PCB air-cooled motor structure

Abstract

The utility model relates to the technical field of motor air cooling, especially to a PCB air cooling motor structure, which prolongs the overall service life of the motor, the motor casing is composed of a motor upper cover and a motor lower cover, the rotor assembly comprises a rotor shaft, a rotor back iron fixed on the rotor shaft, the rotor back iron is composed of a rotor lower back iron and a rotor upper back iron, a first rotor magnetic tile and a second rotor magnetic tile are fixedly arranged on the rotor back iron respectively, the stator assembly comprises a PCB printed board and a printed coil printed on the PCB printed board, the PCB printed board is fixed on the motor lower cover, the stator assembly and the first rotor magnetic tile and the second rotor magnetic tile form an air gap, a centrifugal impeller is coaxially fixed on the rotor shaft through an impeller insert, a space guide vane ring is located between the air outlet of the centrifugal impeller and the PCB printed board, and a fan upper cover is connected with the motor upper cover to form an air duct.

Description

Technical Field

[0001] This utility model relates to the technical field of air-cooled motors, and in particular to a PCB air-cooled motor structure. Background Technology

[0002] With increasingly stringent requirements for energy conservation and environmental protection, pumps, as key power sources, also need to meet standards of high efficiency and low energy consumption. Water pumps, as machines that transport or pressurize liquids, transfer the mechanical energy of a prime mover or other external energy to the liquid, increasing its energy. They are widely used in the transport of liquids such as water, oil, acids and alkalis, emulsions, suspensions, and liquid metals.

[0003] Traditional electric motors have certain structural limitations, especially in terms of heat dissipation. PCB motors (i.e., motors based on printed circuit board technology, such as PCB-wound motors or motor systems with integrated control circuits) use a PCB-wound stator design, eliminating the cogging torque of traditional motors and significantly reducing vibration and noise. Their high-precision etching process ensures winding consistency, reducing additional losses caused by uneven resistance. Simultaneously, the brushless DC (BLDC) structure avoids brush wear, extending the motor's lifespan to tens of thousands of hours.

[0004] However, PCB motors also have significant heat dissipation issues. Due to their small heat dissipation area, approximately 90% of the heat is conducted through the air gap, making it easy for the winding temperature to exceed the limit. For example, when the current density reaches 17A / mm², the winding temperature can rise to 119℃, approaching the temperature limit of the FR-4 substrate (130℃), which seriously affects the reliability and lifespan of the motor.

[0005] To address the aforementioned heat dissipation issues, existing technologies typically employ external fans or natural cooling, but these methods have limited effectiveness and are insufficient to meet the heat dissipation requirements of high-power-density motors. Especially in high-speed, high-airflow applications, traditional cooling methods are ineffective in controlling temperature rise, limiting further improvements in PCB motor performance. Utility Model Content

[0006] To solve the above-mentioned technical problems, this utility model provides a PCB air-cooled motor structure that improves service life.

[0007] This utility model discloses a PCB air-cooled motor structure, including a lower motor cover, a lower rotor back iron, a first rotor magnet, a PCB printed circuit board, a rotor shaft, inserts, printed coils, a second rotor magnet, an upper rotor back iron, an impeller insert, a motor upper cover, a spatial guide vane ring, upper and lower impeller cover plates, a centrifugal impeller, and a fan upper cover. The motor housing consists of an upper motor cover and a lower motor cover; The rotor assembly includes a rotor shaft and a rotor back iron fixed on the rotor shaft. The rotor back iron is composed of a lower rotor back iron and an upper rotor back iron. A first rotor magnet and a second rotor magnet are respectively fixed on the rotor back iron. The stator assembly includes a PCB printed circuit board and printed coils printed thereon. The PCB printed circuit board is fixed to the lower cover of the motor. The stator assembly forms an air gap with the first rotor magnet and the second rotor magnet. The centrifugal impeller is coaxially fixed to the rotor shaft by an impeller insert; A spatial guide vane ring is located between the air outlet of the centrifugal impeller and the PCB printed circuit board; The fan cover connects to the motor cover to form an air duct; The spatial guide vane ring converts the radial airflow generated by the centrifugal impeller into axial airflow. Part of the airflow forms the main flow channel to provide air pressure and air volume for the fan, while the other part forms the secondary flow channel, flowing into the motor to force-cool the PCB printed circuit board and windings. Through the spatial guide vane ring, the high-speed airflow generated by the centrifugal impeller is diverted and guided, and the resulting secondary flow channel airflow is precisely guided into the motor to force-cool the PCB printed circuit board and its printed coils. This improves the limitation of PCB motors mainly relying on air gap conduction for heat dissipation. Without adding an additional independent cooling device, this structure uses the motor's own drive components to complete heat dissipation, achieving timely heat dissipation and extending the overall life of the motor.

