An integrated cooling, braking and feedback system for integral motor bearings

Abstract

This application provides an integrated cooling, braking, and feedback system for an integrated motor bearing. The integrated motor bearing includes a rotating shaft with a permanent magnet array and a flange fixing end with a coil assembly. The flange fixing end has an integrated cooling channel for cooling the coil assembly. A drum brake mechanism is integrated at the lower part of the flange fixing end for braking the rotating shaft. A grating reading system is located at the lower part of the rotating shaft. By integrating the grating reading system at the lower part of the rotating shaft, high-precision feedback of the motor speed and the rotating shaft position can be achieved.

Description

Technical Field

[0001] This utility model relates to the field of motor bearing technology, and more specifically, to an integrated cooling, braking and feedback system for an integral motor bearing. Background Technology

[0002] Integrated motor bearings, as core components of motor transmission systems, are widely used in industrial equipment, automated production lines, precision machine tools, and other fields. Their performance directly affects the motor's operational stability, efficiency, and service life. During high-speed motor operation, the coil components inside the bearing generate a large amount of heat due to electromagnetic induction. If this heat cannot be dissipated in time, the coil temperature will rise, not only reducing motor efficiency but also potentially causing problems such as insulation aging and permanent magnet demagnetization. Meanwhile, the braking function of traditional motor bearings often relies on external braking devices, which suffer from complex structures, slow response times, and large space requirements, making it difficult to meet the rapid braking demands of high-precision equipment. Furthermore, existing motor bearing speed and position feedback systems often use independently installed encoders, which are not only difficult to install and susceptible to external interference but also increase the overall size of the equipment, hindering integrated design.

[0003] However, existing integrated motor bearing systems suffer from several shortcomings: First, cooling systems often employ external fans or simple water-cooling structures, resulting in low cooling efficiency and an inability to precisely target the coil components, leading to localized overheating. Second, the separate design of the braking device from the bearing body results in slow braking response, high transmission losses, and cumbersome installation and debugging. Finally, the low integration of the feedback system with the bearing makes signal transmission susceptible to vibration and electromagnetic interference, affecting feedback accuracy. These problems severely restrict the performance improvement and integrated development of integrated motor bearings, necessitating improvements to existing technologies. Utility Model Content

[0004] The purpose of this application is to provide an integrated cooling, braking and feedback system for an integral motor bearing, which can achieve efficient and precise cooling of the motor bearing coil assembly, improve braking response speed and reliability, ensure high accuracy of speed and position feedback, and has a high degree of structural integration, saving installation space.

[0005] This application provides an integrated cooling, braking, and feedback system for an integrated motor bearing. The integrated motor bearing includes a rotating shaft with a permanent magnet array and a flange fixing end with a coil assembly. The system is characterized by: a cooling channel integrated inside the flange fixing end for cooling the coil assembly; a drum brake mechanism integrated at the lower part of the flange fixing end for braking the rotating shaft; and a grating reading system located at the lower part of the rotating shaft, which enables high-precision feedback of the motor speed and shaft position.

[0006] It is important to note that the integrated motor bearing discussed in this article refers to a component that integrates the motor stator coil with the bearing structure. Its core function is to convert electrical energy into mechanical energy through the interaction between the permanent magnet array on the shaft and the coil assembly at the flange fixed end, while also supporting the rotation of the shaft. Since the coil assembly continuously generates heat when the motor is running at high speed, and braking and feedback functions are crucial for ensuring precise motor control, cooling, braking, and feedback systems need to be integrated into the bearing body to meet the equipment's requirements for efficient heat dissipation, rapid braking, and high-precision feedback.

[0007] Meanwhile, in some embodiments, it is exemplarily shown that the cooling systems of motor bearings in existing designs are mostly external, using fans to blow air onto the outside of the bearing or wrapping cooling water pipes around the bearing housing. This results in poor cooling performance and an inability to specifically cool the coil assembly. Braking devices often employ external brake pads separated from the shaft, requiring a transmission structure to transmit braking torque during braking, leading to delayed response and wear. Feedback systems often use independent encoders connected to the shaft via couplings, resulting in large installation deviations and susceptibility to vibration interference. In this application, by directly integrating cooling channels inside the flange fixing end, the cooling medium directly contacts the surrounding area of ​​the coil assembly, significantly improving cooling efficiency. The braking mechanism is integrated into the lower part of the flange fixing end, acting directly on the shaft, shortening the braking response path. The grating reading system is integrated between the lower part of the shaft and the flange fixing end, reducing installation deviations and external interference. The most significant difference lies in the integrated design, which merges cooling, braking, and feedback functions with the bearing body, solving the problems of low efficiency, slow response, poor accuracy, and large space occupation inherent in traditional discrete structures.

[0008] By constructing an integrated architecture, the system achieves coordinated operation of cooling, braking, and feedback functions. The flange mounting end serves as the core integrated carrier, with internal cooling channels for precise heat dissipation of the coil components, preventing performance degradation caused by localized overheating. The lower integrated drum brake mechanism directly acts on the rotating shaft, reducing braking transmission losses and improving response speed. The grating reading system between the lower part of the rotating shaft and the flange mounting end, through close cooperation, reduces installation deviations and external interference, ensuring feedback accuracy. The cooling channels employ a structure combining annular grooves and vertical straight channels, ensuring uniform coverage of the cooling medium around the coil components, replacing traditional external cooling methods and avoiding uneven cooling. The drum brake mechanism, through the cooperation of a deformable elastic wall and an air cavity, achieves flexible braking, reducing mechanical wear and extending service life compared to traditional rigid brake pads. The grating reading system uses a close-range relative setting between the grating ruler and the reading head, replacing the long-distance transmission of an independent encoder, improving the stability and accuracy of the feedback signal. The entire system, through multi-functional integration, significantly reduces equipment size and simplifies installation processes while ensuring independent and efficient operation of each function, adapting to the needs of high-precision, integrated equipment.

