Brushless DC Motor Connection Housing Heat Dissipation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

High-power motors with compact motor controllers face challenges in heat dissipation, leading to inefficient cooling, complex structures, high costs, and limited suitability for multiple motors due to large radiators and complex installation procedures.

Innovation Solution

The design incorporates a connection housing with heat dissipation holes, radially arranged heat dissipation panels on the control box, and centrifugal fan blades to enhance heat dissipation, along with a simplified locking device and convex columns to support components, creating a more efficient and cost-effective cooling system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If radiators are added to dissipate heat from power modules, then heat dissipation effect is improved, but device complexity increases and manufacturing cost increases

Engineering Contradiction:

Improveheat dissipation effectVSAvoidstructure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The connection housing integrates multiple functions: it connects the motor body to the control box, provides structural support, and incorporates heat dissipation holes for thermal management. This merging of connection and heat dissipation functions eliminates the need for separate radiators, reducing device complexity while maintaining effective heat dissipation.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If radiators are added to dissipate heat, then heat dissipation effect is improved, but manufacturing cost increases

Engineering Contradiction:

Improveheat dissipation effectVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat dissipation function is integrated into the connection housing, which is a necessary structural component anyway. This eliminates the need for additional radiator parts, reducing part count, simplifying assembly, and lowering manufacturing costs while achieving effective heat dissipation through the integrated heat dissipation holes.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If a compact motor controller structure is used, then device size is reduced, but heat dissipation effect deteriorates

Engineering Contradiction:

Improvecontroller sizeVSAvoidheat dissipation effect

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The connection housing features locally optimized heat dissipation holes positioned strategically on its surface. This local quality approach allows compact overall dimensions while providing sufficient heat dissipation capacity at the critical locations where power modules generate heat, resolving the contradiction between compact size and heat dissipation effectiveness.

Inventive Principle:

Principle #3Local quality

4Temperature

If volume of radiator is increased to improve heat dissipation, then heat dissipation effect is improved, but adaptability decreases

Engineering Contradiction:

Improveheat dissipation effectVSAvoidmotor compatibility

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The connection housing serves as a universal component that simultaneously provides mechanical connection between motor body and control box, structural support, and heat dissipation functionality. This multi-functional design makes the system adaptable to different motor configurations without requiring size-adjustable radiators, enhancing versatility while maintaining effective heat dissipation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration improves heat dissipation efficiency, reduces manufacturing complexity and costs, and allows for broader motor compatibility by expanding the heat dissipation area and utilizing centrifugal fan blades for effective cooling.

Implementation Method 1

A plurality of heat dissipation holes is arranged on the sidewall of the connection housing

Methodology Applied

Scientific EffectHeat dissipation: Thermal Radiation

Implementation Method 2

A centrifugal fan blade is positioned inside the connection housing on the rear part of the shaft

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS9160207B2High power brushless DC motor and control box structure with heat dissipation arrangement

Publication Date: 2015.10.13 ZHONGSHAN BROAD OCEAN

AI summary

A motor, including: a motor body, the motor body including two ends; a damping ring, the damping ring including a bottom; a mounting bracket; a locking device; a control box; and a connection housing, the connection housing including two ends, and a sidewall. The damping ring is disposed on each end of the motor body. The bottom of the damping ring is supported by the mounting bracket. The damping ring is fixed on the mounting bracket by the locking device. One end of the connection housing is connected to a bottom of the motor body; the other end of the connection housing is connected to a top of the control box. A plurality of heat dissipation holes is arranged on the sidewall of the connection housing.