Electric ducted fan

Abstract

The utility model provides an electric ducted fan. The electric ducted fan comprises a duct body, a static blade supporting assembly, an inner rotor motor, a movable blade assembly, a fan controller and a flow guide cover. A shell of the inner rotor motor is fixedly connected with the stationary blade supporting assembly. The movable blade assembly comprises a middle rotating disc and a plurality of movable blades arranged on the middle rotating disc at intervals in the circumferential direction, and the middle rotating disc is connected to a rotating shaft of the inner rotor motor in an anti-torque mode. The fan controller comprises a controller shell, a control board, a power driving board, a capacitor filtering board and a plurality of supporting column assemblies, wherein the control board, the power driving board and the capacitor filtering board are sequentially stacked in the axial direction, and the control board, the power driving board and the capacitor filtering board are sequentially and fixedly connected through the supporting column assemblies. The flow guide cover comprises a front flow guide cover body and a rear flow guide cover body, the front flow guide cover body is fixed to one axial side of the movable blade assembly, and the rear flow guide cover body is fixed to the other axial side of the fan controller. Through the integrated design of parts, redundant parts are reduced, the structural compactness of the ducted fan is improved, and then the design of small size and light weight of the ducted fan is achieved.

Description

Technical Field

[0001] This application relates to the field of ducted fan technology, and more specifically to electric ducted fans. Background Technology

[0002] In the propulsion system design of electric aircraft (such as flying cars and drones), ducted fans have become a core power component for lightweight electric vertical takeoff and landing (EVTOL) aircraft due to their high propulsion efficiency, low noise characteristics, and safety advantages. The main working principle of a ducted fan is to draw in air and accelerate the airflow through the rotation of the fan blades, thereby generating thrust to enable the aircraft to take off and land. Its structure typically consists of fan blades, a motor, and an electronic control system.

[0003] In traditional ducted fan designs, the fan blades, motor, and electronic control system are typically designed and manufactured separately, and then assembled into a complete system. This design has certain limitations.

[0004] (1) Low integration of components: Because the fan blades, motor and electronic control system are designed separately, each component can only perform a single function and cannot achieve high functional integration. This leads to an increase in the number of components and an increase in the complexity of assembly and debugging, thereby affecting the overall efficiency of the system.

[0005] (2) Redundancy in size and weight: In traditional designs, fan blades, motors, and electronic control systems each occupy space independently, resulting in a large overall fan size and weight. For electric aircraft, especially flying cars and other applications that are extremely sensitive to size and weight, redundant size and weight will directly affect the aircraft's performance and range.

[0006] (3) Insufficient power density: Traditional ducted fans have relatively low power density and cannot provide enough thrust to meet the needs of high-performance electric aircraft.

[0007] (4) Heat dissipation problem: During high-power operation, the motor and electronic control system will generate a lot of heat. In traditional designs, the heat dissipation system is usually set up independently, resulting in low thermal management efficiency.

[0008] Therefore, in order to meet the demands of modern electric aircraft, especially flying cars, for miniaturization, high power density, lightweighting, and efficient heat dissipation, how to integrate the structure of ducted fans has become a problem that needs to be solved. Utility Model Content

[0009] To overcome or mitigate at least one of the shortcomings of the prior art, one object of this application is to provide an electric ducted fan. Through component integration design, redundant parts are reduced, improving the structural compactness of the ducted fan, thereby achieving a small size and light weight design.

[0010] To achieve the above objectives, this application adopts the following technical solution.

[0011] This application provides an electric ducted fan, which includes:

[0012] The ductwork has airflow channels formed on its inner wall;

[0013] A stator blade support assembly includes a plurality of stator blades evenly distributed circumferentially, the plurality of stator blades being integrally formed with the inner wall of the duct body;

[0014] An internal rotor motor, the outer casing of which is fixedly connected to the stationary blade support assembly;

[0015] The moving blade assembly includes an intermediate turntable and a plurality of moving blades, the plurality of moving blades being spaced apart on the intermediate turntable along the circumferential direction, and the intermediate turntable being torsionally connected to the shaft of the inner rotor motor;

[0016] A fan controller includes a controller housing, a control board, a power drive board, and a capacitor filter board stacked sequentially along an axial direction, and multiple support column assemblies. The control board, the power drive board, and the capacitor filter board are sequentially fixedly connected via the support column assemblies.

