US-20260128649-A1 - MOTOR ASSEMBLY HAVING END FRAME COOLING SYSTEM

Abstract

A motor assembly is provided that includes a housing, and a mounting bracket coupled to an end of the housing. The mounting bracket and the housing defining a first compartment. The motor assembly also includes a motor positioned within the first compartment, and a heatsink casing coupled to the housing, opposite the mounting bracket. The heatsink casing includes a plurality of heatsink protrusions disposed within the heatsink casing. Additionally, the motor assembly includes a shroud positioned adjacent the heatsink casing, opposite the mounting bracket, where the shroud defines a second compartment. The motor assembly also includes a shaft coupled to the motor, extending axially through the heatsink casing and the second compartment. Furthermore, the motor assembly also includes a fan coupled to the shaft and is positioned within the second compartment, between the shroud and the plurality of heatsink protrusions disposed within the heatsink casing.

Inventors

• Jeffrey William Crosson
• Rafal Pawel Rohoza
• Jibu John
• Joshua Daniel Bragagnolo
• Greg Heins

Assignees

• REGAL BELOIT AMERICA, INC.

Dates

Publication Date

20260507

Application Date

20241107

Claims (20)

1. 1 . A motor assembly comprising: a housing; a mounting bracket coupled to an end of said housing, said mounting bracket and said housing defining a first compartment; a motor positioned within said first compartment; a heatsink casing coupled to said housing, opposite said mounting bracket, said heatsink casing including a plurality of heatsink protrusions disposed within said heatsink casing and configured to receive airflow surrounding said housing; a shroud positioned adjacent said heatsink casing, opposite said mounting bracket, said shroud defining a second compartment; a shaft coupled to said motor and configured to rotate about an axis, said shaft extends axially through said heatsink casing and said second compartment defined by said shroud; and a fan coupled to said shaft and positioned within said second compartment, between said shroud and said plurality of heatsink protrusions disposed within said heatsink casing, said fan configured to draw airflow from said plurality of heatsink protrusions.
2. 2 . The motor assembly of claim 1 , wherein said fan includes: a shaft aperture configured to receive said shaft; a plurality of blades radially positioned around the axis; and a fan shroud coupled to each of said plurality of blades, said fan shroud concentrically aligned with said shaft aperture.
3. 3 . The motor assembly of claim 2 , wherein said fan shroud includes an opening concentrically aligned with said shaft aperture and enabling fluid communication between said plurality of heatsink protrusions and said second compartment of said shroud.
4. 4 . The motor assembly of claim 2 , wherein said fan shroud of said fan is one of, positioned directly between said plurality of heatsink protrusions and said plurality of blades, or positioned between said plurality of blades and said shroud.
5. 5 . The motor assembly of claim 2 , wherein said plurality of blades one of extend radially beyond an outer perimeter of said fan shroud, or positioned inward of the outer perimeter of said fan shroud.
6. 6 . The motor assembly of claim 1 , wherein said plurality of heatsink protrusions is formed as at least one of: a plurality of radial fins, a plurality of parallel fins, and a plurality of pins.
7. 7 . The motor assembly of claim 1 , further comprising a heatsink cover coupled to said heatsink casing, said heatsink cover including: opposing sidewalls positioned directly adjacent said heatsink casing; a wall portion extending between said opposing sidewalls, said wall portion positioned between said plurality of heatsink protrusions and said fan; a recess formed in said wall portion for enabling fluid communication between said plurality of heatsink protrusions and said fan; and an inlet defined by said opposing sidewalls and said wall portion, said inlet formed directly adjacent and exposing at least a portion of said plurality of heatsink protrusions.
8. 8 . The motor assembly of claim 7 , further comprising a plurality of guide vanes formed on at least one of: said opposing sidewalls of said heatsink cover, an outer surface of said heatsink casing, and an inner surface of said shroud, adjacent said heatsink cover or said heatsink casing.
9. 9 . The motor assembly of claim 1 , wherein said shroud further includes: an end wall positioned adjacent said fan; two opposing sidewalls extending from said end wall toward said housing, said two opposing sidewalls extending adjacent and at least partially surrounding at least one of said heatsink casing and said housing; a top wall extending from said end wall toward said heatsink casing and disposed over said fan; and a bottom wall extending from said end wall toward said heatsink casing and disposed below said fan, wherein said plurality of heatsink protrusions are exposed adjacent at least one of said top wall and said bottom wall.
