Modular EC Motor Assembly With Thermal Plate and Static Sealing
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Solution Overview
Problem
Existing electronically commutated motors with integrated control electronics suffer from poor heat dissipation via the motor housing to ambient air, leading to additional components and increased costs, and require dynamic seals for media separation in fluid pumps.
Innovation Solution
An electronically commutated motor design featuring a non-magnetic overmolding that surrounds the stator, grooves for heat dissipation, and a thermal plate for electronics, combined with a modular assembly that allows for efficient heat dissipation and media separation without dynamic seals, using insulation-displacement contacts and a compact, scalable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is dissipated from the stator and electronic components via the motor housing to ambient air, then the motor structure is simple, but heat dissipation efficiency is poor
Solution Approach 1:
A thermal plate is introduced as an intermediary component between the electronic components and the motor housing. The thermal plate has high thermal conductivity and serves as a heat transfer mediator, conducting heat away from the electronic components and stator more efficiently than the housing alone could achieve.
Solution Approach 2:
The housing is segmented to include integrated cooling fins on its outer surface. This segmentation increases the effective heat dissipation surface area, allowing more efficient heat transfer from the thermal plate through the housing to the ambient air.
2Temperature
If a containment shell is arranged between the rotor and stator for heat dissipation in fluid pumps, then heat dissipation improves, but the number of components and material costs increase
Solution Approach 1:
The functions of the containment shell and the cooling structure are merged into a single integrated housing design. The housing simultaneously provides mechanical containment for the motor components and serves as a heat dissipation structure through integrated cooling fins, eliminating the need for a separate containment shell.
Solution Approach 2:
The housing is designed to perform multiple functions: it provides structural support, contains the motor components, and serves as a heat dissipation device through integrated cooling fins. This multi-functionality reduces the total number of components needed in the motor system.
3Reliability
If dynamic seals are used for media separation in fluid pumps, then media separation is achieved, but reliability decreases during long operating times
Solution Approach 1:
Dynamic seals are completely removed from the system. Instead, a static sealing arrangement is used where the housing and end plates form fixed sealing surfaces that separate the media chamber from the external environment, eliminating the wear and failure issues associated with dynamic seals.
Solution Approach 2:
The mechanical dynamic seal system is replaced with a static sealing structure. The sealing function is achieved through precisely machined mating surfaces between stationary components (housing and end plates) rather than through moving seal elements, dramatically improving reliability for long-duration operation.
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
Ensures efficient heat dissipation, reduces component count, and enables flexible, cost-effective scaling of fluid pumps and electric drives with different power ratings while maintaining reliable media separation and lubrication.
Implementation Method 1
heat is dissipated from the stator and electronic components on the printed circuit board (PCB) via the motor housing to the ambient air
Implementation Method 2
a thermal plate are accommodated
Data Source
AI summary
The invention relates to an electronically commutated motor, comprising a permanent magnet rotor supported on a motor shaft, a stator lamination stack, at least one insulating cap arranged on an axial end face of the stator lamination stack, a winding that runs across all coils of the stator lamination stack and is contacted by means of insulation-displacement contacts.