Turbo Fan
20180245598 ยท 2018-08-30
Inventors
Cpc classification
F04D29/4253
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D25/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/667
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D17/165
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/444
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K9/14
ELECTRICITY
H02K5/207
ELECTRICITY
H02K7/14
ELECTRICITY
F04D29/5806
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D25/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/58
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D25/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K9/14
ELECTRICITY
F04D29/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A fan has a motor, a fan impeller, a cooling body and a housing. The motor is electrically driven and has a stator and has a rotor which is mounted so as to be rotatable about an axis of rotation, wherein the motor has at least one winding through which an electrical current flows during operation. The fan impeller is fastened rotationally conjointly to the rotor and serves for drawing in and conveying a gaseous medium. The cooling body has an inner wall which delimits an interior space for accommodating the motor, and has air-guiding elements which extend in each case in an axial direction over a major part of the longitudinal extent of the winding, through which electrical current flows, in order to conduct the gaseous medium, which is conveyed by the fan impeller, along the cooling body for motor cooling purposes. The housing has an outer wall which delimits a cavity for accommodating the cooling body and the motor.
Claims
1. A fan comprising: an electrically driven motor having a stator and having a rotor which is mounted so as to be rotatable about an axis of rotation, wherein a radial and an axial direction of the fan are defined based on the axis of rotation, and wherein the motor has at least one winding through which an electrical current flows during operation; a fan impeller which is fastened rotationally conjointly to the rotor and which serves for drawing in and conveying a gaseous medium; a cooling body having an inner wall which delimits an interior space for accommodating the motor, and having air-guiding elements which extend in each case in the axial direction over a major part of a longitudinal extent of the winding through which electrical current flows, in order to conduct the gaseous medium, which is conveyed by the fan impeller, along the cooling body or cooling the motor; and a housing having an outer wall which delimits a cavity for accommodating the cooling body and the motor.
2. The fan according to claim 1, wherein the air-guiding elements extend in the axial direction over a major part of the longitudinal extent of the stator.
3. The fan according to claim 1, wherein the inner wall of the cooling body radially surrounds the stator along its entire longitudinal extent.
4. The fan according to claim 1, wherein the air-guiding elements extend in each case rectilinearly along the axial direction.
5. The fan according to claim 1, wherein the fan impeller is designed to convey the drawn-in gaseous medium in a radially outward direction.
6. The fan according to claim 1, wherein a diffuser is provided along the axial direction between the fan impeller and the cooling body in order to divert the gaseous medium, which is conveyed by the fan impeller, into the axial directiontoward the cooling body.
7. The fan according to claim 6, wherein the diffuser has guide blades which have in each case one end, facing toward the fan impeller, with an edge which tapers to a point.
8. The fan according to claim 6, wherein each of the air-guiding elements of the cooling body is assigned a guide blade, and wherein the air-guiding elements in each case adjoin the guide blades in the axial direction and transition into said guide blades in a flush manner.
9. The fan according to claim 1, wherein the electrically driven motor is a brushless direct-current motor.
10. The fan according to claim 1, wherein, for the mounting of the rotor 4, there is provided at least one bearing (19) which is fastened in a bearing arrangement element, and wherein the bearing arrangement element has at least one pressure equalization bore for permitting a pressure equalization in the direction of the bearing.
11. The fan according to claim 1, wherein the inner wall of the cooling body has an outer surface whose diameter decreases continuously in the axial direction with increasing distance from the fan impeller.
12. The fan according to claim 11, wherein the diameter of the outer surface of the inner wall decreases continuously in the axial direction with increasing distance from the fan impeller along substantially an entire longitudinal extent of the inner wall.
13. The fan according to claim 1, wherein the outer wall of the housing has a cylindrical inner surface.
14. The fan according to claim 1, wherein the housing has an air inlet which widens continuously in the axial direction toward the fan impeller and/or has an air outlet which narrows continuously in the axial direction away from the fan impeller.
15. The fan according to claim 1, wherein the housing, the fan impeller, the diffuser and the cooling body together delimit a flow chamber which, during the operation of the fan, is flowed through by the gaseous medium along a main flow direction and which, along the main flow direction, in thea region of the fan impeller, narrows toward the diffuser and, in a region of the cooling body, widens with increasing distance from the diffuser.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Preferred embodiments of the invention will be described below on the basis of the drawings, which serve merely for illustration and which are not to be interpreted as being restrictive. In the drawings:
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
DESCRIPTION OF PREFERRED EMBODIMENTS
[0062]
[0063] As can be clearly seen in
[0064] The inlet cover 103 has a connection piece 1031 which delimits an inlet opening 1033, and the outlet cover 104 has an outlet connector 1041 which delimits an outlet opening 1043. The outer wall 101, the inlet cover 103 and the outlet cover 104 together delimit a cavity 102 of the fan. While the inlet opening 1033 serves for allowing air to flow from the outside into the cavity 102, the outlet opening 1043 serves for allowing the air to flow out of the cavity 102 again to the outside.
