Controller assembly mounting and cooling structure for aircraft motor

Abstract

The utility model relates to controller assembly installation and cooling structure for aircraft motor, including stator assembly, circuit board and cooling plate, the stator assembly includes stator casing and the winding of setting on the outside wall of stator casing, the bottom of stator casing is fixed with the bottom plate, the circuit board and cooling plate are fixed in the cavity formed by bottom plate and stator casing, and the circuit board is connected with the winding, interval is established with IGBT module on the circuit board, a plurality of cooling grooves are established in one side of cooling plate, and IGBT module snap -fits fixed on the cooling groove, still be provided with cooling pipeline that communicates with outside cooling device on cooling plate, all cooling grooves are communicated by cooling pipeline. The utility model structure is compact, reduces the volume and weight of whole power system, and realizes accurate, efficient cooling to core heating element, overcomes the problem that the heat dissipation path is long in traditional scheme, and the thermal resistance is big, improves the thermal reliability and long -term work stability of controller.

Description

Technical Field

[0001] This utility model relates to the field of aircraft motor structure technology, and in particular to a controller assembly installation and cooling structure for an aircraft motor. Background Technology

[0002] With the rapid development of electric aircraft technology (including UAVs, electric vertical takeoff and landing (eVTOL) aircraft, higher requirements are being placed on the power density, reliability, and thermal management performance of the power system. The motor controller, as the core component of the power system, is responsible for driving the motor, and its performance directly affects the overall flight efficiency and safety of the aircraft. In particular, the insulated gate bipolar transistor (IGBT) module in the controller, as a high-power switching device, generates a large amount of heat during operation. If it cannot be dissipated in time, the device temperature will become too high, leading to decreased efficiency, shortened lifespan, or even failure.

[0003] Currently, common controller cooling methods mainly include air cooling and liquid cooling. Air cooling has a simple structure and low cost, but its heat dissipation efficiency is limited and it is difficult to meet the heat dissipation requirements of high power density aircraft motor controllers. Although liquid cooling (including water cooling and oil cooling) has a strong heat dissipation capacity, its system integration, flow channel layout and installation reliability still face significant challenges in applications such as aircraft where weight and space are extremely sensitive.

[0004] In existing technologies, most liquid-cooled controllers employ an independent cooling plate structure, introducing coolant into the internal channels of the cooling plate through external pipes to dissipate heat from the power devices. However, this type of structure often suffers from the following problems: 1. Long heat dissipation path and high thermal resistance: IGBT modules typically contact the cooling plate through thermally conductive grease or insulating pads, resulting in multiple layers of interfacial thermal resistance and reduced heat transfer efficiency; 2. Complex structure and difficult installation: The controller is usually installed separately from the motor, requiring additional support and sealing structures, increasing system weight and assembly complexity; 3. Inappropriate flow channel layout: Cooling channels are often straight or simply curved, easily leading to uneven coolant distribution and difficulty in eliminating local hot spots. Utility Model Content

[0005] To address the aforementioned technical problems, the purpose of this utility model is to provide a highly integrated, efficient heat dissipation, and compact structure for mounting and cooling controller components for aircraft motors. This structure meets the requirements of electric aircraft for high performance and high reliability of the power system.

[0006] To achieve the above-mentioned objectives, this utility model adopts the following technical solution:

[0007] A controller assembly and cooling structure for an aircraft motor includes a stator assembly, a circuit board, and a cooling plate. The stator assembly includes a stator housing and windings disposed on the outer wall of the stator housing. A base plate is fixed to the bottom of the stator housing. The circuit board and the cooling plate are fixed within the cavity formed by the base plate and the stator housing, and the circuit board is connected to the windings. IGBT modules are spaced apart on the circuit board. Multiple cooling slots are provided on one side of the cooling plate, and the IGBT modules are fastened and fixed to the cooling slots. Cooling pipes communicating with an external cooling device are also provided on the cooling plate, and the cooling pipes connect all the cooling slots.

[0008] As a preferred embodiment, the cooling pipeline includes an inner arc-shaped cooling groove and an outer arc-shaped cooling groove disposed on the other side of the cooling plate. The bottom of the cooling groove has elongated through holes on both radial sides. The inner arc-shaped cooling groove connects the elongated through holes on the radially inner side of all the cooling grooves. The outer arc-shaped cooling groove connects the elongated through holes on the radially outer side of all the cooling grooves. The inner arc-shaped cooling groove and the outer arc-shaped cooling groove are also provided with an oil outlet pipe and an oil inlet pipe that are connected to the external cooling oil circuit.

