Resilient printed circuit board retaining arrangement

Abstract

The invention relates to a resilient printed circuit board retaining arrangement. A controller for an electric machine of a turbomachine is provided, comprising a support structure, a printed circuit board and a fastener arrangement for retaining the printed circuit board on the support structure, the fastener arrangement comprising a resilient member for resiliently biasing the printed circuit board toward the support structure.

Description

Technical Field

[0001] The present disclosure relates generally to turbomachinery, and more particularly to an integrated motor controller for a turbomachinery having a fastening arrangement, such as for fastening a printed circuit board therein. Background Art

[0002] Some turbomachines include an electric machine, such as an electric motor or a generator. More specifically, some turbochargers, superchargers, or other fluid compression devices may include an electric motor that is operably coupled to the same shaft that supports a compressor impeller, a turbine impeller, or the like. For example, an electric motor may drive a shaft to rotate to assist a turbine stage of the device. In some embodiments, the electric machine may be configured as a generator that converts the mechanical energy of a rotating shaft into electrical energy.

[0003] These devices may also include a controller that controls the operation of the motor, for example. More specifically, the control system may control the torque, speed or other operating parameters of the motor, and thus control the operating parameters of the rotating group of the device.

[0004] However, conventional controllers for such fluid compression devices have various drawbacks. These controllers may be heavy and / or bulky. In addition, the electronic devices included in the controller may generate a large amount of heat, which may negatively affect operation. Similarly, the operating environment of the device may subject the electronic devices to high temperatures, vibration loads, or other conditions that may negatively affect operation. In addition, the manufacture and assembly of conventional control systems may be difficult, time-consuming, or inefficient.

[0005] Therefore, it is desirable to provide a motor controller for a fluid compression device that is compact and held in a robust manner. It is also desirable to thermally isolate the controller from high temperature vehicle components and to provide electrical isolation of current carrying parts from each other and from electrical ground. Current carrying parts may expand and contract during operation, thus requiring isolation gaps that compensate for changes in physical size. It is also desirable to provide such a controller that provides manufacturing efficiencies. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims in conjunction with the accompanying drawings and this background discussion. Summary of the invention

[0006] In one embodiment, a controller for an electric machine of a turbomachine having a rotating group supported for rotation about an axis is disclosed. The controller includes a support structure, a printed circuit board, and a fastener arrangement that holds the printed circuit board on the support structure, the fastener arrangement including a resilient member that resiliently biases the printed circuit board toward the support structure.

[0007] In another embodiment, a method of manufacturing a controller for an electric machine of a turbomachine having a rotating group supported for rotation about an axis. The method of manufacturing includes providing a support structure, providing a printed circuit board, and attaching the printed circuit board to the support structure using a fastener arrangement, wherein the fastener arrangement includes a resilient member that resiliently biases the printed circuit board toward the support structure.

[0008] In addition, a turbocharger including an integrated controller is disclosed, the integrated controller having a rotating group supported to rotate about an axis. The turbocharger includes: a support structure including a recess for receiving a spring clip, and wherein the recess limits lateral movement of the spring clip; a printed circuit board; a fastener arrangement that holds the printed circuit board on the support structure, the fastener arrangement including a spring clip to resiliently bias the printed circuit board toward the support structure, wherein the spring clip includes a first arm and a second arm that are attached and resiliently deflectable relative to each other, wherein the first arm engages the printed circuit board and the second arm engages the support structure to resiliently bias the printed circuit board toward the support structure; a boss attached to a surface of one of the printed circuit board and the support structure, wherein the spring clip engages the boss to hold the printed circuit board on the support structure; and a guide pin rigidly attached to the support structure and extending through an aperture in the printed circuit board so that lateral movement of the printed circuit board relative to the support structure is limited. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure will hereinafter be described in conjunction with the following drawings, wherein like numerals represent like elements, and wherein:

[0010] Figure 1 is a schematic diagram of an engine system having a fluid compressor apparatus including an integrated controller according to an example embodiment of the present disclosure;

[0011] Figure 2 is an exploded isometric view of an integrated controller according to an exemplary embodiment of the present disclosure;

[0012] Figure 3 is a cross-sectional view of an electronic package integrating a controller according to an exemplary embodiment of the present disclosure;

[0013] Figure 4 is a cross-sectional view of a fastener arrangement of an integrated controller according to an exemplary embodiment of the present disclosure;

[0014] Figure 5 is a cross-sectional view of a fastener arrangement of an integrated controller according to an exemplary embodiment of the present disclosure;

[0015] Figure 6is a diagram of a fastener arrangement of an integrated controller according to an additional exemplary embodiment of the present disclosure; and

[0016] Figure 7 is a view of a fastener arrangement of an integrated controller according to another exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0017] The following detailed description is merely exemplary in nature and is not intended to limit the disclosure or the application and uses of the disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

[0018] Broadly, example embodiments disclosed herein include an improved controller for a turbomachine. The controller can be integrated in, packaged in, and compactly arranged on a turbomachine to improve performance and reduce the size and profile of the turbomachine. In some embodiments, the integrated controller can be circumferentially wrapped, extended, spanned, or otherwise arranged around an axis of rotation defined by a rotating group of the turbomachine. In some embodiments, the housing of the controller can be generally arc-shaped, and internal components (e.g., support structures, electronic components, and / or coolant system features) can be formed, constructed, assembled, and arranged around the axis to reduce the size of the turbomachine.

[0019] In addition, the turbomachinery can be a compressor device, and the integrated controller can be arranged near the compressor section (e.g., near the compressor casing). In addition, the turbomachinery can include a turbine section, and the compressor device can be arranged near the turbine section (e.g., near the turbine casing). In some embodiments, the controller can be compactly arranged between the compressor section and the turbine section of the turbomachinery. In addition, in some embodiments, the integrated controller can be wrapped or arranged around the motor (e.g., motor) of the turbomachinery. The controller can be configured to control the motor, and their close proximity can increase operating efficiency.

[0020] Thus, the controller can be tightly integrated and packaged within the turbomachinery. The integrated controller can also include a fastener arrangement that firmly supports the electronic components. The fastener arrangement can hold the printed circuit board within the assembly and can include at least one resilient member. The fastener arrangement can provide a secure attachment of the printed circuit board to the support structure. The resilient member can facilitate the manufacture and assembly of the integrated controller. In addition, the fastener arrangement can take up a relatively small space, which can allow more electrical components to be included on the printed circuit board. In addition, the resilient member can be resiliently flexed to account for thermal expansion / contraction of parts within the assembly.

