Motor lightweight noise suppression package material structure

Abstract

The utility model discloses a kind of motor lightweight noise reduction package material structure, it is related to new energy motor technical field, including protective layer, the inner wall of protective layer is equipped with noise reduction layer, the inner wall of noise reduction layer is equipped with buffer layer, the inner wall of buffer layer is equipped with functional layer, and noise reduction layer includes damping material plate and metal foam.The utility model, by selecting boron nitride nanosheet composite insulation film, polypropylene honeycomb foam, metal foam and the like low-density material, and carbon fiber reinforced composite material replace traditional heavier material, while combining integrated forming reduces connecting piece, modular design reasonably distributes the structure optimization of material, under the premise of guaranteeing package material performance, substantially reduce the overall weight of motor, improve the energy utilization efficiency of new energy equipment, secondly, multilayer structure synergistic effect, form all-round noise reduction system, effectively reduce motor operating noise, improve use comfort and environmental friendliness.

Description

Technical Field

[0001] This utility model relates to the field of new energy motor technology, and in particular to a lightweight noise-suppressing packaging structure for motors. Background Technology

[0002] With increasing global emphasis on environmental protection and sustainable development, the new energy industry is experiencing rapid growth. In the new energy vehicle sector, the market share of pure electric vehicles and hybrid vehicles is continuously expanding, placing higher demands on the power density, efficiency, and reliability of drive motors. Lightweight generators can reduce the load on towers and foundations, decrease construction costs, and simultaneously improve the starting performance and power generation efficiency of wind turbines.

[0003] However, existing motor packaging structures have many shortcomings in terms of lightweighting and noise reduction. On the one hand, traditional packaging structures are relatively heavy, failing to meet the lightweighting requirements of new energy equipment; on the other hand, existing noise reduction measures have limited effectiveness and cannot effectively reduce the noise generated by the motor during operation. Therefore, developing a new type of packaging structure that can both achieve motor lightweighting and effectively reduce noise is of significant practical importance. Utility Model Content

[0004] The purpose of this utility model is to solve the problems existing in the prior art by proposing a lightweight noise-suppressing packaging structure for motors.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a lightweight noise-suppressing packaging structure for motors, including a protective layer, a noise-reducing layer installed on the inner wall of the protective layer, a buffer layer installed on the inner wall of the noise-reducing layer, a functional layer installed on the inner wall of the buffer layer, the noise-reducing layer including a damping material plate and a metal foam, and multiple sets of trapezoidal holes penetrating through the outer wall of the metal foam.

[0006] Preferably, the metal foam is bonded to the damping material plate with an adhesive, and the inner wall of the damping material plate is fixed to the outer wall of the buffer layer.

[0007] Preferably, the outer wall of the metal foam is fixed to the inner wall of the protective layer.

[0008] Preferably, the outer wall of the protective layer is equipped with two sets of mounting plates, and the outer wall of the protective layer is equipped with a controller and a noise sensor.

[0009] Preferably, vibration sensors are installed in two reserved slots on the inner wall of the functional layer, and the lower ends of the controller and noise sensor are fixed to the upper ends of the two sets of mounting plates, respectively.

[0010] Preferably, both sets of vibration sensors and noise sensors are connected to the controller signal.

[0011] Compared with the prior art, the advantages and positive effects of this utility model are as follows:

[0012] 1. In this utility model, by selecting low-density materials such as boron nitride nanosheet composite insulating film, polypropylene honeycomb foam, and metal foam, and replacing traditional heavy materials with carbon fiber reinforced composite materials, and by combining integrated molding to reduce connecting parts and modular design to rationally allocate materials, the overall weight of the motor is significantly reduced while ensuring the performance of the packaging material, thereby improving the energy utilization efficiency of new energy equipment.

[0013] 2. In this utility model, by setting a noise reduction layer, with the cooperation of damping material plate, metal foam and multiple sets of trapezoidal holes, it can absorb noise of different frequencies. The damping material plate can suppress structural vibration, the buffer layer absorbs mechanical vibration, and the protective layer blocks the transmission of noise. The multi-layer structure works together to form a comprehensive noise reduction system, effectively reducing the operating noise of the motor, improving user comfort and environmental friendliness. Attached Figure Description

[0014] Figure 1 This utility model provides a three-dimensional structural diagram of a lightweight noise-suppressing packaging material for motors.

[0015] Figure 2 A side view of a lightweight noise-suppressing packaging structure for an electric motor is provided in this utility model;

[0016] Figure 3 This utility model proposes a schematic diagram of a noise reduction layer structure for a lightweight noise-suppressing packaging material for motors.

[0017] Figure 4 A top view of a lightweight noise-suppressing packaging structure for an electric motor is presented in this utility model.