[0017] The air deflector includes a front air deflector and a rear air deflector, the front air deflector being fixed to one axial side of the moving blade assembly, and the rear air deflector being fixed to the other axial side of the fan controller.

[0018] In at least one embodiment, the internal rotor motor includes a motor rear end cover, one axial end of which is connected to the housing of the internal rotor motor, and the other axial end of which is connected to the housing of the controller, and the motor rear end cover is installed on the inner wall of the controller housing.

[0019] In at least one embodiment, the ducted fan includes connecting posts and lug sheaths. A connecting hole is provided on the radially outer side of the motor rear end cover. The lug sheath is installed in the connecting hole. The lug sheath has three non-connected connecting post mounting holes. The connecting posts are respectively installed in the connecting post mounting holes, such that one end of the connecting post extends into the interior of the inner rotor motor and is threaded to the three-phase terminals of the stator assembly of the inner rotor motor. The other end of the connecting post extends into the interior of the fan controller and is threaded to the three-phase terminals of the control board.

[0020] In at least one embodiment, a plurality of the support column assemblies are spaced apart along the circumferential direction, and the support column assembly includes a first support column, a second support column, and a third support column; wherein, the first support column is fixed between the motor rear end cover and the control board, the second support column is fixed between the control board and the power drive board, and the third support column is fixed between the power drive board and the capacitor filter board.

[0021] In at least one embodiment, the ducted fan includes a MOSFET, the inner wall of the controller housing includes a plurality of raised planes evenly distributed along the circumference, the mounting surface of the raised planes is parallel to the axial direction of the fan controller, and the MOSFET is fixedly mounted on the mounting surface of the raised planes.

[0022] In at least one embodiment, the outer wall of the controller housing includes a plurality of heat dissipation teeth evenly arranged along the circumference, the axial position of the heat dissipation teeth is the same as the axial position of the protruding plane, and the spacing between adjacent heat dissipation teeth is 1.2 to 1.5 times the height of the heat dissipation teeth.

[0023] In at least one embodiment, the culvert body includes two symmetrically arranged mounting seats, each mounting seat being disposed on the outer wall of the culvert body and including reinforcing ribs and mounting holes; and / or

[0024] The duct body is provided with a wiring harness through hole, through which the wiring harnesses of the inner rotor motor and the fan controller pass.

[0025] In at least one embodiment, the rear fairing includes two symmetrically distributed support blades for supporting the ducted fan, and the wiring harnesses of the inner rotor motor and the fan controller pass through the support blades.

[0026] In at least one embodiment, the fan controller includes a controller back cover, the controller back cover includes a high-voltage connector and a communication interface, the high-voltage connector is electrically connected to the capacitor filter board, and the communication interface is electrically connected to the inner rotor motor and the fan controller.

[0027] In at least one embodiment, the control board, the power drive board, and the capacitor filter board are all circular in design.

[0028] By adopting the above technical solution, this application provides an electric ducted fan. By integrating the duct body, motor housing, and stator blade support assembly into a single component, redundant parts are reduced, allowing a single component to connect multiple components. This design reduces redundant parts and independent designs, while achieving compactness of the ducted fan, further reducing its size and weight. Furthermore, the fan controller's circuit board can include three circuit boards with different functions, stacked along the axial direction, thereby reducing the longitudinal dimension of the circuit board to accommodate the size requirements of different fans. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of an electric ducted fan according to an embodiment of this application;

[0030] Figure 2 for Figure 1 A cross-sectional view of an electric ducted fan taken along the central axis of its motor.