[0009] In one embodiment, the cooling channel includes a main inlet pipe disposed above the flange fixed end, an upper annular groove disposed above the flange fixed end, and multiple vertical straight channels connecting the upper annular groove and the lower annular groove; the input end of the upper annular groove and the output end of the lower annular groove are both connected to a transverse channel, the lower annular groove is connected to a main outlet pipe through the transverse channel it is connected to, and the upper annular groove is connected to a main inlet pipe through the transverse channel it is connected to.

[0010] By optimizing the structural layout of the cooling channels, uniform and efficient cooling of the coil assembly is achieved. The main inlet pipe is located at the lower part of the flange fixing end, facilitating the stable entry of cooling media (such as coolant or cooling oil) from the bottom of the equipment. The upper annular groove surrounds the upper part of the flange fixing end, evenly distributing the cooling media to each vertical direct flow channel. Multiple vertical direct flow channels connect the upper and lower annular grooves, forming a longitudinal cooling path that directly covers the installation area of ​​the coil assembly, ensuring that the cooling media can fully contact the heat-generating parts around the coil assembly. The lower annular groove collects the cooling media after heat exchange and discharges it through the main outlet pipe, forming a complete cooling cycle. This structural design avoids the problem of uneven distribution of cooling media in traditional cooling methods, ensuring that the temperature of each area of ​​the coil assembly remains consistent. This effectively prevents aging of the coil insulation layer or demagnetization of the permanent magnet caused by local overheating. At the same time, the cooling channels are integrated inside the flange fixing end, eliminating the need for additional external space and improving the equipment's integration.

[0011] In one embodiment, the multiple vertical straight channels are evenly distributed circumferentially along the fixed end of the flange and are parallel to the vertical surface of the flange.

[0012] By defining the distribution and orientation of the vertical flow channels, cooling uniformity and structural stability are further improved. The vertical flow channels are evenly distributed circumferentially along the flange fixing end, allowing the cooling medium to form a ring-shaped cooling zone inside the flange fixing end. This ensures that all positions around the coil assembly receive equal cooling intensity, avoiding localized temperature differences in the coil due to uneven cooling. The vertical flow channels are parallel to the flange vertical plane, which facilitates manufacturing, reduces the difficulty of channel forming, and allows for smooth flow of the cooling medium within the channels, reducing flow resistance and improving circulation efficiency. Furthermore, the parallel flow channel structure does not compromise the overall mechanical properties of the flange fixing, ensuring the structural stability of the bearing during high-speed operation and preventing a decrease in flange strength due to the flow channel design.

[0013] In one embodiment, the drum brake mechanism includes at least one air chamber, the wall of which near the pivot is a deformable elastic wall.

[0014] By integrating a drum brake mechanism into the lower part of the flange fixing end, rapid and flexible braking of the rotating shaft is achieved. The drum brake mechanism is directly integrated into the flange fixing end, eliminating the need for additional external installation space and simplifying the overall structure of the equipment. The air chamber serves as the braking power source. By inflating the air chamber, the elastic wall near the rotating shaft deforms and comes into close contact with the shaft surface, utilizing friction to achieve braking. Compared to traditional mechanical braking, the pneumatic control method has a faster response speed, and the deformable characteristics of the elastic wall can avoid shaft wear caused by rigid contact, extending the shaft's service life. A single air chamber can meet basic braking requirements, and in scenarios requiring greater braking torque, the number of air chambers can be increased to improve the braking effect, adapting to the braking needs of different equipment. This design solves the problems of slow response and complex structure of traditional external braking devices, while achieving seamless integration of the braking function with the bearing body.

[0015] In one embodiment, the drum brake mechanism includes a plurality of air chambers arranged in a circumferential array.

[0016] By circumferentially arranging multiple air chambers, the stability and uniformity of the braking effect are improved. Multiple air chambers are evenly distributed circumferentially along the flange fixed end. When air is introduced into the chambers, the elastic walls of each chamber deform synchronously towards the rotating shaft, ensuring a uniform braking torque on the circumference of the shaft. This avoids uneven force on the shaft, eccentric wear, or brake deviation problems caused by braking from a single air chamber. The circumferentially arrayed air chambers form a ring-shaped braking area, increasing the contact area between the elastic walls and the rotating shaft, providing a greater braking torque under the same air pressure conditions, and improving braking efficiency. Furthermore, the multiple air chamber design also has redundancy; even if one air chamber fails, the remaining chambers can still operate normally, ensuring the reliability of the braking system and avoiding the risk of brake failure due to the failure of a single air chamber. This design is suitable for precision equipment with high requirements for braking reliability.

[0017] In one embodiment, an integrated air supply ring is also included for uniformly supplying air to all the air chambers.

[0018] By incorporating an integrated air supply ring, synchronous and precise air supply control for multiple air chambers is achieved. The integrated air supply ring surrounds the upper part of all air chambers and connects to them, ensuring even distribution of compressed air to each chamber. This guarantees consistent inflation pressure and synchronized inflation speed, preventing uneven inflation caused by individual air supply. Consequently, it ensures consistent deformation of the elastic walls during braking, resulting in uniform braking torque applied to the shaft. The unified air supply method simplifies the air circuit design, eliminating the need for separate air supply lines for each chamber, reducing connection points and the risk of leakage. It also facilitates air supply control of all chambers through a single control valve, improving the ease of operation and control precision of the braking system. The integrated design of the air supply ring, drum brake mechanism, and flange fixing end further enhances system integration, avoiding the need for external air circuits and accommodating equipment miniaturization requirements.

[0019] In one embodiment, the partition between adjacent air chambers is an inclined plate that slopes inward toward the interior of the air chamber, serving to guide airflow and reinforce the structure.

[0020] By designing the baffle between the air chambers as an inclined plate, both airflow guidance and structural reinforcement functions are achieved. The inclined plate slopes inwards towards the air chamber, guiding the airflow during air supply. This allows compressed air to fill the air chamber quickly and evenly, preventing eddies from forming at the corners, improving inflation efficiency, and ensuring rapid and uniform deformation of the elastic wall. Structurally, compared to a vertical baffle, the inclined plate better disperses stress between the flange fixing end and the drum brake mechanism, enhancing the structural strength between the air chambers and preventing fatigue damage to the baffle caused by repeated inflation and deflation, thus extending the service life of the drum brake mechanism. Furthermore, the inclined plate reduces the dead volume inside the air chamber, making full use of the internal space. With the same air chamber volume, it provides greater elastic wall deformation space, increasing the braking torque adjustment range and adapting to different braking scenarios.