10. 10 . The motor assembly of claim 9 , wherein said top wall of said shroud contacts said heatsink casing.
11. 11 . The motor assembly of claim 9 , wherein said top wall and said bottom wall of said shroud are substantially curved to concentrically correlate to said fan.
12. 12 . The motor assembly of claim 9 , wherein said two opposing sidewalls of the shroud are substantially curved and concentrically correlate to at least one of said heatsink casing and said housing.
13. 13 . A motor assembly comprising: a housing defining a first compartment; a mounting bracket coupled to an end of said housing; a motor positioned within the first compartment; a heatsink casing coupled to said housing, opposite said mounting bracket, said heatsink casing including a plurality of heatsink protrusions disposed within said heatsink casing and configured to receive airflow surrounding said housing; a shroud positioned adjacent said heatsink casing, opposite said mounting bracket, said shroud defining a second compartment; and a fan positioned within the second compartment, between said shroud and said plurality of heatsink protrusions disposed within said heatsink casing, said fan configured to draw airflow from said plurality of heatsink protrusions.
14. 14 . The motor assembly of claim 13 , further comprising a shaft coupled to said motor and configured to rotate about an axis, said shaft extending axially through said heatsink casing and the second compartment defined by said shroud, wherein said fan is coupled to said shaft.
15. 15 . The motor assembly of claim 13 , further comprising: a motor shaft coupled to said motor and configured to rotate about an axis; and a fan shaft coupled to said fan and configured to rotate, said fan shaft extending through the second compartment defined by said shroud and received by a hole formed in said shroud.
16. 16 . The motor assembly of claim 13 , wherein said fan includes: a plurality of blades radially positioned around the axis; and a fan shroud coupled to each of said plurality of blades, said fan shroud concentrically aligned with the shaft aperture.
17. 17 . The motor assembly of claim 13 , further comprising a heatsink cover coupled to said heatsink casing, said heatsink cover including: opposing sidewalls positioned directly adjacent said heatsink casing; a wall portion extending between said opposing sidewalls, said wall portion positioned between said plurality of heatsink protrusions and said fan; a recess formed in said wall portion for enabling fluid communication between said plurality of heatsink protrusions and said fan; and an inlet defined by said opposing sidewalls and said wall portion, said inlet formed directly adjacent and exposing at least a portion of said plurality of heatsink protrusions.
18. 18 . The motor assembly of claim 13 , wherein said shroud further includes: an end wall; two opposing sidewalls extending from said end wall toward said housing, said two opposing sidewalls extending adjacent and at least partially surrounding at least one of said heatsink casing and said housing; a top wall extending from said end wall toward said heatsink casing and disposed over said fan; and a bottom wall extending from said end wall toward said heatsink casing and disposed below said fan, wherein said plurality of heatsink protrusions are exposed adjacent at least one of said top wall and said bottom wall.
19. 19 . A method of operating a motor assembly, wherein the motor assembly includes a housing defining a first compartment; a mounting bracket coupled to an end of the housing; a motor positioned within the first compartment; a heatsink casing coupled to the housing, opposite the mounting bracket, the heatsink casing including a plurality of heatsink protrusions disposed within the heatsink casing; a shroud positioned adjacent the heatsink casing, opposite the mounting bracket, the shroud defining a second compartment; a shaft coupled to the motor and extending axially through the heatsink casing and the second compartment defined by the shroud; and a fan coupled to the shaft and positioned within the second compartment, between the shroud and the plurality of heatsink protrusions disposed within the heatsink casing, said method comprising: drawing airflow from outside the motor assembly through the plurality of heatsink protrusions included within the heatsink casing; flowing the airflow from the plurality of heatsink protrusions to the fan positioned within the second compartment defined by the shroud; circulating the airflow within the second compartment of the shroud based on a rotation of the fan; and directing the airflow from the second compartment of the shroud to an exterior of the housing.
20. 20 . The method of claim 19 , wherein said flowing of the airflow from the plurality of heatsink protrusions to the fan positioned within the second compartment defined by the shroud further includes inducing the airflow through an opening formed through a fan shroud of the fan to contact a plurality of blades of the fan, the fan shroud coupled to each of the plurality of blades of the fan.