[0031] Figure 3 This is a schematic diagram of the structure of an electric ducted fan according to an embodiment of this application, wherein the duct body is not included;

[0032] Figure 4 This is a structural schematic diagram of an electric ducted fan according to an embodiment of this application from another perspective, wherein the duct body, the fairing, and the stator blade support assembly are not included.

[0033] Figure 5 This is a schematic diagram of the structure of a motor according to an embodiment of this application;

[0034] Figure 6 for Figure 2 A schematic diagram of the moving blade assembly and the rotor assembly of the motor.

[0035] Figure 7 for Figure 2 A schematic diagram of the structure of the motor rear end cover and fan controller;

[0036] Figure 8 for Figure 2 Another structural diagram of the motor rear end cover and fan controller;

[0037] Figure 9 This is a schematic diagram of the structure of a fan controller according to an embodiment of this application from another perspective;

[0038] Figure 10 This is a schematic diagram of the circuit board structure of a fan controller according to an embodiment of this application.

[0039] Explanation of reference numerals in the attached figures

[0040] 10. Ductwork; 11. Mounting base;

[0041] 20. Stationary blade support assembly; 21. Stationary blade;

[0042] 30 Internal rotor motor; 31 Rotary shaft; 32 Stator assembly;

[0043] 33 Rotor assembly; 330 Rotor back iron; 331 Rotor magnet; 332 Rotor sheath; 333 Rotor core;

[0044] 34 Motor front cover; 35 Motor rear cover; 36 Hall effect speed and position sensor;

[0045] 37 Front bearing; 38 Rear bearing;

[0046] 40 Moving blade assembly; 41 Intermediate turntable; 42 Moving blade; 43 Moving blade retaining nut

[0047] 50 Fan controller; 51 Controller housing; 510 Raised flat surface; 520 Heat dissipation fins;

[0048] 52 Control board; 53 Power drive board; 54 Capacitor filter board; 55 MOSFET;

[0049] 56 Controller back cover; 560 High voltage connector; 561 Communication interface;

[0050] 57 Support column assembly; 570 Fixing nut; 571 First support column; 572 Second support column; 573 Third support column;

[0051] 60 fairing; 61 front fairing; 62 rear fairing; 620 support blades;

[0052] 70 Connecting post; 71 Wire lug sheath;

[0053] R is radial;

[0054] A-axis;

[0055] C Zhou Xiang Detailed Implementation

[0056] Exemplary embodiments of this application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are for teaching those skilled in the art how to implement this application only, and are not intended to exhaust all possible methods of this application, nor to limit the scope of this application.

[0057] Embodiments of this application provide an electric ducted fan (hereinafter, sometimes simply referred to as a "fan"). Unless otherwise specified, "axial", "radial", and "circumferential" refer to the axial, radial, and circumferential directions of the inner rotor motor (hereinafter, sometimes simply referred to as a "motor") of the electric ducted fan of this application, respectively.

[0058] Furthermore, "radial outer side" refers to the side radially away from the motor's central axis; "axial side" refers to... Figure 2 and Figure 7 The left side of the axis, "the other side of the axis" refers to Figure 2 and Figure 7 On the right side of the middle.

[0059] Furthermore, in this application, "torsional connection" refers to a connection between two components that can transmit torque, including direct or indirect connections. For example, the two components can be directly torsional connected via a spline.

[0060] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0061] like Figure 1 and Figure 2 As shown, an embodiment of this application provides an electric ducted fan, which may include a duct body 10, a stationary blade support assembly 20, an inner rotor motor 30, a moving blade assembly 40, a fan controller 50, and a shroud 60.

[0062] In this embodiment, as Figure 1 As shown, the inner wall of the duct 10 can form an airflow channel, which can be a hollow cylinder with flanges on both sides.

[0063] Furthermore, the outer wall of the duct 10 may be symmetrically provided with two mounting seats 11, each mounting seat 11 may also be provided with multiple mounting holes, so as to fix the fan to, for example, an external aircraft. Additionally, as... Figure 1 As shown, the mounting base 11 may also be provided with reinforcing ribs to increase its strength. At the same time, the duct body 10 may also be provided with wiring harness through holes on the cylinder wall for leading out the wiring harnesses of the motor 30 and the fan controller 50.