[0021] In one embodiment, the system includes a grating ruler disposed on a rotating shaft and a reading head disposed on a flange fixed end and disposed opposite to the grating ruler.

[0022] By integrating a grating reading system into the lower part of the rotating shaft, high-precision feedback of motor speed and shaft position is achieved. The grating scale is directly mounted on the rotating shaft and rotates synchronously with it. The reading head is fixed on the flange end and is close to the grating scale, allowing real-time reading of the scale's graduations. By calculating the rate of change and cumulative change, the rotational speed and position data of the shaft are accurately obtained. Compared to traditional independent encoders connected to the shaft via couplings, the direct contact between the grating scale and the shaft, and the close proximity of the reading head and the grating scale, significantly reduces installation deviations and transmission errors. It also avoids interference from coupling clearances and vibrations on the feedback signal, significantly improving feedback accuracy. The grating reading system is integrated between the lower part of the rotating shaft and the flange end, requiring no additional external space and unaffected by external electromagnetic environments or dust, ensuring the stability and reliability of the feedback system and providing data support for precise motor control.

[0023] In one embodiment, the grating ruler is attached to the outer ring of the bearing of the rotating shaft.

[0024] By attaching the grating ruler to the outer ring of the bearing on the rotating shaft, the installation and operational stability of the grating reading system are optimized. The outer ring of the bearing is a high-precision, high-stability component on the rotating shaft, with minimal surface flatness and roundness errors. Attaching the grating ruler directly to it ensures coaxiality as the grating ruler rotates with the shaft, preventing eccentricity caused by insufficient mounting precision and thus guaranteeing the accuracy of the reading head. The integrated connection between the outer ring of the bearing and the rotating shaft eliminates relative movement between the grating ruler and the shaft, preventing feedback errors caused by grating ruler loosening. Simultaneously, the sealing structure of the outer ring of the bearing provides protection for the grating ruler, preventing dust, oil, and other contaminants from adhering to its surface and affecting reading accuracy. This installation method eliminates the need for additional shaft machining, simplifying the installation process, reducing processing costs, and facilitating upgrades to existing integrated motor bearings, thus enhancing the system's versatility.

[0025] The integration of a cooling, braking, and feedback system into a five-axis rotary table significantly improves its operational performance and precision. As a core component of precision machining equipment, the five-axis rotary table places extremely high demands on the heat dissipation of the motor bearings, braking response speed, and position feedback accuracy. The integrated system proposed in this application meets these stringent requirements: the cooling channels efficiently cool the motor bearing coil assembly, ensuring stable motor temperature during prolonged high-speed operation and preventing a decrease in rotary table positioning accuracy due to temperature rise; the rapid and flexible braking of the drum brake mechanism allows the five-axis rotary table to stop quickly during machining station changes, reducing station changeover time, improving machining efficiency, and avoiding the impact of rigid braking on the rotary table's mechanical structure; the high-precision feedback from the grating reading system provides real-time data support for the precise positioning of the five-axis rotary table, ensuring the dimensional accuracy and surface quality of the machined workpiece. The combination of the integrated system and the five-axis rotary table not only simplifies the overall structure of the rotary table and reduces component installation space, but also improves the operational stability, reliability, and machining accuracy of the five-axis rotary table through the coordinated operation of various functions, meeting the needs of high-precision machining fields such as aerospace and precision mold making. Attached Figure Description

[0026] Figure 1 This is a cross-sectional view of an integrated cooling, braking and feedback system for an integral motor bearing provided in one embodiment of this application.

[0027] Figure 2 for Figure 1 A magnified view of a portion of the image.

[0028] Figure 3 This is a structural diagram of the drum brake mechanism.

[0029] Figure 4 This is an exploded view of an integrated cooling, braking and feedback system for an integral motor bearing provided in one embodiment of this application.

[0030] Figure 5 This is a structural diagram of the flange fixed end of this application.

[0031] Explanation of main component symbols

[0032] 2. Shaft;

[0033] 4. Flange fixed end; 41. Cooling flow channel; 411. Liquid inlet main pipe; 412. Upper annular groove; 413. Vertical straight flow channel; 414. Lower annular groove; 415. Liquid outlet main pipe; 418. Horizontal flow channel;

[0034] 5. Drum brake mechanism; 51. Air chamber; 52. Integrated air supply ring; 53. Inclined plate;

[0035] 61. Grating ruler; 62. Reading head.

[0036] The following detailed description, in conjunction with the accompanying drawings, will further illustrate this utility model. Detailed Implementation

[0037] The technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following drawings indicate similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0038] In existing technologies, the integrated motor bearings used in precision equipment such as five-axis rotary tables often employ separate designs for cooling, braking, and feedback functions: cooling relies on external fans or water cooling of the housing, which cannot precisely target the coil assembly and is prone to localized overheating; braking uses external brake pads connected to the rotating shaft 2 via a transmission structure, resulting in delayed response and severe wear; feedback uses independent encoders, which suffer from large installation deviations and are susceptible to interference, leading to low feedback accuracy. For example, in one existing technology, the cooling water pipes of the motor bearing are wound around the outside of the bearing housing, and the center temperature of the coil assembly is 20-30°C higher than the housing temperature, causing the coil insulation layer to age after long-term use; the braking device is connected to the rotating shaft 2 via a coupling, and the braking response time exceeds 0.5 seconds, failing to meet the requirements of rapid workstation switching; the encoder is mounted on the end of the rotating shaft 2 via a bracket, and vibration causes a feedback error exceeding 0.01mm, affecting machining accuracy.

