Dual-Fan Battery Motor Cooling for Electronics Heat Control
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Solution Overview
Problem
Electric motors and their control electronics generate significant heat during operation, necessitating effective cooling solutions to maintain performance and efficiency.
Innovation Solution
The motor unit incorporates an auxiliary cooling system with a heat sink and a separate fan to direct airflow across the heat sink, as well as a duct to channel airflow for cooling the heat sink before passing through the electric motor, along with various cooling circuits and systems to manage heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling system is used for both the electric motor and control electronics, then the device complexity is reduced, but the cooling effectiveness for each component deteriorates due to shared airflow
Solution Approach 1:
The cooling system is segmented into two independent subsystems: a primary cooling system with a first fan for the electric motor, and a secondary cooling system with a second fan for the control electronics. This segmentation allows each component to receive dedicated cooling airflow, resolving the contradiction between system simplicity and cooling effectiveness.
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, contains both cooling systems, and facilitates airflow management. The housing integrates mounting surfaces for the electric motor, control electronics, and both fans, creating a multi-functional platform that achieves effective cooling without proportionally increasing overall system complexity.
2Ease of operation
If the motor fan outlet is positioned adjacent to the gear case, then the airflow can cool the control electronics, but the airflow may not be sufficient for dedicated electronics cooling
Solution Approach 1:
A duct is introduced as an intermediary component to channel and direct the airflow from the motor fan outlet to the control electronics. This intermediary structure ensures that the airflow is properly directed and concentrated on the heat-generating components, improving cooling effectiveness without requiring a separate fan for the electronics.
Solution Approach 2:
The cooling approach transitions from relying solely on proximity (spatial arrangement) to utilizing structured airflow paths (dimensional control). By positioning the motor fan outlet adjacent to the gear case and using ducts to channel airflow, the system adds a dimensional element of controlled flow direction, ensuring adequate cooling reach and intensity.
3Use of energy by moving object
If the motor is not running, then power consumption is reduced, but the control electronics still generate heat requiring cooling
Solution Approach 1:
The secondary cooling fan for the control electronics is configured to operate independently of the motor fan, allowing it to run when the motor is not running. This self-service capability enables the control electronics to self-cool during idle periods, maintaining operational temperature without requiring the motor to be running, thus resolving the contradiction between power consumption and cooling effectiveness.
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
The cooling systems effectively manage heat generated by the motor and control electronics, ensuring efficient operation and reducing energy consumption by allowing independent control of cooling mechanisms, even when the motor is not running.
Implementation Method 1
a first fan driven by the electric motor and configured to induce an airflow through the electric motor
Implementation Method 2
a second fan configured to direct an airflow across the heat sink separate from the airflow induced through the electric motor by the first fan
Implementation Method 3
a heat sink coupled to the control electronics
Implementation Method 4
direct an airflow across the heat sink
Implementation Method 5
a duct extending between the electric motor and the heat sink. The duct is configured to draw the airflow induced by the fan around the heat sink prior to the airflow passing through the electric motor
Implementation Method 6
The motor fan outlet is positioned adjacent the gear case such that the airflow discharged from the motor fan passes over the control electronics and the gear case to cool the control electronics
Implementation Method 7
The pump is configured to circulate a working fluid through the heat exchanger to absorb heat therefrom
Implementation Method 8
a cooling circuit including a heat exchanger and a pump. The heat exchanger is coupled to at least one of the electric motor or the control electronics
Data Source
AI summary
A stand-alone motor unit for use with a piece of power equipment includes a housing, an electric motor, a first fan driven by the electric motor and configured to induce an airflow through the electric motor, a power take-off shaft receiving torque from the motor, and control electronics positioned within the housing and electrically connected to the electric motor. The motor unit also includes a battery pack, and a battery receptacle coupled to the housing and engageable with the battery pack to transfer current between the battery pack and the electric motor. The motor unit further includes an auxiliary cooling system located within the housing. The auxiliary cooling system includes a heat sink coupled to the control electronics, and a second fan configured to direct an airflow across the heat sink separate from the airflow induced through the electric motor by the first fan.