[0009] As a preferred embodiment, both the inner arc-shaped cooling groove and the outer arc-shaped cooling groove are C-shaped, with the outer arc-shaped cooling groove located outside the inner arc-shaped cooling groove, and the two are concentrically arranged.

[0010] As a preferred embodiment, the openings of the inner arc-shaped cooling groove and the outer arc-shaped cooling groove are opposite each other, and the oil outlet pipe and the oil inlet pipe are spaced 180° apart.

[0011] As a preferred embodiment, the IGBT module is fixed to the cooling tank on both sides by pressure blocks, and a sealing ring is also sandwiched between the IGBT module and the cooling tank.

[0012] As a preferred embodiment, the inner wall of the stator housing is further provided with a plurality of auxiliary fixing blocks, the cooling plate is fixed to the stator housing through the auxiliary fixing blocks, and the circuit board is fixed to the cooling plate.

[0013] As a preferred embodiment, the stator housing is further provided with a mounting bracket, and the cooling plate is fixed to the auxiliary fixing block through the mounting bracket.

[0014] As a preferred embodiment, a terminal block is also provided inside the stator housing. The inner ring of the terminal block is connected to the IGBT module, and the outer side of the terminal block is connected to a power connector disposed outside the stator housing.

[0015] As a preferred embodiment, the terminal block is also fixed to the mounting bracket, and the terminal block is sandwiched between the mounting bracket and the cooling plate.

[0016] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0017] This invention directly installs the circuit board (controller core) and cooling plate in the cavity formed by the stator housing and the base plate, realizing deep integration of the controller and the motor body. This greatly reduces the need for external connection lines and independent housings, significantly reduces the size and weight of the entire power system, and meets the stringent requirements of aircraft for high power density and lightweight design.

[0018] Meanwhile, by setting multiple cooling slots on the cooling plate and directly fastening the IGBT module (the main heat source) to the cooling slots, a very short, low thermal resistance heat dissipation path is established. Heat can be directly conducted from the IGBT module to the cooling slot wall filled with coolant, achieving precise and efficient cooling of the core heat-generating components and overcoming the problems of long heat dissipation paths and high thermal resistance in traditional solutions. Furthermore, the cooling plate has internal cooling pipes that connect all the cooling slots, forming an integrated cooling circulation system. This allows the coolant to flow through the cooling slot under each IGBT module, ensuring that all critical power devices receive uniform and sufficient cooling, avoiding localized overheating, and greatly improving the thermal reliability and long-term operational stability of the controller. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0020] Figure 1 This is a schematic diagram of the overall structure of an aircraft motor using the structure of this utility model;

[0021] Figure 2 and Figure 3 These are two different exploded structural diagrams of this utility model;

[0022] Figure 4 This is a schematic diagram of the structure of the cooling plate of this utility model;

[0023] Figure 5 This is a schematic diagram of the fixing structure of the IGBT module and the cooling plate of this utility model.

[0024] The reference numerals in the accompanying drawings are as follows: 1. Outer rotor assembly; 110. Bearing outer ring pressure plate; 2. Stator assembly; 210. Bearing inner ring pressure plate; 220. Power connector; 20. Base plate; 21. Stator housing; 22. Winding; 25. Circuit board; 251. IGBT module; 252. Pressure block; 26. Cooling plate; 261. Oil inlet pipe; 262. Oil outlet pipe; 263. Cooling groove; 264. Long strip-shaped through hole; 266. Inner arc-shaped cooling groove; 265. Outer arc-shaped cooling groove; 27. Terminal block; 28. Mounting bracket; 29. ​​Transition oil pipe; 3. Radiator assembly; 5. Sealing cover; 6. Bearing. Detailed Implementation

[0025] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0026] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0027] Furthermore, in the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0029] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0030] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0031] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0032] like Figure 1 The aircraft motor shown includes an outer rotor assembly 1, a stator assembly 2, a controller assembly, and a heat sink assembly 3. The outer rotor assembly 1 is rotatably connected to the stator assembly 2 via a bearing 6. The outer rotor assembly 1 and the stator assembly 2 are respectively provided with an inner bearing ring pressure plate 210 and an outer bearing ring pressure plate 110 for limiting the bearing 6. The stator assembly 2 includes a stator housing 21 and a winding 22 disposed on the outer wall of the stator housing 21. A sealing cover 5 is fixed to the outside of the winding 22. A base plate 20 is fixed to the bottom of the stator housing 21, and the heat sink assembly 3 is fixed to the lower part of the base plate 20.

