Controller Assembly Cooling via Ducted Airflow and Vertical Heat Sinks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Utility vehicle controller assemblies face challenges in heat dissipation as they handle increasing functionality, leading to overheating issues, and traditional solutions like increasing the size of the assembly are costly and consume more space.
Innovation Solution
The implementation of systems and methods that harness airflow from auxiliary devices and vehicle movement to improve heat dissipation, using structural heat sinks and ducts to direct air across heat generation points within the controller assembly, allowing for increased functionality without size increases or reducing assembly size while maintaining functionality and saving material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the size of the controller assembly is increased to provide more heat dissipation capacity, then heat dissipation is improved, but material costs increase and package space is consumed
Solution Approach 1:
The patent extends the heat sink base plate in the vertical dimension through the mowing deck, utilizing the third dimension for heat dissipation. This allows the heat sink to project downward through the deck, increasing heat dissipation surface area without expanding the horizontal footprint of the controller assembly, thereby resolving the contradiction between heat dissipation capacity and package space consumption.
Solution Approach 2:
The patent introduces a duct as an intermediary component that channels airflow generated by the rotating blades directly to the heat sink base plate. This duct mediates between the airflow source (blades) and the heat dissipation surface, ensuring efficient heat transfer without requiring the controller assembly itself to be larger, thus maintaining compact size while improving heat dissipation.
2Temperature
If the size of the controller assembly is increased to provide more heat dissipation capacity, then heat dissipation is improved, but material costs increase
Solution Approach 1:
The heat sink base plate serves multiple functions: it acts as a mounting surface for the controller assembly, provides structural support, and functions as a heat dissipation surface. By making the base plate extend through the mowing deck, it simultaneously serves as both a structural component and a thermal management component, eliminating the need for separate heat dissipation structures and reducing overall material costs.
Solution Approach 2:
The system utilizes the airflow already generated by the rotating blades to cool the heat sink, rather than requiring an additional fan or forced cooling system. The blades' rotation naturally creates airflow that is directed through the duct to the heat sink, allowing the system to self-cool using its own operational movements, thereby reducing material costs for additional cooling components.
3Adaptability or versatility
If functionality of the controller assembly is increased, then performance is improved, but heat generation increases leading to overheating
Solution Approach 1:
The patent implements a preliminary cooling action by extending the heat sink base plate through the mowing deck before the controller assembly operates at high functionality. This pre-positioned heat dissipation structure is ready to immediately handle the heat generated when the controller is subjected to high functional demands, preventing overheating before it occurs rather than reacting to it afterward.
Solution Approach 2:
The cooling system operates continuously whenever the vehicle is in motion and the blades are rotating, as the airflow is constantly generated by the blade rotation. This continuous cooling action matches the continuous operation of the controller assembly, ensuring that heat dissipation is maintained throughout the entire operational period, preventing overheating even during extended high-functionality use.
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
These cooling systems effectively manage heat dissipation, preventing overheating, reducing material costs, and conserving package space in utility vehicles, enabling existing assemblies to handle more functionality without size increases.
Implementation Method 1
harness airflow created through use of auxiliary devices and/or movement of the vehicle may be harnessed to improve dissipation of heat generated by a controller assembly
Implementation Method 2
efficiently place structural heat sinks designed to absorb and conduct heat away from concentrated heat generation points within the controller assembly
Implementation Method 3
structural heat sinks designed to absorb and conduct heat away from concentrated heat generation points
Data Source
AI summary
Apparatus and methods for cooling controller assemblies for electric utility vehicles are disclosed. Auxiliary implements powered by electric motors onboard a utility vehicle create airflow that is captured and directed to provide increased ambient airflow across heat sinks used to dissipate heat from heat generating components. Airflow across heated surfaces is further created by vehicle movement and vacuum pressure. Fins and other heat dissipating architecture are employed. Features of the cooling systems enable increased controller assembly functionality and/or decreased controller assembly package size.