Patent Description:
The present invention has been derived from research conducted as part of the Core Technology Development For Energy Demand Management project of the Ministry of Trade, Industry and Energy of Republic of Korea. [Project Identification Number: <NUM>, Research Title: Development and Demonstration of Robot-Based Rapid Automatic Charging System For Electric Automobile].

An actuator module may have a sealed structure formed by a housing. Components of the actuator module may be located in the sealed structure formed by the housing. The actuator module can protect the components of the actuator module from external impact through the sealed structure of the housing and can prevent foreign substances from entering the components.

When the actuator module is driven, heat may be generated from some components of the actuator module. For example, heat may be generated from a motor and a controller among the components of the actuator module. The heat generated from the components of the actuator module located inside the housing needs to be dissipated out of the housing.

The actuator module may be mounted to a predetermined device to provide a driving force for driving the device. The actuator module may have a sealed structure that protects its components from external impact and prevents the inflow of foreign substances. When the actuator module is driven, heat may be generated from the components of the actuator module. Due to the sealed structure, the heat generated from the components of the actuator module is not dissipated to the outside and remains inside the housing. This may reduce the efficiency of dissipating the heat out of the housing.

If the heat generated from the components of the actuator module is not smoothly dissipated to the outside of the housing, some of the components of the actuator module may be damaged or malfunction due to high temperature, thereby causing problems in the operations of the components. For example, if an electronic circuit board or the like is damaged due to the heat, it may be difficult to operate the actuator module normally. A separate cooling line may be proposed in order to dissipate the heat generated from the components of the actuator module to the outside of the housing. However, such a cooling line increases the size of the actuator module, which may cause difficulties in miniaturization of the actuator module. In addition, such a cooling line is required to separately manage a refrigerant, which may cause difficulties in managing the actuator module by a user.

<CIT> discloses a mechanical joint configured for providing dissipation of heat generated therein, the mechanical joint comprisinga housing containing a motor assembly configured to drive a gear assembly for driving the mechanical joint. The motor assembly is configured to be controlled by a control assembly for controlling rotation of a rotor of the motor assembly. A brake disk of the control assembly is configured to increase air flow within the housing.

The present invention provides an actuator module including a heat dissipation structure.

Embodiments of the present disclosure solve the aforementioned problems and provide an actuator module that not only can have a sealed structure for protecting the components inside the actuator module but also can effectively dissipate heat generated inside the actuator module to the outside.

An actuator module according to the present invention is defined in claim <NUM> and includes a motor part including a drive shaft and a drive part which includes the stator of an electric motor and is configured to rotate the drive shaft, a reducer installed on one axial side of the drive part and configured to increase an output torque according to driving of the motor part, a brake installed on the opposite axial side of the drive part and configured to suppress rotation of the motor part, an encoder installed on the axial side of the brake opposite to the drive part and configured to sense an operation of the drive shaft, a controller installed on the axial side of the encoder opposite to the brake and electrically connected to the motor part to control the motor part, and a first housing configured to surround the motor part, the reducer, the brake, the encoder and the controller. An airflow path through which an airflow can flow in order to dissipate the heat generated inside the actuator module to the outside is formed to extend from the motor part. An airflow circulation member configured to circulate an airflow located around the motor part is formed in the drive shaft at an axial position between the motor part and the brake. The airflow circulation member extends such that at least a portion of the airflow circulation member is located within the airflow path.

In one embodiment, the actuator module may further include a heat dissipation structure installed on one side of the controller and configured to dissipate heat generated from the motor part. The airflow path may be formed to extend up to the heat dissipation structure.

In one embodiment, the actuator module may further include a second housing coupled to one side of the first housing. The second housing may form a sealed structure together with the first housing.

In one embodiment, a flexible sealing member may be disposed between the first housing and the second housing.

In one embodiment, the heat dissipation structure includes a heat dissipation plate made of a metal material.

In one embodiment, a gap may be formed between the controller and the heat dissipation structure, and the heat dissipation structure may be attached to an inner surface of the first housing.

In one embodiment, one end of the airflow path may be opened toward the motor part, and an opposite end of the airflow path may be opened toward the heat dissipation structure.

