Kinetically Decoupled Fan for Motor Coil Cooling
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Solution Overview
Problem
High-end video game steering wheel motors used for force feedback experience significant thermal latency issues due to inadequate cooling, especially when the motor is blocked, leading to reduced power output and shortened lifecycle, as existing solutions like multiple motors or external fans are costly, complex, and inefficient in cooling the internal coils uniformly.
Innovation Solution
A kinetically decoupled fan system is integrated within the motor casing, allowing forced air ventilation independent of the rotor's rotation speed, with the fan speed controlled by temperature and current sensors to ensure homogeneous heat extraction from the coils, even when the motor is immobile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an external fan is used to cool the motor, then cooling capability is improved, but device complexity and size increase
Solution Approach 1:
The cooling fan is integrated within the motor housing and shares the same structural space as the motor components. The fan is positioned between the stator and rotor, utilizing the existing motor assembly space rather than adding external cooling components, thereby reducing overall device complexity while maintaining effective cooling capability.
Solution Approach 2:
The cooling fan is nested within the motor structure, specifically positioned in the space between the stator and rotor. This nested arrangement allows the cooling system to be contained within the motor's existing footprint, avoiding additional external components and reducing overall device size and complexity.
2Temperature
If cooling fins are added to the motor casing, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling function is extracted from the external motor casing and relocated to the internal space between the stator and rotor. By positioning the cooling fan internally, the external casing can remain smooth and simple without requiring complex cooling fin structures, thereby easing manufacturing while maintaining effective heat dissipation.
3Device complexity
If the fan is fixed to the rotor shaft, then structure is simplified, but cooling effectiveness decreases when motor is blocked
Solution Approach 1:
The cooling fan is segmented from the rotor shaft, with each component having independent rotational capability. The fan is mounted on its own bearing system rather than being fixed to the rotor shaft, allowing the fan to rotate independently even when the motor is blocked, ensuring continuous cooling effectiveness while maintaining reasonable structural complexity.
4Duration of action of stationary object
If motor power is reduced to prevent overheating, then motor lifecycle is extended, but force feedback performance degrades
Solution Approach 1:
The cooling fan operates continuously or in advance to prevent heat accumulation before it reaches critical levels. By maintaining proactive cooling, the motor can sustain full power output for force feedback without risking overheating, thus preserving both performance and lifecycle through preventive thermal management rather than power reduction.
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 provides effective and uniform cooling of the motor coils, maintaining performance and extending the motor's lifecycle while being simple, reliable, and cost-effective, without interfering with the motor's rotation or increasing size.
Implementation Method 1
a forced air ventilation from the outside of the casing to the inside said casing by a fan arranged on the rotor and kinetically decoupled from the rotor
Data Source
AI summary
A method and system for cooling an electric motor of a simulation or video game controller that comprises a rotor arranged in a casing, wherein the method comprises a forced air ventilation from the outside of the casing to the inside of the casing by a fan arranged on the rotor and kinetically decoupled from the rotor. As such, cold outside air is recovered and circulates through the coils which constitute the heat source and expulsed to the other end of the motor. There is therefore a homogeneous extraction of the heat from the coils. As the fan is kinetically decoupled from the rotor, the cooling system therefore operates independently of the speed of rotation of the main shaft of the motor.