Motor Air-Guiding Cover Layout for Uniform Stator Cooling
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Solution Overview
Problem
Traditional motors suffer from uneven cooling of the outer stator, coil, and rotor due to inadequate airflow distribution, leading to local high temperatures and frequent over-temperature protection in DC tools. Additionally, prior art lacks optimal structural dimensions for motor heat dissipation and fan power consumption.
Innovation Solution
The motor design incorporates an air-guiding cover with a first and second air-guiding ring, along with a fan positioned within the second ring. The air-guiding cover's dimensions, including inner diameters and axial heights, are optimized to enhance airflow and heat dissipation, with specific ratios and relationships between components to improve airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional air-guiding plate is used to guide airflow into the fan inlet, then airflow guidance is provided to some extent, but the motor heat dissipation flow cannot be reasonably distributed to the air gap and stator casing channel, resulting in uneven cooling and local high temperatures
Solution Approach 1:
The air-guiding cover is segmented into multiple functional regions: a first air-guiding ring for guiding airflow into the air gap, a second air-guiding ring for guiding airflow into the stator casing channel, and an air-guiding plate with multiple air-guiding holes. This segmentation allows different parts of the air guidance structure to perform specific cooling functions, achieving uniform heat dissipation across the motor components.
2Productivity
If the inner diameter of the first air-guiding ring is increased to improve airflow to the air gap, then cooling of the inner rotor and air gap improves, but the structural dimensions must be precisely optimized to maintain balance between fan power consumption and heat dissipation efficiency
Solution Approach 1:
The patent optimizes multiple geometric parameters of the air-guiding cover, including the inner diameter of the first air-guiding ring (d3≥d1), the inner diameter of the second air-guiding ring (d7≥2d6-d4), the axial heights of the air-guiding rings (h1/d4≤0.5, h2≥h3), and the hub-to-fan diameter ratio (0.2≤d5/d6≤0.5). These parameter changes ensure optimal airflow distribution that balances heat dissipation efficiency with fan power consumption.
3Loss of energy
If airflow is increased to improve heat dissipation, then motor heat dissipation flow increases by up to 15%, but the fan power consumption and system balance must be maintained
Solution Approach 1:
The air-guiding cover integrates multiple functions into a single component: it guides airflow into the air gap through the first air-guiding ring, guides airflow into the stator casing channel through the second air-guiding ring, and distributes airflow through the air-guiding plate with multiple holes. This multi-functionality achieves comprehensive cooling of the motor while avoiding the need for separate air guidance components for each function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved motor heat dissipation performance increases airflow through the fan by at least 10%, enhances motor heat dissipation flow by up to 15%, and reduces winding temperature rise by more than 2°C, addressing the issues of uneven cooling and over-temperature protection.
Implementation Method 1
The fan is located at an axial front end of the outer stator and rotates with the shaft to generate airflow to cool the outer stator
Data Source
AI summary
The present disclosure relates to a motor. The motor includes a shaft extending in an axial direction, an inner rotor fixed on the shaft, an outer stator sleeved on the inner rotor, and a fan on the shaft. The fan can rotate with the shaft to generate airflow to cool the outer stator. The motor further includes an air-guiding cover including a first air-guiding ring and a second air-guiding ring arranged along the axial direction. The first air-guiding ring is located between the outer stator and the second air-guiding ring. The fan is located within the second air-guiding ring. The first air-guiding ring has an inner diameter d3, the outer stator has a first inner diameter d1, and the inner diameter d3 is greater than or equal to the first inner diameter d1. The heat dissipation effect is significantly improved.