials have high thermal conductivity, typically 1.0–2.8 W / mK, with some high-quality products reaching 1.0–3.5 W / mK. This allows for rapid dispersion and dissipation of generated heat, significantly reducing temperature, extending service life, and improving the overall system stability. It also ensures uniform heat transfer, effectively preventing localized overheating. Furthermore, potting technology enhances the overall strength, shock resistance, and insulation of the device, achieving waterproofing, moisture protection, component protection, and device miniaturization. Therefore, this invention applies potting technology to the motor 200, ensuring good heat dissipation performance, excellent sealing, waterproofing, moisture protection, and shock absorption, effectively protecting the motor 200.

[0024] In one preferred embodiment, a potting port 231 is formed on the housing 230 for injecting potting compound; at the same time, the potting port 231 itself is the cable outlet of the motor 200 for extending some cables out of the motor 200. This design utilizes the structure of the motor 200 itself, avoids adding extra structures, and further provides favorable conditions for simplifying the motor structure.

[0025] In one preferred embodiment, the outer shell 230 is made of steel casting or steel plate welding. The outer shell 230 is preferably placed horizontally and is the main supporting component of the motor 200. The filling port 231 is welded to the outer shell 230 or cast together.

[0026] In one preferred embodiment, the stator core 220 is formed by stacking multiple stator laminations, and the windings are embedded in the core slots of the stator core 220.

[0027] In one preferred embodiment, the central shaft 210 is made of fiberglass non-magnetic material wound around itself and is inserted from the end of the motor 200.

[0028] In one preferred embodiment, the potting fixture 100 includes a main body 110 and a separating cylinder 120. The main body 110 is sleeved on the central shaft 210, and the outer wall of the main body 110 abuts against the inner wall of the outer shell 230. The bottom of the separating cylinder 120 is fixedly connected to the main body 110. The space enclosed by the outer side of the separating cylinder 120, the main body 110, the central shaft 210, the stator core 220, and the outer shell 230 constitutes the potting cavity. The separating cylinder 120 is disposed in the potting opening 231 for separating other unpotted components.

[0029] In one preferred embodiment, both the main body 110 and the separation cylinder 120 are made of non-metallic epoxy sheets bent or glued together.

[0030] In one preferred embodiment, the main body 110 includes an annular body 111, a reinforcing body 112, and a connecting body 113. The inner diameter of the annular body 111 is adapted to the outer diameter of the central shaft 210, and the outer diameter of the annular body 111 is adapted to the inner diameter of the outer shell 230. The annular body 111 has a notch. The reinforcing body 112 is disposed at the notch and its two ends are fixedly connected to the annular body 111. One end of the connecting body 113 is fixed to the reinforcing body 112, and the other end of the connecting body 113 abuts against the inner wall of the outer shell 230. The bottom of the separating cylinder 120 is fixed to the upper surface of the connecting body 113.

[0031] In one preferred embodiment, the connector 113 has a through hole, and the internal space of the separator 120 communicates with the through hole and the filling port 231 so that the cable of the motor 200 can extend smoothly out of the motor 200.

[0032] In one preferred embodiment, the annular body 111 is composed of at least two detachably connected arc-shaped blocks. This arrangement facilitates the removal of the main body 110 from the central shaft 210 after potting, thereby simplifying the structural composition of the motor 200.

[0033] In one preferred embodiment, the cooling structure further includes a sealing body (not shown in the figure), which is disposed at the gap between the main body 110 and the central shaft 210, and between the separation cylinder 120 and the main body 110, to prevent leakage of potting compound during the potting process.

[0034] In one preferred embodiment, the potting body 130 is formed after the potting adhesive has cured, and its shape is determined by the shape of the potting cavity formed. When the potting adhesive is poured, the potting body 130 needs to be poured in a vacuum environment to reduce potting air bubbles. At the same time, heating is required during the pouring process to make the potting adhesive more fluid. The potting adhesive is preferably an epoxy resin material.

[0035] The usage process of the cooling structure 100 provided by the present invention is as follows: During potting, the housing 230 is placed horizontally. First, a central shaft 210 is placed in the middle of the stator core 220. The central shaft 210 is used to provide a support base for the potting mold 110 and to limit the inner flow boundary of the potting compound. Then, the body 110 is placed on the central shaft 210. The shape of the body 110 matches the outer contour of the end winding. Finally, a separation cylinder 120 is placed above the body 110. The separation cylinder 120 is used to define the upper end face boundary of the potting compound 6.

[0036] Through the above assembly, the central shaft 210, the main body 110, the separation cylinder 120 and the inner wall of the outer shell 230 together form a sealed and fillable cavity, which is the "potting cavity" described in this invention. The specific location of the potting cavity is located on the periphery of the motor end winding, completely covering all the coils and insulation structures of the end winding. Its range extends radially outward from the end face of the stator core 220 to the inner wall of the outer shell 230, and axially to the height defined by the separation cylinder 120. The potting cavity is the molding space for the subsequent potting adhesive.