[0008] Preferably, the spatial guide vane ring comprises 3-7 spiral twisted guide vanes with a twist angle of 30°-60°.

[0009] Preferably, the blades of the centrifugal impeller are centrifugal blades, with 7 blades and a blade inclination angle of 15°-35°.

[0010] Preferably, the lower back iron and the upper back iron of the rotor are connected by an insert made of powder metallurgy, and the rotor shaft is provided with a rotor bearing, with the insert and the rotor bearing being interference-fitted.

[0011] Preferably, the PCB is an axial flux PCB stator made of FR-4 or aluminum substrate, and the printed coils on it are multi-layer windings.

[0012] Preferably, the airflow path of the secondary flow channel is as follows: it flows into the motor interior in the radial direction through the space guide vane ring, flows through the rotor internal air passage and stator region in sequence, and finally flows out from the motor lower cover.

[0013] Preferably, the centrifugal impeller and the upper and lower impeller cover plates are formed by ultrasonic welding, and the fan cover and the motor cover are connected by ultrasonic welding.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows: by using the space guide vane ring, the high-speed airflow generated by the centrifugal impeller is diverted and guided, and the resulting secondary flow channel airflow is precisely guided into the motor to force air cooling of the PCB printed circuit board and its printed coils. This improves the limitation of PCB motors mainly relying on air gap conduction for heat dissipation. Without adding an additional independent cooling device, this structure uses the motor's own drive components to complete heat dissipation, realizes timely heat dissipation, and extends the overall life of the motor. Attached Figure Description

[0015] Figure 1 This is a cross-sectional structural schematic diagram of the present invention; Figure 2 This is a schematic diagram of the isometric structure of this utility model; Figure 3 This is a schematic diagram of the airflow structure of this utility model.

[0016] The following are labels in the attached diagram: 1. Lower cover of motor; 4. Lower back iron of rotor; 5. No. 1 rotor magnet; 6. PCB printed circuit board; 7. Rotor shaft; 8. Insert; 9. Printed coil; 10. No. 2 rotor magnet; 11. Upper back iron of rotor; 12. Impeller insert; 13. Rotor bearing; 14. Upper cover of motor; 15. Spatial guide vane ring; 16. Upper and lower cover plates of impeller; 17. Centrifugal impeller; 18. Upper cover of fan. Detailed Implementation

[0017] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. This utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to make the disclosure of this utility model more thorough and complete. Example

[0018] like Figures 1 to 3 As shown, the present invention discloses a PCB air-cooled motor structure, including a lower motor cover 1, a lower rotor back iron 4, a first rotor magnet 5, a PCB printed circuit board 6, a rotor shaft 7, an insert 8, a printed coil 9, a second rotor magnet 10, an upper rotor back iron 11, an impeller insert 12, a motor upper cover 14, a spatial guide vane ring 15, upper and lower impeller cover plates 16, a centrifugal impeller 17, and a fan upper cover 18. The motor housing consists of an upper motor cover 14 and a lower motor cover 1; The rotor assembly includes a rotor shaft 7 and a rotor back iron fixed on the rotor shaft 7. The rotor back iron is composed of a lower rotor back iron 4 and an upper rotor back iron 11. A first rotor magnet 5 and a second rotor magnet 10 are respectively fixed on the rotor back iron. The stator assembly includes a PCB printed circuit board 6 and printed coils 9 printed thereon. The PCB printed circuit board 6 is fixed on the motor lower cover 1. The stator assembly forms an air gap with the first rotor magnet 5 and the second rotor magnet 10. The centrifugal impeller 17 is coaxially fixed to the rotor shaft 7 via the impeller insert 12; The spatial guide vane ring 15 is located between the air outlet of the centrifugal impeller 17 and the PCB printed circuit board 6; The fan cover 18 is connected to the motor cover 14 to form an air duct; The space guide vane ring 15 converts the radial airflow generated by the centrifugal impeller 17 into axial airflow. A portion of the airflow forms the main flow channel to provide the fan with air pressure and air volume, while another portion of the airflow forms the secondary flow channel and flows into the motor to provide forced air cooling to the PCB printed circuit board 6 and the windings. The spatial guide vane ring 15 includes 3-7 spiral twisted guide vanes, with a guide vane twist angle of 30°-60°. The blades of the centrifugal impeller 17 are centrifugal blades, with 7 blades and a blade inclination angle of 15°-35°. The lower back iron 4 and the upper back iron 11 of the rotor are connected by an insert 8 made of powder metallurgy. The rotor shaft 7 is provided with a rotor bearing 13. The insert 8 and the rotor bearing 13 are press-fitted together. The PCB printed circuit board 6 is an axial flux PCB stator, made of FR-4 or aluminum substrate material, and the printed coil 9 on it is a multi-layer winding. The airflow path of the auxiliary flow channel is as follows: it flows into the motor interior in the radial direction through the space guide vane ring 15, flows through the rotor internal air passage and stator area in sequence, and finally flows out from the motor lower cover 1. The centrifugal impeller 17 and the upper and lower impeller cover plates 16 are formed by ultrasonic welding, and the fan cover 18 and the motor cover 14 are connected by ultrasonic welding.