[0018] Legend: 1. Protective layer; 2. Functional layer; 3. Mounting plate; 4. Controller; 5. Vibration sensor; 6. Noise reduction layer; 61. Damping material plate; 62. Metal foam; 63. Trapezoidal hole; 7. Buffer layer; 8. Noise sensor. Detailed Implementation

[0019] To better understand the above-mentioned objectives, features, and advantages of this utility model, the present utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0020] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the present invention is not limited to the specific embodiments disclosed in the following specification.

[0021] Example 1: As Figure 1-4 As shown, this utility model provides a lightweight noise reduction packaging structure for motors, including a protective layer 1, a noise reduction layer 6 installed on the inner wall of the protective layer 1, a buffer layer 7 installed on the inner wall of the noise reduction layer 6, and a functional layer 2 installed on the inner wall of the buffer layer 7. The noise reduction layer 6 includes a damping material plate 61 and a metal foam 62. Multiple sets of trapezoidal holes 63 are opened through the outer wall of the metal foam 62. The metal foam 62 is bonded to the damping material plate 61 by an adhesive. The inner wall of the damping material plate 61 is fixed to the outer wall of the buffer layer 7, and the outer wall of the metal foam 62 is fixed to the inner wall of the protective layer 1.

[0022] The specific settings and functions of this embodiment are described below. A noise reduction layer 6 is installed on the inner wall of the protective layer 1, a buffer layer 7 is installed on the inner wall of the noise reduction layer 6, and a functional layer 2 is installed inside the buffer layer 7.

[0023] Functional layer 2 employs a boron nitride nanosheet composite insulating film, which directly contacts the motor to dissipate heat generated during motor operation and provide insulation protection. This film is prepared by uniformly dispersing boron nitride nanosheets in an insulating resin matrix through casting or coating processes. It possesses high thermal conductivity and insulation, effectively ensuring stable motor operating temperature and preventing leakage risks.

[0024] The buffer layer 7 is a honeycomb polypropylene honeycomb foam. Its unique honeycomb structure can reduce the weight of the packaging material while providing good cushioning performance and absorbing the mechanical vibration generated during motor operation. The polypropylene honeycomb foam is prepared by a molding process, and the pore size and wall thickness of the honeycomb are optimized according to the vibration characteristics of the motor.

[0025] The noise reduction layer 6 is composed of a damping material plate 61 and a metal foam 62. Multiple sets of trapezoidal holes 63 are opened through the outer wall of the metal foam 62. The pore size and porosity vary in gradient along the thickness direction. The pore size and porosity are smaller and lower on the side closer to the motor to absorb high-frequency noise, while the pore size and porosity are larger and higher on the outer side to absorb low-frequency noise. The damping material plate 61 is made of magnetorheological damping material or electrorheological damping material and is a thin plate with a thickness of 0.8 to 1.2 mm. Micron-level wire mesh is embedded inside. The damping material plate 61 and the metal foam 62 are bonded together with an adhesive to form a structure with synergistic noise reduction effect.

[0026] The protective layer 1 is made of high-strength carbon fiber reinforced composite material, which is formed by combining high-performance carbon fiber with a lightweight resin matrix in an optimized layup direction and ratio. It has excellent impact resistance, corrosion resistance and wear resistance, protecting the internal structure from damage by the external environment. The carbon fiber reinforced composite material is prepared by compression molding process, and its mechanical properties meet the requirements of motor operation.

[0027] Example 2: Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, two sets of mounting plates 3 are installed on the outer wall of the protective layer 1. A controller 4 and a noise sensor 8 are provided on the outer wall of the protective layer 1. Vibration sensors 5 are installed in two reserved slots on the inner wall of the functional layer 2. The lower ends of the controller 4 and the noise sensor 8 are fixed to the upper ends of the two sets of mounting plates 3 respectively. The two sets of vibration sensors 5 and noise sensors 8 are all connected to the controller 4 for signal transmission.

[0028] The overall effect of this embodiment is that the vibration sensor 5 is installed on the inner wall of the functional layer 2 with two symmetrically distributed reserved slots. The slots are filled with thermally conductive silicone for shock absorption and insulation. Each reserved slot is embedded with a miniature acceleration vibration sensor 5 (model: ICP-352A24). This sensor uses MEMS technology and is connected to the controller 4 through a high-temperature shielded cable. The direct contact design between the sensor and the motor surface can accurately capture vibration signals from key parts such as motor bearings and stator cores.

