Brushless DC Motor Controller Insulation and Drainage

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Brushless DC motor controllers face issues with electrical leakage and poor insulation, and when used outdoors, they suffer from water ingress and drainage problems due to inadequate sealing, leading to short circuits.

Innovation Solution

The motor controller incorporates an IGBT module isolated by an insulating piece, with an insulating bush and a water channel system to prevent direct contact between the dissipater and control box, ensuring good insulation and effective drainage of water.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the dissipater directly contacts with the control box, then the structure is simple, but electrical leakage occurs and insulation is poor

Engineering Contradiction:

Improveelectrical insulationVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An insulating piece is introduced as an intermediary component between the dissipater and the control box. This insulating piece prevents direct contact between the dissipater and the control box, thereby eliminating electrical leakage risks while maintaining structural simplicity through the addition of a single functional component.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a seal washer is used to seal the mounting hole, then the structure is simple, but the seal washer ages easily and water penetrates into the motor

Engineering Contradiction:

Improvewaterproof performanceVSAvoidservice life of seal washer

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The seal washer is removed from the sealing system and replaced by an integrated water channel structure. The water channel is formed directly in the control box, eliminating the need for separate sealing components like seal washers that are prone to aging and failure, thereby achieving durable waterproof performance.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A water channel system is introduced to actively manage water drainage. The water channel provides a controlled hydraulic pathway that guides water away from critical components, transforming the passive sealing approach into an active water management system that reliably prevents water ingress.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If the control box is tightly sealed, then waterproof performance is good, but water that enters cannot be drained out

Engineering Contradiction:

Improvewaterproof performanceVSAvoiddrainage function

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The control box is segmented into distinct functional zones: a sealed enclosure for electrical components and an integrated water channel system for water management. This segmentation allows the control box to maintain tight sealing for waterproof protection while simultaneously providing dedicated drainage pathways through the water channel structure.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9614421B2Motor controller and brushless DC motor comprising the same

Publication Date: 2017.04.04 ZHONGSHAN BROAD OCEAN

AI summary

A motor controller, including: a control box including an inner wall; a circuit board; a dissipater; an IGBT module; and an insulating piece. The circuit board is disposed inside the controller box. The dissipater is disposed on the inner wall of the control box. The IGBT module is disposed on the dissipater and is in electric connection with the circuit board. The insulating piece is disposed between the dissipater and the controller and prevents the dissipater from contacting with the control box.