Design:
The motor controller will be screwed (M4) onto a heat sink which will be enclosed by a multi print 3-D printed (cracks sealed with JB weld) ASA enclosure with splash proof connectors and lid. The heat sink will need to be cut and drilled.
Motor Controller Datasheet:
https://docs.prohelion.com/Motor_Controllers/WaveSculptor22/User_Manual/Cooling.html
Heat Sink Selected:
https://www.digikey.com/en/products/detail/advanced-thermal-solutions-inc/ATS-EXL6-254-R0/5848412
Fans Selected:
Enclosure Connector:
https://amphenol-industrial.com/products/epower-lite-and-epower-lite-mini/
Calculations:
Ploss = ReqIo2 + (αIo + β)Vbus + C𝑓eqVbus2 (from datasheet)
Req= 1.0800E-2, 𝛼= 3.3450E-3, β= 1.8153E-2, C𝑓eq= 1.5625E-4
Vbus = 134.4V (battery 100% SOC), Io = 60/sqrt(2) A (rms value)
Ploss = 43.7757W (heat generated)
We can assume that all of the power loss will be converted to heat, therefore the heat generated will be considered 43.78W.
Q = hAtotal(Tobject−Tambient) (Newton’s Law of Cooling)
Re = ρvL/μ (reynold’s number)
ρ is the air density (typically 1.2 kg/m³ at room temperature).
v is the airflow velocity (m/s), which can be estimated from the fan's specifications.
L is a characteristic length (such as the length of a fin).
μ is the dynamic viscosity of air.
Using Re , you can calculate the convective heat transfer coefficient h based on empirical correlations (such as the Dittus-Boelter equation for turbulent flow):