Electrical Machine Control Unit Cooling via Fluid-Filled Actuator Chamber
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Solution Overview
Problem
Conventional electrical machines require dedicated cooling apparatuses, which occupy valuable installation space and increase component mass, while also being vulnerable to environmental influences.
Innovation Solution
An electrical machine with a carrier plate cast in a heat-conductive casting compound that contacts a fluid-filled chamber, allowing direct heat transfer and eliminating the need for separate cooling apparatuses, using polyurethane with a Shore A hardness between 48 and 53 for effective cooling and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If dedicated cooling apparatuses are arranged on the carrier plate, then electronic components are effectively cooled, but installation space is occupied and component mass increases
Solution Approach 1:
The patent merges the cooling function with the carrier plate itself by integrating a cooling chamber directly into the carrier plate structure. The mounting elements are arranged on a cooling chamber formed within the carrier plate, eliminating the need for separate cooling apparatuses. This integration allows heat to be conducted directly from the mounting elements through the carrier plate material to the cooling fluid in the chamber, achieving effective cooling while saving installation space.
Solution Approach 2:
The carrier plate is designed to serve multiple functions simultaneously: it provides mechanical support for the electronic components, acts as a heat conduction path, and contains the cooling chamber. This multi-functionality eliminates the need for dedicated cooling apparatuses, as the carrier plate itself performs both structural and thermal management roles.
2Temperature
If dedicated cooling apparatuses are arranged on the carrier plate, then electronic components are effectively cooled, but component mass increases
Solution Approach 1:
The cooling function is merged into the carrier plate structure, eliminating separate cooling apparatuses. The carrier plate material itself serves as the heat conduction path, and the cooling chamber is formed within the carrier plate volume. This integration removes the mass of additional cooling components while maintaining effective heat dissipation from the mounting elements.
3Temperature
If the carrier plate is surrounded by casting compound, then heat is transferred directly into the casting compound and cooling effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The casting compound is applied to the carrier plate before final assembly, creating a pre-formed heat conduction path. The mounting elements are then arranged on the cooling chamber within the carrier plate, and the casting compound encapsulates the entire assembly. This preliminary application of the casting compound simplifies the overall manufacturing process by establishing the thermal management structure in advance.
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 solution enables compact, efficient cooling of electronic components, reduces installation space, and shields components from environmental factors, while minimizing mass and eliminating the need for cables between the control unit and actuator.
Implementation Method 1
heat is transferred from mounting elements of the carrier plate, which produce power loss, directly into the casting compound. The open-loop or closed-loop control unit makes contact with the fluid-filled chamber of the actuator in the region of the casting compound. As a result, heat transmitted to the casting compound is output to the fluid.
Data Source
AI summary
An electrical machine includes an open-loop or closed-loop control unit and a fluidic actuator, wherein the open-loop or closed-loop control unit is established for open-loop or closed-loop control of the actuator, where the open-loop or closed-loop control unit has a carrier plate cast in a thermally conductive casting compound, and where the open-loop or closed-loop control unit makes contact with a fluid-filled chamber of the actuator in the region of the casting compound such that it becomes possible to dispense with separate cooling devices in the open-loop or closed-loop control unit.