Ultrahigh-speed rotating rectifier for brushless synchronous motor
By employing aluminum profile heat sinks and symmetrical rotating diode module designs in brushless synchronous motors, the heat dissipation and stability issues of high-speed brushless synchronous motors are solved, achieving stable operation at high speeds and easy maintenance.
Patent Information
- Application Number
- CN202520326422.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-27
- Publication Date
- 2026-01-13
- Estimated Expiration
- 2035-02-27
AI Technical Summary
Existing rotary rectifiers are difficult to adapt to the high-speed requirements of high-speed or ultra-high-speed brushless synchronous motors.
The system employs six evenly distributed aluminum profile heat sinks, combined with rotating diode modules and DC bus lead-out brackets, designed into a symmetrical structure. It is fixed and insulated using insulating tape and insulating pads, and copper busbars are connected to improve stability and heat dissipation.
It achieves stable operation at high speeds, has good heat dissipation, a compact structure, is easy to install and replace modules, and has an overvoltage absorption function to protect the rotating diode module and prevent reverse breakdown.
Smart Images
Figure CN223798060U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of rectifier technology, specifically to an ultra-high speed rotary rectifier for a brushless synchronous motor. Background Technology
[0002] A rectifier is an electronic device that converts alternating current (AC) into direct current (DC) to provide a stable DC current. In general, a rectifier can be understood as a converter that transforms current from AC to DC, a form more suitable for various devices.
[0003] With the development of technology, high-speed or ultra-high-speed motors are increasingly used in the application of brushless synchronous motors. High-speed or ultra-high-speed (≥3000rpm) brushless synchronous motors are also gradually being used, and their rectifiers are also constantly being developed.
[0004] However, existing rotary rectifiers are mainly suitable for medium and low speed synchronous motors, and are difficult to adapt to high speed or ultra-high speed brushless synchronous motors. Therefore, an ultra-high speed rotary rectifier for brushless synchronous motors is proposed to solve the above problems. Utility Model Content
[0005] To address the shortcomings of existing technologies, this invention provides an ultra-high-speed rotating rectifier for brushless synchronous motors, which has the advantage of being able to adapt to higher speeds and solves the problem that rectifiers are difficult to adapt to high speeds.
[0006] To achieve the above objectives, this utility model provides the following technical solution: an ultra-high-speed rotating rectifier for a brushless synchronous motor, comprising a rotating rectifier disk, six aluminum profile heat sinks fixed on the inner side of the rotating rectifier disk, two rotating diode modules pressed onto the inner side of each aluminum profile heat sink, the six aluminum profile heat sinks being divided into one group and two groups, one group having four aluminum profile heat sinks and the other group having two aluminum profile heat sinks, two rotating varistor modules pressed onto each of the four aluminum profile heat sinks in the one group, and DC bus lead-out brackets pressed onto each of the two aluminum profile heat sinks in the two groups, a semi-circular hole being provided on the rotating rectifier disk near the wiring position of the rotating diode modules, an AC input copper busbar passing through the semi-circular hole being fixed on each rotating diode module, positive and negative busbars being fixed on each DC busbar lead-out bracket, and a motor rotor being connected to the other side of each positive and negative busbar.
[0007] By adopting this technical solution, the aluminum profile heat sink can play a good role in heat dissipation, which promotes the stable and continuous operation of the rotating diode module and the DC bus lead-out bracket.
[0008] Furthermore, the six aluminum profile heat sinks are evenly distributed, and each aluminum profile heat sink has heat dissipation teeth fixed on its outer side.
[0009] By adopting this technical solution, the heat dissipation fins are used to increase the heat dissipation area. At the same time, many narrow channels are formed between the heat dissipation fins. When air flows through these channels, natural convection is formed, which further improves the heat dissipation effect.
[0010] Furthermore, in one group, each of the four aluminum profile heat sinks is press-fitted with two rotating diode modules and two rotating varistor modules, with each rotating varistor module located to the right of the rotating diode module. In the second group, each of the two aluminum profile heat sinks is press-fitted with two rotating diode modules and two DC bus lead-out brackets.
[0011] By adopting this technical solution, the two DC bus lead-out supports are symmetrical. This structure can improve the overall stability and uniformity, and ensure that the rectifier maintains dynamic balance when it rotates.
[0012] Furthermore, each of the positive and negative busbar copper busbars has an insulating strip fixed to its outer surface, and each of the positive and negative busbar copper busbars is fixed to the motor shaft by the insulating strip.
