Actively Cooled Feeder Cables for Motor Controller Heat Isolation
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Solution Overview
Problem
High power electrical systems, particularly in aircraft, face challenges in effectively managing heat generated by feeder cables, which can exceed the temperature rating of auxiliary circuitries due to resistive heating, leading to inefficiencies and potential damage.
Innovation Solution
An electronics assembly with a coolant jacket surrounding the feeder cable, in liquid communication with a cold plate, actively circulates liquid coolant to absorb heat from the feeder cable, preventing it from entering the motor controller housing and maintaining the feeder cable at a lower temperature than the auxiliary circuitries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the feeder cable is sized to accommodate continuous and peak current, then the current carrying capacity is improved, but the heat generated by resistive heating increases temperature of the electrical conductor and insulation
Solution Approach 1:
The patent extracts the heat management function from the feeder cable by introducing a separate coolant jacket and coolant flow system. The coolant jacket is positioned around the feeder cable to actively remove heat, allowing the cable to be sized for current capacity without being constrained by thermal limits. This separation enables the electrical conductor to be optimized for electrical performance while the cooling system handles thermal management.
Solution Approach 2:
The coolant acts as an intermediary between the feeder cable and the ambient environment. Instead of relying on passive air cooling or direct thermal conduction to surrounding components, the coolant jacket provides an active thermal pathway that efficiently transfers heat from the feeder cable to the coolant flow, which then dissipates heat to the environment through the heat exchanger.
2Power
If the electrical conductor is sized to accommodate peak current, then the power transmission capability is improved, but the heat communicated to auxiliary circuitries increases
Solution Approach 1:
The patent extracts the heat from the feeder cable before it can be communicated to the motor controller. The coolant jacket is positioned to intercept heat along the cable length, and the heat exchanger removes this heat from the coolant flow. This active heat extraction prevents thermal conduction to the motor controller housing and internal circuitry, allowing higher power transmission without compromising auxiliary component thermal limits.
Solution Approach 2:
The coolant jacket serves as a thermal intermediary between the feeder cable and the motor controller housing. By providing an active cooling pathway, it interrupts the passive thermal conduction path that would otherwise transfer heat to temperature-sensitive auxiliary circuitries. The coolant absorbs heat from the cable and transports it away from the motor controller region.
3Device complexity
If passive cooling through ambient air is used, then the system complexity is reduced, but the temperature management effectiveness is insufficient for high power applications
Solution Approach 1:
The patent employs a liquid coolant-based cooling system instead of passive air cooling. The coolant circulates through the coolant jacket surrounding the feeder cable, providing efficient heat transfer through forced convection. The system includes a pump to drive coolant circulation and a heat exchanger to dissipate heat to the environment, creating an active thermal management system that can handle high power applications.
Solution Approach 2:
The system changes the cooling parameter from passive ambient air temperature to active controlled coolant temperature. By regulating the coolant flow rate and temperature through the coolant pump and heat exchanger, the system can dynamically adjust cooling capacity to match the thermal load of the feeder cable, providing superior temperature control compared to passive cooling methods.
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 effectively limits heat transfer from the feeder cable to the motor controller, allowing feeder cables to operate at higher temperatures than auxiliary circuitries, reducing the need for oversized cables and preventing overheating, thus enhancing the reliability and efficiency of high power electrical systems.
Implementation Method 1
the feeder cable is in liquid communication with the cold plate to limit communication of heat from the feeder cable to an interior of the housing
Implementation Method 2
a liquid coolant circulating between the coolant jacket and the cold plate
Implementation Method 3
a cold plate arranged within the housing and in thermal communication with the solid-state switch array
Data Source
AI summary
An electronics assembly including a motor controller electronics arrangement includes a housing enclosing a solid-state switch array, a cold plate arranged within the housing and in thermal communication with the solid-state switch array, and a feeder cable. The feeder cable is electrically connected to the solid-state switch array, has a coolant jacket extending thereabout, is separated from the switch arrangement by the housing, and is in liquid communication with the cold plate to limit heat communicated by the feeder cable into the housing. Electrical systems and methods of cooling feeder cables are also described.