Robot Controller Airflow Layout for Differential Component Cooling
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Solution Overview
Problem
Existing robot controllers face challenges in cooling the power supply board, power circuit board, and regenerative resistor under suitable conditions due to their placement in the same space within the case main body, leading to inefficient cooling and reliability issues.
Innovation Solution
The robot controller features a case with an intake port and exhaust port connected by a flow channel, where a circuit board converts current types and a regenerative resistor is placed downstream, allowing for separate cooling of these components based on their heat generation profiles, with a fan-enhanced airflow system to optimize cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the power supply board, power circuit board, and regenerative resistor are placed side by side in the same space within the case main body, then the device complexity is reduced and space is saved, but the cooling efficiency of each component deteriorates because they are under similar cooling conditions
Solution Approach 1:
The case main body is divided into a first space and a second space by a partition wall. The circuit board is placed in the first space while the regenerative resistor is placed in the second space. This spatial segmentation allows each component to be cooled under different conditions, with the circuit board receiving cooling from the first flow channel and the regenerative resistor being cooled by the second flow channel, thereby resolving the contradiction between structural simplicity and cooling efficiency.
2Temperature
If separate cooling systems are provided for each component, then the cooling efficiency improves, but the device complexity and space requirement increase
Solution Approach 1:
The partition wall serves multiple functions: it separates the first space and second space for differential cooling, while also integrating the first flow channel and second flow channel into a unified cooling system. The intake port and exhaust port are shared between both cooling channels, merging the cooling infrastructure while maintaining separate cooling zones. This approach achieves component-specific cooling without proportionally increasing overall system complexity.
3Reliability
If the circuit board and regenerative resistor are placed in different spaces with separate flow channels, then the reliability improves due to optimized cooling, but the manufacturing complexity increases
Solution Approach 1:
The internal space is segmented by a partition wall that creates distinct first and second spaces. The first flow channel extends from the intake port to the exhaust port through the first space, while the second flow channel does the same through the second space. This segmentation allows independent optimization of cooling paths for each component, improving reliability by ensuring each component operates within its optimal temperature range, while the modular design facilitates manufacturing.
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 enhances the reliability of the robot controller by ensuring each component is cooled under optimal conditions, increasing the system's overall reliability and safety while allowing for compact installation and easy maintenance.
Implementation Method 1
a circuit board placed within the flow channel and converting one of an alternating current and a direct current into the other
Implementation Method 2
a regenerative resistor placed downstream of the circuit board within the flow channel and consuming a counter electromotive force generated from a motor included in a robot
Implementation Method 3
a case having an intake port and an exhaust port and a flow channel connecting the intake port and the exhaust port, in which a gas supplied from the intake port flows toward the exhaust port
Data Source
AI summary
A robot controller includes a case having an intake port and an exhaust port and a flow channel connecting the intake port and the exhaust port, in which a gas supplied from the intake port flows toward the exhaust port, a circuit board placed within the flow channel and converting one of an alternating current and a direct current into the other, and a regenerative resistor placed downstream of the circuit board within the flow channel and consuming a counter electromotive force generated from a motor of a robot. Further, the intake port and the exhaust port are placed in a same surface.