Brushless Power Tool Circuit Board Heat Dissipation
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Solution Overview
Problem
The continuous use of conventional bolt tightening tools, such as shear wrenches, leads to overheating of commutator motors and circuit components, potentially causing them to fail due to inadequate cooling efficiency.
Innovation Solution
A power tool design incorporating a brushless motor, a switching element, a rectifying device, and a heat releasing member, where the heat releasing member is connected to the switching element and rectifying device to enhance cooling efficiency, and the tool includes a housing with an intake port for air flow to facilitate heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a commutator motor is used in a bolt tightening tool, then the tool can achieve the required driving force, but the motor and circuit components overheat during continuous use
Solution Approach 1:
The patent extracts the harmful heating element (commutator) from the motor system and replaces it with a brushless motor design. This removes the source of excessive heat generation while maintaining the required driving force, directly resolving the contradiction between power output and temperature control.
Solution Approach 2:
The patent introduces a heat releasing member as an intermediary component between the circuit board and the housing. This mediator transfers heat away from critical components, enabling the system to maintain high power output without excessive temperature rise.
2Productivity
If switching elements and rectifying devices are mounted on a circuit board, then the tool achieves efficient motor control, but the components generate excessive heat
Solution Approach 1:
The heat releasing member serves as a thermal intermediary, coupled to the switching elements and rectifying device on the circuit board. It provides a dedicated heat dissipation path that allows efficient motor control to continue without causing component overheating.
Solution Approach 2:
The patent segments the thermal management function from the electrical control function by introducing a separate heat releasing member. This allows the circuit board to maintain its efficient control functionality while the thermal management is handled by the dedicated heat dissipation structure.
3Reliability
If adequate cooling is provided to prevent overheating, then component lifespan is extended, but the device structure becomes more complex
Solution Approach 1:
The housing serves multiple functions: it provides structural support, electrical insulation, and acts as part of the heat dissipation system through the integrated heat releasing member. This multi-functionality extends component lifespan without adding separate cooling system complexity.
Solution Approach 2:
The patent merges the heat dissipation function with the existing housing structure through the heat releasing member. This combination approach provides adequate cooling to extend component lifespan while avoiding the complexity of a separate, dedicated cooling system.
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
The design effectively prevents overheating of the motor and circuit components, thereby extending their lifespan and ensuring reliable operation by improving cooling efficiency through the use of a brushless motor and strategic heat management.
Implementation Method 1
The heat releasing member is connected to the switching element and the rectifying device
Implementation Method 2
The brushless motor includes a stator having a coil, and a rotor rotatable relative to the stator
Data Source
AI summary
A power tool includes a brushless motor, a switching element, a power cable a rectifying device, a heat releasing member. The switching element controls a drive of the brushless motor. The power cable supplies an electric current to the brushless motor from power source. The rectifying device rectifies the electric current from the power cable. The heat releasing member is connected to the switching element and the rectifying device in order to enhance a cooling efficiency for the same.