Integrated Motor Electronics With Separate Heat Dissipation Paths
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Solution Overview
Problem
Existing electric motors for camshaft adjusters in internal combustion engines require external control units and cabling, leading to increased complexity and effort in integration and operation.
Innovation Solution
Integration of the control electronics system with the electric motor as a single unit, utilizing a base motor module and an electronic module with separate heat dissipation paths and press-fit connections for efficient heat management and assembly, allowing for modular design and redundancy in motor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external control units and cabling are used with the electric motor, then the control functions can be implemented, but the device complexity and integration effort increase
Solution Approach 1:
The control electronics system is integrated directly into the electric motor as a single unit, merging the motor and control functions into one component. This eliminates the need for external control units and cabling, thereby reducing device complexity and integration effort while maintaining full control functionality.
2Device complexity
If the control electronics system is integrated into the electric motor as a single unit, then the device complexity is reduced, but heat management becomes more challenging
Solution Approach 1:
The integrated unit is divided into two separate heat dissipation paths: one path for the electric motor and another path for the control electronics system. This segmentation allows each subsystem to manage its own heat independently, preventing heat from the motor from affecting the heat-sensitive electronics while maintaining the benefits of integration.
3Temperature
If heat dissipation paths are separated for the motor and electronics, then heat management efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The housing is designed with segmented heat dissipation paths that are integrated into the overall structure. By planning the thermal management architecture during the design phase, the separate heat paths are incorporated into the housing structure itself, which manages heat effectively without requiring separate manufacturing processes for each path.
4Productivity
If press-fit contacts are used to connect the coil to the printed circuit board, then assembly efficiency improves, but the positioning precision requirements increase
Solution Approach 1:
The housing structure includes pre-formed supporting surfaces and positioning features that are created during housing manufacturing. These pre-prepared features guide the printed circuit board and press-fit contacts into correct positions during assembly, ensuring precise alignment without requiring complex adjustment procedures or high-precision manual positioning.
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
Enables simplified integration, efficient heat dissipation, and fail-safe operation by separating heat paths and using modular components, reducing the need for external control units and cabling while ensuring reliable performance at high temperatures.
Implementation Method 1
a heat-conducting paste is applied between at least one of the supporting surfaces and the printed circuit board. The heat-conducting paste facilitates the dissipation of heat via the housing
Data Source
AI summary
The disclosure relates to an electric motor having a base motor module and an electronic module. The electronic module is electrically and mechanically connected to the base motor module and comprises a printed circuit board and an electronics housing. The electronics housing forms two supporting surfaces, with which the printed circuit board can be brought into contact.