In one embodiment, the actuator module may further include a partition wall configured to hold the encoder and disposed between the brake and the encoder. The opposite end of the airflow path may penetrate through the partition wall and may be opened toward the heat dissipation structure.

In one embodiment, the airflow path may include, as a boundary surface thereof, an inner surface of the first housing and at least a portion of outer surfaces of the motor part, the brake and the partition wall.

In one embodiment, the airflow heated by the motor part may flow into the airflow path through the one end of the airflow path and may flow out from the airflow path through the opposite end of the airflow path.

In one embodiment, the airflow circulation member may be formed to protrude from the drive shaft in a radially outward direction when the drive shaft is rotated.

In one embodiment, the airflow circulation member may be rotated together with the drive shaft.

In one embodiment, the airflow circulation member may be a plurality of fans, and the plurality of fans may be disposed at an equal interval along a circumference of the drive shaft.

According to the embodiments of the present invention, the actuator module can have the sealed structure formed by the housing, thereby protecting the components inside the actuator module from external impact and preventing inflow of foreign substances.

According to the embodiments of the present invention, the actuator module not only can have the sealed structure, but also can effectively dissipate the heat generated inside the actuator module to the outside.

Further, according to the embodiments of the present invention, the heated airflow can be smoothly circulated in the actuator module, thereby dispersing the heat inside the housing of the actuator module. Therefore, it is possible to prevent the components of the actuator module from being damaged or from malfunctioning.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present invention.

Embodiments of the present invention are illustrated for the purpose of explaining the technical idea of the present invention. The scope of rights according to the present invention is not limited to the embodiments presented below or the detailed descriptions of such embodiments.

An "embodiment" in the present invention is any classification for easily explaining the technical idea of the present invention, and individual embodiments do not need to be mutually exclusive to one another. For example, components disclosed in one embodiment may be applied to and embodied in another embodiment. The components disclosed in one embodiment may be applied and embodied by being modified as far as they do not depart from the scope of the invention, which is defined by the appended claims.

All technical terms and scientific terms used in the present disclosure include meanings that are commonly understood by those of ordinary skill in the technical field to which the present disclosure pertains unless otherwise defined. All terms used in the present disclosure are selected for the purpose of describing the present invention more clearly, and are not selected to limit the scope of the rights according to the present invention.

Expressions such as "comprising," "including," "having," and the like used in the present disclosure are to be understood as open-ended terms having the possibility of encompassing other embodiments, unless otherwise mentioned in the phrase or sentence containing such expressions. Further, the terms such as "part," "module," and the like used in the present disclosure mean a unit performing at least one function or operation.

A "longitudinal direction" of an element throughout the specification may be a direction in which the element extends along one directional axis of the element. In this regard, the one directional axis of the element may mean a direction in which the element extends longer than the other directional axis transverse to the one directional axis.

Expressions such as "consisting of only an element" and the like used in the present disclosure are to be understood as closed-ended terms excluding the possibility of encompassing another element other than said element.

Singular expressions described in the present disclosure may encompass plural expressions unless otherwise mentioned, which will also be applied to singular expressions recited in the claims.

Expressions such as "first," "second," etc. used in the present disclosure are used to separate a plurality of elements from each other, and are not intended to limit an order or importance of the elements.

The directional terms "one side" used in the present disclosure means any one direction with reference to a center of one element, while the directional terms "opposite side" means a direction opposite to the one side direction. However, this is merely a reference for purposes of explanation for clear understanding of the present invention. The one side and the opposite side may be defined differently depending on where the reference is set.

Like reference numerals in the drawings denote like or corresponding elements. Further, in the following descriptions of the embodiments, redundant descriptions for the same or corresponding elements may be omitted. However, even if the descriptions of the elements are omitted, such elements are not intended to be excluded in any embodiment.

<FIG> is a perspective view of an actuator module according to one embodiment.

The actuator module <NUM> includes a first housing <NUM> and may include a second housing <NUM> which form the exterior of the actuator module <NUM>. The first housing <NUM> and the second housing <NUM> may be separated from each other. The second housing <NUM> may be coupled to one side of the first housing. The first housing <NUM> and the second housing <NUM> may be coupled to each other to form a sealed structure therein.