[0039] To address the aforementioned issues, the inventors discovered through analysis that the core flaw of traditional discrete structures lies in the separation of functions from the bearing body, resulting in low efficiency, slow response, poor accuracy, and large space occupation. Based on this, they proposed integrating the cooling channel 41 inside the flange fixing end 4 to directly dissipate heat from the coil assembly; integrating the drum brake mechanism 5 into the lower part of the flange fixing end 4 to directly act on the rotating shaft 2; and integrating the grating reading system between the lower part of the rotating shaft 2 and the flange fixing end 4 to reduce installation deviations and interference. This integrated design achieves synergistic optimization of all functions.

[0040] Therefore, as Figure 1-5 As shown, this application proposes an integrated cooling, braking and feedback system for an integrated motor bearing. The integrated motor bearing includes a rotating shaft 2 with a permanent magnet array and a flange fixing end 4 with a coil assembly. The flange fixing end 4 has an integrated cooling channel 41 for cooling the coil assembly. It also includes a drum brake mechanism 5 integrated at the lower part of the flange fixing end 4 and a grating reading system located at the lower part of the rotating shaft 2.

[0041] The integrated motor bearing refers to a component that integrates the motor stator coil with the inner and outer rings of the bearing. The permanent magnet array on the shaft 2 is generally made of neodymium iron boron permanent magnet material and is fixed to the surface of the shaft 2 by pasting or embedding. The flange fixing end 4 has a coil groove inside, and the coil assembly is wound in the coil groove. When energized, it generates electromagnetic force with the permanent magnet array, driving the shaft 2 to rotate. The cooling channel 41 is a channel for the flow of cooling medium opened inside the flange fixing end 4. It is generally made of metal material (such as bearing steel or stainless steel) and is formed by drilling, milling, etc. The cooling medium can be water, ethylene glycol solution, or special cooling oil. The drum brake mechanism 5 is a component that achieves braking through air control. The air chamber 51 is generally made of elastic metal material with deformable elastic walls. Compressed air drives the elastic walls to contact the shaft 2 to generate braking torque. The grating reading system refers to a system that uses a grating ruler 61 and a reading head 62 to detect position and rotation speed. The grating ruler 61 is generally an incremental grating, which forms uniform scales on a metal or glass substrate through photolithography. The reading head 62 has a built-in light source, grating and photoelectric sensor, and reads scale information through photoelectric conversion.

[0042] Specifically, during motor operation, the cooling medium enters the cooling channel 41 from the inlet manifold 411, is distributed to each vertical direct current channel 413 via the upper annular groove 412, flows downward along the vertical direct current channel 413 to the lower annular groove 414, absorbs the heat generated by the coil assembly during the process, and is finally discharged from the outlet manifold 415, completing the cooling cycle. When braking is required, compressed air enters each air chamber 51 through the integrated air supply ring 52. The elastic wall of the air chamber 51 deforms towards the rotating shaft 2 under the action of air pressure and makes close contact. The rotating shaft 2 is decelerated until it stops through friction. After braking, the gas in the air chamber 51 is discharged and the elastic wall returns to its original position. When the grating reading system is working, the grating 61 rotates synchronously with the rotating shaft 2. The reading head 62 reads the scale changes of the grating ruler 61 in real time, converts the light signal into an electrical signal, transmits it to the control system, and calculates the rotation speed and position data of the rotating shaft 2.

[0043] Compared with existing technologies, traditional solutions involve indirect contact between the cooling medium and the coil assembly, resulting in low cooling efficiency. In this solution, the cooling channel 41 directly surrounds the coil assembly, improving cooling efficiency. Traditional braking devices have long response times, while in this solution, the drum brake mechanism 5 acts directly on the rotating shaft 2, shortening the response time. Traditional encoders have large feedback errors, while in this solution, the feedback error of the grating reading system is controlled within 0.001mm. Furthermore, this application, through integrated design, reduces the system size compared to traditional discrete structures, significantly saving installation space.

[0044] Through the above technical solution, this application achieves deep integration of cooling, braking, and feedback functions with an integrated motor bearing, solving the problems of low efficiency, slow response, poor accuracy, and large size of traditional discrete structures, and providing a high-efficiency, reliable, and high-precision motor bearing solution for precision equipment.

[0045] This application further proposes that the cooling channel 41 includes a liquid inlet manifold 411 disposed on the upper part of the flange fixed end 4, an upper annular groove 412 disposed on the upper part of the flange fixed end 4, and multiple vertical straight channels 413 connecting the upper annular groove 412 and the lower annular groove 414; the input end of the upper annular groove 412 and the output end of the lower annular groove 414 are both connected to a transverse channel 418, the lower annular groove 414 is connected to a liquid outlet manifold 415 through the transverse channel 418 it is connected to, and the upper annular groove 412 is connected to a liquid inlet manifold 411 through the transverse channel 418 it is connected to.

[0046] The main inlet pipe 411 is the main channel through which the cooling medium enters the cooling channel 41. It typically has a circular cross-section, with the diameter designed according to the required cooling medium flow rate. The inlet of the main inlet pipe 411 has a threaded interface for easy connection to an external supply line. The upper annular groove 412 and lower annular groove 414 are annular channels surrounding the flange fixing end 4. Their cross-section is typically rectangular or semi-circular, used to evenly distribute the cooling medium to each vertical direct current channel 413 or collect the cooling medium flowing out of the vertical direct current channel 413. The vertical direct current channel 413 is the longitudinal channel connecting the upper and lower annular grooves. Its number is determined by the size of the flange fixing end 4 and the cooling requirements, typically 8-24 strands, evenly distributed around the flange fixing end 4 to ensure uniform coverage of the coil assembly. The main outlet pipe 415 is the main channel through which the cooling medium exits the cooling channel 41. Its structure is similar to the main inlet pipe 411, and its diameter matches that of the main inlet pipe 411, ensuring smooth flow of the cooling medium within the channel without stagnation.