[0021] Figure 11 is a schematic diagram of an example turbomachinery such as a turbocharger 100 that is incorporated into an engine system 101 and includes one or more features of the present disclosure. It should be understood that in additional embodiments of the present disclosure, the turbocharger 100 can be another turbomachinery (e.g., a supercharger, a turboless compressor device, etc.). In addition, the turbomachinery of the present disclosure can be incorporated into many systems other than the engine system without departing from the scope of the present disclosure. For example, the turbomachinery of the present disclosure can be incorporated into a fuel cell system for compressing air supplied to a fuel cell stack, or the turbomachinery can be incorporated into another system without departing from the scope of the present disclosure.

[0022] Generally speaking, turbocharger 100 may include a housing 103 and a rotating group 102 supported within housing 103 for rotation about axis 104 by a bearing system 105. Bearing system 105 may be of any suitable type, such as a roller element bearing or an air bearing system.

[0023] As shown in the illustrated embodiment, the housing 103 may include a turbine housing 106, a compressor housing 107, and a center housing 109. The center housing 109 may be disposed axially between the turbine housing 106 and the compressor housing 107.

[0024] In addition, the rotating group 102 may include a turbine wheel 111, a compressor wheel 113, and a shaft 115. The turbine wheel 111 is substantially located within the turbine housing 106. The compressor wheel 113 is substantially located within the compressor housing 107. The shaft 115 extends through the intermediate housing 109 along the rotation axis 104 to connect the turbine wheel 111 to the compressor wheel 113. Therefore, the turbine wheel 111 and the compressor wheel 113 can rotate together around the axis 104 as a unit.

[0025] The turbine housing 106 and the turbine wheel 111 cooperate to form a turbine stage (i.e., a turbine section) that is configured to circumferentially receive a high-pressure and high-temperature exhaust gas flow 121 from an engine (specifically, from an exhaust manifold 123 of an internal combustion engine 125). The turbine wheel 111 and thus the other components of the rotating group 102 are driven to rotate about the axis 104 by the high-pressure and high-temperature exhaust gas flow 121, which becomes a low-pressure and low-temperature exhaust gas flow 127 released into a downstream exhaust pipe 126.

[0026] The compressor housing 107 and the compressor impeller 113 form a compressor stage (i.e., a compressor section). The compressor impeller 113, which is driven to rotate by the exhaust-driven turbine impeller 111, is configured to compress the received input air (e.g., ambient air or already pressurized air from the previous stage in the multi-stage compressor) into a pressurized air flow 133 ejected circumferentially from the compressor housing 107. The compressor housing 107 may have a shape (e.g., a volute shape or other shape) configured to guide and pressurize the air blown out from the compressor impeller 113. Due to the compression process, the pressurized air flow is characterized by an increase in temperature compared to the temperature of the input air 131.

[0027] The pressurized air flow 133 may be directed through an air cooler 135 (i.e., an intercooler), such as a convectively cooled charge air cooler. The air cooler 135 may be configured to dissipate heat from the pressurized air flow 133, thereby increasing its density. The resulting cooled and pressurized output air flow 137 is directed to an intake manifold 139 of the internal combustion engine 125, or alternatively to a subsequent stage tandem compressor.

[0028] In addition, the turbocharger 100 may include a motor stage 112. The motor stage 112 may be cooperatively defined by the intermediate housing 109 and the motor 114 housed in the intermediate housing 109. The shaft 115 may extend through the motor stage 112, and the motor 114 may be operably coupled to the shaft 115. The motor 114 may be an electric motor, a generator, or a combination of the two. Therefore, the motor 114 may be configured as a motor to convert electrical energy into mechanical (rotational) energy of the shaft 115 for driving the rotating group 102. In addition, the motor 114 may be configured as a generator to convert the mechanical energy of the shaft 115 into electrical energy stored in a battery or the like. As described above, the motor 114 may be configured as a combined motor / generator, and in some embodiments the motor 114 may also be configured to switch functions between a motor mode and a generator mode.

[0029] For the purpose of discussion, the electric machine 114 will be referred to as the motor 116. The motor 116 may include a rotor component (e.g., a plurality of permanent magnets) supported on the shaft 115 so as to rotate with the rotating group 102. The motor 116 may also include a stator component (e.g., a plurality of windings, etc.) housed and supported within the intermediate housing 109. In some embodiments, the motor 116 may be axially disposed between a first bearing 141 and a second bearing 142 of the bearing system 105. In addition, the motor 116 may be housed by a motor housing 118 of the intermediate housing 109. The motor housing 118 may be a thin-walled or shell-like housing that encloses the stator component of the motor 116. The motor housing 118 may also surround the axis 104, and the shaft 115 may extend through the motor housing.

[0030] In addition, the turbocharger 100 may include an integrated controller 150. The integrated controller 150 may generally include a controller housing 152 and a plurality of internal components 154 (e.g., circuits, electronic components, cooling components, support structures, etc.) contained in the controller housing 152. The integrated controller 150 may control various functions. For example, the integrated controller 150 may control the motor 116, thereby controlling certain parameters (torque, angular velocity, start / stop, acceleration, etc.) of the rotating group 102. In some embodiments, the integrated controller 150 may also communicate with a battery, an electrical control unit (ECU), or other components of the corresponding vehicle. More specifically, the integrated controller 150 may receive DC power from the vehicle battery, and the integrated controller 150 may convert the power into AC power for controlling the motor 116. In additional embodiments in which the motor 114 is a combined motor / generator, the integrated controller 150 may operate to switch the motor 114 between its motor and generator functions.

[0031] In some embodiments, the integrated controller 150 can be axially disposed between the compressor stage and the turbine stage of the turbocharger 100 relative to the axis 104. Therefore, as shown, the integrated controller 150 can be disposed and can be integrated near the motor 116. For example, as shown in the illustrated embodiment, the integrated controller 150 can be disposed above the motor housing 118 and can be radially arranged above the motor housing 118. More specifically, the integrated controller 150 can extend and wrap around the axis 104 to cover above the motor 116, so that the motor 116 is radially disposed between the shaft 115 and the integrated controller 150. The integrated controller 150 can also extend in a circumferential direction around the axis 104 and can cover, overlap, and wrap over at least a portion of the motor housing 118. In some embodiments, the integrated controller 150 can be wrapped around the axis 104 between approximately forty-five degrees (45°) and three hundred and sixty-five degrees (365°). For example, as Figures 2 to 4 As shown in , the controller 150 wraps approximately one hundred eighty degrees (180°) about the axis 104 .

