Vacuum Pump Regenerative Resistor Relocation for Thermal Management
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Solution Overview
Problem
Existing vacuum pumps face challenges in effectively dissipating heat from regenerative resistors, leading to potential malfunctions due to temperature rises, especially in compact designs where space and cooling solutions are limited.
Innovation Solution
The regenerative resistor is relocated from the control apparatus to the vacuum pump's base, which has a larger heat capacity, and is connected via a wire, with a gap for thermal insulation and a cover to reduce electrical noise, allowing for improved heat dissipation without the need for additional cooling devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the regenerative resistor is installed in the control apparatus, then the control can be integrated, but the heat dissipation becomes difficult and temperature rises drastically
Solution Approach 1:
The regenerative resistor is extracted from the control apparatus and relocated to the vacuum pump body. This separation removes the heat-generating component from the temperature-sensitive control environment, allowing the control apparatus to maintain lower temperatures while still achieving functional integration through electrical connections.
Solution Approach 2:
A thermal insulation structure is introduced as an intermediary between the regenerative resistor and the control apparatus. This mediator prevents heat transfer from the resistor to the control components, enabling both to coexist in close proximity without thermal interference.
2Temperature
If a heatsink is provided separately to cool the regenerative resistor, then heat dissipation improves, but the vacuum pump size increases and space requirements increase
Solution Approach 1:
The cooling function for the regenerative resistor is merged with the vacuum pump's existing cooling system. The resistor utilizes the pump's internal cooling passages and airflow paths, eliminating the need for separate heatsinks and reducing overall system volume while maintaining effective heat dissipation.
Solution Approach 2:
The vacuum pump's cooling system is designed to serve multiple functions: cooling the pump components and cooling the regenerative resistor. This multi-functionality reduces the need for dedicated cooling components for each heat-generating element, thereby minimizing the overall pump size.
3Temperature
If an air-cooling fan is attached to enhance coolability, then heat dissipation improves, but noise increases and reliability decreases
Solution Approach 1:
The system utilizes the vacuum pump's own operational airflow and cooling mechanisms to cool the regenerative resistor and control apparatus, rather than requiring external active cooling devices. The pump's rotation and internal airflow patterns naturally provide cooling, eliminating the need for additional fans and improving reliability.
Solution Approach 2:
Active mechanical cooling systems (fans) are replaced with passive cooling approaches that utilize the pump's inherent operational characteristics. The cooling effect is achieved through the pump's rotation-induced airflow and thermal conduction paths, eliminating mechanical cooling components that would add noise and potential failure points.
4Temperature
If a water-cooled plate is connected to the control apparatus, then heat dissipation improves, but the system complexity and cost increase
Solution Approach 1:
The complex water-cooling system with embedded pipes is extracted and replaced with a simpler cooling approach. The regenerative resistor is cooled using the vacuum pump's existing cooling infrastructure, which eliminates the need for separate water-cooled plates and complex piping within the control apparatus.
Solution Approach 2:
Instead of implementing expensive and complex water-cooling infrastructure, the design utilizes simpler, more reliable cooling methods that are already integrated into the vacuum pump. The solution accepts short-term heat management challenges that can be addressed through design optimization rather than investing in complex cooling systems.
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 enhances heat dissipation capabilities, reduces the temperature increase of the control apparatus, and allows for a more compact design by eliminating the need for separate cooling systems, while minimizing electrical noise and improving safety.
Implementation Method 1
The regenerative resistor is a resistor that converts the regenerative energy into thermal energy and consumes the resultant thermal energy
Implementation Method 2
the regenerative resistor is inserted into a hollow portion provided in an outer portion of a base of a vacuum pump main body... with a gap for thermal insulation
Data Source
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AI summary
To realize a vacuum pump capable of improving the heat dissipation capability of a regenerative resistor with a simple configuration, and a control apparatus associated with the vacuum pump. The regenerative resistor is removed from the control apparatus and disposed in the vacuum pump. More specifically, the regenerative resistor is detached from a control board (control apparatus) on which a control circuit is mounted, and then disposed in a base of the vacuum pump via a wire. Further, a gap is provided between the base of the vacuum pump and the control apparatus. Moreover, a cover (outer covering body) is provided in the regenerative resistor disposed in the base part of the vacuum pump and the wire part. Since the regenerative resistor is provided in the base of the vacuum pump having a large heat capacity, a temperature increase of the control apparatus is reduced. By providing the gap between the base of the vacuum pump and the control apparatus, the heat insulation effect using air is improved, reducing a temperature increase of the control apparatus. By providing the cover in the part where the regenerative resistor is provided, electrical noises to be generated can be reduced and an indirect surface temperature of the base can be reduced.