Integrated Electric Motor With Separated Heat Paths
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Solution Overview
Problem
Existing electric motors for camshaft adjusters in internal combustion engines require external control units and additional cabling, leading to increased complexity and effort in integration with internal combustion engines.
Innovation Solution
Integration of the control electronics system with the electric motor as a single unit, featuring separate heat paths for the motor and electronics modules to facilitate efficient heat dissipation and reduce overheating risks, with the base motor module and plug module connected via insulation displacement connections and a flange plate for enhanced thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If external control units and additional cabling are used to control the electric motor, then the control function can be implemented, but the device complexity and integration effort increase
Solution Approach 1:
The patent combines the control electronics system, driver bridge, and electric motor into a single integrated unit. The control electronics system is housed within the motor housing, eliminating the need for separate external control units and reducing cabling requirements. This merging of components directly reduces device complexity and simplifies integration into the internal combustion engine.
2Device complexity
If the control electronics system is integrated into the electric motor as a single unit, then the device complexity is reduced, but the heat management becomes more challenging due to combined heat sources
Solution Approach 1:
The patent segments the heat dissipation paths into two separate channels: one for the electric motor and another for the electronics module. The motor housing and electronics housing are thermally coupled to different heat sinks, allowing independent heat management. This segmentation prevents heat from one component from adversely affecting the other, maintaining reliable operation despite integration.
3Device complexity
If the electronics module and base motor module share a common heat sink, then the structure is simplified, but the temperature control for heat-sensitive electronics deteriorates
Solution Approach 1:
The patent assigns separate heat sinks to the electronics module and base motor module. The electronics housing is coupled to a first heat sink, while the motor housing is coupled to a second heat sink. This segmentation ensures that heat-sensitive electronics are isolated from the higher temperatures generated by the motor, maintaining reliability while keeping the overall structure relatively simple.
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 simplifies the integration of electric motors into internal combustion engines by reducing the need for external control units, enabling efficient heat management and increased reliability through separate heat dissipation paths and modular design, allowing for operation at high temperatures and mechanical loads.
Implementation Method 1
the base motor module dissipates heat via a heat path A, wherein the heat is conducted via a heat-conducting plate into a heat sink
Implementation Method 2
the electronics module and the base motor module dissipate heat via one heat path each, wherein the heat paths are separated from one another
Data Source
AI summary
The disclosure relates to an electric motor comprising a base motor module and a plug module which is electrically and mechanically connected to the base motor module and is designed as an electronics module. The electronics module comprises a power electronics system, a driver electronics system and a control electronics system, and the electronics module and the base motor module each dissipate heat via separated heat paths. The disclosure further relates to an electric motor arrangement and also to a construction kit for electric motors.