[0013] By adopting this technical solution, the insulating tape can serve both fixing and insulation functions, thereby ensuring a stable and reliable fixation between the positive and negative busbars and the motor shaft.
[0014] Furthermore, each of the AC input copper busbars passes through a semi-circular hole and is close to the inner wall of the semi-circular hole. An isolation pad is fixed on the side of each AC input copper busbar close to the inner wall of the semi-circular hole. The side of each AC input copper busbar close to the rotating diode module is U-shaped.
[0015] By adopting this technical solution, the semi-circular hole can ensure that the AC input copper busbar can pass through smoothly, while also serving a heat dissipation function.
[0016] Furthermore, an insulating pad is fixed to the outside of each of the aluminum profile heat sinks, and each of the aluminum profile heat sinks is isolated from the rotating rectifier disk by the insulating pad.
[0017] By adopting this technical solution, the insulating pad plays an insulating role, preventing current from flowing between the rotating rectifier disk and the aluminum profile heat sink.
[0018] Furthermore, the two rotating diode modules on each aluminum profile heat sink are connected in parallel, and each aluminum profile heat sink is threaded with multiple insulating bolts, and each aluminum profile heat sink is fixed to the rotating rectifier disk by insulating bolts.
[0019] By adopting this technical solution, the insulating bolts can help fix the aluminum profile heat sink, and at the same time play a good insulating role during the fixing process. In conjunction with the insulating pad, the insulation effect between the aluminum profile heat sink and the rotating rectifier disk is further improved.
[0020] Furthermore, a connecting copper busbar is fixed between the two rotating diode modules on each aluminum profile heat sink and between the two rotating varistor modules on each aluminum profile heat sink, and each aluminum profile heat sink is connected to the other via the connecting copper busbar.
[0021] By adopting this technical solution, the copper busbar can play a good connection role.
[0022] Compared with the prior art, the technical solution of this application has the following beneficial effects:
[0023] This brushless synchronous motor uses an ultra-high-speed rotating rectifier, which is easy to wire. It adopts copper busbar connection and cable connection, which has a larger current carrying capacity and lighter weight. It has a compact structure and can adapt to higher speeds. The rotating diode module and rotating varistor module are configured in parallel for redundancy. Even if some are damaged, it can still work normally. It has an overvoltage absorption function, which can effectively protect the rotating diode module and prevent the rotating diode module from being reverse broken down. The structural design makes each module easy to install and replace. Attached Figure Description
[0024] Figure 1 This is a schematic diagram of the structure of this utility model;
[0025] Figure 2 This is a diagram showing the connection relationship between the rotating diode module and the aluminum profile heat sink of this utility model;
[0026] Figure 3 This is a diagram showing the connection relationship between the rotary varistor module and the aluminum profile heat sink of this utility model;
[0027] Figure 4 This is a perspective view showing the connection between the rotary varistor module and the aluminum profile heat sink of this utility model.
[0028] In the diagram: 1. Aluminum profile heat sink; 2. Rotating diode module; 3. DC bus lead-out bracket; 4. Rotating varistor module; 5. AC input copper busbar; 6. Positive and negative busbar copper busbar; 7. Rotating rectifier disk. Detailed Implementation
[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0030] Please see Figures 1 to 4In this embodiment, an ultra-high-speed rotating rectifier for a brushless synchronous motor includes a rotating rectifier disk 7, which is a concave-shaped disk with a central hole. Six aluminum profile heat sinks 1 are fixed to the inner side of the rotating rectifier disk 7. Two rotating diode modules 2 are pressed onto the inner side of each aluminum profile heat sink 1. The total number of rotating diode modules 2 is 12, with six serving as cathodes pressed onto three adjacent aluminum profile heat sinks 1, and the other six serving as anodes pressed onto symmetrically positioned aluminum profile heat sinks 1. The six aluminum profile heat sinks 1 are divided into one group and two groups. One group consists of four aluminum profile heat sinks 1, and the two groups consist of two aluminum profile heat sinks 1. Each of the four aluminum profile heat sinks 1 in the first group has two rotating varistor modules 4 crimped onto them. Each of the two aluminum profile heat sinks 1 in the second group has a DC busbar lead-out bracket 3 crimped onto them. A semi-circular hole is provided on the rotating rectifier disk 7 near the wiring position of the rotating diode module 2. The semi-circular hole allows the AC input copper busbar 5 to pass through, thereby effectively ensuring a stable connection between the AC input copper busbar 5 and the rotating diode module 2, and also providing heat dissipation and ventilation. Each rotating diode module 2 has an AC input copper busbar 5 that passes through the semi-circular hole. Each DC busbar lead-out bracket 3 has a positive and negative busbar copper busbar 6 fixed on it. The other side of each positive and negative busbar copper busbar 6 is connected to a motor rotor.
