Thermal Limitations of the Existing Enclosure Architecture of a Low-Cost Delta-Robot Joint Under Increased Sealing

Increasing enclosure closure can compromise heat removal in compact robotic joints. This study assesses the thermal limitations of an existing low-cost Delta-robot joint with an additively manufactured ABS enclosure. Under an equivalent constant thermal load of 4.744 W the predicted steady-state driver temperatures were 79.11°C with forced ventilation, 145.11°C with open natural convection, and 172.42°C with closed natural convection. The driver remained the dominant numerical hotspot, reaching 108.0°C after 300 s in the closed transient simulation. These predictions exclude thermal radiation and protection-related shutdown; the closed steady-state result, therefore, represents a numerical limiting condition rather than an attainable operating temperature. Preliminary measurements and thermography identified the electronics region as thermally critical and documented shutdown following ventilation removal, but did not provide quantitative CFD validation. The findings establish a baseline for redesigning the joint’s heat-removal paths as environmental protection is increased; IP54 remains a future design target rather than a demonstrated rating.