Axial Flux Motor Controller Nesting for HVAC Airflow
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Solution Overview
Problem
Existing air propulsion units in HVAC systems face aerodynamic losses due to radial flux motors extending into fan cavities, increasing thickness, weight, and complexity, along with inadequate heat dissipation from integrated controllers.
Innovation Solution
An axial flux electrical machine with a controller assembly positioned radially outward from the stator assembly within housing extensions, eliminating the need for a shaft and coupling mechanisms, and using a modular controller layout for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a radial flux motor is used to drive the fan, then the motor can provide sufficient power, but the motor extends into the fan cavity causing aerodynamic losses and reduced airflow efficiency
Solution Approach 1:
The motor is extracted from the fan cavity and positioned externally, eliminating the interference with airflow paths. The motor housing is separated from the fan assembly, allowing the fan to operate independently within the cavity without motor components obstructing air flow, thus resolving the contradiction between maintaining motor power and improving airflow efficiency.
Solution Approach 2:
The motor is repositioned from a radial flux configuration (where the rotor extends axially into the fan cavity) to an axial flux configuration with external mounting. This dimensional repositioning moves the motor out of the critical airflow path while maintaining power transmission through a different spatial arrangement, resolving the conflict between motor power delivery and airflow efficiency.
2Productivity
If the motor is moved outside the fan cavity to improve airflow, then aerodynamic losses are reduced, but the overall assembly thickness increases significantly
Solution Approach 1:
The motor is nested within a dedicated motor housing that is integrated with the fan assembly structure. The motor housing contains the motor components in a compact arrangement that minimizes the axial thickness of the overall assembly, allowing the motor to be positioned outside the fan cavity while maintaining a compact overall profile.
3Reliability
If coupling mechanisms are used to attach the fan to the motor shaft, then the fan can be securely mounted, but the assembly thickness, weight, and complexity increase
Solution Approach 1:
The motor shaft is directly integrated with the fan hub, eliminating the need for separate coupling mechanisms. The fan hub is designed with a central bore that directly receives and mounts to the motor shaft, creating a unified assembly that reduces the number of parts, simplifies the structure, and decreases both thickness and weight while maintaining secure mounting.
4Extent of automation
If an integrated controller is attached to the end of the air propulsion unit, then control functions are provided, but the thickness of the fan assembly increases
Solution Approach 1:
The controller is nested within the motor housing, utilizing the existing space within the motor assembly. The controller is mounted on the motor housing interior surfaces or on dedicated mounting plates within the housing, allowing control functions to be integrated without increasing the external dimensions or thickness of the fan assembly.
5Length of stationary object
If complex controller board arrangements are used to reduce thickness, then the assembly thickness is reduced, but cost and complexity increase and heat dissipation becomes inadequate
Solution Approach 1:
The motor housing, which generates heat during operation, is utilized as a heat sink for the controller. The controller is positioned within the motor housing where it can thermally couple with the housing structure, converting the previously harmful heat generation into a beneficial cooling mechanism. This eliminates the need for complex thin controller board arrangements and provides adequate heat dissipation through the motor housing's thermal mass and surface area.
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
This design enhances airflow efficiency, reduces noise, and minimizes the overall thickness and weight of the fan assembly while lowering costs by eliminating unnecessary components and improving heat management.
Implementation Method 1
an axial flux electrical machine including a rotor assembly, a stator assembly
Implementation Method 2
improving heat management
Data Source
AI summary
A fluid circulating assembly includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The housing includes an annular center section and at least two extension portions extending radially outward from the annular center section of the housing. The fluid circulating assembly also includes a controller assembly coupled to the housing. The said controller assembly is positioned radially outward from the stator assembly and located in at least one of the at least two extension portions.