Motor End Cap Controller Layout for Compact BLDC Tool Cooling
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Solution Overview
Problem
Conventional power tools with brushless DC electric motors require large motor controller PCBs and separate heat sinks, leading to increased space and complexity in tool design.
Innovation Solution
Integration of a motor controller with a power board and control board onto a motor end cap, utilizing the end cap as a heat sink and eliminating the need for a separate heat sink, simplifies manufacturing and reduces component count, allowing for more compact tool designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate heat sink is added to dissipate heat from the motor controller PCB, then heat dissipation capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the heat sink function with the motor end cap structure. The end cap is designed with heat dissipation features (such as fins or heat channels) that allow it to serve dual purposes: mechanical enclosure/protection and thermal management. This eliminates the need for a separate heat sink component while maintaining effective heat dissipation from the motor controller PCB.
Solution Approach 2:
The motor end cap is transformed from a single-function mechanical component into a multi-functional element that simultaneously provides structural support, electrical insulation, and heat dissipation. By integrating heat sink capabilities into the end cap design, the system reduces overall component count while achieving thermal management goals.
2Adaptability or versatility
If a large motor controller PCB is used to accommodate all control components, then functional completeness is improved, but space requirements and device size increase
Solution Approach 1:
The patent divides the motor controller system into multiple smaller circuit boards or module groups that can be arranged in a compact configuration. Instead of one large PCB housing all components, the control functions are distributed across several smaller boards that fit within the motor assembly space, reducing the footprint while maintaining all necessary control functionalities.
Solution Approach 2:
The patent utilizes three-dimensional space within the motor assembly by stacking or arranging circuit boards vertically or at angles rather than spreading them out in a single plane. This dimensional reorganization allows complete control functionality to be achieved within a smaller overall footprint by exploiting the Z-axis and angular arrangements.
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 enables the creation of more compact power tools by integrating the motor controller directly onto the motor end cap, effectively dissipating heat and reducing the number of components needed, resulting in simpler manufacturing processes.
Implementation Method 1
A thermal conductive pad is disposed between the power board and the motor end cap
Implementation Method 2
The motor end cap is used as a heat sink to dissipate heat created by the power and control boards
Data Source
AI summary
A motor controller for a motor having an end cap. The motor controller including a power board adapted to couple with a first surface of the end cap, on an internal side of the motor, and including opposing first and second sides and a control board adapted to couple to a second surface of the end cap, on an external side of the motor, and including a processor. The power board including position sensors disposed on the first side and switching elements disposed on the second side.