[0033] like Figures 2 to 5 As shown, the controller assembly includes a circuit board 25 and a cooling plate 26. The circuit board 25 and the cooling plate 26 are fixed within the cavity formed by the base plate 20 and the stator housing 21, and the circuit board 25 is connected to the winding 22. IGBT modules 251 are spaced apart on the circuit board 25, and multiple cooling slots 263 are provided on one side of the cooling plate 26. The IGBT modules 251 are fastened and fixed to the cooling slots 263. Cooling pipes communicating with an external cooling device are also provided on the cooling plate 26, connecting all the cooling slots 263. The entire structure is encapsulated within a robust stator housing, providing a solid mounting foundation for the circuit board and cooling plate. This structure can better withstand vibrations and shocks during aircraft operation, improving the mechanical reliability of the entire power system.

[0034] The cooling pipeline includes an inner arc-shaped cooling groove 266 and an outer arc-shaped cooling groove 265 disposed on the other side of the cooling plate 26. The bottom of the cooling groove 263 has elongated through holes 264 on both radial sides. The inner arc-shaped cooling groove 266 connects the elongated through holes 264 on the radially inner side of all the cooling grooves 263. The outer arc-shaped cooling groove 265 connects the elongated through holes 264 on the radially outer side of all the cooling grooves 263. The inner arc-shaped cooling groove 266 and the outer arc-shaped cooling groove 265 are also provided with an oil outlet pipe 262 and an oil inlet pipe 261 that are connected to the external cooling oil circuit.

[0035] The aforementioned structure employs a double-layer flow channel design with inner and outer arc-shaped cooling slots, conforming to the circular layout of the motor stator assembly. Coolant enters from one side (e.g., the oil inlet pipe), flows through radially inner or outer through-holes in all cooling slots, and then exits from the other side, ensuring uniform coolant flow through each cooling slot. This provides consistent cooling for each IGBT module and eliminates cooling dead zones. Furthermore, the structure maximizes the use of limited space by creating arc-shaped cooling slots on the opposite side of the cooling plate and connecting the upper and lower flow channels using elongated through-holes. This structure achieves a complex and efficient cooling channel without increasing additional volume.

[0036] Both the inner arc-shaped cooling groove 266 and the outer arc-shaped cooling groove 265 are C-shaped, with the outer arc-shaped cooling groove 265 positioned outside the inner arc-shaped cooling groove 266, and both are concentrically arranged. This structure matches the geometric characteristics of rotating machinery: the "C-shape" and "concentric arrangement" ensure that the shape of the cooling channel perfectly matches the circular stator assembly and the internal space of the motor. This layout most effectively utilizes the annular space, optimizes the coolant flow path, helps reduce flow resistance, ensures coolant flow velocity, and further improves heat dissipation uniformity and efficiency.

[0037] The inner arc-shaped cooling groove 266 and the outer arc-shaped cooling groove 265 have opposite openings, and the oil outlet pipe 262 and the oil inlet pipe 261 are spaced 180° apart. The C-shaped grooves with opposite openings and the oil inlet and outlet pipes spaced 180° apart form a flow path that is approximately U-shaped or annular. The coolant needs to flow through the entire semicircle from the inlet to the outlet, which helps to ensure that the coolant flows fully in the entire flow channel and avoids the flow short-circuiting phenomenon that may occur due to the inlet and outlet being too close (i.e., the coolant flows directly from the inlet to the outlet without fully flowing through the middle area), thereby making heat dissipation more uniform.

[0038] The IGBT module 251 is fixed to the cooling tank 263 on both sides by clamping blocks 252, and a sealing ring is also clamped between the IGBT module 251 and the cooling tank 263. Using clamping blocks to fix it from both sides provides uniform and sufficient clamping force, ensuring tight contact between the IGBT module and the surface of the cooling tank, reducing contact thermal resistance, and ensuring efficient heat dissipation. In addition, the sealing ring between the IGBT module and the cooling tank effectively prevents coolant from leaking onto the circuit board through the mounting interface, avoiding short circuits and device damage, and greatly improving the reliability and safety of the system in harsh environments.

[0039] The stator housing 21 also has multiple auxiliary fixing blocks on its inner wall, and a mounting bracket 28 is provided inside the stator housing 21. The cooling plate 26 is fixed to the auxiliary fixing blocks via the mounting bracket 28, and the circuit board 25 is fixed to the cooling plate 26. Through the auxiliary fixing blocks and mounting bracket, internal components such as the cooling plate and circuit board are modularly fixed to the stator housing. This structure simplifies the internal assembly process, improves production efficiency and consistency, and also facilitates later maintenance. Furthermore, these additional fixing points tightly connect heavy components such as the cooling plate to the robust stator housing, enhancing the structural stability of the controller assembly in vibration environments and preventing loosening or fatigue damage due to vibration.