[0029] Noise sensors 8 are installed on both sides of the outer wall of the protective layer 1, with an L-shaped mounting plate 3 installed on each side. The plate is made of carbon fiber reinforced composite material and coated with an anti-ultraviolet coating. Each mounting plate 3 has a dedicated slot on its vertical surface for fixing the noise sensor 8 (model: BSWAMP201). The sensor conforms to the IEC61672-1 standard, has a built-in windproof cover and preamplifier, and transmits data to the controller 4 via a wireless module (2.4GHz band) to avoid the impact of cable layout on the packaging structure.

[0030] The controller 4 is installed on the horizontal surface of one of the mounting plates 3. It adopts a waterproof and dustproof metal shell (IP67 protection level). The controller 4 integrates an ARM Cortex-M7 microprocessor, signal conditioning circuit, power amplifier and wireless communication module. The controller 4 is connected to the vibration sensor 5 and the noise sensor 8 through a dedicated interface. At the same time, it is connected to the magnetorheological damping material plate 61 in the noise reduction layer 6 through a shielded cable, realizing the integrated function of signal acquisition, processing and control command output.

[0031] Vibration sensor 5 monitors the acceleration, frequency, and other parameters of motor vibration in real time, while noise sensor 8 synchronously collects the sound pressure level and frequency components of ambient noise. Both types of sensors transmit analog signals to controller 4 at a sampling frequency of 10kHz.

[0032] The controller 4 has a built-in digital signal processing (DSP) algorithm to perform fast Fourier transform (FFT) analysis on the acquired signal, separate the vibration and noise characteristics of different frequency bands, and compare them with preset thresholds (such as vibration acceleration > 2g, noise sound pressure level > 65dB).

[0033] Magnetorheological damping material control: When the controller 4 determines that the motor vibration or noise is abnormal, it outputs a controllable current of 0-2A through the power amplifier to drive the electromagnetic coil in the damping material plate 61 to generate a magnetic field strength of 0-1T. Under the action of the magnetic field, the micron-sized magnetic particles (such as carbonyl iron powder) inside the magnetorheological material quickly arrange themselves along the direction of the magnetic field lines to form a chain structure, so that the material viscosity increases from 0.1Pa·s to 5Pa·s within 10-30ms, effectively increasing the damping force and suppressing the propagation of structural vibration;

[0034] Control of electrorheological damping material: If electrorheological damping material is used, the controller 4 outputs an electric field strength of 0-5kV / mm, which causes the polar molecules inside the material to undergo orientation polarization, enhances the interaction between molecular chains, and instantly changes the viscosity and elastic modulus, thereby realizing real-time adjustment of damping performance.

[0035] The feedback optimization mechanism controller 4 continuously monitors sensor feedback signals and dynamically adjusts damping parameters using an adaptive PID control algorithm. When the vibration frequency changes rapidly during motor startup, the system can optimize and adjust the damping force within 200ms. During steady-state operation, parameters are fine-tuned every 500ms to ensure that the noise reduction effect is always optimal. At the same time, the controller 4 supports OTA remote upgrade function, which can update the control algorithm through a wireless module to adapt to different working conditions.

[0036] The usage and working principle of this device: Functional layer 2 uses boron nitride nanosheet composite insulating film, which is directly and tightly attached to the motor surface. The boron nitride nanosheet has high thermal conductivity, which can quickly conduct heat away when the motor generates heat during operation. The heat is transferred to buffer layer 7 through thermal conduction and then diffused into the external environment. This can effectively reduce the surface temperature of the motor and ensure the stability of the motor's operating temperature. At the same time, the polyimide resin matrix provides excellent insulation performance, isolating the live parts of the motor from the outside world, preventing the risk of leakage, and ensuring the safe operation of the motor.

[0037] The buffer layer 7, composed of honeycomb polypropylene honeycomb foam, absorbs the mechanical vibration generated during motor operation using its unique honeycomb structure. When the motor vibration is transmitted to the buffer layer 7, the honeycomb wall bends and deforms, and the cell generates elastic compression, converting the vibration energy into the deformation energy of the material. This structural design effectively buffers vibration while significantly reducing the weight of the packaging material due to the low density of polypropylene material, thus achieving the goal of lightweighting.

[0038] The noise reduction layer 6 is composed of a damping material plate 61 and a metal foam 62. The trapezoidal pores 63 of the metal foam 62 are distributed in a gradient. The structure with small pores and low porosity near the motor side reflects high-frequency sound waves multiple times and absorbs them through air viscosity. The large pores and high porosity on the outer side cause low-frequency sound wave resonance loss, thus achieving passive absorption of noise of different frequencies. The damping material plate 61 uses magnetorheological or electrorheological damping material. Under the action of an external magnetic field or electric field, it can actively adjust its own damping performance, suppress structural vibration, and reduce the noise generated by vibration. Together with the metal foam 62, it forms a comprehensive noise reduction system.

