Fan Housing with Integrated Motor Electronics
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Solution Overview
Problem
Existing fan designs with integrated motor electronics face challenges such as high axial space requirements, complex assembly, limited cooling options, and suboptimal EMC design due to the integration of motor control electronics within the fan housing, which restricts the size and efficiency of the electronics and increases production costs.
Innovation Solution
A one-piece fan housing with an integrated receiving space for motor electronics, featuring a cylindrical housing wall with a motor flange and radial connecting ribs, allowing for a compact design with improved cooling and assembly, and the integration of a circuit board within a sealed compartment filled with a casting compound for enhanced protection and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor control electronics are integrated in a sealed electronics housing directly connected to the motor, then the electronics are protected from environmental influences, but the cooling ability is severely limited and axial space requirement increases
Solution Approach 1:
The patent divides the housing into separate functional parts: a motor housing for the motor and a fan housing for the electronics. This segmentation allows the electronics to be positioned in the fan housing where cooling is more effective, while the motor remains in its own housing, thus reducing the axial space requirement compared to a fully integrated sealed housing design.
Solution Approach 2:
The electronics housing is designed with a substantially rectangular cross-section instead of following the cylindrical motor housing contour. This dimensional change allows more efficient space utilization and positioning of the electronics in the fan housing, optimizing both cooling access and space requirements.
2Reliability
If motor control electronics are integrated in a sealed electronics housing, then the electronics are protected from environmental influences, but the number of housing components increases and assembly complexity increases
Solution Approach 1:
The motor housing and fan housing are designed as separate but complementary components that assemble together to form the complete fan assembly. The motor housing contains the motor, while the fan housing contains the electronics and fan wheel. This merging of separate housings reduces the total number of components compared to a fully integrated sealed housing, while still providing environmental protection for the electronics.
3Device complexity
If motor control electronics are integrated in a sealed electronics housing with direct motor connection, then the structure is compact, but replacing motor control electronics during service is not possible or requires great assembly effort
Solution Approach 1:
By separating the electronics into their own fan housing that can be independently accessed, the patent enables service personnel to remove and replace motor control electronics without disassembling the motor housing. This segmentation maintains structural compactness while significantly improving ease of repair.
4Device complexity
If the circuit board is positioned with a central opening for the bearing tube, then the motor and electronics can be integrated, but the circuit board layout is restricted and not optimized for EMC requirements
Solution Approach 1:
The circuit board is designed with a substantially rectangular cross-section that eliminates the need for a central opening for the bearing tube. This dimensional change allows the circuit board to be positioned optimally for EMC shielding and layout, while the motor and electronics remain integrated in the same housing structure.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a fan housing (1) of an axial fan for receiving a motor (2) and a motor electronics system (3), wherein the fan housing (1) has a substantially cylindrical housing wall (10) which extends in the axial direction (A) with a first end side (S1) and a second end side (S2), in the axial centre of which fan housing (1) a motor flange (11) for receiving a motor (2) is configured, wherein the motor flange (11) configures a hollow-cylindrical bearing tube (12) which is open on one side for mounting the rotor shaft (14) of a rotor (13), wherein the bearing tube (12) is closed at one bearing tube end (12u) thereof in the region of the motor flange (11) and the motor flange (11) configures a receiving chamber (15) for receiving the motor electronics system (3), which receiving chamber (15) is arranged completely in the interior of the cylindrical housing wall (10) between the bearing tube end (12u) and the first end side (S1).