[0032] The controller housing 152 is Figure 2. As shown, the housing 152 can be generally arcuate so as to extend about the axis 104 and generally conform to the rounded contour of the turbocharger 100. The housing 152 can also be an outer shell-like member that is hollow and encloses the internal component 154. An electrical connector can extend through the housing 152 for electrically connecting the internal component 154. In addition, there can be an opening for a fluid connector (e.g., a connector for a fluid coolant). In addition, the controller housing 152 can define a portion of the exterior of the turbocharger 100. The outer surface 153 of the controller housing 152 can extend about the axis 104 and can radially away from the axis 104. As shown, the outer surface 153 can be at least partially smoothly contoured about the axis 102, or the outer surface 153 can include one or more flat panels arranged tangentially relative to the axis 104 (e.g., a series of such flat panels arranged about the axis 104). As shown Figure 1 As shown in , the outer surface 153 may be disposed substantially at the same radius as the adjacent compressor housing 107 and / or turbine housing 106. Thus, the overall size and profile of the turbocharger 100 including the controller 150 may be very compact.

[0033] The internal components 154 can be housed within the controller housing 152. In addition, at least some of the internal components 154 can extend in an arc, wrap around the axis 104, and / or can be arranged around the axis 104, as will be discussed. In addition, as will be discussed, the internal components 154 can be stacked in close proximity axially along the axis 104, making the controller 150 very compact. Therefore, the integrated controller 150 can be compactly arranged and integrated with the turbine stage, compressor stage, and / or other components of the turbocharger 100. In addition, the internal components 154 of the controller 150 can be in close proximity to the motor 116 to provide certain advantages. For example, due to this close proximity, there can be reduced noise to achieve more efficient control of the motor 116.

[0034] In addition, the controller 150 may include multiple components that provide robust support and provide efficient cooling. Thus, the turbocharger 100 may operate under extreme conditions due to elevated temperatures, mechanical loads, electrical loads, etc. Regardless, the controller 150 may be tightly integrated into the turbocharger 100 without compromising performance.

[0035] Reference now Figure 2 , the internal components 154 of the integrated controller 150 will be discussed in more detail according to various embodiments. In general, from Figure 1The integrated controller 150 may include a coolant core 202. The coolant core 202 may be configured to support a plurality of electronic components, fastening structures, and other parts of the integrated controller 150. The coolant core 202 may also define one or more coolant channels through which a fluid coolant flows to cool the electronic components. The coolant core 202 may receive a coolant flow therethrough for cooling the integrated controller 150. Figure 2 As shown in , the coolant core extends at least partially above the motor 116 in a circumferential direction about the axis 104 .

[0036] The coolant core 202 may be elongated but curved and arcuate in shape and may extend in a tangential and / or circumferential direction around the axis 104. In other words, the coolant core 202 may be at least partially wrapped around the axis 104 to fit around the motor 116 of the turbocharger 100. Thus, the coolant core 202 may define an inner radial region 204 facing the axis 104 and an outer radial region 206 facing away from the axis 104. In addition, the coolant core 202 may include a first axial end 208 and a second axial end 210 that face away from each other in opposite axial directions. In some embodiments, the first axial end 208 may face the compressor section of the turbocharger 100, and in some embodiments, the second axial end 210 may face the turbine section. The coolant core 202 may also define an axial width 212 that may be defined parallel to the axis 104 between the first axial end 208 and the second axial end 210. Additionally, the coolant core 202 may be semicircular and elongated to extend circumferentially between first and second angular ends 231 , 232 that are angularly spaced about the axis (eg, approximately one hundred and eighty degrees (180°) apart).

[0037] The coolant core 202 can be cooperatively defined by multiple parts such as a reservoir body and a cover plate 216. Both the reservoir body and the cover plate 216 can be made of a strong and lightweight material (e.g., a metal such as aluminum) having relatively high thermal conductivity characteristics. In some embodiments, the reservoir body and / or the cover plate 216 can be formed via a casting process (e.g., high pressure die casting).

[0038] The cover plate 216 may be relatively flat, may be arcuate (e.g., semicircular), and may be placed substantially perpendicular to the axis 104. In addition, the cover plate 216 may define a first axial end 208 of the coolant core 202. The reservoir body may be a generally thin-walled and hollow body having an open side covered by the cover plate 216 and a second side defining a second axial end 210 of the coolant core 202. The cover plate 216 may be fixed to the reservoir body and sealed to the reservoir body with a gasket, a seal, etc. One or more fasteners (e.g., bolts or other fasteners) may extend axially through the cover plate 216 and the reservoir body for attaching them. The cover plate 216 and the reservoir body may include one or more fastener holes 270 that receive bolts or other fasteners for attaching the first side electronic device to the coolant core 202. Thus, the cover plate 216 and the reservoir body may cooperate to define a fluid channel 220 extending through the coolant core 202. In some embodiments, the fluid channel 220 can be elongated and can extend generally about the axis 104 from a first angular end 231 to a second angular end 232 .

[0039] The coolant core 202 may also include at least one fluid inlet 222 leading to the fluid channel 220 and at least one fluid outlet 224 from the fluid channel 220. In some embodiments, for example, there may be a single, unique inlet 222. The inlet 222 may be disposed proximate the first angular end 231 and may include a circular, cylindrical, and hollow connector that extends from the cover plate 216 away from the first axial end 208 along the axis 104. Additionally, in some embodiments, there may be a single, unique outlet 224. The outlet 224 may be disposed proximate the second angular end 232 and may include a circular, cylindrical, and hollow connector that extends from the cover plate 216 away from the first axial end 208 along the axis 104.

[0040] The coolant core 202 may be fluidly connected to a coolant circuit 225 that is Figure 1 The coolant circuit 225 may circulate any suitable fluid such as a liquid coolant between the fluid channel 220 and the heat exchanger 203 ( Figure 1 ). More specifically, the coolant may flow from the inlet 222 through the fluid channel 220 to the outlet 224, thereby removing heat from the integrated controller 150, and may continue to flow through the heat exchanger 203 to be cooled before flowing back to the inlet 222 of the coolant core 202, and so on. Figure 1 As shown in , in some embodiments, the heat exchanger 203 may be separate and fluidly independent from an engine coolant system 207 that cools the engine 125 .

[0041] The second axial end 210 of the coolant core 202 may include one or more internal orifices. The internal orifices may include a plurality of pits, recesses, receptacles, etc., which are open at the second side of the reservoir body and are arranged in a radial direction close to the inner radial region 204 of the core 202. As shown, in some embodiments, the internal orifice may be generally cylindrical, having a circular profile and its longitudinal axis is arranged parallel to the axis 104. There may be a plurality of internal orifices, which are arranged at different angular positions relative to the axis 104 along the inner radial region 204 of the core 202. The size and shape of the internal orifice may correspond to certain components of the internal components 154 of the integrated controller 150. For example, the internal orifice may be cylindrical, as shown, to receive and support internal electronic components, such as a series of capacitors 241 ( Figure 2 ). The reservoir body may define an aperture having relatively thin walls or other structures that separate the capacitor 241 within the aperture from the coolant within the fluid channel 220. Thus, the capacitor 241 may be effectively cooled by the coolant circuit 225.

