Stator Module Cooling Unit for Planar Drive Thermal Management
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Solution Overview
Problem
Planar actuator systems face challenges with overheating due to high resistance losses in current-carrying conductors and electromagnetic alternating fields disrupting electronic components, leading to functional operation issues, especially at high environmental temperatures.
Innovation Solution
A stator module design with a cooling unit and carrier device that dissipates heat effectively through a housing cover and base, using thermally conductive elements and a heat sink to manage heat transfer and reduce eddy currents, ensuring reliable operation even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current strength is used to generate adequate drive force, then the drive force is improved, but resistance losses increase causing significant heating of the stator module
Solution Approach 1:
The harmful thermal energy (heat) is extracted from the stator module through a dedicated cooling unit. The cooling unit includes a cooling body with cooling channels that receive cooling fluid, actively removing the heat generated by resistance losses to prevent excessive temperature rise while maintaining high drive force capability
Solution Approach 2:
Cooling fluid serves as an intermediary medium to transfer heat away from the stator module. The cooling fluid flows through cooling channels in the cooling body, absorbing thermal energy from the stator module and carrying it away, thus mediating the heat removal process without directly contacting the electrical components
2Ease of operation
If drive current is generated as alternating current to enable movement, then the drive function is improved, but electromagnetic alternating fields are generated that can disrupt electronic components
Solution Approach 1:
The stator module is segmented into functionally separated regions: an upper region for drive components (coil conductors, magnets) and a lower region for electronic components (power electronics, control electronics). This spatial segmentation isolates the electromagnetic interference-generating drive section from the sensitive electronic components, reducing disruption while maintaining drive function
Solution Approach 2:
A housing structure serves as an intermediary barrier between the drive components and electronic components. The housing provides electromagnetic shielding and physical separation, acting as a mediator that blocks or attenuates electromagnetic alternating fields from reaching sensitive electronics while allowing the drive function to operate with alternating current
3Device complexity
If electronic components are arranged underneath the stator unit to save space, then device compactness is improved, but the electronic components are exposed to heat and electromagnetic fields
Solution Approach 1:
The stator module is divided into distinct functional zones: an upper drive section and a lower electronic components section, separated by a housing. This segmentation allows compact vertical arrangement while providing protective separation, enabling electronic components to be positioned underneath for space efficiency while shielding them from heat and electromagnetic fields through the housing structure
Solution Approach 2:
The housing structure provides beforehand protection (cushioning) for electronic components against thermal and electromagnetic stress. By designing the housing with thermal insulation properties and electromagnetic shielding capabilities before the components are exposed to harsh conditions, the reliability of electronic components is maintained even in the compact arrangement underneath the stator unit
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 solution provides reliable cooling of the stator module, preventing overheating and ensuring functional operation at high temperatures, with efficient heat dissipation and reduced thermal resistance, allowing for a wide range of applications.
Implementation Method 1
The housing cover is thermally connected, at least in part, to a stator underside of the stator unit at a cover upper side of the housing cover. The housing cover is thermally connected to the housing base on a cover underside facing away from the stator unit.
Implementation Method 2
The housing base is arranged at the module underside and has a first fastening portion at the module underside. The first fastening portion is thermally connectable to a heat sink.
Implementation Method 3
The stator unit has at least one coil conductor which can be energized by a drive current to generate a magnetic field for driving a moving body
Implementation Method 4
using thermally conductive elements and a heat sink to manage heat transfer and reduce eddy currents
Data Source
AI summary
A stator module is disclosed, and a planar drive system with a stator module. The stator module has a lower face opposite an upper face, a stator unit situated on the upper face, and a cooling unit. The stator unit has a coil to which current can be supplied to generate a magnetic field to drive a mover, positionable on the upper face of the stator module. The cooling unit has a cover thermally connected to a lower face of the stator unit and to the bottom of the housing. The bottom of the housing has a first fastening section on the lower face of the stator module, thermally connectable to a heat sink. The cover is designed to conduct heat out of the stator unit to the bottom of the housing, which is designed to conduct the heat at least partially to the first fastening section.