Motor Controller Thermoelectric Cooling Using Braking Current

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Solution Overview

Problem

Electric motor braking systems dissipate regenerated energy as heat using braking resistors, leading to increased motor controller temperatures and reduced lifespan of electronic components, necessitating larger passive cooling elements to manage heat.

Innovation Solution

Integration of thermoelectric cooling components replaces or complements braking resistors, utilizing the Peltier effect to actively dissipate heat and reduce thermal loads within the motor controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a braking resistor is used to dissipate regenerated energy, then deceleration speed can be increased, but heat generation increases causing motor controller temperature to rise

Engineering Contradiction:

Improvedeceleration speedVSAvoidmotor 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 thermoelectric coolers. The thermoelectric coolers use the Peltier effect to transfer heat from the motor controller to the braking resistor, thereby reducing motor controller temperature while maintaining effective deceleration capability

Inventive Principle:

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

Solution Approach 2:

The patent introduces thermoelectric coolers as an intermediary device between the motor controller and the braking resistor. This intermediary actively manages heat transfer, allowing the system to achieve both fast deceleration and temperature control by mediating the thermal interaction between components

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If passive cooling elements are increased in size to remove heat from the motor controller, then temperature management is improved, but device complexity and size increase

Engineering Contradiction:

Improvemotor controller temperatureVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent replaces passive mechanical cooling systems with an active thermoelectric cooling system. Instead of relying on large passive heat sinks and fans, the system uses solid-state thermoelectric coolers that actively pump heat, achieving superior temperature management with a more compact and less complex design

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operational parameters of the cooling system by using electrically controllable thermoelectric coolers instead of passive thermal conduction paths. This allows dynamic adjustment of cooling capacity based on real-time temperature conditions, improving efficiency while reducing the overall size of cooling components

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If braking resistor dissipates regenerated energy as heat, then energy recovery is prevented, but heat waste reduces system efficiency

Engineering Contradiction:

Improveenergy dissipationVSAvoidsystem efficiency

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The patent converts the wasted thermal energy from braking resistor dissipation into a useful resource by using it to drive thermoelectric coolers. The heat that would otherwise be wasted is now utilized for active cooling of the motor controller, simultaneously addressing energy recovery concerns and improving overall system efficiency

Inventive Principle:

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

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

Thermoelectric cooling effectively reduces heat generation and enhances heat dissipation, increasing the reliability and extending the life expectancy of motor controller components by converting braking energy into a cooling effect.

Implementation Method 1

Methodology Applied

Scientific EffectPeltier effect: Peltier Effect

Data Source

PatentEP2717463B1Electric motor braking using thermoelectric cooling

Publication Date: 2021.04.28 HAMILTON SUNDSTRAND CORP

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AI summary

An electric motor controller, 202, includes controller electronics, 208, configured to control an electric motor, 204. The electric motor controller, 202, 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.