[0064] Preferably, the duct body 10 has two symmetrically distributed through holes, the location of which is not limited. Furthermore, the duct body 10 can be made of aluminum alloy and manufactured by machining.

[0065] In this embodiment, as Figure 2 and Figure 3 As shown, the stator blade support assembly 20 may include a plurality of stator blades 21 evenly distributed along the circumferential direction C, and their cross-section may be leaf-shaped. Furthermore, the stator blade support assembly 20 may be made of aluminum alloy. The plurality of stator blades 21 may be individually machined and then welded to the duct body 10 and the housing of the motor 30 to form a single integral component.

[0066] It is understood that the stator blade support assembly 20 can provide support for the motor 30 within the duct 10 and transmit the thrust generated by the stator blades 21 to the duct 10. In addition, it can also promote airflow within the duct 10, increase air volume, and meet the airflow pressure required by the system.

[0067] In this embodiment, as Figure 4 As shown, the moving blade assembly 40 may include an intermediate turntable 41 and multiple moving blades 42. The intermediate turntable 41 is torsionally connected to the rotating shaft 31, and the multiple moving blades 42 are spaced C apart circumferentially on the intermediate turntable 41. Furthermore, the intermediate turntable 41 can be fixedly connected to the rotating shaft 31 via moving blade fixing nuts 43. Thus, when the motor 30 drives the rotating shaft 31 to rotate, it can drive the multiple moving blades 42 to rotate, thereby generating airflow and achieving air flow and circulation.

[0068] Specifically, the moving blade assembly 40 can generate wind by rotating, drawing air into one side of the fan and expelling it to the other side through the pushing action of the blades, thus forming a continuous airflow. Furthermore, the rotation direction of the moving blades 42 can be adjusted by adjusting the rotation direction of the rotating shaft 31, thereby achieving the adjustment of the fan airflow direction.

[0069] In this embodiment, as Figure 2 As shown, the air deflector 60 can reduce airflow resistance, making airflow smoother and thus improving the fan's operating efficiency. Specifically, the air deflector 60 may include a front air deflector 61 and a rear air deflector 62, wherein the front air deflector 61 can be fixedly connected to one axial side of the blade assembly 40, and the rear air deflector 62 can be fixedly connected to the other axial side of the fan controller 50.

[0070] Preferably, the front fairing 61 can be fixedly connected to the intermediate turntable 41 by bolts, and the rear fairing 62 can be fixedly connected to the controller rear cover 56 of the fan controller 50 by bolts.

[0071] See Figure 3 The rear fairing 62 may also be provided with multiple support blades 620, which are hollow structures, i.e., have hollow channels. In this embodiment, the rear fairing 62 may be provided with two symmetrically distributed support blades 620.

[0072] It is understandable that the support blades 620 can increase support for the fan controller 50, reduce axial sway, and thus improve the stability of the fan. Furthermore, the hollow structure of the support blades 620 can further reduce weight, and the wiring harnesses of the motor 30 and controller can pass through the interior of each support blade 620, preventing wiring harness swaying caused by gas flow and reducing the fan's gas resistance. The through holes on the duct body 10 can be connected to or aligned with the hollow channels of the support blades 620.

[0073] Furthermore, when the motor 30 is cooled using a water-cooling structure, its water-cooling pipes can also pass through the interior of the support blade 620 and connect to the cooling water jacket of the motor 30. Alternatively, at least one hollow channel of the support blade 620 can be used as a cooling water channel.

[0074] like Figure 2 and Figure 5 As shown, the motor 30 may include a rotating shaft 31, a stator assembly 32, a rotor assembly 33, a front end cover 34, and a rear end cover 35. The front end cover 34, rotor assembly 33, and rear end cover 35 are sequentially mounted on the rotating shaft 31 along the axial direction A. The rotor assembly 33 is torsionally connected to the rotating shaft 31, and the stator assembly 32 is mounted on the outer side of the rotor assembly 33 in the radial direction R and fixed to the housing of the motor 30.

