How to solve the internal heat dissipation problem of wired air pump

Analysis of Difficulties in Internal Heat Dissipation
The main heat sources inside the Wired Air Pump are concentrated in the motor windings, drive circuits, and mechanical friction components. The air pump has a relatively compact structure, limited space, and narrow heat dissipation channels, which makes it difficult for heat to be quickly transferred to the external environment. At the same time, the heat generated during long-term continuous operation accumulates. If the heat is not dissipated smoothly, it will cause excessive temperature, resulting in aging of winding insulation, thermal failure of circuit components, and degradation of lubricant performance.
In addition, working conditions with high ambient temperature and limited air circulation place higher requirements on heat dissipation effects. Sealing structures usually limit the setting of ventilation holes to prevent dust and water, further exacerbating the difficulty of heat dissipation. The above factors make internal heat dissipation of the Wired Air Pump a difficult problem in design and manufacturing.

Optimize heat dissipation structure design
The heat dissipation path planning should be given priority in the design stage. Using materials with high thermal conductivity to make key components, such as aluminum alloy shells instead of plastic shells, helps to speed up the heat conduction to the outside. The contact surface between the motor stator and windings and the shell should be maximized, and thermal grease or thermal pads should be used to improve the heat conduction efficiency.
In terms of structural layout, the position of the heating components should be arranged reasonably to avoid stacking of high-temperature components. At the same time, a built-in air guide slot or heat dissipation channel is designed to use the natural convection of airflow to remove heat. Some high-end products can adopt a double-layer heat dissipation structure, with heat dissipation fins on the outer layer to increase the contact area with the air.
Reasonably leave heat dissipation holes or air inlets to ensure that effective airflow circulation is formed inside the air pump and improve the convection heat dissipation capacity. The heat dissipation hole position should avoid the inhalation of dust or moisture, and cooperate with the dust filter design.

Introducing active heat dissipation technology
Natural heat dissipation has limitations on high-power air pumps, and the appropriate use of active heat dissipation has become an important means to improve heat dissipation efficiency. The built-in small fan accelerates heat removal by forced air flow, which is suitable for models where space allows. The fan design needs to focus on low noise and durability.
Liquid cooling technology has begun to be used in some high-end or special application scenarios. The heat of the motor and circuit is removed by circulating cooling liquid through the pipeline, which greatly improves the heat dissipation efficiency, but the cost and complexity increase, and it is suitable for occasions with extremely high performance requirements.
Heat pipe technology has also been gradually introduced, using efficient heat conduction characteristics to quickly transfer hot spot heat to the heat dissipation fins or housing, shortening the heat transfer path and slowing down temperature accumulation.

Improve the heat resistance of internal components
While improving the heat dissipation capacity, optimizing the heat resistance of internal components is a double guarantee. Use high-temperature insulating materials to make motor windings, select industrial-grade electrolytic capacitors and high-temperature resistant chips to delay thermal aging.
Lubricants use grease with good high-temperature stability to keep mechanical parts low friction and reduce the intensity of the heat source. Seals use high-temperature resistant elastic materials to prevent leakage due to temperature fluctuations.
Temperature-sensitive electronic modules use insulation design, or set heat sinks and thermal interface materials to ensure stable operation of electronic components.

Intelligent temperature control and protection mechanism
The built-in temperature sensor monitors the internal temperature changes of the air pump in real time to achieve intelligent temperature control. The motor speed or start-stop cycle is adjusted through the control algorithm to avoid overheating caused by long-term full-load operation.
When the temperature reaches the preset threshold, the protection program is automatically started to reduce power or stop operation to prevent equipment damage. The user interface displays the temperature status, which is convenient for maintenance personnel to take timely measures.
Combined with remote monitoring technology, real-time feedback on the temperature status of the equipment is provided to achieve fault warning and remote maintenance, and improve equipment management efficiency.

Heat dissipation testing and verification
Multiple rounds of thermal simulation and physical testing should be conducted during the design phase to evaluate the effects of different structures and heat dissipation solutions. Use thermal imagers and temperature sensors to monitor the temperature of key parts and find potential heat dissipation blind spots.
Use environmental chamber testing to verify the heat dissipation performance of the equipment under extreme conditions such as high temperature, high humidity, and closedness to ensure that mass-produced equipment has stable heat dissipation capabilities.
Combined with accelerated life testing, verify the effectiveness of heat dissipation design in extending the life of the equipment.