[0037] Apply sealant evenly and fill the contact gaps between the central shaft 210 and the main body 110, as well as the contact gaps between the main body 110 and the separation cylinder 120, to ensure that the sealant does not leak from these gaps during the entire potting process.

[0038] The assembled motor 200 is placed into a dedicated vacuum potting device. The vacuum system is activated to evacuate the inside of the potting device and the potting cavity to remove gas from the potting cavity and the potting adhesive, preventing the formation of air bubbles. Under the condition of maintaining the vacuum state, liquid potting adhesive is injected from the preset potting port 231 on the motor 200.

[0039] The flow path and final forming position of the potting compound are as follows: After entering through the potting port 231, the potting compound, due to vacuum pressure and gravity, first flows into the bottom of the potting cavity (i.e., near the end face of the stator core 220). Then, the liquid compound gradually spreads upwards and outwards, climbing upwards along the gaps of the end windings. The potting compound completely fills the entire space defined by the central shaft 210, the main body 110, the separation cylinder 120, and the outer shell 230, and completely immerses and wraps every part of the motor end windings. Finally, the potting compound forms a solid thermally conductive insulating layer in the potting cavity that is tightly bonded to the inner wall of the outer shell 230, the end face of the stator core 220, and the surface of the windings. At this time, the heat generated by the end windings can be efficiently transferred directly to the outer shell 230 through the potting compound (i.e., the potting body 130) and dissipated outwards. At the same time, the cured potting compound can also effectively isolate external moisture, preventing the insulation of the motor windings from decreasing due to water ingress.

[0040] After the potting compound has fully cured, demolding is required. Since a release agent was evenly applied to the inner surfaces of the main body 110 and the separator 120 before potting, the cured potting compound will not adhere to these mold components. For removal, first pull the separator 120 upwards along the axial direction; then, loosen the connecting screws between the arc-shaped blocks, and each arc-shaped block can be moved radially out sequentially, thus achieving complete removal. After removal, only the cured potting body 130 remains, and the motor end has a unified, dense, and thermally conductive potting layer.

[0041] like Figure 6 As shown, a second aspect of the present invention provides a method for using the motor end potting fixture provided in the first aspect of the present invention, comprising the following steps: Step S1: The separating cylinder 120 is fixedly connected to the main body 110, and the main body 110 is detachably sleeved on the central shaft 210 of the motor 200. Then, the space enclosed by the outside of the separating cylinder 120, the main body 110, the central shaft 210, the outer shell 230 of the motor 200 and the stator core 220 forms a sealed potting cavity. The potting compound is filled into the potting cavity, and after the potting compound cures, a potting body 130 is formed to conduct heat and provide sealing protection for the motor end.

[0042] In one preferred embodiment, the potting fixture 100 includes a main body 110 and a separation cylinder 120. During implementation, the main body 110 is first fitted onto the central shaft 210, and the outer wall of the main body 110 abuts against the inner wall of the outer shell 230. Then, the bottom of the separation cylinder 120 is fixedly connected to the main body 110, and the space enclosed by the outside of the separation cylinder 120, the main body 110, the central shaft 210, the stator core 220 and the outer shell 230 constitutes the potting cavity.

[0043] In one preferred embodiment, step S1 further includes filling the gaps where the body 110 connects to the central shaft 210 and the separation cylinder 120 connects to the body 110 with sealant to form a seal.

[0044] In one preferred embodiment, in step S2, the entire motor 200 needs to be placed into a potting container, a vacuum is drawn in the potting container, and potting adhesive is injected from the potting port 231. The potting adhesive fills the entire potting cavity. After the potting adhesive cures to form the potting body 130, the potting mold 110 is removed, and then the next installation step can be carried out.

[0045] In one preferred embodiment, a release agent is applied to the inner wall of the potting mold 110 before it is removed to facilitate removal.

[0046] In summary, the motor end potting fixture and its application method provided by this invention have the following beneficial effects: 1. Significantly improves the heat dissipation efficiency of the end windings and reduces temperature rise. Shortening the heat transfer path: In traditional motors, the heat generated by the end windings must first be transferred to the frame or housing through internal air convection before dissipating outwards. The low thermal conductivity of air creates significant thermal resistance. In contrast, this invention uses a potting compound 130 to directly fill the potting cavity, creating a continuous solid heat conduction path between the end windings and the housing 230. Heat is directly transferred from the heat source (winding copper wires) through the potting compound 130 to the metal wall of the housing 230, significantly shortening the heat transfer path and reducing thermal resistance. High thermal conductivity potting compound: The potting compound forming the potting body 130 in this invention is usually selected from insulating materials with high thermal conductivity (such as epoxy resin or silicone resin with added thermally conductive filler), whose thermal conductivity is tens or even hundreds of times higher than that of still air; therefore, the winding temperature rise can be significantly reduced under the same operating conditions, thereby allowing the motor to operate safely under higher thermal loads, or to increase the power density without increasing the volume.