The first housing <NUM> may be divided into one end portion 110a and an opposite end portion 110b. The one end portion 110a and the opposite end portion 110b of the first housing <NUM> may be coupled to each other to form an internal space. Components of the actuator module <NUM> may be disposed in the internal space.

A connection member <NUM> may protrude toward one side of the second housing <NUM>. The connection member <NUM> may be connected to a predetermined device. The connection member <NUM> connected to the predetermined device may provide the predetermined device with a driving force for driving the device.

<FIG> is an exploded cross-sectional perspective view of the actuator module shown in <FIG>, which is taken along line <NUM>-<NUM> in <FIG>.

The internal components of the actuator module <NUM> will be described with reference to <FIG>. The actuator module <NUM> includes a motor part <NUM> installed in the first housing <NUM>. The motor part <NUM> includes a drive shaft <NUM> and a drive part <NUM> configured to rotate the drive shaft <NUM>.

The drive part <NUM> may convert electrical energy into rotational energy by using a force applied to a conductor in a magnetic field. The drive part <NUM> includes a stator. The stator may include a plurality of stator cores. The drive part <NUM> may include coils that are wound around the stator cores so as to form a rotating magnetic field. When an electric current flows through the coils, the drive part <NUM> may rotate the drive shaft <NUM> through electrical interaction.

The drive shaft <NUM> may be held in the drive part <NUM>. The drive shaft <NUM> may be held in the drive part <NUM> through a bearing. When an electrical current flows through the drive part <NUM>, the drive part <NUM> may generate an electromagnetic field that gives an electromagnetic influence to the drive shaft <NUM>. The drive shaft <NUM> held in the drive part <NUM> may be rotated through electrical interaction with the drive part <NUM>. The drive shaft <NUM> may rotate the connection member <NUM> protruding toward one side of the second housing <NUM>. The drive shaft <NUM> may extend from one side to the opposite side in an elongated shape. The drive shaft <NUM> may be a member that transmits the rotational energy of the motor part <NUM>. The drive shaft <NUM> may transmit the output of the motor part <NUM>.

The actuator module <NUM> includes a reducer <NUM> installed on one side of the drive part <NUM>. The reducer <NUM> increases the output of the motor part <NUM>. The reducer <NUM> increases torque according to the output of the motor part <NUM>. The reducer <NUM> may be, for example, at least one of a gear-type reducer, a rolling ball-type reducer, a harmonic drive reducer and a cycloidal reducer.

The gear-type reducer is a widely used reducer, and may use an involute tooth form. The rolling ball-type reducer may be a reducer which performs speed reduction rotation by balls rolling along a guide groove having a shape in which an epicycloid curve and a hypocycloid curve face each other. The harmonic drive reducer may be a reducer which induces speed reduction by transmitting only an elliptical motion component to a flexspline due to an elliptically turning bearing when an elliptical wave generator assembly rotates, and slowly rotating the flexspline such that the flexspline skips an outermost ring gear by one tooth at a time. The cycloidal reducer may be a reducer which achieves speed reduction rotation by fixing pins, and eccentrically rotating a trochoid gear as a planetary gear, and then causing the trochoid gear to only rotate through the pins and the pin holes arranged in the trochoid gear at the same angle.

The actuator module <NUM> includes a brake <NUM> installed on the opposite side of the drive part <NUM>. The brake <NUM> may be connected to the drive shaft <NUM>. The brake <NUM> suppresses rotation of the motor part <NUM> when an electric power source is not connected to the motor part <NUM>. That is, when an electric power source is not connected to the motor part <NUM>, the brake <NUM> may prevent the rotation of the motor part <NUM> to hinder the motor part <NUM> from being driven.

The actuator module <NUM> includes an encoder <NUM> installed on one side of the brake <NUM>. The encoder <NUM> senses the operation of the motor part <NUM>. The encoder <NUM> may measure a rotation angle of the drive shaft <NUM> of the motor part <NUM>. The encoder <NUM> may detect the rotation of the drive shaft <NUM> by measuring the angle of the drive shaft <NUM>. The encoder <NUM> may output an electrical signal when the drive shaft <NUM> is rotated. The encoder <NUM> may be, for example, a potentiometer or an optical rotary encoder, but the type of the encoder <NUM> is not limited thereto.

