Motor Controller Cooling via Immersion and Sealed Housing
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Solution Overview
Problem
Motor assemblies, particularly in aircraft, face inefficiencies and reliability issues due to inadequate cooling of electric motors and controllers, especially when operating on the ground or at low speeds, and the use of harsh ambient air for cooling leads to reduced reliability and shortened component lifespan.
Innovation Solution
A cooling arrangement that utilizes a heat exchanger to ingest ambient air, which is then used for two-phase immersion cooling of the motor controller and motor, with the cooling fluid routing both components efficiently and sealing the electronics from harsh external conditions, eliminating the need for forced air cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor controller is located remotely from the motor, then the cooling requirements for both components can be met, but the system complexity and number of cooling sources increase
Solution Approach 1:
The motor controller is integrated into the motor housing, creating a unified motor assembly. This merging eliminates the need for separate cooling sources and flow paths for the controller and motor, reducing system complexity while maintaining effective cooling through shared cooling fluid circulation
2Device complexity
If the motor controller is located close to the fan, then the cooling system is simplified, but the controller is exposed to harsh ambient conditions reducing reliability
Solution Approach 1:
A sealed housing acts as an intermediary barrier between the motor controller and the harsh ambient environment. The housing protects the controller from moisture, corrosive substances, and foreign objects while allowing the cooling system to function effectively through integrated cooling fluid circulation
3Temperature
If forced air cooling is used for the motor controller, then cooling effectiveness is improved, but the controller is exposed to harsh ambient air reducing reliability
Solution Approach 1:
The system transitions from forced air cooling to liquid cooling using circulation pumps and cooling fluid. This hydraulic approach provides superior cooling effectiveness while the sealed housing prevents exposure to harsh ambient conditions, eliminating the reliability issues associated with air cooling
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 and efficient cooling for both the motor and controller, reducing the risk of overheating and increasing reliability by using a single cooling source and path, while protecting the electronics from harsh environments.
Implementation Method 1
A cooling arrangement that utilizes a heat exchanger to ingest ambient air, which is then used for two-phase immersion cooling of the motor controller and motor
Implementation Method 2
two-phase immersion cooling of the motor controller and motor
Implementation Method 3
the cooling fluid routing both components efficiently
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cooling arrangement (10) for a motor assembly includes a motor (30) operably connected to a load. A motor controller (50) is disposed adjacent to, and fluidly coupled to, the motor (30), the motor controller (50) disposed within a housing (52) enclosing a cooling fluid for immersion of a plurality of motor controller components. A duct arrangement (20) is configured to route a cooling flow (21) to a location proximate the housing (52) of the motor controller (50) for cooling therealong.