Heat Sink Module Layout for Single-Board Excited Motor Control
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Solution Overview
Problem
Existing electrical circuit devices for externally excited electric machines require separate control boards for power and exciter modules, leading to increased material costs and assembly complexity due to heating issues and the need for precise alignment and cooling systems.
Innovation Solution
A method involving a heat sink with positioning sections for precise alignment and attachment of power and exciter modules, allowing a single control board design by using modules with connecting pins that point in the same direction, eliminating the need for separate circuit boards and reducing assembly effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate control boards are provided for power module and exciter module, then control functionality is ensured, but device complexity and assembly complexity increase
Solution Approach 1:
The patent combines the control boards for the power module and exciter module into a single integrated control board. The control board includes a power module control unit connected to the power module and an exciter module control unit connected to the exciter module, eliminating the need for separate control boards and reducing assembly complexity while maintaining control functionality.
2Temperature
If heat sink is used for cooling power module and exciter module, then thermal management is improved, but manufacturing precision requirements increase due to positioning accuracy needs
Solution Approach 1:
The patent incorporates positioning protrusions on the heat sink that engage with corresponding positioning recesses on the power module and exciter module. This preliminary positioning structure is built into the heat sink design, allowing modules to be automatically positioned with high precision during assembly without requiring complex external positioning fixtures or procedures.
3Manufacturing precision
If positioning sections are used for aligning exciter module on heat sink, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The patent employs asymmetric positioning protrusions and recesses where the geometry of the protrusions on the heat sink does not match the recesses, creating a unique fit that ensures precise positioning. The protrusions have specific shapes and orientations that only fit into corresponding asymmetric recesses, preventing misalignment and ensuring accurate module placement without requiring complex positioning mechanisms.
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 approach simplifies manufacturability, reduces material costs, and enhances thermal contact for effective cooling, while maintaining precise module positioning and electrical connectivity.
Implementation Method 1
The heat sink is in thermal contact, such as physical contact, with the power module and the exciter module for cooling these components
Data Source
AI summary
A method for producing an electrical circuit device for operating an externally excited electric machine is provided and may comprise positioning and attaching at least one power module at a marked attachment position on an outside of a heat sink, positioning at least one exciter module on the outside of the heat sink, attaching the exciter module to the outside of the heat sink. The at least one power module may include power module-side connecting pins. The at least one exciter module may include exciter module-side connecting pins. During the positioning, at least one heat sink-side positioning section may be inserted into or may receive at least one exciter module-side positioning section. After attaching the power module and the exciter module to the heat sink, a control board may be plugged onto the power module-side and the excited module-side connecting pins pointing in the same direction.