[0042] The second side of the reservoir body may include a second side aperture 246 having an oval profile and recessed into the reservoir body in the axial direction. The second side aperture 246 may be arranged such that the long axis of its oval shape extends tangentially relative to the axis 104. In addition, the short axis may extend radially and may be large enough to extend over the inner radial region 204 and the outer radial region 206 of the coolant core 202. In addition, the second side aperture 246 may be shaped to correspond to another electronic component, such as an inverter, a capacitor, a battery, or another piece of control equipment.

[0043] In addition, the outer radial region 206 of the coolant core 202 can extend around the axis 104 and can include one or more seats. The seats can be rectangular and can be located in corresponding tangent planes relative to the axis 104. The seats can be arranged and spaced apart at different angular positions relative to the axis 104. In addition, the seats can include corresponding external orifices 250 extending radially therethrough. In some embodiments, at least one external orifice 250 can be a rectangular hole centered within the corresponding seat and passing through the reservoir body to the fluid channel 220 therein. These external orifices 250 can be sized and configured to receive external electronic components 251 ( Figure 2), such as substantially flat and rectangular transistors, circuit components, switch components, MOSFET transistors, etc. The electronic component 251 can be partially received in the corresponding outer aperture 250 and can be supported and mounted on the corresponding seat so as to cover the corresponding outer aperture 250. There can be a gasket or other sealing member that seals the electronic component 251 to the seat 251. In addition, the electronic component 251 may include one or more thermally conductive protrusions 254 ( Figure 2 ), such as an array of fins, rails, posts, pins, etc. extending from its underside to extend into the fluid channel 220. Thus, the coolant within the coolant loop 225 can flow across the protrusion 254 to provide highly efficient cooling to the electronic component 251.

[0044] In addition, the first axial end 208, which is substantially defined by the cover plate 216, may provide one or more surfaces for mounting and supporting the first side electronic package 260. The first side electronic package 260 may be provided at Figure 2 202, and it should be understood that the first side electronic package 260 may include a plurality of electronic components, such as one or more conductive bus bars, circuit board assemblies, etc. There may also be a support structure, such as a bracket, a plate, etc., for supporting the electronic package 260. In addition, there may be a fastener arrangement for attaching the first side electronic package 260 to the first axial end 208 of the coolant core 202. The fastener arrangement may include a support structure with a threaded cavity, a bolt, a washer, a bushing, etc. The first side electronic package 260 may be stacked on the first axial end 208 so that both extend arcuately around the axis 104. The first side electronic package 260 may be attached to the first axial end 208 in any suitable manner, such as a fastener. Therefore, the first side electronic package 260 may be in close proximity with at least one surface of the package 260, which is stacked on and adjacent to the opposite surface of the coolant core 202, so that the coolant core 202 can absorb heat therefrom with high efficiency and effectiveness.

[0045] Likewise, the second axial end 210 of the coolant core 202 may provide one or more surfaces for mounting and supporting the second side electronic package 262. Similar to the first side electronic package 260, the second side electronic package 262 is schematically represented, however, it should be understood that the package 262 may include a plurality of electronic and / or mechanical support / fastening parts. The second side electronic package 262 may be arcuate and may extend partially around the axis 104. The second side electronic package 262 may be stacked on the second axial end 210 so that both extend arcuately around the axis 104. The second side electronic package 262 may be attached to the second axial end 210 in any suitable manner. In addition, the second side electronic package 262 may be in close proximity to the coolant core 202, wherein at least one surface of the package 262 is stacked on and adjacent to an opposing surface of the coolant core 202 for efficient and effective cooling. In at least one exemplary embodiment, a first bus bar 263 and a second bus bar 264 may be mounted between the second side electronic package 262 and the second axial end 210. The first bus bar 263 and the second bus bar 264 may be used to conduct current to the second side electronic package 262, the external electronic component 251, and / or the first side electronic package 260. The conducted current may be direct current or alternating current.

[0046] A fluid channel 220 for coolant within the coolant core 202 can be defined between the inner surface of the reservoir body, the inner face of the cover plate 216, and the inner face of the external electronic component 251. The fluid channel 220 can also extend arcuately around the axis 104 from an inlet 222 to an outlet 224. The coolant can enter via the inlet 222, flow generally from the first angular end 231 to the second angular end 232 and exit via the outlet 224. Thus, the coolant can flow in close proximity to and across the core-facing surfaces of the external electronic component 251, the capacitor 241, the first side electronic package 260, and the second side electronic package 262.

[0047] Thus, in some embodiments, the coolant core 202 can be substantially surrounded by heat-generating electronic components. The coolant core 202 can be thermally coupled to these components due to close proximity and, in some areas, due to abutting contact therebetween. Some interfaces (e.g., at the protrusions 254) can provide direct fluid contact with the coolant. Figure 2As shown in FIG. 1 , the coolant core 202 can be thermally coupled to the electronic components on the inner radial region 204, the outer radial region 206, the first axial end 208, and the second axial end 210. The fluid channel 220 can be radially defined between the inner radial region 204 and the outer radial region 206 to receive heat from both the internal electronic components (e.g., capacitor 241) and the external electronic components 251. In addition, the fluid channel 220 can be axially defined between the first axial end 208 and the second axial end 210 to receive heat from both the first side electronic package 260 and the second side electronic package 262.

[0048] In addition, the controller 150 can be integrated and packaged between the turbine section, the motor 116, and / or the compressor section, any of which may operate at high temperatures. The coolant core 202 and the coolant loop 225 can also provide cooling to these surrounding components. Therefore, it should be understood that the controller 150 can be compactly packaged and there can be several features that generate heat during operation; however, the coolant core 202, the coolant loop 225, and the other features discussed above can provide effective and efficient cooling.

[0049] Additionally, the controller 150 may be stably supported on the turbocharger 100. The coolant core 202 may provide mechanical support while also providing a compact package for the controller 150. Additionally, the number of parts may be relatively low, and the controller 150 may be manufactured and assembled in an efficient manner.

[0050] Now go to Figure 3 , shows an exemplary cross-sectional view of an electronic package 300 integrating a controller 150. Figure 2 As described, the exemplary electronic package 300 may generally represent one or more of the first side electronic package 260 or the second side electronic package 262. The exemplary electronic package 300 may include a support structure 310, a first bus bar 315, a second bus bar 320, a backing plate 325, a printed circuit board 330, at least one fastener arrangement 340, and a plurality of non-conductive sheets 345. The exemplary fastener arrangement 340 may include bolts, bushings, and spring washers for rigidly attaching the first bus bar 315, the second bus bar 320, and the backing plate 325 to the support structure 310.