The actuator module <NUM> includes a controller <NUM> installed on one side of the encoder <NUM>. The controller <NUM> may be electrically connected to the motor part <NUM> to control the motor part <NUM>. The controller <NUM> may include a motor driver. The controller <NUM> may receive a user's signal to control the output of the motor part <NUM>. For example, the controller <NUM> may increase the output of the motor part <NUM> or reduce the output of the motor part <NUM> according to the user's signal. As the output of the motor part <NUM> is increased or reduced according to the user's signal, the output of the actuator module <NUM>, i.e., the driving force of the actuator module <NUM>, may be controlled, and the movement of the predetermined device connected to the actuator module <NUM> may be controlled.

The actuator module <NUM> may include a partition wall <NUM> configured to hold the encoder <NUM>. The encoder <NUM> may be mounted on the partition wall <NUM>. The partition wall <NUM> may be located between the brake <NUM> and the encoder <NUM>. The partition wall <NUM> may be connected to the first housing <NUM>. The partition wall <NUM> may be connected to the first housing <NUM> to partition one side of the partition wall <NUM> and the opposite side of the partition wall <NUM>. For example, the motor part <NUM>, the reducer <NUM> and the brake <NUM> may be disposed on one side of the partition wall <NUM>, and the encoder <NUM>, the controller <NUM> and a heat dissipation structure <NUM> may be disposed on the opposite side of the partition wall <NUM>.

The actuator module <NUM> may include the heat dissipation structure <NUM> installed on one side of the controller <NUM>. The heat dissipation structure <NUM> may be installed on one side of the controller <NUM> so as to be spaced apart from the controller <NUM> by a predetermined distance. The heat dissipation structure <NUM> may be installed on the inner surface of the first housing <NUM> so as to be spaced apart from the controller <NUM> by a predetermined distance. The heat dissipation structure <NUM> may be fixed to the inner surface of the opposite end portion 110b of the first housing <NUM>.

The heat dissipation structure <NUM> may absorb heat of the inside of the first housing <NUM> and may transfer the heat to the outside of the first housing <NUM>. The heat dissipation structure <NUM> may be made of a metal material. The metal material may include, but is not limited to, copper (Cu), aluminum (Al) and the like having excellent thermal conductivity. The heat dissipation structure <NUM> may include a plurality of heat dissipation plates made of a metal material. The heat dissipation plates may protrude in a direction from the inner surface of the opposite end portion 110b of the first housing <NUM> toward the motor part <NUM>.

A sealing member <NUM> may be disposed between the one end portion 110a of the first housing <NUM> and the second housing <NUM>. The sealing member <NUM> may be flexible. The sealing member <NUM> may be, for example, rubber, but the material of the sealing member <NUM> is not limited thereto.

The sealing member <NUM> may extend along a contact portion between the one end portion 110a of the first housing <NUM> and the second housing <NUM>. For example, when the contact portion between the one end portion 110a of the first housing <NUM> and the second housing <NUM> has a circular shape, the sealing member <NUM> may also extend in a circular shape. The one end portion 110a of the first housing <NUM> and the second housing <NUM> may be airtightly coupled to each other through the sealing member <NUM>. A sealed structure may be formed by the first housing <NUM> and the second housing <NUM>.

<FIG> is a cross-sectional view of the actuator module shown in <FIG>, which is taken along the line <NUM>-<NUM> in <FIG>.

<FIG> shows the components of the actuator module <NUM> that are disposed in a direction transverse to the line <NUM>-<NUM> in the actuator module <NUM>.

