Integrated Motor Drive Encapsulation for Compact Heat Separation
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Solution Overview
Problem
Electric motor arrangements face excessive heat generation due to the development of smaller and more powerful motor drives, leading to performance degradation and potential thermal destruction or damage, as well as reduced component lifetime.
Innovation Solution
The electric motor arrangement features a low impedance electrical conducting path with components nearly touching each other, thermally separated encapsulation portions using thermal isolating layers, and the use of high-power density components like SiC, GaN, or IGBT switches to minimize heat dissipation and energy losses, allowing for compact design and efficient thermal management without forced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If motor drive components are made smaller and more powerful to increase power density, then power output is improved, but heat generation increases excessively leading to thermal damage and reduced component lifetime
Solution Approach 1:
The patent divides the motor drive system into multiple separate encapsulation portions (first encapsulation portion, second encapsulation portion, third encapsulation portion) that are thermally isolated from each other. Each encapsulation contains specific power components (IGBTs, diodes, capacitors) and dissipates heat independently through dedicated thermal paths to heat sinks, preventing heat accumulation and thermal damage while maintaining high power output capability.
2Volume of moving object
If components are placed closer together to reduce space and increase compactness, then volume is reduced, but thermal management becomes more difficult and heat dissipation increases
Solution Approach 1:
The patent segments the motor drive into multiple encapsulation portions that are thermally isolated, allowing each segment to have its own optimized thermal management path. This enables compact overall design while maintaining effective heat dissipation through separate thermal routes for each encapsulation portion.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement by stacking encapsulation portions vertically and providing independent thermal paths in different directions (radial and axial heat sinks), effectively managing heat dissipation in a compact volume by exploiting multiple spatial dimensions.
3Device complexity
If a single encapsulation is used to simplify structure, then device complexity is reduced, but thermal separation between components with different thermal properties becomes difficult
Solution Approach 1:
The patent divides the motor drive into multiple encapsulation portions (first, second, third encapsulation portions) that are thermally isolated from each other. Each encapsulation contains specific power components and has its own thermal management system, allowing components with different thermal properties to be thermally separated while maintaining a relatively simple overall structure.
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 solution significantly reduces heat dissipation within a compact space, ensuring efficient operation, minimizing energy losses, and allowing for scalable and thermally efficient electric motor designs with improved thermal separation and EMI performance.
Implementation Method 1
the first encapsulation portion, the second encapsulation portion and/or the motor are thermally separated from each other by at least one thermal isolating layer
Data Source
AI summary
An electric motor arrangement including an electric motor, in particular a servo integrated motor, an encapsulation containing a motor drive, in particular a servo drive, for driving the motor with a low impedance electrical conducting path comprising a stacked power module, a power PCBA and a power connector. The electric motor arrangement further includes an electric motor and first and second encapsulation portions containing a motor drive for driving the motor, wherein the first encapsulation portion, the second encapsulation portion and/or the motor are thermally separated from each other by at least one thermal isolating layer.