[0031] In addition, the six aluminum profile radiators 1 are evenly distributed, with each aluminum profile radiator 1 spaced 60° apart. Each aluminum profile radiator 1 has heat dissipation teeth fixed on its outer side. The heat dissipation teeth form numerous raised structures on the surface of the aluminum profile radiator 1, which greatly increases the contact area between the aluminum profile radiator 1 and the air. According to the principle of heat dissipation, the larger the heat dissipation area, the better the heat dissipation effect. In addition, many narrow channels are formed between the heat dissipation teeth. When the air flows through these channels, natural convection is formed. This is like forming countless miniature ventilation ducts on the surface of the aluminum profile radiator 1, which accelerates the air circulation and allows the heat to be carried away more quickly.
[0032] It should be further explained that each of the four aluminum profile heat sinks 1 in the first group has two rotating diode modules 2 and two rotating varistor modules 4 crimped onto it. Each rotating varistor module 4 is located to the right of the rotating diode module 2. Each of the two aluminum profile heat sinks 1 in the second group has two rotating diode modules 2 and two DC bus lead-out brackets 3 crimped onto it. The two DC bus lead-out brackets 3 are symmetrically distributed. Through the six aluminum profile heat sinks 1, the rotating diode modules 2, rotating varistor modules 4 and DC bus lead-out brackets 3 can be effectively cooled at the same time, thereby effectively improving the overall heat dissipation effect.
[0033] In addition, connecting copper busbars are fixed between the two rotating diode modules 2 on each aluminum profile heat sink 1 and between the two rotating varistor modules 4 on each aluminum profile heat sink 1. Each aluminum profile heat sink 1 is connected to each other through connecting copper busbars. Aluminum profile heat sink 1 with rotating diode modules 2 of the same polarity are connected to each other to form the common anode bridge arm and common cathode bridge arm of the rectifier bridge. They are directly connected to other adjacent rotating varistor modules 4 through connecting copper busbars to form parallel connections. They are also connected to other adjacent aluminum profile heat sink 1 with rotating varistor modules 4 through connecting copper busbars to form series and parallel connections.
[0034] In this embodiment, the setting of six aluminum profile heat sinks 1 can effectively improve the overall heat dissipation effect. At the same time, through the parallel redundant configuration of rotating diode module 2 and rotating varistor module 4, it can still work normally when some are damaged, and has an overvoltage absorption function.
[0035] Please refer to it again. Figures 1 to 3 To improve insulation, each AC input copper busbar 5 in this embodiment passes through a semi-circular hole and is close to the inner wall of the semi-circular hole. The semi-circular hole provides good heat dissipation. An isolation pad is fixed on the side of each AC input copper busbar 5 near the inner wall of the semi-circular hole. The side of each AC input copper busbar 5 near the rotating diode module 2 is U-shaped. This structure facilitates the replacement of the rotating diode module 2, that is, the AC input copper busbar 5 can be removed, the insulating bolts and the connecting copper busbars connected to other modules can be loosened before replacement.
[0036] It should be further explained that each positive and negative busbar copper bus 6 has an insulating strip fixed on its outer surface. Each positive and negative busbar copper bus 6 is fixed to the motor shaft through the insulating strip. This connection method can reduce the centrifugal force it can withstand and is supported by the motor shaft, which can further improve the stability of the positive and negative busbar copper bus 6.
[0037] In addition, an insulating pad is fixed to the outside of each aluminum profile heat sink 1, and each aluminum profile heat sink 1 is isolated from the rotating rectifier disk 7 by the insulating pad. The two rotating diode modules 2 on each aluminum profile heat sink 1 are connected in parallel, and multiple insulating bolts are threaded onto each aluminum profile heat sink 1. Each aluminum profile heat sink 1 is fixed to the rotating rectifier disk 7 by the insulating bolts. The insulating pad and the insulating bolts work together to achieve a good insulation effect, further improving the insulation between the aluminum profile heat sink 1 and the rotating rectifier disk 7.