The first housing <NUM> and the second housing <NUM> of the actuator module <NUM> may be coupled to each other to form the sealed structure therein. The first housing <NUM> may surround the motor part <NUM>, the reducer <NUM>, the brake <NUM>, the encoder <NUM>, the controller <NUM>, and the heat dissipation structure <NUM>. The components of the actuator module <NUM> may be disposed inside the sealed structure. The actuator module <NUM> may include the motor part <NUM> that includes the drive shaft <NUM> and the drive part <NUM> for rotating the drive shaft <NUM>. The reducer <NUM> for increasing the torque according to the output of the motor part <NUM> may be disposed on one side of the drive part <NUM>. The brake <NUM> for suppressing the rotation of the drive shaft <NUM> may be disposed on the opposite side of the drive part <NUM>. The encoder <NUM> for sensing the operation of the drive shaft <NUM> may be disposed on one side of the brake <NUM>. The partition wall <NUM> may be disposed between the brake <NUM> and the encoder <NUM>. The controller <NUM> electrically connected to the motor part <NUM> to control the motor part <NUM> may be disposed on one side of the encoder <NUM>. The heat dissipation structure <NUM> may be disposed on one side of the controller <NUM>. The heat dissipation structure <NUM> may be disposed so as to be spaced apart from the controller <NUM> by a predetermined distance.

In the actuator module <NUM> according to an embodiment, an airflow path <NUM> through which an airflow can flow may be formed to extend from the motor part <NUM> up to the heat dissipation structure <NUM>. The airflow path <NUM> may be a path through which the airflow heated in the motor part <NUM> flows to the heat dissipation structure <NUM>.

<FIG> is an enlarged partial cross-sectional view showing the airflow path shown in <FIG>.

The airflow path <NUM> may include one end <NUM> and the opposite end <NUM>. The one end <NUM> of the airflow path <NUM> may be opened toward the motor part <NUM>, and the opposite end <NUM> of the airflow path <NUM> may be opened toward the heat dissipation structure <NUM>.

The opposite end <NUM> of the airflow path <NUM> may penetrate through the partition wall <NUM> disposed between the brake <NUM> and the encoder <NUM>. That is, a through-hole may be formed in the partition wall <NUM>, and the opposite end <NUM> of the airflow path <NUM> may include the through-hole of the partition wall <NUM>. As the opposite end <NUM> of the airflow path <NUM> penetrates through the partition wall <NUM>, the airflow flowing along the airflow path <NUM> may flow from the motor part <NUM> toward the heat dissipation structure <NUM> without being blocked by the partition wall <NUM>.

The airflow path <NUM> may include, as a boundary surface, the inner surface of the first housing <NUM> and at least a portion of the outer surfaces of the motor part <NUM>, the brake <NUM>, and the partition wall <NUM>. That is, a predetermined boundary surface of the airflow path <NUM> may be the inner surface of the first housing <NUM> and at least a portion of the outer surfaces of the motor part <NUM>, the brake <NUM>, and the partition wall <NUM>. The airflow path <NUM> may be a portion surrounded by the inner surface of the first housing <NUM> and at least a portion of the outer surfaces of the motor part <NUM>, the brake <NUM> and the partition wall <NUM>.

The airflow heated by the heat generated in the motor part <NUM> may be circulated while passing through the airflow path <NUM>. The heated airflow may flow into the airflow path <NUM> through the one end <NUM> of the airflow path <NUM>. The airflow flowing into the airflow path <NUM> may pass through the airflow path <NUM> which includes, as the boundary surface, the inner surface of the first housing <NUM> and at least a portion of the outer surfaces of the motor part <NUM>, the brake <NUM> and the partition wall <NUM>. The airflow may flow out from the airflow path <NUM> through the opposite end <NUM> of the airflow path <NUM>. Here, the opposite end <NUM> may include the through-hole formed in the partition wall <NUM>. The airflow flowing out from the airflow path <NUM> may reach the heat dissipation structure <NUM> and thereafter may be rapidly cooled.

An airflow circulation member <NUM> configured to circulate the airflow located around the motor part <NUM> is formed in the drive shaft <NUM> of the actuator module <NUM>. The airflow circulation member <NUM> circulates the airflow located around the drive shaft <NUM>. The airflow circulation member <NUM> may circulate the heated airflow located around the drive shaft <NUM> to prevent the heated airflow from remaining around the drive shaft <NUM> for more than a certain period of time.

