Integrated Motor-Controller Cooling Layout for Lightweight Aircraft
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Solution Overview
Problem
Current aircraft power systems face challenges in achieving lightweight design and efficient heat dissipation while maintaining high output power, often requiring additional components and water cooling systems that compromise reliability.
Innovation Solution
A highly integrated motor and electronic controller combination system with dual heat dissipation channels, where a connecting member links the motor and controller units, and a centrifugal fan enhances airflow for efficient cooling, utilizing both propeller-generated airflow and internal channels with staggered heat dissipation fins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate motor and controller design is used, then ease of manufacture is maintained, but device complexity increases and weight increases
Solution Approach 1:
The patent merges the motor unit and electronic controller unit into a highly integrated combination system. The controller unit is fixably arranged below the motor unit with aligned centers, forming a unified assembly that reduces overall system complexity and weight while maintaining manufacturing feasibility through modular integration.
Solution Approach 2:
The integrated combination system serves multiple functions within a single assembly: the motor unit provides propulsion while the controller unit provides electronic control, and both share common cooling through the heat dissipation channel. This multi-functionality reduces the number of separate components needed.
2Temperature
If water cooling system is used, then heat dissipation efficiency is improved, but device complexity and weight increase
Solution Approach 1:
The patent extracts the cooling function from a separate water cooling system and integrates it directly into the motor-controller assembly through built-in heat dissipation channels. This eliminates the need for external water cooling infrastructure while maintaining effective heat removal.
Solution Approach 2:
The system uses its own operational airflow (from propeller rotation) to drive the cooling process through the heat dissipation channels. The propeller-generated airflow naturally passes through the channels, cooling both the motor and controller without requiring separate cooling fans or active cooling systems.
3Weight of moving object
If lightweight design is pursued, then weight is reduced, but heat dissipation capability deteriorates
Solution Approach 1:
The patent implements localized heat dissipation channels specifically positioned around the motor unit and controller unit. The channels are strategically routed to maximize cooling of high-heat-generation areas while maintaining overall system lightweight design. The centrifugal fan is positioned to create targeted airflow patterns.
Solution Approach 2:
The patent utilizes three-dimensional heat dissipation pathways including radial channels around the motor, axial channels through the controller, and vertical channels for the centrifugal fan. This multi-dimensional cooling approach maximizes heat dissipation efficiency within the compact lightweight 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
The system achieves reduced weight, improved production efficiency, and enhanced cooling efficiency, lowering motor and control unit temperatures by 10% and 20% respectively, while eliminating the need for extra components and water cooling systems.
Implementation Method 1
a centrifugal fan arranged at a top of the motor unit and the electronic controller unit... wherein the centrifugal fan generates negative pressure at an air inlet of the heat dissipation channel to improve an air intake capability
Implementation Method 2
a heat dissipation channel, wherein a gas flows through the heat dissipation channel, which is built through the highly integrated motor and electronic controller combination system, to cool down the motor unit and the electronic controller unit
Data Source
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AI summary
The present invention belongs to the technical field of aircraft, and discloses a highly integrated motor-controller integrated system comprising a motor unit, an electronic controller unit, a connecting member, and a heat dissipation channel. The electronic controller unit is fixedly disposed below the motor unit and controls the motor unit, with a center of the motor unit aligned with a center of the electronic controller unit. The motor unit and the electronic controller unit form the motor-controller integrated system via the connecting member, and the connecting member penetrates the motor unit and the electronic controller unit to connect them in series. A flowing gas dissipates heat from the motor unit and the electronic controller unit by means of the built-in heat dissipation channel passing through the motor-controller integrated system.