[0038] In this embodiment, the insulating tape can play a good role in connection stability, effectively improving the stability of the positive and negative busbar copper busbars 6, while also providing good insulation. During use, it can effectively reduce the influence of centripetal force. The insulating pad and insulating bolt can effectively improve the insulation between the aluminum profile heat sink 1 and the rotating rectifier disk 7.
[0039] Understandably, by using multiple rotating diode modules 2 and multiple rotating varistor modules 4 in parallel redundant configuration, it can be ensured that the system can still work normally even if some parts are damaged. At the same time, by cooperating with the connecting copper busbar and the positive and negative busbar copper busbar 6, it can carry more current, be lighter, and adapt to higher speeds.
[0040] The working principle of the above embodiments is as follows:
[0041] This brushless synchronous motor uses an ultra-high-speed rotating rectifier, which is easy to wire. It adopts copper busbar connection and cable connection, which has a larger current carrying capacity and lighter weight. It has a compact structure and can adapt to higher speeds. The rotating diode module 2 and rotating varistor module 4 are configured in parallel for redundancy. Even if some are damaged, they can still work normally. It has an overvoltage absorption function, which can effectively protect the rotating diode module 2 and prevent the rotating diode module 2 from being reverse broken down. The structural design makes each module easy to install and replace.
Claims
1. A high-speed rotary rectifier for a brushless synchronous motor, comprising a rotary rectifier disk (7), characterized in that: The rotating rectifier disk (7) has six aluminum profile heat sinks (1) fixed on its inner side. Each aluminum profile heat sink (1) has two rotating diode modules (2) pressed onto its inner side. The six aluminum profile heat sinks (1) are divided into one group and two groups. The number of aluminum profile heat sinks (1) in the first group is four, and the number of aluminum profile heat sinks (1) in the second group is two. Each of the four aluminum profile heat sinks (1) in the first group has two rotating varistor modules (4) pressed onto its inner side. Each of the two aluminum profile heat sinks (1) in the second group has a DC busbar lead-out bracket (3) pressed onto its inner side. A semi-circular hole is opened on the rotating rectifier disk (7) near the wiring position of the rotating diode module (2). Each rotating diode module (2) has an AC input copper busbar (5) that passes through the semi-circular hole. Each DC busbar lead-out bracket (3) has a positive and negative busbar copper busbar (6) fixed onto its inner side. Each positive and negative busbar copper busbar (6) is connected to a motor rotor on the other side.
2. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: The six aluminum profile radiators (1) are evenly distributed, and each aluminum profile radiator (1) has heat dissipation teeth fixed on its outer side.
3. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: Two rotating diode modules (2) and two rotating varistor modules (4) are press-fitted onto each of the four aluminum profile heat sinks (1) in one group. Each rotating varistor module (4) is located to the right of the rotating diode module (2). Two rotating diode modules (2) and two DC bus lead-out brackets (3) are press-fitted onto each of the two aluminum profile heat sinks (1) in the second group.
4. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: Each of the positive and negative busbar copper busbars (6) has an insulating strip fixed on its outer surface, and each of the positive and negative busbar copper busbars (6) is fixed to the motor shaft by the insulating strip.
5. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: Each of the AC input copper busbars (5) passes through a semi-circular hole and is close to the inner wall of the semi-circular hole. Each of the AC input copper busbars (5) has an isolation pad fixed on the side close to the inner wall of the semi-circular hole. Each of the AC input copper busbars (5) is U-shaped on the side close to the rotating diode module (2).
6. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: An insulating pad is fixed to the outside of each of the aluminum profile radiators (1), and each of the aluminum profile radiators (1) is isolated from the rotating rectifier disk (7) by the insulating pad.
7. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: The two rotating diode modules (2) on each aluminum profile heat sink (1) are connected in parallel. Each aluminum profile heat sink (1) is threaded with multiple insulating bolts. Each aluminum profile heat sink (1) is fixed to the rotating rectifier disk (7) by insulating bolts.
8. The ultra-high-speed rotating rectifier for a brushless synchronous motor according to claim 1, characterized in that: A connecting copper busbar is fixed between the two rotating diode modules (2) on each aluminum profile heat sink (1) and between the two rotating varistor modules (4) on each aluminum profile heat sink (1). Each aluminum profile heat sink (1) is connected to each other through the connecting copper busbar.