[0075] like Figure 2 As shown, the rotating shaft 31 is connected to the front end cover 34 of the motor via the front end bearing 37, and at the same time, the rotating shaft 31 is connected to the rear end cover 35 of the motor via the rear end bearing 38.

[0076] See Figure 2 and Figure 5 The blade assembly 40 can be torsionally connected to one side of the motor front end cover 34. Specifically, the intermediate turntable 41 of the blade assembly 40 can be connected to the rotating shaft 31 via a key or keyway. It is understood that the rotating shaft 31 can be provided with a keyway to enable quick installation of the blade assembly 40 and the rotating shaft 31 and to transmit torque. Furthermore, the rotating shaft 31 can be a hollow structure to reduce weight and moment of inertia.

[0077] Furthermore, the other end of the rotating shaft 31 ( Figure 2 The right side of the motor 30 may also be equipped with a Hall speed and position sensor 36, which is used to measure the position and speed of the rotor assembly 33 of the motor 30.

[0078] See Figure 2 The stator assembly 32 may include a stator core and a stator winding, the stator winding being wound around the stator core, and the stator core being fixedly connected to the housing of the motor 30.

[0079] In this embodiment, as Figure 2 and Figure 3 As shown, the stator blade support assembly 20 is fixed to the housing of the motor 30 by welding, that is, multiple stator blades 21 are fixed to the housing of the motor 30 at intervals. Therefore, during the operation of the fan, the heat generated by the motor 30 can be transferred to each stator blade 21, thereby achieving heat dissipation of the motor 30 (especially the stator winding).

[0080] In this embodiment, as Figure 6As shown, the rotor assembly 33 may include rotor magnets 331, rotor back iron 330, rotor sleeve 332, and rotor core 333. The rotor magnets 331 can be mounted on the rotor core 333 and are evenly spaced along the circumferential direction C. Furthermore, the rotor magnets 331 can employ a Halebec magnet array or a concentrated tangential magnet array design to improve the air gap magnetic field strength of the motor 30. The rotor magnets 331 can be directly attached to the surface of the rotor core 333 by adhesive bonding.

[0081] The rotor sheath 332 can cover the radially outer side of the rotor magnet 331 to protect the rotor magnet 331 from centrifugal force during high-speed rotation. The rotor sheath 332 can be machined from metal or manufactured by winding carbon fiber composite material. In addition, the surface of the rotor back iron 330 can also be provided with multiple threaded holes along the circumferential direction C to facilitate installation and fixation with the rotating shaft 31.

[0082] In this embodiment, as Figure 2 As shown, one end of the motor rear end cover 35 ( Figure 2 The left side can be fixedly connected to the housing of motor 30, while the other end ( Figure 2 The right side of the motor (30) can be fixedly connected to the housing of the fan controller 50. In this way, the rear end cover 35 of the motor can simultaneously seal and fix the motor 30 and the fan controller 50, thereby reducing the number of fan components.

[0083] Furthermore, the motor rear end cover 35 can also be used to fix and support the circuit board (such as control board 52) of the fan controller 50.

[0084] In this embodiment, as Figure 7 and Figure 8 As shown, the radially outer side of the axial mounting hole of the mounting shaft 31 of the motor rear end cover 35 may also be provided with a connecting hole, into which the wire lug sleeve 71 can be installed and fixedly connected to the motor rear end cover 35 by bolts. The wire lug sleeve 71 is made of insulating material (such as plastic) and its main function is insulation.

[0085] Further, see Figure 8 The lug sheath 71 may have three non-connected connector mounting holes, each of which can accommodate a connector 70. The connector 70 is conductive, with one end extending into the interior of the motor 30 and the other end extending into the interior of the fan controller 50. Both ends of the connector 70 may be threaded for connecting the three-phase terminals of the stator assembly 32 and the control board 52, respectively. In this way, the high-voltage lines within the motor 30 and the fan controller 50 can be directly connected inside the fan via the connector 70.