[0039] The protective layer 1 is made of high-strength carbon fiber reinforced composite material. With optimized layup design, it has good mechanical properties in both the axial and circumferential directions. Its surface nano-coating treatment forms a dense protective film that can resist the corrosion of harsh environments such as salt spray and acid and alkali. The surface hardness of ≥5H can effectively prevent sand and gravel impact and mechanical wear, protect the internal structure from damage by the external environment, and extend the service life of the packaging material.

[0040] The vibration sensor 5 installed in the reserved slot on the inner wall of the functional layer 2 is a miniature acceleration vibration sensor 5 using MEMS technology. It can accurately capture vibration signals of key parts such as motor bearings and stator cores, and monitor the acceleration, frequency and other parameters of motor vibration in real time. The noise sensor 8 installed on the outer wall of the protective layer 1 conforms to the IEC61672-1 standard and can accurately collect the sound pressure level and frequency components of ambient noise. The two types of sensors transmit analog signals to the controller 4 at a sampling frequency of 10kHz.

[0041] The controller 4 has a built-in ARM Cortex-M7 microprocessor, which integrates signal conditioning circuit, power amplifier and wireless communication module. After receiving the signal transmitted by the sensor, it performs fast Fourier transform (FFT) analysis through digital signal processing (DSP) algorithm to separate the vibration and noise characteristics of different frequency bands and compare them with preset thresholds. If the motor vibration or noise is determined to be abnormal, the required damping parameters are calculated based on the analysis results.

[0042] Finally, when the controller 4 determines that the performance of the damping material needs to be adjusted, the controller 4 outputs a controllable current of 0-2A through the power amplifier to drive the electromagnetic coil in the damping material plate 61 to generate a magnetic field strength of 0-1T. Under the action of the magnetic field, the magnetic particles inside the magnetorheological damping material quickly arrange themselves along the direction of the magnetic field lines to form a chain structure, so that the material viscosity increases from 0.1Pa·s to 5Pa·s within 10-30ms, increasing the damping force and effectively suppressing the propagation of structural vibration.

[0043] The controller 4 continuously monitors the sensor feedback signals and uses an adaptive PID control algorithm to dynamically adjust the damping parameters. When the vibration frequency changes rapidly during the motor start-up phase, the system can complete the optimization adjustment of the damping force within 200ms. During steady-state operation, the parameters are fine-tuned every 500ms to ensure that the noise reduction effect is always in the optimal state. At the same time, the controller 4 supports OTA remote upgrade function and can update the control algorithm through the wireless module to adapt to different working conditions.

[0044] By combining the basic functions of the multi-layered composite structure with the dynamic adjustment of the intelligent control system, the lightweight noise-suppressing packaging structure of this motor can effectively reduce the weight of the motor, suppress operating noise, and improve the overall performance and user experience of new energy equipment.

[0045] The above are merely preferred embodiments of this utility model and are not intended to limit the utility model in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model without departing from the technical solution of this utility model shall still fall within the protection scope of this utility model.

Claims

1. A lightweight noise-suppressing packaging structure for motors, characterized in that: It includes a protective layer (1), a noise reduction layer (6) installed on the inner wall of the protective layer (1), a buffer layer (7) installed on the inner wall of the noise reduction layer (6), a functional layer (2) installed on the inner wall of the buffer layer (7), and the noise reduction layer (6) includes a damping material plate (61) and a metal foam (62), with multiple sets of trapezoidal holes (63) penetrating through the outer wall of the metal foam (62).

2. The lightweight noise-suppressing packaging structure for a motor according to claim 1, characterized in that: Metal foam (62) is bonded to damping material plate (61) by an adhesive, and the inner wall of damping material plate (61) is fixed to the outer wall of buffer layer (7).

3. The lightweight noise-suppressing packaging structure for a motor according to claim 2, characterized in that: The outer wall of the metal foam (62) is fixed to the inner wall of the protective layer (1).

4. The lightweight noise-suppressing packaging structure for a motor according to claim 1, characterized in that: Two sets of mounting plates (3) are installed on the outer wall of the protective layer (1), and a controller (4) and a noise sensor (8) are provided on the outer wall of the protective layer (1).

5. The lightweight noise-suppressing packaging structure for a motor according to claim 4, characterized in that: Vibration sensors (5) are installed in two reserved slots on the inner wall of the functional layer (2). The lower ends of the controller (4) and the noise sensor (8) are fixed to the upper ends of the two sets of mounting plates (3).

6. The lightweight noise-suppressing packaging structure for a motor according to claim 5, characterized in that: Both sets of vibration sensors (5) and noise sensors (8) are connected to the controller (4) via signal.

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