Description

BACKGROUND The field of the disclosure relates generally to a motor assembly and, more particularly, to a motor assembly having an end frame cooling system. At least some known electric motor assemblies include various components that generate heat during operation and include fans for cooling those components. However, directing airflow to a desired location relative to the electric motor assembly, with sufficient volume, can be challenging. Typical electric motor assemblies use components to assist in directing the airflow to the desired location. However, additional components require the assembly to be larger and have a higher cost. Therefore, a need exists for a simplified electric motor assembly to accomplish directing airflow to the desired location. This background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with supporting information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art. BRIEF DESCRIPTION In one aspect, a motor assembly is provided that includes a housing, and a mounting bracket coupled to an end of the housing. The mounting bracket and the housing defining a first compartment. The motor assembly also includes a motor positioned within the first compartment, and a heatsink casing coupled to the housing, opposite the mounting bracket. The heatsink casing includes a plurality of heatsink protrusions disposed within the heatsink casing and configured to receive airflow surrounding the housing. Additionally, the motor assembly includes a shroud positioned adjacent the heatsink casing, opposite the mounting bracket, where the shroud defines a second compartment. The motor assembly also includes a shaft coupled to the motor and is configured to rotate about an axis. The shaft extends axially through the heatsink casing and the second compartment defined by the shroud. Furthermore, the motor assembly also includes a fan coupled to the shaft and is positioned within the second compartment, between the shroud and the plurality of heatsink protrusions disposed within the heatsink casing. The fan is configured to draw airflow from the plurality of heatsink protrusions. In another aspect, a motor assembly is provided that includes a housing defining a first compartment, a mounting bracket coupled to an end of the housing, and a motor positioned within the first compartment. The motor assembly also includes a heatsink casing coupled to the housing, opposite the mounting bracket. The heatsink casing includes a plurality of heatsink protrusions disposed within the heatsink casing that are configured to receive airflow surrounding the housing. The motor assembly further includes a shroud positioned adjacent the heatsink casing, opposite the mounting bracket, where the shroud defines a second compartment. Furthermore, the motor assembly includes a fan positioned within the second compartment, between the shroud and the plurality of heatsink protrusions disposed within the heatsink casing. The fan is configured to draw airflow from the plurality of heatsink protrusions. In yet another aspect, a method of operating a motor assembly is provided, where the motor assembly includes a housing defining a first compartment, a mounting bracket coupled to an end of the housing, a motor positioned within the first compartment, and a heatsink casing coupled to the housing, opposite the mounting bracket. The heatsink casing includes a plurality of heatsink protrusions disposed within the heatsink casing. The motor assembly also includes a shroud positioned adjacent the heatsink casing, opposite the mounting bracket, where the shroud defines a second compartment. The motor assembly also includes a shaft coupled to the motor and extends axially through the heatsink casing and the second compartment defined by the shroud, and a fan coupled to the shaft and positioned within the second compartment, between the shroud and the plurality of heatsink protrusions disposed within the heatsink casing. The method of operating includes drawing airflow from outside the motor assembly through the plurality of heatsink protrusions included within the heatsink casing, and flowing the airflow from the plurality of heatsink protrusions to the fan positioned within the second compartment defined by the shroud. The method also includes circulating the airflow within the second compartment of the shroud based on a rotation of the fan, and directing the airflow from the second compartment of the shroud to an exterior of the housing. As used herein, “a”, “an”, and “the” refer to both singular and plural referents unless the context clearly dictates otherwise. As used herein, the term