[0051] In some embodiments, support structure 310 may represent Figure 2However, it should be understood that the support structure 310 can be another part of the integrated controller 150 or another engine component, turbomachine, integrated controller, or other vehicle component. The support structure can form a rigid structure for providing support to the electronic components of the exemplary electronic package 300. Ideally, the support structure 310 can be integrated into the turbomachine 100 and the controller 150.

[0052] The first bus bar 315 and the second bus bar 320 in this exemplary configuration can be used to conduct voltages used by the electronic package and / or the turbomachinery and the integrated controller. The first bus bar 315 can carry a first voltage, such as a DC voltage at a first direct current (DC) voltage level or an AC signal having a first alternating current (AC) voltage and a first phase. Similarly, the second bus bar 320 can carry a second voltage, such as a DC voltage at a second direct current (DC) voltage level or an AC signal having a second alternating current (AC) voltage and a second phase. The support structure 310, the first bus bar 315, the second bus bar 320, and the pad 325 can be electrically isolated from each other by a plurality of non-conductive sheets 345. In some exemplary embodiments, the non-conductive sheets are separated from other components and fixed in place during the assembly of the electronic package 300. In other embodiments, the non-conductive sheets 345 can be formed by coating various components such as the first bus bar 315 and the second bus bar 320 with a film or layer of a non-conductive material such as polyamide.

[0053] When the fastener arrangement 340 is attached to the support structure 310, the backing plate 325 can be used to support the first bus bar 315 and the second bus bar 320 and distribute a uniform clamping force on the first bus bar 315 and the second bus bar 320. The fastener arrangement 340 can have a threaded portion for engaging a threaded cavity in the support structure 310. The fastener arrangement 340 can also have a smooth portion for free rotation within a bushing or within a non-threaded cavity in the support structure 310. The fastener arrangement 340 can also have portions of different diameters to secure different components at different layers of the electronic package.

[0054] A printed circuit board 330 may be further attached to the electronics package 300 for regulating or controlling the voltage on the first bus bar 315 and the second bus bar 320, and for providing control information, sensors, etc. to the integrated controller 150 of the turbomachine 100. The printed circuit board 330 may be attached within the electronics package using a fastener arrangement 340, or may be attached by other means independent of the fastener arrangement 340. The printed circuit board 330 may be attached with other fasteners such as screws, or with bosses to avoid any possible deformation caused by the holding force of the fastener arrangement 340.

[0055] Now go to Figure 4, shows an additional embodiment of a cross-sectional view of a fastener assembly 400 of an integrated controller according to an exemplary embodiment of the present disclosure. For example, the exemplary fastener assembly 400 may be formed for Figure 1 The controller 150 is part of the motor 116 of the turbomachine 100 .

[0056] In one or more exemplary embodiments, the support structure 410 may form a portion of the coolant core 202 of the integrated controller 150, etc. The support structure 410 will have a different electrical potential than the electrical potential of the first bus bar 420 and the second bus bar 430. The support structure 410 may be configured to provide physical support and may be electrically and / or thermally isolated from the first bus bar 420 and the second bus bar 430.

[0057] The first bus bar 420 may be configured to supply a first voltage to the integrated controller 150, and the second bus bar 430 may be configured to supply a second voltage to the integrated controller 150. In some embodiments, the first voltage and the second voltage are different DC voltages, wherein the first voltage is not equal to the second voltage. Alternatively, the first bus bar 420 and the second bus bar 430 may conduct an alternating current (AC) voltage, wherein the voltage carried by the first bus bar 420 is out of phase or has a different phase from the voltage carried by the second bus bar 430. In some embodiments, the first bus bar 420 and the second bus bar 430 may be separated by one or more non-conductive sheets 450. These non-conductive sheets 450 may be formed separately from the first bus bar 420 and the second bus bar 430, or the first bus bar 420 and the second bus bar 430 may be coated with a non-conductive material. For example, the non-conductive material may be a dielectric material or other electrically insulating material. In addition, the non-conductive sheet 450 may also include thermal insulation properties. In some exemplary embodiments, the non-conductive sheet 450 may be a polyamide material having a thickness between approximately 0.001 and 0.002 inches.

[0058] In an exemplary embodiment, the first bus bar 420 may be elongated and may extend around the axis 104. Likewise, the second bus bar 430 may be elongated and may extend around the axis 104. In addition, the second bus bar may be stacked on the first bus bar in an axial direction relative to the axis 104. The first bus bar 420 and the second bus bar 430 may be formed by Figure 3 The fastener arrangement 340 is attached to the support structure 410 .

[0059] In some exemplary embodiments, Figure 3The fastener arrangement 340 may include a sleeve bushing 460, a fastener 440, and a resilient washer 475. In some embodiments, the fastener 440 may be a partially threaded fastener, such as a bolt, etc. The sleeve bushing 460 may be a tubular structure. The sleeve bushing 460 may have an inner surface 461 having an inner radius, an outer surface 462 having an outer radius, and a flange 463 attached to the outer surface 462 of the sleeve bushing 460. The flange 463 may be circular in some embodiments and may define a flange radius. In some embodiments, the sleeve bushing 460 may be formed of a non-conductive material such as a dielectric material, ceramic, etc., or the bushing 460 may be formed of a conductive material coated with an electrically insulating material.

[0060] In some embodiments, support structure 410 may include a receiver cavity 470 for receiving fastener 440. Receiver cavity 470 may include a cavity threaded portion 471 having a radius corresponding to the radius of fastener 440 for threaded attachment therebetween. Receiver cavity 470 may also include an unthreaded portion 472 corresponding to the outer radius of sleeve bushing 460 for a clearance fit therebetween. Thus, fastener 440 may be threadedly attached to threaded portion 471 of receiver cavity 470, while bushing 460 is received in unthreaded portion 472 of receiver cavity 471.

[0061] The first bus bar 420 may include a first circular aperture 473 having a first radius corresponding to the outer radius of the sleeve bushing 460, so that there is a clearance fit between the two. The second bus bar 430 may include a second circular aperture 474 having a second radius corresponding to the flange radius of the flange 463 of the sleeve bushing 460, so that there is a clearance fit between the two. In addition, the second radius of the second circular aperture 474 may be greater than the first radius of the first circular aperture. In some embodiments, the first bus bar 420 may be applied to the support structure 410 so that the first circular aperture 473 is aligned with the receiver cavity 470, and the second bus bar 430 may be laminated to and applied to the outer surface of the first bus bar so that the second circular aperture 474 is aligned with the first circular aperture 473 and the receiver cavity 470. The sleeve bushing 460 can be positioned so that a first portion of the outer surface 462 is located within and received in the unthreaded portion 472 of the receiver cavity 470, a second portion of the outer surface 462 is located within and received in the first circular aperture 473 of the first bus bar 420, and the flange 463 is located within and received in the second circular aperture 474 of the second bus bar 430. In this embodiment, the fastener 340 is then located within the inner surface 461 of the sleeve bushing 460, with the fastener threaded portion engaged with the cavity threaded portion 471 and the fastener head 441 received in the recess of the backing plate 480.