[0065] With the exception of the inlet opening 1033 and the outlet opening 1043, the cavity 102 is entirely closed off with respect to the outside by the housing 10. The outer wall 101 and the connection pieces 1031 and 1041 are in each case arranged concentrically with respect to an axis of rotation DA of the fan. An axial direction AR and a radial direction RR of the fan are defined on the basis of the axis of rotation DA.
[0066] The outer wall 101 of the housing 10 has a number of radial bores 1011 which serve for the screw fixing of the fan components that are arranged in the cavity 102.
[0067] The two connection pieces 1031 and 1041 have, in each case on their radially outer side, external grooves 1032 and 1042 respectively into which seal rings 21 can be inserted. The connection pieces 1031 and 1041 can thus serve, depending on the application, for the air-tight connection of further devices, such as for example air hoses or other connection devices of any other design.
[0068] The inner surfaces, which face toward the cavity 102, of the inlet cover 103 and of the outlet cover 104 transition, in the axial direction AR, in each case in a flush manner into the inner surface of the outer wall 101. In the region of the inlet cover 103 and of the outlet cover 104, the cavity 102 narrows in each case in continuous fashion in the axial direction AR toward the inlet opening 1033 and toward the outlet opening 1043 as far as the respective connection piece 1031 and 1041 respectively, which has an in each case cylindrical inner surface in the region of the inlet opening 1033 and of the outlet opening 1043 respectively. The inner surfaces of the connection pieces 1031 and 1041 widen in the outward direction in each case at the ends which open to the outside. Owing to these altogether continuous profiles of the inner surfaces of the housing 10, it is possible to realize optimum aerodynamic values.
[0069] As can be seen for example in
[0070] In the inlet cover 103 there are provided radial bores 1035 (
[0071] As can be seen in
[0072] The design of the cooling body 11 can be clearly seen in particular in
[0073] As can be clearly seen for example in
[0074] A multiplicity of rib-like air-guiding elements 133 is formed at regular intervals along the circumferential direction on the outer surface of the inner wall 111, which air-guiding elements extend in each case rectilinearly and parallel to the axis of rotation DA over the entire longitudinal extent of the cooling body 11. Between the air-guiding elements 113 there are provided air-guiding ducts 114 which are in each case delimited to both sides in the circumferential direction by one of the air-guiding elements 113. Owing to the fact that the diameter of the outer surface of the inner wall 111 decreases in the direction of the outlet opening 1043, the air-guiding ducts 114 each have an increasing depth in the same direction.
[0075] The air-guiding elements 113 also serve, in particular, as cooling ribs for the transfer of thermal energy from the interior space 112 of the cooling body 11 to the air that flows through the air-guiding ducts 114 in the axial direction AR. The thermal energy generated in the interior space 112 can thus be dissipated to the outside.
[0076] The air-guiding ducts 114 are delimited in the radial direction RR in each case by the inner wall 111 of the cooling body 11 and by the outer wall 101 of the housing 10 and in the circumferential direction by in each case two air-guiding elements 113. By virtue of the fact that the air-guiding ducts 114 are thus delimited, along the entire longitudinal extent, only by continuously smooth surfaces, it is possible for a laminar and thus aerodynamically optimum and resistance-free air flow to form in said air-guiding ducts during fan operation.
[0077] To ensure an optimum dissipation of heat, the air-guiding elements 113 are advantageously formed in one piece with the inner wall 111 and from the same material as the latter, which exhibits good thermal conductivity. It has been found that optimum aerodynamic values with simultaneously satisfactorily efficient heat dissipation are achieved if the cooling body 11 has between 10 and 26, in particular between 14 and 22, and most preferably, as the case here, exactly 18 air-guiding elements 113, which are arranged at regular intervals along the circumferential direction.
[0078] In the radial direction RR, the air-guiding elements 113 bear preferably along their entire longitudinal extent against the inner surface of the outer wall 101, such that heat energy can be transmitted not only to the air flowing through the air-guiding ducts 114 but also to the housing 10 (
[0079] As can be seen for example from
[0080] The first bearing shield 17 serves, together with a second bearing shield 18 which is arranged on that side of the cooling body 11 which faces toward the outlet opening 1043, for the mounting of a drive shaft 13. The first and the second bearing shield 17 and 18 are thus static, like the housing 10, the cooling body 11 and the diffuser 16. For the mounting of the drive shaft 13, a first ball bearing 19 is mounted in the first bearing shield 17 and a second ball bearing 20 is mounted in the second bearing shield 18. The two ball bearings 19 and 20 are preloaded. Between the first and second bearing shield 17 and 18 respectively and the respective radial outer side of the ball bearings 19 and 20, there is provided in each case one 0-ring 191 and 201 respectively, whereby optimum vibration damping is realized.
