Motor Controller Cooling via Centrifugal Airflow and Flexible Duct
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Solution Overview
Problem
Conventional cooling methods for electric motors and motor controllers add weight, complexity, and expense, reducing reliability and increasing maintenance costs, as they require additional components like fans or liquid cooling systems.
Innovation Solution
Integrating fan features into the electric motor, such as fins or blades, to create centrifugal airflow that passes through both the motor and controller, using a flexible duct to connect them, allowing for passive cooling without additional components, with airflow proportional to heat dissipation needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (fans or liquid cooling systems) are used for motor controllers, then heat dissipation is effective, but device complexity and weight increase
Solution Approach 1:
The patent combines the motor and motor controller into a single integrated assembly, where the motor's rotating assembly directly drives airflow through ducts that pass over the controller's heat sinks. This merging eliminates the need for separate cooling components like fans or liquid cooling systems, reducing device complexity while maintaining effective heat dissipation.
Solution Approach 2:
The motor's rotating assembly serves dual functions: it both drives the propulsion system and simultaneously provides cooling airflow for the controller. The airflow generated by motor rotation is utilized to cool both the motor itself and the controller through integrated ducting, making the motor a multi-functional component that eliminates the need for dedicated cooling systems.
2Temperature
If conventional cooling methods are used, then heat dissipation is achieved, but weight increases
Solution Approach 1:
By merging the cooling function into the motor assembly itself, the patent eliminates the weight of separate cooling systems. The motor housing and rotating assembly directly generate and channel airflow through integrated ducts to cool the controller, removing the need for additional cooling components and their associated weight.
Solution Approach 2:
The motor serves itself and the controller by using its own rotation to generate cooling airflow. The rotating assembly naturally draws air through the controller's heat sinks via integrated ducts, providing self-powered cooling without requiring external fans, pumps, or liquid cooling systems, thereby eliminating their weight.
3Temperature
If separate cooling components are added, then cooling capability is improved, but reliability decreases
Solution Approach 1:
The patent merges the cooling function into the motor assembly, eliminating multiple separate cooling components that could fail. By using the motor's own rotation to drive airflow through integrated ducts to cool the controller, the system reduces the number of potential failure points while maintaining effective cooling capability.
Solution Approach 2:
The motor uses its own operational motion to provide cooling, eliminating the need for separate cooling components that require additional power sources, controls, and maintenance. This self-service approach improves reliability by removing potential failure points associated with dedicated cooling systems.
4Temperature
If active cooling control systems are used, then cooling demand is met, but power consumption increases
Solution Approach 1:
The motor's rotation naturally generates airflow that provides cooling proportional to its operational load. As the motor runs harder and generates more heat, its increased rotation speed automatically produces more cooling airflow through the integrated ducts, eliminating the need for additional power-consuming active cooling control systems.
Solution Approach 2:
The cooling airflow is generated continuously through the motor's rotational operation, with the cooling capacity naturally varying with motor speed and load. This periodic action tied to motor operation provides cooling demand satisfaction without requiring separate power-consuming control 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 solution provides effective heat dissipation, increasing motor longevity and load capabilities, reducing complexity and weight, while matching cooling demand with minimal power consumption, independent of aircraft speed, and eliminating the need for active cooling control.
Implementation Method 1
Integrating fan features into the electric motor, such as fins or blades, to create centrifugal airflow that passes through both the motor and controller
Implementation Method 2
at least one motor controller each comprising a heat sink positioned in an air intake path from a source of air to the electric motor
Data Source
AI summary
Embodiments of cooling a motor controlling using a motor are disclosed. In some embodiments, a system includes an electric motor including at least one rotor with integrated features positioned and configured to pull air into and through the electric motor. The system also includes at least one motor controller each comprising a heat sink positioned in an air intake path from a source of air to the electric motor. A method of manufacturing the system includes arranging at least one motor controller and at least one electric motor, coupling the at least one motor controller and at least one electric motor via a flexible duct, and adapting the arrangement of the at least one motor controller and the at least one electric motor to passively provide cooling via airflow through the at least one motor controller and at least one electric motor in proportion to a load on the at least one electric motor.