Fan Motor Controller Circumferential Mounting for Weight Reduction

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Solution Overview

Problem

Traditional fan motor controllers are heavy and costly due to their box-shaped metal housing, and they reduce fan efficiency by bleeding airflow for convection cooling, which is not directly utilized by the fan housing.

Innovation Solution

A fan motor controller with a component mounting base extending circumferentially around the fan inner housing, formed as a polygonal shape, using a plastic outer housing with a metallization interconnect layer to connect controller components, eliminating the need for discrete connectors and motherboards, and positioning components for direct heat conduction to the inner housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional box-shaped metal housing is used for controller components, then structural strength and component protection are improved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidcontroller weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The controller components are integrated directly into the fan housing structure, merging the controller housing function with the existing fan housing. This eliminates the need for a separate box-shaped metal housing, reducing weight while maintaining structural strength through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fan housing serves multiple functions: it provides structural support, houses the motor, and now also serves as the mounting structure for controller components. This multi-functionality eliminates the need for additional dedicated housing structures, reducing overall weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If traditional box-shaped metal housing is used for controller components, then structural strength and component protection are improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The controller components are extracted from the traditional enclosed box housing and mounted directly on the fan housing inner surface. This extraction eliminates the need for separate housing panels and fasteners, simplifying manufacturing and reducing cost.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If convection cooling is provided to controller components using fan airflow, then component cooling is improved, but fan efficiency and pressure rise deteriorate

Engineering Contradiction:

Improvecomponent coolingVSAvoidfan efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The controller components are positioned to utilize the natural cooling effect of the fan housing structure and ambient airflow, eliminating the need for dedicated convection cooling paths. The components self-cool through their mounting position and heat dissipation design without requiring additional airflow diversion.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The controller components are mounted on the inner surface of the fan housing, utilizing the three-dimensional space within the housing rather than requiring separate cooling ducts or airflow paths. This spatial arrangement allows cooling through the housing structure itself without diverting main fan airflow.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 configuration reduces weight, minimizes cooling airflow bleed, and enhances fan efficiency by integrating metalized interconnects and mounting components on a cooled area, improving heat transfer and airflow.

Implementation Method 1

positioning components for direct heat conduction to the inner housing

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a fan motor configured to draw air into an inlet of the fan duct and inner housing

Methodology Applied

Scientific EffectAirflow generation: Fan

Data Source

PatentUS9011106B2Fan motor controller

Publication Date: 2015.04.21 HAMILTON SUNDSTRAND CORP

AI summary

A fan motor controller for a turbine engine comprises a component mounting base and a plurality of fan controller components mounted to the component mounting base. The component mounting base comprises a plurality of sections that are configured to extend circumferentially around a fan inner housing.