[0081] To prevent the bearing grease from being forced out of the ball bearings 19 and 20 during fan operation at very high rotational speeds, pressure equalization bores 171 are provided in the first bearing shield 17. The pressure equalization bores 171 correspond to pressure equalization cutouts 115 which are provided in the region of that face surface of the inner wall 111 of the cooling body which faces toward the inlet opening 1033 (
[0082] The second bearing shield 18 has a kidney-shaped leadthrough opening 181 through which connection cables 123 of the motor 12 can be led (
[0083] A rotor 121 of the motor 12 is mounted rotationally conjointly on the drive shaft 13. Concentrically outside the rotor 121, there is provided a stator 122 with a stator winding 1221. The stator winding 1221 constitutes a winding through which electrical current flows during operation. During fan operation, a major part of the thermal energy that has to be dissipated is produced in the stator winding 1221 and in the adjacent stator regions. The motor 12 is a brushless direct-current motor which is accommodated entirely in the interior space 112 of the cooling body 11. The motor 12 and in particular the stator 122 bear by way of their outer surfaces against the inner surface of the inner wall 111 of the cooling body. An optimum transfer of heat from the motor 12 to the cooling body 11 is realized in this way. Since the air-guiding elements 113 of the cooling body 11 extend in the axial direction AR over the entire longitudinal extent of the motor 12 and in particular of the stator 122 and even beyond, the thermal energy produced in the motor 12 can be dissipated in optimum fashion.
[0084] The motor used in the present embodiment is an electric motor as is presented and described in EP 2 180 581. Corresponding to the disclosure of EP 2 180 581, the stator winding 1221 has, in particular, multiple rhombic individual coils which are produced from flat wire and which overlap one another in the manner of roof tiles, as can also be seen from
[0085] At approximately the level of the inlet cover 103 in the axial direction AR, the fan impeller 14 is mounted rotationally conjointly on the drive shaft 13. The fan impeller 14 is of similar design to a compressor wheel of a turbocharger and has a rotationally symmetrical main body with a central through opening 143. The fan impeller 14 may therefore also be referred to as compressor wheel. The inner diameter, which defines the through opening 143, of the main body is only slightly larger than the outer diameter of the drive shaft 13, which projects through the through opening 143. At its end facing toward the inlet opening 1033, the main body 141 has an outer diameter which is only slightly larger than its inner diameter. In the axial direction AR toward the cooling body 11, the outer diameter of the main body 141 however increases in continuous fashion and with an increase similar to an exponential function.
[0086] Multiple fan blades 142 are mounted, at regular intervals along the circumferential direction, on the main body 141 on the side facing toward the inlet cover 103. The fan blades 142 serve for conveying the air by virtue of the fan impeller 14 being rotated by the motor 12 and, in this way, air being drawn through the inlet opening 1033 into the cavity 102 and being discharged to the outside again through the outlet opening 1043 via the air-guiding ducts 114.
[0087] It is preferable for 6 to 10, or as is the case here exactly 8, fan blades to be provided, which are advantageously formed in one piece with the main body 141. In the frontal view of the air inlet region of the fan from the front in
[0088] The fan impeller 14 is fastened rotationally conjointly to the drive shaft 13, and thus to the rotor 121, by way of a fan impeller nut 15 which is screwed onto that end of the drive shaft 13 which is arranged in the region of the inlet opening 1022. The fan impeller nut 15 is designed such that its outer surface transitions flush into the outer surface of the main body 141 of the fan impeller 14 in the axial direction AR. Toward the outside in the direction of the inlet opening 1033, the fan impeller nut 15 has an end which tapers to a point.
[0089] During a rotation of the fan impeller 14, air is drawn in the axial direction AR through the inlet opening 1033 and is conveyed by the fan blades 142 initially in the axial direction AR toward the cooling body 11 and then in the radial direction RR toward the outside.
[0090] A diversion of the air, which is conveyed radially toward the outside by the fan impeller 14, into the axial direction AR is realized owing to the shape of the inner surface of the inlet cover 103 and then owing to the inner surface, which defines the further flow direction, of the outer wall 101.
