Electronic Controller Fan Mounting via Air Duct
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Solution Overview
Problem
The existing electronic controllers with fans require complex assembly processes, including waterproofing and direct transmission of fan vibrations to solder connections, which can lead to contact failures due to fine sliding wear.
Innovation Solution
The electronic controller design includes a circuit board, a housing with radiation fins, an air duct, a fan, and connectors. The fan and fan connector are fixed to the air duct, and the feeder connector is attached to the circuit board, allowing for improved assembly efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fan is directly attached to the case wall using sealing material and soldered to the circuit board, then the assembly process becomes complicated and time-consuming, but the electrical connection reliability deteriorates due to vibration-induced fine sliding wear of the solder
Solution Approach 1:
The air duct serves as an intermediary structure between the fan and the circuit board. The fan is attached to the air duct, which in turn is attached to the housing, rather than directly soldering the fan terminal to the circuit board. This intermediary structure isolates the fan's vibration from the solder connection, preventing fine sliding wear while maintaining electrical connectivity through the air duct's mounting structure.
Solution Approach 2:
The mounting structure is segmented into distinct components: the fan, the air duct, and the housing. The fan is separately mounted on the air duct, which is then mounted on the housing, creating a modular assembly. This segmentation allows for easier assembly and disassembly while isolating vibration paths, improving both manufacturing efficiency and connection reliability.
2Reliability
If the fan is directly attached to the case wall with sealing material, then waterproofing is achieved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The air duct integrates multiple functions into a single component: it serves as the mounting structure for the fan, provides a pathway for air flow, and acts as a structural element of the housing assembly. By merging these functions, the number of separate parts and assembly steps is reduced, improving productivity while maintaining waterproofing through the integrated design.
Solution Approach 2:
The air duct is designed as a multi-functional component that performs structural support, fan mounting, and air flow guidance simultaneously. This universal design reduces the need for additional specialized components, simplifying the assembly process and improving manufacturing efficiency while preserving the waterproof performance of the overall structure.
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 simplifies the assembly process, reduces the risk of contact failures due to vibration, and enhances the reliability of electrical connections, while also allowing for cost reduction through the use of general-purpose fan and connector products.
Implementation Method 1
a fan that causes cooling air to flow through the channel
Implementation Method 2
a plurality of radiation fins formed on the housing
Data Source
AI summary
An electric controller includes: a circuit board (7); a housing (2) that houses the circuit board (7); a plurality of radiation fins (21a) formed on the housing (2); an air duct (4) attached to the housing (2) in such a way as to cover the plurality of radiation fins (21a); a fan (8) that is held between the housing (2) and the air duct (4) and that sends cooling air to a channel formed by the plurality of radiation fins (21a); a fan connector (8a) electrically connected to the fan (8) via cables (8c); and a feeder connector (7b) electrically connected to the circuit board (7) and fixed to the housing. The fan connector (8a) is detachably connected to the feeder connector (7b), and the fan (8) and the fan connector (8a) are fixed to the air duct (4).