[0040] The stator housing 21 also houses a terminal block 27. The inner ring of the terminal block 27 connects to the IGBT module, and the outer ring connects to a power connector 220 located outside the stator housing 21. The terminal block 27 is also fixed to the mounting bracket 28 and is sandwiched between the mounting bracket 28 and the cooling plate 26. The terminal block provides a centralized and reliable electrical connection hub. Its inner ring connects to the IGBT, and its outer ring connects to the external power connector, achieving an orderly layout of the power circuit. Sandwiching it between the mounting bracket and the cooling plate not only provides a secure fixation but also saves space, shortens the distance of high-current traces, and helps reduce parasitic inductance and electrical losses.

[0041] This invention, through its highly integrated integrated structure, efficient directional liquid cooling system targeting the core heat source (especially the optimized arc-shaped flow channel design), reliable mechanical fixing and sealing design, and modular internal layout, works synergistically to achieve significant technical effects in improving the power density, heat dissipation efficiency, vibration resistance, and overall reliability of the aircraft's motor controller, effectively solving many of the technical problems mentioned in the background art.

[0042] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0043] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A mounting and cooling structure for a controller assembly used in an aircraft motor, characterized in that: The device includes a stator assembly (2), a circuit board (25), and a cooling plate (26). The stator assembly (2) includes a stator housing (21) and a winding (22) disposed on the outer side wall of the stator housing (21). A base plate (20) is fixed to the bottom of the stator housing (21). The circuit board (25) and the cooling plate (26) are fixed in the cavity formed by the base plate (20) and the stator housing (21), and the circuit board (25) is connected to the winding (22). IGBT modules (251) are spaced apart on the circuit board (25). A plurality of cooling slots (263) are provided on one side of the cooling plate (26). The IGBT modules (251) are fastened and fixed on the cooling slots (263). A cooling pipe connected to an external cooling device is also provided on the cooling plate (26). The cooling pipe connects all the cooling slots (263).

2. The controller assembly mounting and cooling structure for an aircraft motor according to claim 1, characterized in that, The cooling pipeline includes an inner arc-shaped cooling groove (266) and an outer arc-shaped cooling groove (265) disposed on the other side of the cooling plate (26). The bottom of the cooling groove (263) is provided with elongated through holes (264) on both radial sides. The inner arc-shaped cooling groove (266) connects the elongated through holes (264) on the radial inner side of all cooling grooves (263). The outer arc-shaped cooling groove (265) connects the elongated through holes (264) on the radial outer side of all cooling grooves (263). The inner arc-shaped cooling groove (266) and the outer arc-shaped cooling groove (265) are also provided with an oil outlet pipe (262) and an oil inlet pipe (261) connected to the external cooling oil circuit.

3. The controller assembly mounting and cooling structure for an aircraft motor according to claim 2, characterized in that, The inner arc-shaped cooling groove (266) and the outer arc-shaped cooling groove (265) are both C-shaped. The outer arc-shaped cooling groove (265) is located outside the inner arc-shaped cooling groove (266), and the two are concentrically arranged.

4. The controller assembly mounting and cooling structure for an aircraft motor according to claim 2, characterized in that, The inner arc-shaped cooling groove (266) and the outer arc-shaped cooling groove (265) have opposite openings, and the oil outlet pipe (262) and the oil inlet pipe (261) are spaced 180° apart.

5. The mounting and cooling structure for the controller assembly of an aircraft motor according to claim 1, characterized in that, The IGBT module (251) is fixed to the cooling tank (263) on both sides by pressure blocks (252), and a sealing ring is also sandwiched between the IGBT module (251) and the cooling tank (263).

6. The controller assembly mounting and cooling structure for an aircraft motor according to claim 1, characterized in that, The inner wall of the stator housing (21) is also provided with a number of auxiliary fixing blocks. The cooling plate (26) is fixed to the stator housing (21) through the auxiliary fixing blocks, and the circuit board (25) is fixed to the cooling plate (26).

7. The controller assembly mounting and cooling structure for an aircraft motor according to claim 6, characterized in that, The stator housing (21) is also provided with a mounting bracket (28), and the cooling plate (26) is fixed to the auxiliary fixing block through the mounting bracket (28).

8. The controller assembly mounting and cooling structure for an aircraft motor according to claim 7, characterized in that, The stator housing (21) is also provided with a terminal block (27). The inner ring of the terminal block (27) is connected to the IGBT module, and the outer side of the terminal block (27) is also connected to a power connector (220) located outside the stator housing (21).

9. The controller assembly mounting and cooling structure for an aircraft motor according to claim 8, characterized in that, The terminal block (27) is also fixed to the mounting bracket (28), and the terminal block (27) is sandwiched between the mounting bracket (28) and the cooling plate (26).

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