[0062] The assembly may optionally include a backing plate 480 also secured by the fastener 440 to distribute the load on the first bus bar 420, the second bus bar 430, and the support structure 410. The backing plate 480 may be a relatively flat plate that is elongated and extends at least partially around the axis 104. In some embodiments, the backing plate 480 may be referred to as a backing plate. The backing plate 480 may be manufactured, machined, or molded from aluminum and may be rigid and strong to resist deformation due to the force applied by the fastener 440.

[0063] When fastening the first bus bar 420 and the second bus bar 430 to the support structure 410, it is desirable to provide sufficient creep distance between the charge-carrying components and the grounded components. During assembly, a flat wide metal washer (not shown) between the spring washer and the plastic bushing can be used to increase the area of ​​the clamping force applied to the plastic bushing. In addition, appropriate metal features can be formed in the support structure 480 to increase the clamping force area of ​​the elastic washer 475. In order to achieve a safe creep distance around the fastener 440 while limiting the risk of the bus bars 420, 430 contacting each other or other metal structures and shorting, it is advantageous that the first circular aperture 473, the second circular aperture 474, and the first diameter of the second portion of the outer surface of the receiver cavity 470 have different radii so that the edges of the apertures are not aligned during fastening to allow a safe creep distance around the fastener 440. In an alternative embodiment, the support structure 410 and / or the backing plate 480 can be countersunk (not shown), and the adjacent non-conductive sheet 450 can extend to overhang the countersunk aperture. The larger diameter of the countersunk hole increases the safe creep distance around the fastener 440 .

[0064] The fastener arrangement 400 may also include a resilient member, such as a resilient washer 475, located between a portion of the fastener 440 and the backing plate 480. The resilient washer 475 may be a spring washer, a bell-shaped washer, or the like. The resilient washer 475 may be annular and may be received on the fastener 440, axially disposed between the head 441 of the fastener 440 and the backing plate 480. When the fastener 440 is attached to the support structure 410, the resilient washer 475 may be resiliently deflected from a neutral position to a deflected position. In addition, an intermediate metal surface, such as a flat washer or a flat feature of the backing plate 480, may be used to spread the load outward from the resilient washer 475 across the plastic bushing.

[0065] In some embodiments, the sleeve bushing 460 can be ductile or flexible and can be deformed so that the outer radius increases in response to pressure from the fastener assembly. The deformation can have the effect of providing pressure between the deformed sleeve bushing 460 and the interior of the receiver cavity, the inner surface of the first circular aperture 473, and / or the inner surface of the second circular aperture 474. The deformation can then have the beneficial effect of further securing the first bus bar 420 and the second bus bar 430 to the support structure 410. Therefore, the sleeve bushing 460 can include a resilient member that is resiliently flexible between a neutral position and a flexed position, and wherein the resilient member is in the flexed position when the fastener arrangement 400 attaches the first bus bar 420 and the second bus bar 430 to the support structure 410.

[0066] The fastener arrangement 400 can firmly support the components of the integrated controller 150, and can electrically isolate the components from each other as needed. In addition, the fastener arrangement 400 can provide a compact package for the integrated controller 150. The fastener arrangement 400 can be beneficial to improve manufacturing efficiency and facilitate assembly. The fastener arrangement 400 meets the need to fix the first bus bar 420 and the second bus bar 430 to the support structure 410 in a manner that facilitates heat conduction from the bus bars 420, 430 to the support structure 410, and the support structure 410 can be formed by a portion of the coolant core 202. Specifically, for example, the heat of the second bus bar 430 can be conductively transferred to the first bus bar 420, and / or the heat of the first bus bar 420 can be conductively transferred to the support structure 410, and the support structure 410 can provide cooling via a fluid coolant flowing therethrough. The durable sleeve bushing 460 can provide mechanical stability and fixation while providing good electrical isolation. The sleeve bushing 460 may be made of a glass and mineral filled plastic or ceramic composite to allow high pressure clamping by the fastener 440 in a high temperature environment. The sleeve bushing 460 facilitates assembly by electrically isolating the fastener 440 and the fastener head 441 from the electrically active first bus bar 420 and second bus bar 430. The design of the sleeve bushing 460 and the materials selected for the sleeve bushing 460 help to overcome harsh thermal and vibration environments (e.g., environments mounted on vehicle engines), and enable use in high voltage applications, as well as allowing for multiple bus bar configurations instead of just a single bus bar.

[0067] In some exemplary embodiments, the printed circuit board 490 may be attached to the backing plate 480 in a manner that allows for thermal expansion and contraction of the backing plate 480 without damaging the printed circuit board 490. The printed circuit board 490 may include circuits such as power conditioning circuits, power control circuits, power conversion circuits, or other electronic circuits used by the integrated controller 150. It is desirable to avoid repetitive physical stress on the printed circuit board 490 because repeated flexing or deformation of the printed circuit board may result in cracking of the circuit board, separation of surface mounted components, and / or separation of solder joints.

[0068] The integrated controller may include a spring clip 495 to provide a clamping force orthogonally on the printed circuit board 490 while allowing some movement of the printed circuit board 490 laterally along the plane of the printed circuit board 490. The printed circuit board 490 may also include a boss 493 protruding from the printed circuit board 490, wherein the spring clip 495 applies pressure to the boss 493 to provide a clamping force orthogonal to the printed circuit board 490 while reducing wear on the printed circuit board 490 due to lateral movement of the printed circuit board 490 caused by thermal expansion and contraction of the backing plate 480, the first bus bar 420, the second bus bar 430 and / or the support structure 410.

[0069] Now go to Figure 5 , shows an additional embodiment of a cross-sectional view of a fastener arrangement 500 of an integrated controller according to an exemplary embodiment of the present disclosure. The integrated controller may include a printed circuit board 540 and a support structure such as a backing plate 550. The fastener arrangement 500 may hold the printed circuit board 540 on the backing plate 550.

[0070] PCB 540 may be a somewhat flexible board having a plurality of circuit components mounted thereon. In contrast, backing plate 550 may be rigid. In some embodiments, PCB 540 and / or backing plate 550 may be relatively flat, curved, and elongated, similar to Figure 2 . Additionally, in some embodiments, the printed circuit board 540 and / or the backing plate 550 can extend at least partially around the rotation axis 104 within the integrated controller. In some embodiments, the printed circuit board 540 can overlap the backing plate 550.