[0047] Specifically, after the cooling medium enters from the inlet manifold 411, it first flows into the upper annular groove 412. Since the upper annular groove 412 surrounds the flange fixed end 4, the cooling medium will quickly diffuse within the annular groove and be evenly distributed to each vertical direct flow channel 413. Under the action of gravity and external liquid supply pressure, the cooling medium flows downward along the vertical direct flow channel 413. During this process, it makes full contact with the area around the coil assembly inside the flange fixed end 4, absorbs the heat generated by the coil through heat conduction, and its temperature rises. After absorbing heat, the cooling medium flows into the lower annular groove 414, gathers again through the annular channel, and finally flows out of the cooling channel 41 from the outlet manifold 415 and enters the external cooling system for cooling. The cooled cooling medium can then re-enter the channel through the inlet manifold 411 to form a circulating cooling system.

[0048] Compared with existing technologies, traditional cooling channels 41 are mostly single spiral or straight, resulting in uneven distribution of cooling medium and local temperature differences in the coil assembly exceeding 10°C. This solution, through the cooperation of upper and lower annular grooves and multiple vertical straight channels 413, ensures that the cooling medium evenly covers the circumference of the coil assembly, and the local temperature difference is controlled within 3°C. Traditional channels are prone to areas where cooling medium stagnates, leading to local overheating. This solution has a smooth channel structure with no obvious stagnation areas, significantly improving cooling efficiency.

[0049] Through the above technical solution, this application solves the problems of uneven cooling and low efficiency of traditional cooling channels 41, and achieves precise and uniform heat dissipation of coil components, ensuring the stable performance of motor bearings during long-term high-speed operation and extending service life.

[0050] This application further proposes that multiple vertical straight channels 413 are evenly distributed circumferentially along the fixed end 4 of the flange and are parallel to the vertical surface of the flange.

[0051] The uniform circumferential distribution of the vertical straight channels 413 means that the included angle between adjacent vertical straight channels 413 is equal. For example, the included angle of 12 vertical straight channels 413 is 30°, ensuring that the distribution density of the cooling medium in the circumferential direction of the flange fixing end 4 is consistent and avoiding cooling blind spots. The parallelism between the vertical straight channels 413 and the vertical plane of the flange means that the axial direction of the vertical straight channels 413 is parallel to the vertical center line of the flange fixing end 4, with a deviation angle not exceeding 1°. This ensures that the cooling medium flows in a straight line in the flow channel, reducing flow resistance, and also facilitates machining through drilling, reducing processing difficulty and cost.

[0052] Specifically, during the processing of the flange fixed end 4, the number and position of the vertical straight channels 413 are first determined. Based on the outer diameter of the flange fixed end 4, 8-24 vertical straight channels 413 are selected. The CNC drilling equipment is used to drill holes evenly along the circumference of the flange. The drilling direction is strictly parallel to the vertical surface of the flange. After drilling, the upper annular groove 412 and the lower annular groove 414 are milled at the upper and lower ends of the flange, respectively. The transverse flow channel 418 is drilled in the direction perpendicular to the outer circumference of the annular groove, corresponding to the position of the vertical straight channels 413, so that the annular groove is connected to all the vertical straight channels 413. Finally, the liquid inlet manifold 411 and the liquid outlet manifold 415 are processed and connected to the lower annular groove 414 and the upper annular groove 412, respectively, to form a complete cooling flow channel 41.

[0053] Compared with existing technologies, traditional vertical straight channels 413 are often unevenly distributed or tilted to the vertical plane due to machining errors, resulting in differences in cooling medium flow rate. This solution ensures the uniform distribution and parallelism of the vertical straight channels 413 through CNC machining, and the flow rate deviation of each channel is controlled within 5%. Tilted channels increase flow resistance and reduce the flow rate of cooling medium. This solution uses parallel channels to increase the flow rate by 15%, further improving cooling efficiency.

[0054] Through the above technical solution, this application further optimizes the structural precision of the cooling channel 41, ensuring that the cooling medium flows evenly and smoothly, achieving efficient and uniform cooling of the coil assembly, while reducing the difficulty of channel processing and improving production efficiency.

[0055] This application further proposes a drum brake mechanism 5 integrated into the lower part of the flange fixed end 4; the drum brake mechanism 5 includes at least one air chamber 51, the wall of the air chamber 51 near the rotating shaft 2 being a deformable elastic wall.

[0056] The drum brake mechanism 5 is typically integrated at the lower part of the flange fixing end 4, near the rotating shaft 2. It is connected to the flange fixing end 4 by bolts or integrally formed to ensure structural stability. The number of air chambers 51 can be selected according to the braking torque requirements. The elastic walls are made of alloy steel, which has good elasticity and wear resistance, and can withstand repeated deformation without easily being damaged. The non-elastic wall part of the air chamber 51 is sealed to the flange fixing end 4 or the integrated air supply ring 52 to ensure the airtightness of the air chamber 51.

[0057] Specifically, when braking is required, an external air source is connected to the integrated air supply ring 52 through an air pipe. After compressed air enters the integrated air supply ring 52, it is evenly distributed to each air chamber 51. The air pressure inside the air chamber 51 increases, pushing the elastic wall near the rotating shaft 2 to expand and deform towards the rotating shaft 2 until the elastic wall is in close contact with the surface of the rotating shaft 2, generating friction. The magnitude of the friction is proportional to the air pressure. By adjusting the air pressure, the braking torque can be controlled to meet the needs of different braking scenarios (such as slow braking and emergency braking). After braking, the air source is turned off and the exhaust valve is opened. The air pressure inside the air chamber 51 drops to atmospheric pressure, and the elastic wall resets under its own elasticity, separating from the rotating shaft 2, and the braking is released.

[0058] Compared with existing technologies, traditional drum brake mechanisms 5 mostly use mechanical spring drives, which make it difficult to adjust the braking torque. This solution uses a pneumatic control method, which has a large braking torque adjustment range (0-2500 N·m) and a fast response speed. Traditional elastic walls are prone to wear, which leads to a decrease in braking effect. This solution uses high wear-resistant rubber materials, which improves the service life of the elastic walls. Traditional drum brake mechanisms 5 are externally installed and occupy a lot of space. This solution integrates them into the lower part of the flange fixing end 4, which reduces the space occupied.

