Electric Mower Battery-Controller Layout for Cooling and Service Access
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Solution Overview
Problem
Existing electric mowers face challenges in efficiently and accurately mounting large-capacity batteries and associated components, such as controllers, on the body while ensuring space for efficient cooling and maintenance access.
Innovation Solution
The electric mower design includes a support member fixed below the battery to house controllers, allowing them to be placed regardless of battery size, with exposed heat sinks for cooling and independent detachment for maintenance, and uses plates to support the battery from below, ensuring components do not obstruct the mower cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large-sized battery is installed to improve mowing operation efficiency, then the battery capacity is improved, but the space for mounting associated components such as controller becomes insufficient
Solution Approach 1:
The controller is relocated from the traditional battery compartment to a dedicated support member structure below the battery. This spatial redistribution utilizes the vertical dimension and creates separate mounting zones, allowing the battery to occupy maximum horizontal space while the controller is positioned in the unused lower space, thereby resolving the space conflict between battery and controller mounting.
Solution Approach 2:
The support member is designed as a separate, independent component with dedicated mounting functions. It segments the overall structure into distinct functional zones: battery mounting area, controller mounting area, and cooling airflow paths. This segmentation allows each component to be optimized independently without interfering with the other's space requirements.
2Device complexity
If the controller is mounted close to the battery to save space, then the device complexity is reduced, but the cooling efficiency of the controller deteriorates
Solution Approach 1:
The support member acts as an intermediary structure that mediates between the battery and the controller. It provides a dedicated mounting platform that separates the controller from the battery compartment while maintaining structural integration. This intermediary design enables proper spacing for cooling airflow paths to reach the controller's heat sink section without requiring complex additional cooling systems.
Solution Approach 2:
The controller is positioned in the vertical dimension below the battery rather than being mounted adjacent to it horizontally. This dimensional change creates natural airflow paths from above and around the battery to the controller's heat sink section, improving cooling efficiency without increasing horizontal space consumption or structural complexity.
3Manufacturing precision
If the controller is fixed to the body directly, then the manufacturing precision is improved, but the ease of repair deteriorates due to inability to detach independently
Solution Approach 1:
The controller mounting system is segmented into two independent parts: the support member that is fixed to the body with high precision, and the controller that is attached to the support member. This segmentation allows the support member to be manufactured and installed with high precision for accurate positioning, while the controller can be independently detached from the support member for maintenance and repair, resolving the contradiction between mounting precision and ease of repair.
Solution Approach 2:
The support member serves as an intermediary mounting interface between the body and the controller. It provides precise mounting holes for accurate positioning when fixed to the body, while simultaneously providing attachment points for the controller. This intermediary design enables high precision mounting during assembly while allowing easy independent detachment for repair purposes.
4Volume of moving object
If the controller is positioned to coincide with the mower cover, then the space utilization is improved, but the ease of operation deteriorates due to obstruction of mower cover movement
Solution Approach 1:
The controller is positioned asymmetrically on the support member, offset from the central axis and aligned with the rear portion of the mower unit. This asymmetric positioning ensures that the controller does not coincide with the mower cover's movement path, allowing the mower cover to move freely without obstruction while still utilizing available space efficiently through the support member's structured layout.
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 configuration enables efficient mounting and cooling of controllers, facilitates maintenance, and maintains operational efficiency by avoiding interference with the mower cover, while accommodating various battery sizes.
Implementation Method 1
the at least one controller includes, at the lower face, a heat sink section exposed downward through the opening
Data Source
AI summary
An electric mower includes: a body; a battery on the body; at least one motor drivable on electric power from the battery; a mower unit drivable on motive power from the at least one motor; at least one controller configured to control the at least one motor; and a support member disposed below the battery and fixed to the body, the at least one controller being fixed to the support member.