[0019] In this embodiment, the high-speed airflow generated by the centrifugal impeller 17 is diverted and guided by the spatial guide vane ring 15. The resulting secondary flow channel airflow is precisely guided into the motor to provide forced air cooling for the PCB printed board 6 and its printed coils 9. This improves the limitation of the PCB motor relying mainly on air gap conduction for heat dissipation. Without adding an additional independent cooling device, this structure utilizes the motor's own drive components to complete heat dissipation, achieving timely heat dissipation and extending the overall lifespan of the motor.

[0020] The PCB printed circuit board 6 of the PCB air-cooled motor structure of this utility model is purchased from the market. Technical personnel in this industry only need to install and operate it according to the accompanying instruction manual, without requiring any creative work from those skilled in the art.

[0021] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A PCB-based air-cooled motor structure, comprising a lower motor cover (1), a lower rotor back iron (4), a first rotor magnet (5), a PCB printed circuit board (6), a rotor shaft (7), an insert (8), a printed coil (9), a second rotor magnet (10), an upper rotor back iron (11), an impeller insert (12), a motor upper cover (14), a spatial guide vane ring (15), upper and lower impeller cover plates (16), a centrifugal impeller (17), and a fan upper cover (18), characterized in that, The motor housing consists of an upper motor cover (14) and a lower motor cover (1); the rotor assembly includes a rotor shaft (7) and a rotor back iron fixed on the rotor shaft (7). The rotor back iron consists of a lower rotor back iron (4) and an upper rotor back iron (11). A first rotor magnet (5) and a second rotor magnet (10) are fixedly installed on the rotor back iron respectively. The stator assembly includes a PCB (6) and printed coils (9) printed thereon. The PCB (6) is fixed on the motor cover (1). The stator assembly forms an air gap with the first rotor magnet (5) and the second rotor magnet (10). The centrifugal impeller (17) is coaxially fixed on the rotor shaft (7) through the impeller insert (12). The space guide vane ring (15) is located between the air outlet of the centrifugal impeller (17) and the PCB (6). The fan cover (18) is connected to the motor cover (14) to form an air duct. The space guide vane ring (15) converts the radial airflow generated by the centrifugal impeller (17) into axial airflow. A part of the airflow forms the main flow channel to provide the fan air pressure and air volume, and another part of the airflow forms the secondary flow channel, which flows into the motor to force-cool the PCB (6) and windings.

2. The PCB air-cooled motor structure as described in claim 1, characterized in that, The spatial guide vane ring (15) contains 3-7 spiral twisted guide vanes with a twist angle of 30°-60°.

3. The PCB air-cooled motor structure as described in claim 2, characterized in that, The centrifugal impeller (17) has centrifugal blades, with 7 blades and a blade inclination angle of 15°-35°.

4. The PCB air-cooled motor structure as described in claim 3, characterized in that, The lower back iron (4) and the upper back iron (11) of the rotor are connected by an insert (8) made of powder metallurgy. The rotor shaft (7) is provided with a rotor bearing (13), and the insert (8) and the rotor bearing (13) are interference-fitted.

5. The PCB air-cooled motor structure as described in claim 1, characterized in that, The PCB printed circuit board (6) is an axial flux PCB stator, made of FR-4 or aluminum substrate material, and the printed coil (9) on it is a multi-layer winding.

6. The PCB air-cooled motor structure as described in claim 1, characterized in that, The airflow path of the secondary flow channel is as follows: it flows into the motor interior in the radial direction through the space guide vane ring (15), flows through the rotor internal air passage and stator area in sequence, and finally flows out from the motor lower cover (1).

7. The PCB air-cooled motor structure as described in claim 1, characterized in that, The centrifugal impeller (17) and the upper and lower cover plates (16) of the impeller are formed by ultrasonic welding, and the fan cover (18) and the motor cover (14) are connected by ultrasonic welding.

Images