[0059] Through the above technical solution, this application realizes the integration of the drum brake mechanism 5 with the integrated motor bearing, which solves the problems of complex structure, slow response and difficulty in adjusting braking torque of traditional braking devices, and provides the motor with fast, reliable and flexible braking function.

[0060] This application further proposes that the drum brake mechanism 5 includes multiple air chambers 51 arranged in a circumferential array.

[0061] The circumferential array arrangement of the air chambers 51 refers to the uniform distribution of multiple air chambers 51 around the axis of the rotating shaft 2 along the circumference of the lower part of the flange fixing end 4, with the included angle between adjacent air chambers 51 being equal, for example, the included angle of 60° for 6 air chambers 51. The number of air chambers 51 is generally 4-12, specifically determined according to the diameter of the rotating shaft 2 and the braking torque requirement. The larger the diameter of the rotating shaft 2 and the higher the braking torque requirement, the more air chambers 51 are required. The structural dimensions of each air chamber 51 are consistent to ensure that the elastic wall deformation of each air chamber 51 is the same during inflation, and the braking torque is evenly applied to the surface of the rotating shaft 2, avoiding eccentric wear or vibration caused by uneven force on the rotating shaft 2.

[0062] Specifically, in the design process of the drum brake mechanism 5, the number of air chambers 51 (e.g., 6) is first determined according to the diameter of the rotating shaft 2 and the required braking torque. Then, the air chambers 51 are evenly arranged circumferentially in the annular area below the flange fixing end 4. The distance from the center of each air chamber 51 to the axis of the rotating shaft 2 is the same, ensuring that the contact area between the elastic wall and the surface of the rotating shaft 2 is consistent. The air chambers 51 are connected by an integrated air supply ring 52. The annular channel of the integrated air supply ring 52 is sealed to the air inlet of each air chamber 51, ensuring that compressed air can enter all air chambers 51 simultaneously and evenly. The inflation time difference of each air chamber 51 does not exceed 0.02 seconds, ensuring that the elastic wall deforms synchronously.

[0063] Compared with existing technologies, the traditional single-chamber drum brake mechanism 5 is prone to excessive local stress on the rotating shaft 2, resulting in uneven wear. The present solution has a multi-chamber 51 circumferential array arrangement, which makes the rotating shaft 2 uniformly stressed in the circumferential direction and reduces wear. The traditional multi-chamber 51 independent air supply is prone to asynchronous air filling, which leads to brake deviation. The present solution integrates an air supply ring 52 for unified air supply, and the air filling synchronization of each chamber 51 is high, and the brake deviation is controlled within 0.1mm.

[0064] Through the above technical solutions, this application further improves the braking stability and reliability of the drum brake mechanism 5, avoids damage to the rotating shaft 2 caused by uneven braking force, and ensures a smooth braking process without vibration or deviation, thus meeting the braking requirements of high-precision equipment.

[0065] This application further proposes that it also includes an integrated air supply ring 52 for uniformly supplying air to all air chambers 51.

[0066] The integrated air supply ring 52 is an annular air passage component surrounding the upper part of all air chambers 51. It is typically made of aluminum alloy or stainless steel, ensuring sufficient internal space for annular air supply channels. The cross-section of the annular air supply channel is circular or rectangular, ensuring that the compressed air flow meets the air supply requirements of all air chambers 51. The integrated air supply ring 52 has one main air inlet and multiple branch air inlets. The main air inlet connects to an external air source, and the number of branch air inlets matches the number of air chambers 51. Each branch air inlet is connected to the air inlet of an air chamber 51 via an air pipe or directly in a sealed manner, using O-ring seals or welding to ensure airtightness.

[0067] Specifically, external compressed air enters the annular air supply channel of the integrated air supply ring 52 through the main air inlet. Since the annular channel surrounds the flange fixed end 4, the compressed air will diffuse rapidly in the channel, and the pressure will be evenly distributed. Then, the compressed air enters the corresponding air chamber 51 simultaneously through each branch air port. Since the distance from each branch air port to the main air inlet is similar and the pressure in the annular channel is uniform, the intake pressure and intake speed of each air chamber 51 are basically consistent, ensuring that the elastic wall of the air chamber 51 deforms synchronously. After braking, the exhaust valve on the integrated air supply ring 52 opens, and the compressed air in the annular channel and air chamber 51 is discharged through the exhaust valve, and the elastic wall returns to its original position.

[0068] Compared with existing technologies, traditional multi-chamber air supply requires multiple control valves and air supply lines, which are complex and prone to leakage. This solution integrates an air supply ring 52, which simplifies the air path. Only one control valve is needed to control all air chambers 51, reducing the risk of leakage. The pressure deviation of each air chamber 51 in traditional single air supply can reach 0.1MPa. In this solution, the pressure deviation of each air chamber 51 is controlled within 0.02MPa by integrating an air supply ring 52, ensuring uniform braking.

[0069] Through the above technical solution, this application achieves unified and precise air supply control for multiple air chambers 51, simplifies air circuit design, improves the stability and reliability of the braking system, ensures that each air chamber 51 works synchronously, and achieves smooth braking.

[0070] This application further proposes that the partition between adjacent air chambers 51 is an inclined plate 53 that slopes inward toward the interior of the air chamber 51, for guiding flow and reinforcing the structure.

[0071] The inclined plate 53 is tilted towards the inside of the air cavity 51. One end of the inclined plate 53 is connected to the outer wall of the air cavity 51, while the other end tilts towards the center of the air cavity 51. The tilt angle (the angle between the inclined plate 53 and the outer wall of the air cavity 51) is generally 30°-60°, ensuring both airflow guidance and structural strength. The inclined plate 53 is made of the same metal material as the non-elastic wall of the air cavity 51, and is integrally formed or welded to the wall of the air cavity 51 to ensure connection strength, allowing it to withstand the pressure (0.4-0.8 MPa) during air filling of the air cavity 51 without deformation.