The airflow circulation member <NUM> may be formed to protrude from the drive shaft <NUM> in a radially outward direction. At least a portion of the airflow circulation member <NUM> extends so as to be located within the airflow path <NUM>. At least a portion of the airflow circulation member <NUM> may be located at the one end <NUM> of the airflow path <NUM>. The airflow circulation member <NUM> may be rotated together with the drive shaft <NUM> when the drive shaft <NUM> is rotated. The airflow circulation member <NUM> may circulate the airflow while being rotated together with the drive shaft <NUM> according to the rotation of the drive shaft <NUM>. At least a portion of the airflow circulation member <NUM> may allow the heated airflow to pass through the airflow path <NUM> while being rotated in the airflow path <NUM>.

<FIG> is an exemplary perspective view of the airflow circulation member shown in <FIG>.

Referring to <FIG>, the airflow circulation member <NUM> may be a plurality of fans. The plurality of fans may be disposed at an equal interval along the circumference of the drive shaft <NUM>. The plurality of fans may extend in a radially outward direction from a rotation axis about which the drive shaft <NUM> is rotated. The plurality of fans may have a width that gradually increases along the radially outward direction from the rotation axis of the drive shaft <NUM>.

The plurality of fans may cause the airflow to flow in a direction away from the drive shaft <NUM>. The plurality of fans may lower the ambient temperature by causing the ambient airflow to flow. The number and shape of the plurality of fans are not limited to those shown in <FIG>, and may be varied as necessary.

<FIG> is another exemplary perspective view of the airflow circulation member shown in <FIG>.

Referring to <FIG>, the airflow circulation member <NUM> may be a plurality of protrusions. The plurality of protrusions may have the same shape, and may be disposed at an equal interval along the circumference of the drive shaft <NUM>. The plurality of protrusions may generate wind in a direction away from the drive shaft <NUM> when the drive shaft <NUM> is rotated. Each of the protrusions may have a width that gradually decreases in a direction away from the drive shaft <NUM>. Each of the protrusions may be, for example, a prism including a cylinder, or a truncated pyramid including a truncated cone. For example, when each of the protrusions is a truncated quadrangular pyramid, the protrusion may have a quadrangular cross-section, and the area of the quadrangular cross-section may gradually decrease along a direction away from the drive shaft <NUM>.

The actuator module <NUM> according to one embodiment can have the sealed structure formed by the housing, thereby protecting the components inside the actuator module <NUM> from external impact and preventing the inflow of foreign substances. Further, the actuator module <NUM> according to one embodiment not only can have the sealed structure, but also can effectively dissipate the heat generated inside the actuator module <NUM> to the outside. The heated airflow can be smoothly circulated in the actuator module <NUM>, thereby dispersing the heat inside the housing of the actuator module <NUM>. Therefore, it is possible to prevent the components of the actuator module <NUM> from being damaged or from malfunctioning.

Claim 1:
An actuator module (<NUM>), comprising:
a motor part (<NUM>) including a drive shaft (<NUM>) and a drive part (<NUM>) which includes the stator of an electric motor and is configured to rotate the drive shaft (<NUM>) about an axis;
a reducer (<NUM>) installed on one axial side of the drive part (<NUM>) and configured to increase an output torque according to driving of the motor part (<NUM>);
a brake (<NUM>) installed on the opposite axial side of the drive part (<NUM>) and configured to suppress rotation of the motor part (<NUM>);
an encoder (<NUM>) installed on the axial side of the brake (<NUM>) opposite to the drive part (<NUM>) and configured to sense an operation of the drive shaft (<NUM>);
a controller (<NUM>) installed on the axial side of the encoder (<NUM>) opposite to the brake (<NUM>) and electrically connected to the motor part (<NUM>) to control the motor part;
a first housing (<NUM>) configured to surround the motor part (<NUM>), the reducer (<NUM>), the brake (<NUM>), the encoder (<NUM>), and the controller (<NUM>),
wherein an airflow path (<NUM>) through which an airflow can flow in order to dissipate the heat generated inside the actuator module (<NUM>) to the outside is formed to extend from the motor part (<NUM>); characterized in that
an airflow circulation member (<NUM>) configured to circulate an airflow located around the motor part (<NUM>) is formed in the drive shaft (<NUM>) at an axial position between the motor part (<NUM>) and the brake (<NUM>),
wherein the airflow circulation member (<NUM>) extends such that at least a portion of the airflow circulation member (<NUM>) is located within the airflow path (<NUM>).