Positioning Actuator with Integrated Thermal Management
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Solution Overview
Problem
Existing motorized valve actuators face challenges with vibration issues, complex assembly, and thermal management due to the separation of electronic components from cooling circuits, requiring multiple subassemblies and seals.
Innovation Solution
A positioning actuator design comprising two complementary blocks, where one block with high thermal conductivity integrates mechanical components and a printed circuit, and the other block is a monolithic overmolded stator assembly with a rear bearing housing, simplifying assembly and enhancing thermal conductivity for the electronic circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electronic components are positioned close to the stator assembly opposite the cooling circuits, then thermal management is improved, but vibration problems and assembly complexity increase due to multiple subassemblies and seals
Solution Approach 1:
The patent merges the electronic components, stator assembly, and cooling circuits into a single integrated molded structure. The molded envelope encapsulates the stator assembly and electronic components together, while integrating the cooling circuits directly into this envelope, eliminating the need for separate subassemblies and multiple seals, thus reducing assembly complexity while maintaining effective thermal management.
2Temperature
If multiple subassemblies and seals are used to position electronic components, then thermal management is achieved, but vibration resistance and assembly simplicity deteriorate
Solution Approach 1:
The molded envelope encapsulates the stator assembly and electronic components as a single integrated unit, eliminating multiple separate subassemblies and seals. This monolithic structure inherently provides vibration resistance by eliminating interfaces between separate components, while the integrated cooling circuits maintain thermal management effectiveness.
3Manufacturing precision
If a molded stator structure is produced separately and then assembled with other motor components, then manufacturing precision is improved, but assembly complexity and production time increase
Solution Approach 1:
The patent combines the stator assembly, electronic components, and cooling circuits into a single molded envelope structure that can be produced as one integrated component. This eliminates the need for separate assembly steps between the molded stator structure and other motor components, reducing production time while maintaining the manufacturing precision benefits of molding.
4Adaptability or versatility
If mechanical means are used to fix the stator assembly in an envelope, then assembly flexibility is maintained, but thermal conductivity and assembly simplicity worsen
Solution Approach 1:
The molded envelope is designed with integrated cooling circuits that are formed as part of the molding process itself, eliminating the need for separate mechanical thermal connection means. This provides excellent thermal conductivity through the integrated fluid channels while the molding process inherently provides the necessary assembly flexibility and adaptability.
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 design simplifies assembly, ensures effective thermal management, and provides vibration resistance with a single assembly step, eliminating the need for pre-load on bearings and reducing the complexity of assembly operations.
Implementation Method 1
the electronic circuit can benefit from a favorable thermal conductivity of the first block to guarantee an acceptable working temperature
Implementation Method 2
it is known to encapsulate part of the engine components in a plastic material. This overmolding ensures that the components subjected to vibrations are held in place and promotes heat transfer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a positioning actuator which comprises a stator assembly and a rotor (6), a printed circuit (29) provided with electronic components, as well as a reduction gear (4, 5) for driving a rotary member characterised in that it comprises two complementary blocks (1, 2), the first block (1) being made up of a shell having thermal conductivity no lower than 1 W/m/K, said first block (1) including said reduction gear (4, 5) and having a passage for the output shaft (11) of the reducing gear (4, 5) as well as an open opposing surface; said second block (2) being formed by overmoulding the stator assembly (22) and having a rear bearing recess (23) for the rotor, said second block (2) having a joining surface which complements a joining surface of said first block (1), the actuator also being characterised in that said electronic circuit (29) is positioned in a space defined between said first (1) and second (2) blocks. The invention also relates to a method for manufacturing such an actuator.