[0086] Specifically, such as Figure 7 As shown, one axial end of the connecting post 70 can be connected to the three-phase terminals of the stator winding, and the other axial end can be connected to the three-phase terminals of the fan controller 50. In this way, the connection of the two high-voltage lines is realized through the connecting post 70, which effectively reduces the number of connecting parts between the motor 30 and the fan controller 50, simplifies the connection structure, and thus helps to further reduce the weight of the fan.

[0087] Further, see Figure 8 The mounting holes for the connecting posts can be arranged side by side, and the connecting posts 70 can be hexagonal head bolts or countersunk bolts, etc. Preferably, in this embodiment, considering that the motor 30 is powered by a three-phase power supply, that is, three sets of internally threaded hexagonal head bolts can be provided on the rear end cover 35 of the motor.

[0088] like Figure 9 and Figure 10 As shown, the fan controller 50 may include a controller housing 51, a control board 52, a power drive board 53, and a capacitor filter board 54 stacked sequentially along axis A, as well as a support column assembly 57. The controller housing 51 is fixedly connected to the motor rear end cover 35 and the controller rear cover 56.

[0089] Traditional fan controllers typically integrate control, power drive, and capacitor filtering functions onto a single board, a design that imposes size requirements on the board. While suitable for traditional motor drives where size is not critical, this single-board design is not ideal for miniaturized and highly integrated applications.

[0090] In order to enable the fan controller 50 to better adapt to the size of the motor 30, in this embodiment, the circuit board of the traditional controller is designed as three circuit boards: control board 52, power drive board 53 and capacitor filter board 54, to distinguish different functions. The shape of the circuit board can be circular (including approximately circular).

[0091] Specifically, the control board 52 can control and monitor the fan's operating status, including signal transmission, power management, equipment monitoring, and fault diagnosis; the power drive board 53 is the drive circuit for the power module, mainly performing signal amplification, isolation, adjustment, and inversion operations; the capacitor filter board 54 removes noise and interference from the power supply, providing a stable DC voltage to ensure the normal operation of other components. In addition, the capacitor filter board 54 is also connected to the high-voltage connector 560 (see...). Figure 2 ), used to connect to an external high-voltage power supply circuit.

[0092] In this embodiment, as Figure 9 , Figure 10As shown, the control board 52, power drive board 53, and capacitor filter board 54 can be fixed in the cavity of the fan controller 50 by means of support column assemblies 57. Specifically, the fan controller 50 may include three sets of support column assemblies 57 spaced C apart in the circumferential direction to ensure stable support of the circuit board. The support column assembly may include a first support column 571, a second support column 572, and a third support column 573.

[0093] See Figure 10 The first support column 571 can be fixed on the rear end cover 35 of the motor, and the control board 52 can be fixed between the second support column 572 and the first support column 571; then, the power drive board 53 can be fixed between the second support column 572 and the third support column 573; finally, the capacitor filter board 54 can be fixed between the third support column 573 and the fixing nut 570 of the capacitor filter board 54, and finally tightened by the fixing nut 570.

[0094] It is understood that in this embodiment, by stacking three circuit boards axially inside the controller housing 51, this design not only reduces the lateral space of the controller, but also reduces the longitudinal dimension through the optimization of the spatial layout, thereby better adapting to the size requirements of the ducted fan.

[0095] As can be seen from the above, the power driver board 53 can control the conduction and cutoff of devices such as IGBTs (Insulated Gate Bipolar Transistors) or MOSFETs 55 (Metal-Oxide-Semiconductor Field-Effect Transistors) in the power chip. The MOSFET 55 is generally fixed on the power driver board 53.

[0096] In this embodiment, as Figure 9 and Figure 10 As shown, the MOSFET 55 can be fixed on the inner wall of the controller housing 51 and dissipated through the heat dissipation teeth 520 on the outer wall of the controller housing 51.

