Controller Heat Dissipation via Segmented Resistor Extraction
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Solution Overview
Problem
Converting an open-type controller to a sealed-type controller while minimizing size increase and preventing excessive temperature rise due to heat generation from a regenerative resistor.
Innovation Solution
Exposing the regenerative resistor through a heat transfer wall opening, allowing it to be externally attached, thus avoiding excessive temperature increase by relocating the heat source outside the sealed casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the controller is converted to a sealed-type by accommodating it in a sealed container, then dustproof protection is improved, but the controller size increases and heat dissipation deteriorates
Solution Approach 1:
The controller is divided into two separate spaces: a sealed dustproof section containing electronic parts, and an unsealed heat dissipation section containing the regenerative resistor. This segmentation allows the dustproof section to be sealed without increasing overall size, while the heat dissipation section provides thermal management for high-temperature components.
Solution Approach 2:
The regenerative resistor, which generates excessive heat, is extracted from the sealed dustproof section and placed in a separate unsealed heat dissipation section. This extraction removes the heat source from the sealed environment, preventing temperature rise in electronic parts while maintaining compact size.
2Device complexity
If the regenerative resistor is provided inside the sealed casing, then device integration is improved, but excessive temperature increase occurs
Solution Approach 1:
The controller interior is segmented into a sealed dustproof section and an unsealed heat dissipation section. The regenerative resistor is placed in the heat dissipation section, allowing it to be integrated into the controller while maintaining separate thermal zones to prevent overheating of electronic parts.
Solution Approach 2:
Different regions of the controller are assigned different thermal characteristics: the dustproof section maintains a controlled temperature environment for electronic parts, while the heat dissipation section allows high temperature for the regenerative resistor. This local differentiation enables both integration and thermal management.
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
Enables the conversion of an open-type controller to a sealed-type without size increase and effectively manages heat generation, preventing excessive temperature rise in electronic components.
Implementation Method 1
a heat transfer wall arranged so as to extend in a left-right direction; the regenerative resistor being provided inside the casing so as to be located at a position where the regenerative resistor is exposed to the outside through an opening portion of the bottom wall
Data Source
Figure 1
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AI summary
A controller includes: a casing having a rectangular solid shape and including a front panel including an intake port, a rear panel including a discharge port and arranged so as to be opposed to the front panel, and a heat transfer wall including an opening portion and arranged so as to be perpendicular to the front panel and the rear panel; a fan arranged inside the casing and configured to suck outside air into the casing through the intake port and supply the air to the inside of the casing; a regenerative resistor provided inside the casing so as to be located at a position where the regenerative resistor is exposed to the outside through the opening portion of the heat transfer wall, the regenerative resistor being insertable and detachable through the opening portion; electronic parts provided inside the casing and including a servo amplifier which makes the regenerative resistor consume electric power; and a lid body detachably attached to the heat transfer wall and configured to seal the opening portion.