[0091] The diffuser 16 is arranged in the axial direction AR between the fan impeller 14 and the cooling body 11. The diffuser 16 serves for diverting the air, conveyed by the fan impeller 14, into the air-guiding ducts 114 of the cooling body 11. The diffuser 16 thus serves in particular for converting the air flow, which immediately downstream of the fan impeller 14 still has a direction component pointing in the circumferential direction, into an air flow which has a direction component pointing exclusively in the axial direction AR. For this purpose, the diffuser 16 has guide blades 161 which for the purposes of preventing air turbulence have, in the axial direction AR toward the fan impeller 14, an end which tapers in each case to a point. Toward said ends, the guide blades 161 are in each case curved slightly into the circumferential direction counter to the intended direction of rotation of the fan impeller 14. Toward the cooling body 11, the guide blades 161 run in each case so as to be increasingly parallel to the axis of rotation DA.
[0092] In order to realize as low an air resistance as possible, each of the air-guiding elements 113 of the cooling body 11 is assigned in each case one guide blade 161 of the diffuser 16, which guide blade bears in the axial direction AR against the corresponding air-guiding element 113 and transitions flush into said air-guiding element on all sides.
[0093] The diffuser 16 has a number of radial bores 162 which serve for the screw connection of the diffuser 16 to the outer wall 101 via corresponding radial bores 1011 provided in the outer wall 101 (
[0094] During the operation of the fan, it is thus the case that the fan impeller 14 is set in rotational motion about the axis of rotation DA by the motor 12. In this way, air is drawn through the inlet opening 1033 by the fan blades 142 and conveyed to the outside in the axial direction AR and then in the radial direction RR. Owing to the curved form of the inner surface of the inlet cover 103 in the region directly adjacent to the peripheral region of the fan impeller 14, the drawn-in air is diverted into the axial direction AR again. The diffuser 16 is arranged in the region in which the air is diverted from the radial direction into the axial direction. Said diffuser, which is arranged in the high-pressure region of the fan, diverts the air flow, which immediately downstream of the fan impeller 14 still has a direction component pointing in a circumferential direction, into an air flow which flows purely in the axial direction AR. From the diffuser 16, the air is conducted into the air-guiding ducts 114 of the cooling body 11, where a substantially laminar air flow delimited by substantially smooth surfaces can form. As a result of the flow along the inner wall 111 and along the air-guiding elements 113, thermal energy is transferred from the cooling body 11 to the air flowing through the air-guiding ducts 114 and is thus dissipated, whereby extremely efficient motor cooling is effected, with simultaneously optimum aerodynamics. Owing to the decreasing outer diameter of the inner wall 111, the air-guiding ducts 114 increase in depth in the axial direction AR toward the outlet cover 104, which likewise has a positive effect on aerodynamics. The air emerges from the air-guiding ducts 114 in the region of the outlet cover 104. Said region can be referred to as low-pressure region of the fan. Finally, the air passes to the outside again through the outlet opening 1043.
[0095] The embodiment shown in
[0096] To realize a high air pressure or large negative air pressure even at relatively low rotational speeds, it is possible for multiple fans according to the invention to be arranged one behind the other in series. For a high air throughput, it is possible for multiple fans according to the invention to be arranged in parallel with one another.
[0097] A second embodiment of a fan according to the invention is shown in
[0098] By contrast to the embodiment shown in
[0099] The fan impeller 14, diffuser 16, cooling body 11 and motor 12 are advantageously in each case substantially identical to those in the embodiment shown in
LIST OF REFERENCE DESIGNATIONS
[0100]
TABLE-US-00001 10 Housing 101 Outer wall 1011 Radial bores 102 Cavity 103 Inlet cover 1031 Connection piece 1032 External grooves 1033 Inlet opening 1034 Groove 1035 Radial bores 1036 Internal thread 104 Outlet cover 1041 Connection piece 1042 External grooves 1043 Outlet opening 1044 Groove 1045 Internal thread 11 Cooling body 111 Inner wall 1111 First axial bores 1112 Second axial bores 112 Interior space 113 Air-guiding elements 114 Air-guiding ducts 115 Pressure equalization cutout 12 Motor 121 Rotor 122 Stator 1221 Stator winding 123 Connection cable 13 Drive shaft 14 Fan impeller 141 Main body 142 Fan blades 143 Through opening 15 Fan impeller nut 16 Diffuser 161 Guide blades 162 Radial bores 163 Axial bores 17 First bearing shield 171 Pressure equalization bores 172 Axial bores 18 Second bearing shield 181 Leadthrough opening 19 First ball bearing 191 O-ring 20 Second ball bearing 201 O-ring 21 Seal rings DA Axis of rotation RR Radial direction AR Axial direction