[0097] Specifically, see Figure 9 The inner wall of the controller housing 51 may be provided with a plurality of raised planes 510 that are evenly distributed along the circumferential direction C and protrude radially inward. The mounting surface of the raised plane 510 is parallel to the axial direction A of the fan controller 50, and the MOS transistor 55 can be mounted on the mounting surface of the raised plane 510.

[0098] Preferably, in this embodiment, the inner wall of the controller housing 51 may be provided with three sets of raised planes 510, and the MOS transistor 55 may be directly attached to these raised planes 510 by adhesive bonding.

[0099] Furthermore, in the corresponding region of the outer wall of the raised plane 510, a plurality of heat dissipation teeth 520 can be uniformly provided along the circumferential direction C. That is, the axial height of these heat dissipation teeth 520 is equal to the axial height of the raised plane 510, and the axial position of the heat dissipation teeth 520 is the same as the axial position of the raised plane 510. In this way, the heat generated by the MOSFET 55 can be effectively transferred to the heat dissipation teeth 520 and the controller housing 51, thereby achieving rapid heat dissipation.

[0100] Preferably, the spacing between adjacent heat dissipation teeth 520 is 1.2 to 1.5 times the height of the heat dissipation teeth 520, and multiple heat dissipation teeth 520 can be integrally formed with the controller housing 51.

[0101] See Figure 2 The controller rear cover 56 can be used to seal the other end of the fan controller 50. Figure 2 (on the right side), and respectively connected to the controller housing 51 and the rear diffuser 62. Specifically, the controller rear cover 56 may also be provided with a high-voltage connector 560 and a communication interface 561. The high-voltage connector 560 can be used to provide power to the fan controller 50 and the motor 30, while the communication interface 561 can be used to transmit control signals and communicate.

[0102] See Figure 2 and Figure 10 The connection method for the high-voltage circuits of the fan controller 50 and the motor 30 is as follows: the external power supply line can enter the fan cavity through the hollow channel of the support blade of the rear guide shroud 62 and connect to the high-voltage connector 560; the high-voltage connector 560 can connect the high-voltage wire to the capacitor filter board 54 for filtering, and then connect it to the power drive board 53 through the capacitor filter board 54, and then connect it to the control board 52 through the power drive board 53. The three-phase terminals on the control board 52 are connected to the three-phase terminals connected to the stator assembly 32 through the connecting post 70, thereby realizing the connection of the high-voltage circuit of the entire fan.

[0103] Furthermore, the fan cooling structure provided in the embodiments of this application fully utilizes the airflow of the fan to improve the heat transfer coefficient of the motor 30 (i.e., stator cooling). Specifically, the fan airflow flows over the stator blades 21 and the housing of the motor 30, thereby reducing the temperature rise of the motor 30 and improving the heat dissipation capacity and power density of the motor 30. In addition, the stator cooling utilizes a traditional stator support structure, realizing the reuse of the functions of stator support and stator cooling, effectively improving the utilization rate of components. At the same time, by fixing the MOSFET 55 to the controller housing 51 with heat dissipation teeth 520, heat dissipation can be achieved by utilizing the airflow of the fan.

[0104] It is understood that the ducted fan provided in this application reduces unnecessary parts by integrating the duct body 10, motor housing, and stator blade support assembly 20 into a single component. Simultaneously, the motor 30 and fan controller 50 share the same end cover (i.e., the motor rear end cover 35), achieving simultaneous sealing of both the motor 30 and fan controller 50 and providing support for internal components. This integrated design effectively combines the fan blades, motor 30, and fan controller 50 into a compact and lightweight whole.

[0105] The ducted fan provided in this application achieves a compact design by having a single component that connects multiple components, further reducing its size and weight. Simultaneously, the fan controller 50's circuit board can include three circuit boards with different functions, stacked along the axial direction, thereby reducing the longitudinal dimension of the circuit board to accommodate the size requirements of different fans.