[0071] The fastener arrangement 500 may include at least one resilient member, such as a spring clip 510. In some embodiments, the fastener arrangement 500 may include a plurality of resilient members, such as a plurality of spring clips 510, which are transversely across the printed circuit board 540 in a spaced relationship and are arranged circumferentially around the axis 104. The spring clip 510 may be resiliently elastic and may provide a spring biasing force for biasing the printed circuit board 540 orthogonally toward the backing plate 550. Thus, the printed circuit board may be firmly supported on the backing plate 550. In addition, as will be discussed, the spring clip 510 may be resiliently deflected to provide a number of advantages. For example, the resilient member may improve manufacturing efficiency and / or may be resiliently deflected to accommodate thermal expansion / contraction within the assembly. In addition, the fastener arrangement 500 may occupy a relatively small space on the printed circuit board 540. Therefore, there may be more free space on the printed circuit board 540 for circuit components thereon. In some embodiments, the resilient member may be and / or include a spring clip 510. In some embodiments, the spring clip 510 may include a first arm 511 and a second arm 512 that are attached and resiliently deflectable relative to each other, wherein the first arm 511 engages the printed circuit board 540 and the second arm 512 engages the backing plate 550 to resiliently bias the printed circuit board 540 toward the backing plate 550. The backing plate 550 and the printed circuit board 540 may then cooperate to define a radial edge region that extends generally around the rotation axis 104, and wherein the spring clip 510 is engaged to the printed circuit board 540 and the backing plate 550 proximate the radial edge region. The radial edge region may be an outer radial edge region cooperatively defined by the backing plate 550 and the printed circuit board 540.

[0072] The spring clip 510 can provide a normal pressure on the printed circuit board 540 and a reverse pressure on a portion of the pad 550. The normal pressure can be parallel to Figure 2 The backing plate 550 may include a rear portion of the backing plate 550, such as Figure 6A recessed area 651 is formed in the printed circuit board 540, which is molded or milled to facilitate receiving a portion of the spring clip 520. The boss 520 can be attached or applied to the surface of the printed circuit board 540 so that the force exerted by the spring clip 510 on the printed circuit board 540 is exerted through the boss 520. The resulting normal force and reverse force generated by the spring clip 510 act in a manner to secure the printed circuit board 510 to the backing plate 550. In some exemplary embodiments, the spring clip 510 can be positioned on the printed circuit board 540 and the backing plate 550 from the edge of the printed circuit board. Advantageously, the spring clip 510 consumes less printed circuit board space than corresponding fixed fasteners, thereby allowing a higher density of circuit components on the printed circuit board 540. In addition, the spring clip 510 can be resiliently flexed, allowing limited movement of the printed circuit board 540 relative to the backing plate 550. For example, the spring clip 510 can be resiliently flexed to account for and allow for thermal expansion of one or more integrated controller components during operation. In addition, the spring clip 510 can facilitate assembly by reducing assembly time, by reducing the number of parts, etc. Specifically, in order to attach the printed circuit board 540 to the backing plate 550, the spring clip 510 can be Figure 6 As the spring clip 510 advances, the spring clip 510 can be resiliently flexed to open. Then, when the first arm 511 and the second arm 512 move into Figure 5 When the spring clip 510 is in the position shown in FIG. Figure 5 In the position shown in FIG. 5 , the resilience of the spring clip 510 can bias the printed circuit board 540 toward the backing plate 550 and secure the printed circuit board 540 thereto.

[0073] The boss 520 may be attached or applied to a surface of the printed circuit board 540 such that the force applied by the spring clip 510 on the printed circuit board 540 is applied through the boss 520. The boss 520 may be a metal structure soldered to the printed circuit board 540 and may be electrically coupled to a ground plane of the printed circuit board 540. Alternatively, the boss 520 may be electrically isolated from components on the printed circuit board 540 to reduce heat conduction from the pad 550 and other components of the integrated controller. The boss 520 may include a ramped surface that is inclined relative to the surrounding area. As the spring clip 510 advances on the boss 520, the ramped surface may gradually flex the spring clip 510 open to assist in the installation of the spring clip 510 and to help hold the spring clip 510 in place after installation.

[0074] Guide pins 530 may be provided to help position the printed circuit board 540 on the backing plate 550 and prevent creep of the printed circuit board 540 relative to the backing plate 550. The guide pins 530 may be rigidly attached to the backing plate 550 and seat in corresponding apertures in the printed circuit board 540. The apertures in the printed circuit board 540 may be large enough to allow lateral movement of the printed circuit board 540 due to thermal expansion and contraction of the backing plate 550, but small enough to limit lateral movement or creep that accumulates over multiple thermal cycles.

[0075] Now go to Figure 6 , shows an additional embodiment of a fastener arrangement 600 of an integrated controller according to an exemplary embodiment of the present disclosure. The fastener arrangement 600 may include a spring clip 610, a support structure 660, a boss 620, a backing plate 650, a guide pin 640, and a printed circuit board 630.

[0076] An exemplary boss 620 is shown, which may include a metal structure formed on the surface of a printed circuit board 630. In this exemplary embodiment, the corresponding spring clip for the location of the exemplary boss 620 is omitted for clarity. The exemplary boss 620 can be electrically isolated from the ground plane and other components integrated into the printed circuit board 630. The exemplary boss 620 can include raised portions 621 corresponding to the inner surface of the corresponding spring clip 610. These raised portions 621 can be used to hold the spring clip 610 in place and prevent the spring clip 610 from being disassembled due to creep. These raised portions 621 can be shaped as a ramp to assist in the installation of the spring clip 610 and help hold the spring clip 610 in place after installation.

[0077] The spring clip 610 is shown positioned on the outer radial edge 611 of the backing plate 650 and the outer radial edge 612 of the printed circuit board 630. The spring clip 610 can engage a boss 622 that attaches to the surface of the printed circuit board 630 while engaging a portion of the backing plate 650. In some exemplary embodiments, the spring clip 610 can be positioned within a recessed portion 651 on the outer radial edge 611 of the backing plate 650 to further reduce creep and disengagement of the spring clip 610. In some embodiments, the recessed portion 651 can be a notch in one or more of the backing plate 650 and the printed circuit board 630.

[0078] The guide pins 640 may be attached to the backing plate 650 and / or the support structure 660. The apertures in the printed circuit board 630 may be positioned so that the guide pins 640 protrude through the printed circuit board 630. These guide pins 640 may be sized so that limited lateral movement of the printed circuit board 630 is allowed while preventing cumulative lateral movement or creep of the printed circuit board 630.

