Marine Drive Frame Heat Exchanger for Enclosed Power Electronics
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Solution Overview
Problem
Existing marine drive systems face challenges in efficiently cooling electrical components, particularly the power entry module and batteries, which can lead to performance degradation and reduced operational life due to excessive heat generation, without requiring additional cooling fluids or forced air that would increase complexity and cost.
Innovation Solution
The marine drive system incorporates a supporting frame with a monolithic body that acts as a heat exchanger, where a portion of the frame is exposed to the atmosphere, allowing for efficient heat transfer from the electrical power unit, including a power entry module and batteries, without the need for internal cooling fluids or forced air, utilizing a cowling and ribs to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are enclosed in a cowling for protection, then reliability is improved, but heat dissipation deteriorates
Solution Approach 1:
The cowling is designed with differentiated regions: a first portion that encloses electrical components for protection and a second portion that remains exposed to atmosphere for heat dissipation. This local differentiation allows simultaneous achievement of protection and thermal management.
Solution Approach 2:
The supporting frame is segmented into multiple portions with different functions: the first portion is enclosed by the cowling for component protection, while the second portion is exposed to serve as a heat exchanger. This segmentation resolves the contradiction between enclosure and heat dissipation.
2Temperature
If additional cooling mechanisms are added to cool electrical components, then temperature control is improved, but device complexity increases
Solution Approach 1:
The supporting frame itself serves dual functions: structural support and heat exchange. By exposing a second portion of the frame to atmosphere, the system cools electrical components passively without requiring additional active cooling mechanisms, thereby maintaining simplicity.
Solution Approach 2:
The supporting frame is designed as a multi-functional component that simultaneously provides mechanical support and thermal management. This eliminates the need for separate cooling systems, reducing overall device complexity while achieving effective temperature control.
3Temperature
If forced air cooling is implemented, then heat dissipation is improved, but device complexity and cost increase
Solution Approach 1:
The system utilizes natural convection and radiation from the exposed second portion of the supporting frame for passive cooling. This self-service approach eliminates the need for forced air systems, maintaining simplicity while achieving adequate heat dissipation.
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 effectively cools the electrical components by transferring heat to the atmosphere, improving performance and operational life while reducing system complexity and cost by eliminating the need for additional cooling mechanisms.
Implementation Method 1
a second portion of the supporting frame is exposed to atmosphere outside the cowling and functions as a heat exchanger which efficiently transfers the heat from the electrical power unit to the atmosphere
Data Source
AI summary
A marine drive has a supporting frame, an electric motor configured to power a propulsor for generating a thrust force in water, and an electrical power unit for the electric motor which is coupled to the supporting frame. Operation of the electrical power unit generates heat that is transferred to the supporting frame. A cowling encloses the electrical power unit and covers a first portion of the supporting frame. A different, second portion of the supporting frame is exposed to atmosphere outside the cowling. The supporting frame and cowling are configured so that the second portion of the supporting frame provides a heat exchanger that transfers the heat from the electrical power unit to the atmosphere.