Motor Controller Thermoelectric Cooling During Electric Braking

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Solution Overview

Problem

Conventional electric motor braking systems dissipate regenerated energy as heat using braking resistors, leading to increased motor controller temperatures and reduced component lifespan, necessitating larger passive cooling elements to manage heat and enhance reliability.

Innovation Solution

Integration of a thermoelectric cooler within the electric motor controller's thermal path to receive the braking current and actively cool the controller electronics, replacing or reducing the need for braking resistors and enhancing heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a braking resistor is used to dissipate regenerated energy, then braking performance is improved, but heat generation increases causing motor controller temperature to rise

Engineering Contradiction:

Improvedeceleration rateVSAvoidmotor controller temperature

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The patent converts the harmful heat generated by braking resistor dissipation into a beneficial cooling effect by using the braking current to power a thermoelectric cooler that actively cools the motor controller electronics, transforming the waste heat problem into an active cooling solution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent replaces the passive thermal dissipation mechanism (braking resistor) with an active thermoelectric cooling system that uses the Peltier effect to actively pump heat away from the motor controller, substituting a passive thermal management approach with an active controlled cooling system

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If passive cooling elements are increased in size to manage heat from braking resistor, then heat dissipation is improved, but device complexity and size increase

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcooling system size

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent makes the braking current serve multiple functions: it provides the necessary braking torque while simultaneously powering the thermoelectric cooler to manage heat in the motor controller, eliminating the need for separate oversized passive cooling elements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own braking current to power the cooling mechanism, making the motor controller's operational energy (braking current) serve the dual purpose of both braking and thermal management, rather than requiring external power for cooling

Inventive Principle:

Principle #25Self-service

3Loss of energy

If braking resistor dissipates regenerated energy as heat, then energy recovery is prevented, but reliability of electronic components decreases due to heat

Engineering Contradiction:

Improveenergy dissipationVSAvoidelectronic component reliability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent converts the harmful waste heat from braking resistor dissipation into a beneficial cooling effect by using the braking current to power a thermoelectric cooler, transforming the reliability-degrading heat into an active cooling resource that protects electronic components

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Instead of discarding the braking current as waste energy to be dissipated as heat, the system recovers and utilizes the braking current to power the thermoelectric cooler, extracting useful cooling function from what would otherwise be wasted energy

Inventive Principle:

Principle #34Discarding and recovering

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 effectively reduces heat generation during braking, increases the reliability of motor controllers by actively managing heat, and potentially eliminates the need for oversized passive cooling elements.

Implementation Method 1

a thermoelectric cooler configured to receive a braking current associated with braking of the electric motor and provide cooling to the controller electronics

Methodology Applied

Scientific EffectThermoelectric cooling: Peltier Effect

Data Source

PatentUS8975838B2Electric motor braking using thermoelectric cooling

Publication Date: 2015.03.10 HAMILTON SUNDSTRAND CORP

AI summary

An electric motor controller includes controller electronics configured to control an electric motor. The electric motor controller also includes a thermoelectric cooler in thermal communication with the controller electronics. The thermoelectric cooler is configured to receive a braking current associated with braking of the electric motor and provide cooling to the controller electronics.