[0047] 2. Effectively solves the risk of moisture damage to underwater motor insulation and improves environmental adaptability. Completely sealed enclosure: After the potting compound cures, it forms a continuous, dense solid insulation layer that completely encapsulates the coils, insulating frame, and connecting wires of the end windings, thoroughly isolating them from external moisture, humidity, salt spray, or dust. For underwater motors, motors in humid environments, or outdoor motors, this structure can fundamentally prevent insulation resistance reduction, leakage, or short circuit faults caused by water ingress.

[0048] Enhanced insulation strength: The potting compound itself has high dielectric strength, which together with the original insulation of the winding forms a composite insulation system, improving the electrical safety margin at the motor end.

[0049] 3. Compact structure, no permanent additional parts added to the motor body. The tooling can be completely removed: The potting mold 110 of the present invention serves as a temporary tooling and can be completely removed after potting, leaving only the cured potting glue (i.e., the potting body 130). The final external dimensions of the motor are basically the same as those of a traditional motor. There is no need to reserve additional structural space for the potting process, nor to increase the rotational inertia or additional weight of the motor during operation. No modification to the outer casing is required: the potting cavity is directly formed by the inner wall of the outer casing 230 and the potting mold 110, without requiring the outer casing 230 to have a complex casting or machining structure, which facilitates direct promotion and application on existing motor platforms.

[0050] In summary, the technical solution of this invention effectively applies the potting process to the manufacturing of permanent magnet motors. It can effectively solve the heat dissipation problem at the ends of the motor windings, while reducing additional components, simplifying the motor structure, reducing the difficulty of motor manufacturing, shortening the manufacturing cycle, and reducing manufacturing costs. At the same time, the formed potting body also has good sealing and shock absorption properties, improving the heat dissipation performance, sealing protection performance, and vibration and noise reduction performance of the permanent magnet motor.

[0051] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A tooling for potting motor ends, characterized in that, include: The main body is detachably sleeved on the central shaft of the motor, and the outer wall of the main body abuts against the inner wall of the motor housing; The separator is fixedly connected to the main body at its bottom. The space formed by the outside of the separator, the main body, the central shaft, the outer shell, and the stator core of the motor forms a potting cavity. The potting cavity is filled with potting adhesive, which, after curing, forms a potting body to conduct heat and provide sealing protection for the motor end.

2. The motor end potting fixture according to claim 1, characterized in that, The main body includes an annular body, a reinforcing body, and a connecting body. The inner diameter of the annular body is adapted to the outer diameter of the central shaft, and the outer diameter of the annular body is adapted to the inner diameter of the outer shell. The annular body has a notch. The reinforcing body is disposed at the notch and its two ends are fixedly connected to the annular body. One end of the connecting body is fixed to the reinforcing body, and the other end of the connecting body abuts against the inner wall of the outer shell. The bottom of the separating cylinder is fixed to the upper surface of the connecting body.

3. The motor end potting fixture according to claim 2, characterized in that, The annular body is composed of at least two detachably connected arc-shaped blocks.

4. The motor end potting fixture according to claim 2, characterized in that, The outer shell has a filling port, and the separation cylinder is disposed in the filling port.

5. The motor end potting fixture according to claim 1, characterized in that, The gaps connecting the main body and the central shaft, as well as the gaps connecting the separation cylinder and the main body, are all filled with sealant.

6. A method of using the motor end potting fixture as described in any one of claims 1 to 5, characterized in that: Includes the following steps: The separator is fixedly connected to the main body, and the main body is detachably sleeved on the central shaft of the motor. The space enclosed by the outside of the separator, the main body, the central shaft, the outer shell of the motor and the stator core forms a sealed potting cavity. The potting compound is filled into the potting cavity, and after the potting compound cures, it forms a potting body to conduct heat and provide sealing protection for the motor end.

7. The method of use according to claim 6, characterized in that, The method of use also includes: Sealant is filled into the gaps connecting the main body and the central shaft, as well as the gaps connecting the separation cylinder and the main body.

8. The method of use according to claim 6, characterized in that, The method of use also includes: The entire motor is placed into a vacuum-sealed potting container for potting.

9. The method of use according to claim 6, characterized in that, The method of use also includes: After the potting compound has cured into the potting body, the main body and the separation cylinder are removed.

10. The method of use according to claim 9, characterized in that: Before removing the main body and the separation cylinder, a release agent needs to be applied to the inner walls of the main body and the separation cylinder.

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