Motor Converter Copper Plate Heat Dissipation Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing converter motors are not easily producible, environmentally friendly, or suitable for recycling, and they lack efficient heat dissipation methods.
Innovation Solution
A converter motor design featuring a copper plate that dissipates heat to a fan cover, which is cooled by airflow, eliminating the need for thermal paste and allowing for high heat transfer resistance, along with a non-rotatably connected fan for passive airflow and cost-effective production using metal casting and plastic injection molding, and a sensor system for rotational speed detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal paste and processing of the fan cover contact area are used to improve heat dissipation, then heat transfer efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the thermal paste layer from the heat dissipation path. Instead of using thermal paste between the power module and fan cover, the design uses a spring element to create direct mechanical contact pressure, allowing heat to be dissipated through the fan cover's natural thermal conduction without requiring additional thermal interface materials or surface processing.
Solution Approach 2:
The fan cover serves dual functions: it provides structural housing and simultaneously acts as a heat dissipation path. The spring element automatically applies pressure to maintain thermal contact between the power module and fan cover, eliminating the need for separate fastening mechanisms or thermal paste application processes.
2Temperature
If the fan is separately driven to improve cooling performance, then heat dissipation is improved, but device complexity and energy consumption increase
Solution Approach 1:
The invention merges the fan drive function with the motor's rotor shaft. The fan is directly coupled to the rotor shaft, so that the motor's rotation automatically drives the fan to provide cooling airflow. This eliminates the need for a separate drive mechanism, reducing device complexity and energy consumption while maintaining effective cooling performance.
Solution Approach 2:
The rotor shaft serves multiple functions: it drives the motor's internal components and simultaneously drives the fan for cooling the power module. This multi-functional design eliminates redundant components and simplifies the overall system architecture.
3Temperature
If machined surfaces are used on the fan cover contact area to improve heat transfer, then heat dissipation is improved, but production cost increases
Solution Approach 1:
The invention removes the requirement for machined surfaces on the fan cover contact area. By using the spring element to apply pressure and ensure direct contact, the design accepts the as-cast surface finish of the aluminum fan cover, eliminating costly machining operations while maintaining effective heat transfer through the combination of mechanical pressure and aluminum's inherent thermal conductivity.
4Measurement precision
If the sensor is positioned close to the toothed ring to improve detection precision, then rotational speed detection accuracy is improved, but airflow may be impeded
Solution Approach 1:
The invention introduces a magnetic field as an intermediary for the sensor-to-toothed ring interaction. The sensor detects changes in the magnetic field caused by the passing teeth of the toothed ring, allowing for accurate rotational speed detection without requiring the sensor to be in direct physical proximity to the toothed ring, thus avoiding airflow obstruction.
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
The design enhances heat dissipation efficiency, reduces production costs, and allows for easy recycling, while maintaining compactness and effective rotational speed detection without impeding airflow.
Implementation Method 1
the heat from the power module is dissipated via its copper plate to the fan hood
Implementation Method 2
which is cooled by the air flow conveyed by the fan
Data Source
Figure 1
Figure 2
AI summary
A motor converter comprising an electric motor with a housing part and a fan, a fan cowl and a converter, the converter having a housing part, a circuit board and a power module that is connected to the circuit board, more particularly electrically connected, in particular, soldered to said board. The fan cowl is connected, more particularly screwed, to a housing part of the electric motor, and a spring element that is supported on the cover part, more particularly on the inner face of the cover part, presses a plate, more particularly a copper plate of the power module, onto the fan cowl.