[0106] It should be understood that the above-described embodiments, examples, or examples are merely exemplary and are not intended to limit this application. Those skilled in the art can make various modifications and changes to the above-described embodiments, examples, or examples under the teachings of this application without departing from the scope of this application.

Claims

1. An electric ducted fan characterized in that, include: The ductwork has airflow channels formed on its inner wall; A stator blade support assembly includes a plurality of stator blades evenly distributed circumferentially, the plurality of stator blades being integrally formed with the inner wall of the duct body; An internal rotor motor, the outer casing of which is fixedly connected to the stationary blade support assembly; The moving blade assembly includes an intermediate turntable and a plurality of moving blades, the plurality of moving blades being spaced apart along the circumferential direction on the intermediate turntable, and the intermediate turntable being torsionally connected to the shaft of the inner rotor motor; A fan controller includes a controller housing, a control board, a power drive board, and a capacitor filter board stacked sequentially along an axial direction, and multiple support column assemblies, wherein the control board, the power drive board, and the capacitor filter board are sequentially fixedly connected via the support column assemblies; and The air deflector includes a front air deflector and a rear air deflector, the front air deflector being fixed to one axial side of the moving blade assembly, and the rear air deflector being fixed to the other axial side of the fan controller.

2. The electric-duct fan of claim 1, wherein, The internal rotor motor includes a motor rear end cover, one axial end of which is connected to the outer shell of the internal rotor motor, and the other axial end is connected to the outer shell of the controller, and the motor rear end cover is installed on the inner wall of the controller outer shell.

3. The electric ducted fan of claim 2, wherein, The ducted fan includes connecting posts and lug sheaths. A connecting hole is provided on the radially outer side of the motor rear end cover. The lug sheath is installed in the connecting hole. The lug sheath has three non-connected connecting post mounting holes. The connecting posts are respectively installed in the connecting post mounting holes, such that one end of the connecting post extends into the interior of the inner rotor motor and is threaded to the three-phase terminals of the stator assembly of the inner rotor motor. The other end of the connecting post extends into the interior of the fan controller and is threaded to the three-phase terminals of the control board.

4. The electric ducted fan of claim 2, wherein, Multiple support column assemblies are spaced apart along the circumferential direction. Each support column assembly includes a first support column, a second support column, and a third support column. The first support column is fixed between the motor rear end cover and the control board, the second support column is fixed between the control board and the power drive board, and the third support column is fixed between the power drive board and the capacitor filter board.

5. The electric ducted fan of claim 1, wherein, The ducted fan includes a MOSFET, and the inner wall of the controller housing includes a plurality of raised planes evenly distributed along the circumference. The mounting surface of the raised planes is parallel to the axial direction of the fan controller, and the MOSFET is fixedly mounted on the mounting surface of the raised planes.

6. The electric-duct fan of claim 5, wherein, The outer wall of the controller housing includes a plurality of heat dissipation teeth evenly arranged along the circumference. The axial position of the heat dissipation teeth is the same as the axial position of the protruding plane, and the spacing between adjacent heat dissipation teeth is 1.2 to 1.5 times the height of the heat dissipation teeth.

7. The electric-duct fan of claim 1, wherein The culvert body includes two symmetrically arranged mounting seats, which are disposed on the outer wall of the culvert body and include reinforcing ribs and mounting holes; and / or The duct body is provided with a wiring harness through hole, through which the wiring harnesses of the inner rotor motor and the fan controller pass.

8. The electric-duct fan of claim 1, wherein, The rear fairing includes two symmetrically distributed support blades for supporting the ducted fan, and the wiring harnesses of the inner rotor motor and the fan controller pass through the support blades.

9. The electric ducted fan of any of claims 1 to 8, wherein, The fan controller includes a controller back cover, which includes a high-voltage connector and a communication interface. The high-voltage connector is electrically connected to the capacitor filter board, and the communication interface is electrically connected to the inner rotor motor and the fan controller.

10. The electric-duct fan according to claim 9, wherein The control board, the power drive board, and the capacitor filter board all adopt a circular design.

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