[0072] Specifically, when compressed air enters the air chamber 51, the inclined surface of the ramp 53 guides the airflow, causing it to flow along the inclined surface towards the elastic wall inside the air chamber 51. This prevents the airflow from directly impacting the corners of the air chamber 51 and forming vortices, thus accelerating the filling speed of the air chamber 51 and shortening the inflation time. At the same time, the inclined ramp 53 can distribute the air pressure stress on the air chamber 51 to the flange fixing end 4, reducing local stress concentration on the wall of the air chamber 51, enhancing the structural stability between the air chambers 51, preventing fatigue cracking of the partition due to repeated inflation and deflation, and extending the service life of the drum brake mechanism 5. In addition, the inclined design of the ramp 53 can reduce the dead volume inside the air chamber 51 (i.e., the area that the airflow cannot reach), making full use of the internal space of the air chamber 51. Under the same air chamber 51 volume, the deformation space of the elastic wall increases, improving the braking torque adjustment range.

[0073] Compared with existing technologies, the vertical baffle between the traditional air chambers 51 has no guiding effect, resulting in low inflation efficiency of the air chambers 51. The inclined plate 53 in this solution guides the air and significantly improves the inflation efficiency. The traditional vertical baffle is prone to stress concentration and has a short service life. The inclined plate 53 in this solution disperses stress and extends the service life to more than 8,000 braking cycles.

[0074] Through the above technical solution, this application achieves the dual functions of airflow guidance and structural reinforcement, improves the inflation efficiency and structural reliability of the drum brake mechanism 5, and further optimizes the performance of the braking system.

[0075] This application further proposes a grating reading system located at the lower part of the rotating shaft 2, the system including a grating ruler 61 disposed on the rotating shaft 2 and a reading head 62 disposed on the flange fixed end 4 and disposed opposite to the grating ruler 61.

[0076] The grating reading system is installed at the lower part of the rotating shaft 2, generally 10-30mm from the end of the shaft 2, to avoid the influence of vibration at the end of the shaft 2 on the system. The grating ruler 61 adopts an incremental circular grating, the outer diameter of which matches the outer ring diameter of the bearing of the rotating shaft 2. The grating line density is determined according to the feedback accuracy requirements. It is pasted to the surface of the bearing outer ring with special adhesive. After pasting, the radial runout of the grating ruler 61 does not exceed 0.005mm. The reading head 62 is an optical reading head with a built-in LED light source, indicator grating, and photodiode array. It is fixed to the flange fixing end 4 by a bracket. The gap (air gap) between the reading head 62 and the grating ruler 61 is controlled at 0.1-0.3mm to ensure that the reading head 62 can accurately read the scale information of the grating ruler 61, with a gap deviation not exceeding 0.02mm.

[0077] Specifically, when the shaft 2 rotates, the grating ruler 61 rotates synchronously with the shaft 2. The light emitted by the LED light source of the reading head 62 passes through the indicator grating and illuminates the rotating grating ruler 61. Due to the moiré fringe effect between the grating ruler 61 and the indicator grating, the light forms alternating bright and dark moiré fringes after passing through the two gratings. The photodiode array converts the light signal of the moiré fringes into an electrical signal (sine wave or square wave signal). After amplification, shaping, and subdivision processing, the electrical signal is transmitted to the control system. The control system calculates the period of the electrical signal (to determine the rotational speed) and the number of pulses (to determine the position) to obtain the rotational speed (accuracy ±1 rpm) and position (accuracy ±0.001 mm) data of the shaft 2 in real time, providing feedback for the precise control of the motor.

[0078] Compared with existing technologies, traditional independent encoders are connected to the rotating shaft 2 via a coupling, resulting in large installation deviations and low feedback accuracy (deviation ±0.01mm). In this solution, the grating ruler 61 is directly attached to the rotating shaft 2, and the reading head 62 is closely fitted, improving the feedback accuracy by 10 times. Traditional encoders are susceptible to vibration and electromagnetic interference, resulting in poor signal stability. In this solution, the grating reading system is integrated inside the bearing, reducing interference and improving signal stability. Traditional encoders occupy a large amount of space, while the grating reading system in this solution is small in size, reducing space requirements.

[0079] Through the above technical solution, this application achieves high-precision feedback of motor speed and shaft 2 position, solving the problems of low accuracy, poor stability and large size of traditional feedback systems, and providing reliable data support for the precise control of precision equipment.

[0080] This application further proposes that the grating ruler 61 be attached to the outer ring of the bearing of the rotating shaft 2.

[0081] Specifically, before attaching the grating ruler 61, the surface of the bearing outer ring is first cleaned to remove oil, dust, and other impurities, ensuring a clean surface. Then, a special adhesive is evenly applied to the surface of the bearing outer ring, with the adhesive thickness controlled at 5-10μm. This avoids excessive adhesive causing the grating ruler 61 to bulge or insufficient adhesive causing poor adhesion. The grating ruler 61 is aligned with the reference position of the bearing outer ring (generally based on the end face or keyway of the bearing outer ring) and slowly attached to the bearing outer ring. At the same time, a special tool is used to gently press the grating ruler 61 to remove air bubbles in the adhesive, ensuring that the grating ruler 61 is completely attached to the bearing outer ring. Finally, the rotating shaft 2 with the grating ruler 61 attached is placed in an oven for curing. After curing, the radial runout of the grating ruler 61 is detected using a laser diameter gauge to ensure that the runout does not exceed 0.005mm, meeting the feedback accuracy requirements.

[0082] Compared with existing technologies, the traditional grating ruler 61 is mounted on a special bracket at the end of the rotating shaft 2. The vibration of the bracket causes the grating ruler 61 to be eccentric. In this solution, the grating ruler 61 is attached to the outer ring of the bearing, resulting in less radial runout and reduced eccentricity error. The traditional installation method requires additional processing of the rotating shaft 2 (such as machining an installation step). This solution directly utilizes the outer ring of the bearing, eliminating the need for additional processing and reducing processing costs. The traditional grating ruler 61 is susceptible to grease contamination inside the bearing. In this solution, the outer ring of the bearing generally has a sealing structure, which can protect the grating ruler 61 from grease contamination and extend its service life.

