UAV Control Box with Removable Stiffener and Heat Sink
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Solution Overview
Problem
Traditional backplane architectures for unmanned aerial vehicles (UAVs) face structural and thermal challenges due to high-stress environments, limited processing capability, and increased weight and space requirements, which can lead to mechanical and electrical failures.
Innovation Solution
A control box design featuring a housing with a removable stiffener and heat sink, where a system-on-module (SOM) circuit board is positioned between the stiffener and heat sink, utilizing thermal interface material to enhance heat dissipation and structural support through a plurality of fingers, and a second circuit board provides communication interfaces between PM devices and secondary devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional backplane architectures are used in UAVs, then individual hardware components can be provided for each control system, but the weight and space requirements increase
Solution Approach 1:
The patent combines multiple individual hardware components into a single integrated control box that houses both the vehicle control system and mission control system. The control box includes a housing with a circuit board that can accommodate multiple control modules, thereby reducing the overall weight and space requirements while maintaining the functionality of separate components.
Solution Approach 2:
The control box is designed as a universal platform that can perform multiple functions through different control modules. The circuit board can support various modules for navigation, propulsion control, payload management, and other mission-specific functions, allowing a single device to replace multiple specialized components.
2Adaptability or versatility
If traditional backplane architectures are used in UAVs, then individual hardware components can be provided for each control system, but the space requirements increase
Solution Approach 1:
The patent combines multiple individual hardware components into a single integrated control box that houses both the vehicle control system and mission control system. The control box includes a housing with a circuit board that can accommodate multiple control modules, thereby reducing the overall weight and space requirements while maintaining the functionality of separate components.
Solution Approach 2:
The control box employs a nested structure where control modules are integrated within the housing. The circuit board is positioned within the housing, and control modules can be mounted on the circuit board, creating a compact nested arrangement that minimizes space while maintaining individual component functionality.
3Productivity
If computing components are mounted on circuit boards in high-stress environments, then processing capability is enhanced, but thermal management challenges arise
Solution Approach 1:
The patent introduces thermal interface material as an intermediary between the computing components and the heat sink. This thermal interface material facilitates efficient heat transfer from the computing components to the heat sink, addressing thermal management challenges while allowing high-performance computing components to be mounted on the circuit board.
Solution Approach 2:
The patent extracts heat from the computing components through a heat sink that is thermally coupled to the circuit board. The heat sink is positioned to receive heat from the computing components and dissipate it to the surrounding environment, separating the thermal management function from the computing function.
4Strength
If circuit boards are positioned in control boxes, then structural support is provided, but mechanical failures can occur in high-stress environments
Solution Approach 1:
The patent uses a housing material that provides structural support and protection for the circuit board. The housing is designed to withstand high-stress environments and protect the internal components from mechanical failures. The combination of the housing and circuit board creates a composite structure that balances structural strength with component protection.
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 improves thermal management and structural integrity, enhances processing capabilities, and reduces weight and space requirements, providing a more reliable and efficient control system for UAVs.
Implementation Method 1
the first circuit board further comprises a thermal interface material disposed on one or more of the computing components, and wherein the thermal interface material contacts one or more of the fingers
Data Source
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AI summary
A control box 100 includes a housing 110 defining an interior 112, the housing 110 including a cover 114 and a stiffener 116, the stiffener 116 removably connected in contact with the cover 114, the stiffener 116 including an outer frame 142 and at least one cross-member 144. The control box 100 further includes a heat sink 118 removably connected in contact with the stiffener 116. The control box 100 further includes a first circuit board 120 disposed within the interior 112, the first circuit board 120 positioned between the stiffener 116 and the heat sink 118, and a second circuit board 122 disposed within the interior 112, the second circuit board 122 positioned between the cover 114 and the stiffener 116. The cover 114, stiffener 116, and heat sink 118 are stacked along a transverse direction 106.