Thermally efficient motor controller assembly

Details Thermally efficient motor controller assembly Thermally efficient motor controller assembly

1999-08-16

2001-06-19

Picard, Leo P. (Department: 2835)

Electricity: electrical systems and devices

Housing or mounting assemblies with diverse electrical...

For electronic systems and devices

C361S695000, C361S704000, C361S707000, C174S016100, C174S016300, C174S050510, C165S080200, C165S185000, C363S141000

Reexamination Certificate

active

06249435

ABSTRACT:

BACKGROUND OF THE INVENTION
This invention relates to motor controllers, and, more particularly, to thermally efficient motor controller assemblies.
U.S. Pat. No. 5,341,080 entitled Apparatus and Three Phase Induction Motor Starting and Stopping Control Method, describes starters and contactors used to efficiently start and stop industrial rated electric motors. A more recent example of a motor controller unit is found in U.S. Pat. No. 5,760,556 entitled Motor Controller and Protector Unit. In such motor controllers and electrical contractors, solid state switches, such as silicon controlled rectifiers (SCR), for example, are often employed to controllably switch the motor current to provide smooth motor starting and stopping function. Since the SCR's become heated upon current transfer therethrough, heat sinks in the form of large metal blocks of copper, aluminum and their alloys are required to protect the SCR's from overheating. The SCR's are usually spaced apart from the other motor controller components to facilitate cooling. Electrical connection between the SCR's and the other motor controller components is made by means of electrically-insulated thick metal cables, one for each phase of the associated electrical distribution system.
U.S. patent application Ser. No. 08/904,293 entitled Compact Electrical Equipment Enclosure, describes an equipment enclosure that is open at the rear thereof to provide an air flow, so called “chimney effect.” The SCR's connecting with the motor controller are arranged apart from the other motor controller electric components within the air flow path to promote thermal cooling effects. The placement of the SCR's apart from the other electrical components increases the size of the equipment enclosure to some extent. This size limitation is critical when other devices such as circuit breakers and contactors are interconnected as described in U.S. Pat. No. 5,657,193 entitled Electronic Control Module for Motor Controller Units.
BRIEF SUMMARY OF THE INVENTION
In an exemplary embodiment of the invention, an arrangement for connection between motor controller electronic components and SCR's contained within the controller circuit is presented with the line and load straps being arranged on the bottom surface of the motor controller compartment at opposite ends thereof. The SCR's are positioned under the compartment on an elongated heat-sink support plate. Intermediate block connectors interconnect SCR's with the controller line and load straps. A highly-efficient cooling fan is arranged on the elongated heat-sink support plate to rapidly control the temperature of the SCR's during motor start and stop function. A thermistor control switch can be employed for turning the switching the cooling fan in accordance with the SCR cooling requirements. In this exemplary embodiment, the SCR's do not have to be separate from the other components or employ special motor controller equipment enclosure designs, as in the prior art. This arrangement provides efficient means for cooling the SCR's with a minimum space and cost requirement while facilitating electrical connection between the motor controller components and the SCR's as well as between the SCR's and the electrical distribution system connectors.


REFERENCES:
patent: 3693047 (1972-09-01), Hamstra
patent: 4336568 (1982-06-01), Mitchell
patent: 5341080 (1994-08-01), Agut Sanz
patent: 5657193 (1997-08-01), Purkayastha
patent: 5690468 (1997-11-01), Hong
patent: 5742478 (1998-04-01), Wu
patent: 5760556 (1998-06-01), Hamilton, Jr. et al.
patent: 5774353 (1998-06-01), Wieloch
patent: 5946192 (1999-08-01), Ishigami et al.
patent: 6087800 (2000-07-01), Becker et al.
patent: 6091604 (2000-07-01), Plougsgaard et al.
patent: 6104602 (2000-08-01), Morris et al.

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