[0083] Through the above technical solution, this application optimizes the installation method of the grating ruler 61, ensuring the stability and coaxiality of the grating ruler 61 when rotating with the rotating shaft 2, further improving the feedback accuracy and reliability of the grating reading system, while simplifying the installation process and reducing production costs.

[0084] A five-axis rotary table is a precision machining equipment with five motion axes (generally X, Y, and Z linear axes and A and C rotary axes 2). It is mainly used for machining complex curved surfaces in aerospace, mold making, and medical device fields, and has extremely high requirements for the heat dissipation, braking, and feedback performance of the motor bearings. The integrated system of this application is generally applied to the motor bearings of the rotary axis 2 (A or C axis) of the five-axis rotary table. The integrated system is fixed to the rotary table body by bolt or flange connection to ensure installation accuracy, with a coaxiality error not exceeding 0.005mm.

[0085] Specifically, during the operation of the five-axis rotary table, when the motor of the rotating axis 2 is running at high speed (1000-3000 rpm), the cooling channel 41 (41) of the integrated system continuously cools the coil assembly, keeping the motor temperature below 60℃ to avoid a decrease in the positioning accuracy of the rotary table due to temperature rise. When the rotary table needs to switch processing positions, the drum brake mechanism 5 (5) responds quickly, stopping the rotating axis 2 within 0.1 seconds, reducing the switching time and improving processing efficiency. At the same time, the flexible braking avoids impact on the mechanical structure of the rotary table, protecting the accuracy of the rotary table. The grating reading system provides real-time feedback on the rotation speed and position data of the rotating axis 2, with a feedback accuracy of ±0.001mm, ensuring that the rotary table can accurately position itself to the processing position and guaranteeing the dimensional accuracy and surface quality (surface roughness Ra≤0.8μm) of the processed workpiece. In addition, the integrated design of the integrated system makes the structure of the five-axis rotary table more compact, reducing its volume by 30% and its weight by 25% compared to traditional rotary tables using discrete systems, making it easier to install and debug the rotary table.

[0086] Compared with existing technologies, traditional five-axis rotary tables suffer from insufficient cooling of motor bearings, resulting in positioning accuracy deviations exceeding 0.01mm after prolonged operation. This solution integrates a cooling system to control the accuracy deviation within 0.003mm. Traditional rotary tables have slow braking response, with station switching times exceeding 1 second. This solution's drum brake mechanism 5 shortens the switching time to within 0.3 seconds. Traditional rotary table feedback systems are susceptible to interference, resulting in machining errors exceeding 0.005mm. This solution's grating reading system controls machining errors within 0.002mm.

[0087] Through the above technical solution, this application integrates the cooling, braking and feedback system with the five-axis rotary table, which significantly improves the operation stability, machining accuracy and efficiency of the five-axis rotary table, meets the stringent requirements of the high-precision machining field, and has important industrial application value.

[0088] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

[0089] Although this application discloses several aspects and embodiments, other aspects and embodiments will be obvious to those skilled in the art. Various modifications and improvements can be made without departing from the concept of this application, and these all fall within the scope of protection of this application. The various aspects and embodiments disclosed in this application are for illustrative purposes only and are not intended to limit this application. The actual scope of protection of this application is determined by the claims.

Claims

1. An integrated cooling, braking and feedback system for an integrated motor bearing, the integrated motor bearing comprising a rotating shaft (2) with a permanent magnet array and a flanged fixed end (4) with a coil assembly, characterized in that: The flange fixing end (4) has an integrated cooling channel (41) for cooling the coil assembly. The drum brake mechanism (5) integrated at the lower part of the flange fixing end (4) is used to brake the rotating shaft (2). The grating reading system located at the lower part of the rotating shaft (2) provides feedback on the motor speed and the position of the rotating shaft (2) by integrating the grating reading system at the lower part of the rotating shaft (2).

2. The integrated cooling, braking and feedback system for an integrated motor bearing according to claim 1, characterized in that: The cooling channel (41) includes a liquid inlet manifold (411) located on the upper part of the flange fixed end (4), an upper annular groove (412) located on the upper part of the flange fixed end (4), multiple vertical straight channels (413) connecting the upper annular groove (412) and the lower annular groove (414), and a transverse channel (418); the input end of the upper annular groove (412) and the output end of the lower annular groove (414) are both connected to a transverse channel (418), the lower annular groove (414) is connected to a liquid outlet manifold (415) through the transverse channel (418) it connects to; the upper annular groove (412) is connected to a liquid inlet manifold (411) through the transverse channel (418) it connects to.

3. The integrated cooling, braking and feedback system for an integrated motor bearing according to claim 2, characterized in that: The multiple vertical straight channels (413) are evenly distributed around the flange fixed end (4) and are parallel to the vertical surface of the flange.

4. The integrated cooling, braking and feedback system for an integrated motor bearing according to claim 1, characterized in that: The drum brake mechanism (5) includes at least one air chamber (51), the wall of which near the rotating shaft (2) is a deformable elastic wall.

5. An integrated cooling, braking and feedback system for an integrated motor bearing according to claim 4, characterized in that: The drum brake mechanism (5) includes a plurality of air chambers (51) arranged in a circumferential array.

6. An integrated cooling, braking and feedback system for an integrated motor bearing according to claim 5, characterized in that: It also includes an integrated air supply ring (52) for uniformly supplying air to all the air chambers (51).

7. An integrated cooling, braking and feedback system for an integrated motor bearing according to claim 5, characterized in that: The partition between adjacent air chambers (51) is an inclined plate (53) that slopes inward toward the air chamber, which is used for guiding flow and reinforcing the structure.

8. An integrated cooling, braking and feedback system for an integrated motor bearing according to claim 1, characterized in that: The system includes a grating ruler (61) mounted on a rotating shaft (2) and a reading head (62) mounted on a flange fixed end (4) and positioned opposite to the grating ruler (61).

9. An integrated cooling, braking and feedback system for an integrated motor bearing according to claim 8, characterized in that: The grating ruler (61) is attached to the outer ring of the bearing of the rotating shaft (2).

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