The forced cooler was designed to significantly reduce the thermal load of a high-performance drone engine when used in an RC helicopter. Axial cooling ribs and open air ducts conduct a continuous air flow directly over the engine surface.
Forced cooling as a key to performance
Powerful engines can reach critical temperatures under permanent load. The printed cooler uses the rotary motion of the motor to guide air in a targeted manner. The laid-out slats support uniform heat dissipation even at high speeds and load peaks.
Result in the test setup
In conjunction with a 5S battery system, the engine remained below 60 °C during longer flight manoeuvres. In the tested construction with around four kilograms of total weight, flight times of about 20 minutes per battery charge were possible.
- directed airflow instead of uncontrolled turbulence,
- more stable temperature window of the motor,
- lower thermal risk for longer loads,
- Additively manufactured component that can be adapted to the engine and installation space.
Conclusion
Targeted cooling increases the thermal reserve and supports reliable flight operation. The forced cooler shows how a concrete problem can be solved in a short time by measuring, CAD construction and additive manufacturing.