Two-Part Pump Motor Electronics Layout for Compact Cooling
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Solution Overview
Problem
Existing pump motors face challenges in achieving a compact design while ensuring sufficient cooling of control electronics, particularly due to the large size of the electronics housing required for heat dissipation.
Innovation Solution
The pump motor design incorporates a first and second electronics housing, with the first housing accommodating power electronics and a heat sink, and the second housing accommodating less heat-generating components, arranged at the perimeter and axial end of the stator housing, respectively, utilizing a cooling fan to direct airflow for efficient heat dissipation and a compact layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single large electronics housing is used to accommodate all control electronics, then sufficient heat dissipation is achieved, but the overall motor size increases and compactness is reduced
Solution Approach 1:
The electronics housing is divided into two separate housings: a first electronics housing accommodating power electronics (high heat-generating components) and a second electronics housing accommodating control electronics (lower heat-generating components). This segmentation allows each housing to be optimized for its specific thermal requirements, enabling compact design while maintaining sufficient heat dissipation capability for each component type.
2Volume of moving object
If the electronics housing is reduced in size to achieve a compact motor design, then motor compactness is improved, but heat dissipation capability of control electronics becomes insufficient
Solution Approach 1:
By segmenting the electronics into two separate housings, each housing can be minimized in size according to its specific component requirements while maintaining adequate heat dissipation. The first housing for power electronics and the second housing for control electronics can be independently sized, resulting in an overall compact motor design without compromising thermal management.
3Device complexity
If all electronics are arranged in a single housing, then device complexity is reduced, but assembly time increases and manufacturing efficiency decreases
Solution Approach 1:
The two electronics housings are designed as separate, pre-assembled units that can be manufactured and tested independently before final installation in the motor. This segmentation enables parallel manufacturing processes and simplifies assembly, as each housing unit can be prepared separately and then quickly installed in their respective positions, thereby increasing overall productivity despite the increased structural complexity.
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 achieves a more compact and less noisy pump motor with improved cooling efficiency, reducing the risk of electronic damage and facilitating quicker assembly.
Implementation Method 1
a cooling fan at a non-drive-end of the stator housing, so that cooling air flows along the axially extending lateral cooling ribs of the stator housing
Implementation Method 2
a heat sink, wherein the heat sink comprises heat sink cooling ribs facing towards the stator housing
Implementation Method 3
heat sink cooling ribs and stator housing cooling ribs define inlet flow paths towards a cooling fan suction inlet
Data Source
AI summary
A pump motor (1) includes a rotor (2) mounted to a drive shaft (3) extending along a rotor axis (L). The rotor (2) is circumferentially embraced by a stator. A stator housing (5), encloses the stator. The stator housing includes a first axial end and a second axial end. Electronics for powering and controlling the motor operation include a first portion, arranged on a first PCB, and a second portion, arranged on a second PCB (51). A first electronics housing (11) accommodates the first PCB. The first electronics housing (11) is arranged at a perimeter of the stator housing (5). A second electronics housing (47) accommodates the second PCB (51). The second electronics housing (47) is arranged at the second axial end of the stator housing (5). The second electronics housing (47) at least partially rings the drive shaft (3).