Power Tool Controller Cooling via Segmented Airflow Paths
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Solution Overview
Problem
Existing power tools with brushless motors do not effectively cool the controller, leading to potential overheating and reduced performance.
Innovation Solution
A power tool design that includes a body housing with specific inlets and outlets to direct air flow for cooling both the motor and the controller, utilizing a fan mounted on the rotational shaft to divide the air flow into separate paths for cooling the power transmission mechanism and the controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single air outlet is used for cooling both the motor and controller, then the structure is simple, but the controller cannot be sufficiently cooled
Solution Approach 1:
The single air outlet is divided into two separate outlets: a first air outlet for discharging air that has cooled the motor, and a second air outlet for discharging air that has cooled the controller. This segmentation allows each component to have dedicated cooling airflow paths, ensuring the controller is sufficiently cooled without requiring complex additional cooling systems.
2Reliability
If air flow is not divided into separate paths, then the structure is simple, but the controller overheats and performance decreases
Solution Approach 1:
The air flow path is segmented into two distinct paths within the housing: a first air flow path leading to the first air outlet for motor cooling, and a second air flow path leading to the second air outlet for controller cooling. This segmentation ensures that hot air from the motor does not recirculate to the controller, preventing overheating while maintaining a relatively simple overall structure.
Solution Approach 2:
Different regions of the housing are designed with different functions: the first air outlet is positioned to discharge cooled air away from the controller area, while the second air outlet is positioned to discharge controller-cooled air in a direction that prevents heat transfer to the motor. This local differentiation of air discharge qualities ensures optimal cooling for each component.
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 ensures effective cooling of the controller, preventing overheating and enhancing the tool's performance and reliability.
Implementation Method 1
an air blow generated by the rotating fan enters the cylindrical portion through the inlet in the rear of the cylindrical portion of the motor housing and is discharged out of the cylindrical portion through the outlet in the front. The air blow passes by the brushless motor
Implementation Method 2
the body housing is configured to divide air drawn through the inlet and having cooled the brushless motor into a first outlet blow for cooling the power transmission mechanism and being discharged through the first outlet and a second outlet blow for cooling the controller and being discharged through the second outlet
Data Source
AI summary
A power tool includes a body housing including a first grip, inlet facing a front surface of the first grip, first outlet, and second outlet; a brushless motor held on the body housing and including a rotational shaft; an output unit supported on the body housing in a reciprocable manner; a power transmission mechanism between the brushless motor and the output unit in the body housing to transmit rotational motion of the rotational shaft to the output unit; a controller held on the body housing to control the brushless motor; and a fan held on the body housing and mounted on the rotational shaft. The body housing allows air drawn through the inlet and having cooled the brushless motor to be divided into first and second outlet blows respectively cooling the power transmission mechanism and discharged through the first outlet, and cooling the controller and discharged through the second outlet.