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, leading to larger electronics housings that hinder size reduction.
Innovation Solution
The design incorporates a second electronics housing that rings the drive shaft, with the cooling fan mounted to the drive shaft, and a fan cover that guides airflow for efficient cooling, allowing for a compact and quieter motor assembly by decoupling heat dissipation paths and using a radial cooling fan with a 180° airflow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the electronics housing is made larger to accommodate sufficient heat dissipation of control electronics, then cooling effectiveness is improved, but the overall size of the pump motor increases
Solution Approach 1:
The second electronics housing is arranged axially between the cooling fan and the second axial end of the stator housing, with the drive shaft extending through it. This nested arrangement allows the electronics housing to be integrated within the existing motor structure rather than adding external volume, while still providing sufficient space for heat dissipation of the control electronics.
Solution Approach 2:
The patent utilizes the axial dimension between the cooling fan and the stator housing end to position the second electronics housing. By arranging electronics in two separate housings (first at the drive end, second at the non-drive end), the design distributes heat dissipation across different axial positions, improving cooling effectiveness without increasing radial or overall length dimensions.
2Device complexity
If a single electronics housing is used, then device complexity is reduced, but heat dissipation of power electronics becomes insufficient
Solution Approach 1:
The electronics housing is divided into two separate housings: a first electronics housing at the drive end accommodating power electronics, and a second electronics housing at the non-drive end accommodating control electronics. This segmentation allows each housing to be optimized for its specific thermal requirements, with the first housing positioned near the cooling fan for effective heat dissipation and the second housing arranged to avoid thermal interference.
Solution Approach 2:
The power electronics are extracted into a separate first electronics housing positioned at the drive end, away from the control electronics in the second housing. This separation extracts the primary heat source from the control electronics environment, allowing each section to be cooled independently and effectively without requiring a single large housing.
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 results in a more compact, quieter, and easier-to-assemble pump motor with effective heat dissipation, reducing noise and enabling quicker assembly while maintaining efficient cooling of both stator and electronics components.
Implementation Method 1
The pump motor comprises a cooling fan being mounted to the drive shaft, wherein the second electronics housing is arranged axially between the cooling fan and the second axial end of the stator housing
Implementation Method 2
The first PCB is thermally coupled to a heat sink being arranged between the first PCB and the stator housing
Implementation Method 3
cooling air flows along the axially extending lateral cooling ribs of the stator housing
Data Source
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AI summary
The present disclosure refers to a pump motor (1) comprising - a rotor (2) mounted to a drive shaft (3) extending along a rotor axis (L), wherein the rotor (2) is circumferentially embraced by a stator, - a stator housing (5) enclosing the stator, wherein the stator housing (5) comprises a first axial end and a second axial end, - electronics for powering and controlling the motor operation, wherein a first portion of the electronics are arranged on a first PCB and a second portion of the electronics are arranged on a second PCB (51), and - a first electronics housing (11) accommodating the first PCB, wherein the first electronics housing (11) is arranged at a perimeter of the stator housing (5), characterised by further comprising a second electronics housing (47) accommodating the second PCB (51), wherein the second electronics housing (47) is arranged at the second axial end of the stator housing (5), wherein the second electronics housing (47) at least partially rings the drive shaft (3).