[0079] Now go to Figure 7 , shows an additional embodiment of a cross-sectional view of a fastener arrangement 700 of an integrated controller according to an exemplary embodiment of the present disclosure. In some exemplary embodiments, a fastener arrangement 700 can be used to attach a printed circuit board 720 to a support structure 710. The fastener arrangement 700 can include a resilient member such as a resilient washer 742, as will be discussed. Thus, the fastener arrangement 700 can allow for resilient deflection of the printed circuit board 720 relative to the support structure 710. Thus, the fastener arrangement 700 can provide a secure support, but can allow for some thermal expansion of the parts.

[0080] In some embodiments, the fastener arrangement 700 may include a fastener stack including a support 744, a rigid washer 743, and a bolt 741. The stack may also include a resilient member such as a resilient washer 742. The bolt 741 may have a threaded portion for engaging a threaded cavity (not shown) in the support structure 710. One or more bus bars 730 may also be electrically coupled to the printed circuit board 720. In some embodiments, the bus bar 730 may be soldered to the printed circuit board 720. Thermal expansion and contraction of the bus bar 730 may cause movement of the printed circuit board 720 relative to the support structure 710. To accommodate this movement, the printed circuit board 720 may be spaced apart from the support structure 710 by one or more spacers 744. The printed circuit board 720 may be positioned between the spacer 744 and the one or more rigid washers 743. Additionally, a resilient washer 472, such as a spring washer, a Belleville washer, or a rubber washer, may be positioned on the rigid washer 742 such that when the bolt 741 is tightened into the threaded cavity of the support structure 710, the head of the bolt 741 applies pressure to the resilient washer 742. The spacer 744, the printed circuit board 720, the fixed washer 743, and the resilient washer 742 each include corresponding holes such that the bolt 741 may extend orthogonally to the plane of the printed circuit board 720 through the aligned holes and into the threaded cavity within the support structure 710. The resilient washer 742 may be configured to provide sufficient force on the fixed washer 743 to retain the printed circuit board 720 on the support structure 710. However, the resilient washer 742 can resiliently flex (e.g., from the wavy position shown toward the flat position) in response to thermal expansion of the bus bar 730, and the resilient washer 742 can recover in the opposite direction (e.g., from the flat position toward the wavy position shown) in response to thermal contraction of the bus bar 720 and / or other components. The bolt 741 can prevent excessive creep of the printed circuit board 720 by limiting lateral movement of the printed circuit board 720 to the size of the hole in the printed circuit board 720 through which the bolt 741 passes.

[0081] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for those skilled in the art to implement the exemplary embodiments of the present disclosure. It should be understood that various changes may be made to the functions and arrangements of the elements described in the exemplary embodiments without departing from the scope of the present disclosure set forth in the appended claims.

Claims

1. A controller for an electric machine of a turbomachinery, comprising: Support structure; Printed circuit boards; a boss attached to a surface of the printed circuit board; and a fastener arrangement that holds the printed circuit board on the support structure, the fastener arrangement comprising a resilient member that resiliently biases the printed circuit board toward the support structure, The resilient member engages the boss to hold the printed circuit board on the support structure.

2. The controller according to claim 1, wherein: The resilient member is a spring clip having a first arm and a second arm, the first arm and the second arm being attached and capable of resiliently deflecting relative to each other, wherein the first arm engages the printed circuit board and the second arm engages the support structure to resiliently bias the printed circuit board toward the support structure.

3. The controller according to claim 2, wherein: The turbomachine includes a rotating group supported about a rotational axis, wherein the support structure and the printed circuit board cooperate to define a radial edge region extending generally about the rotational axis, and wherein the spring clip is engaged to the printed circuit board and the support structure proximate the radial edge region.

4. The controller according to claim 3, wherein: The radial edge region is an outer radial edge region cooperatively defined by the support structure and the printed circuit board.

5. The controller according to claim 1, wherein: The boss includes at least one ramp surface.

6. The controller of claim 2 further comprising guide pins rigidly attached to the support structure and passing through apertures in the printed circuit board such that lateral movement of the printed circuit board relative to the support structure is limited.

7. The controller according to claim 2, wherein: The support structure includes a notch for receiving the spring clip, and wherein the notch limits lateral movement of the spring clip.

8. The controller of claim 1 further comprising a bus bar configured to carry current, the bus bar being attached to the printed circuit board, the resilient member being configured to resiliently deflect during thermal expansion of the bus bar to maintain attachment of the bus bar to the printed circuit board.

9. The controller according to claim 8, wherein: At least a portion of the bus bar is soldered to the printed circuit board.

10. The controller according to claim 8, wherein: The fastener arrangement comprises a fastener stack that fastens the printed circuit board to the support structure, the fastener stack comprising the resilient member, wherein the resilient member is a resilient washer.

11. A method for manufacturing a controller for an electric machine of a turbomachine, comprising: Provide support structures; Provide printed circuit boards; attaching a boss to a surface of the printed circuit board; and attaching the printed circuit board to the support structure using a fastener arrangement, wherein the fastener arrangement includes a resilient member that resiliently biases the printed circuit board toward the support structure, The resilient member engages the boss to hold the printed circuit board on the support structure.

12. The manufacturing method according to claim 11, wherein: The resilient member is a spring clip having a first arm and a second arm, the first arm and the second arm being attached and capable of resiliently deflecting relative to each other, wherein the first arm engages the printed circuit board and the second arm engages the support structure to resiliently bias the printed circuit board toward the support structure.

13. The manufacturing method according to claim 12, wherein: The turbomachine includes a rotating group supported about a rotational axis, wherein the support structure and the printed circuit board cooperate to define a radial edge region extending generally about the rotational axis, and wherein the spring clip is engaged to the printed circuit board and the support structure proximate the radial edge region.

14. The manufacturing method according to claim 13, wherein: The radial edge region is an outer radial edge region cooperatively defined by the support structure and the printed circuit board.

15. The manufacturing method according to claim 11, wherein: The boss includes at least one ramp surface.

16. The manufacturing method of claim 12, further comprising receiving guide pins rigidly attached to the support structure through apertures in the printed circuit board such that lateral movement of the printed circuit board relative to the support structure is restricted.

17. The method of manufacturing of claim 11 further comprising providing a bus bar configured to carry current and attaching the bus bar to the printed circuit board, the resilient member being configured to resiliently deflect during thermal expansion of the bus bar to maintain attachment of the bus bar to the printed circuit board.

18. A turbocharger with an integrated controller, comprising: a support structure comprising a notch for receiving a spring clip, and wherein the notch limits lateral movement of the spring clip; Printed circuit boards; a fastener arrangement that retains the printed circuit board on the support structure, the fastener arrangement comprising the spring clip to resiliently bias the printed circuit board toward the support structure, wherein the spring clip comprises a first arm and a second arm, the first arm and the second arm being attached and resiliently deflectable relative to each other, wherein the first arm engages the printed circuit board and the second arm engages the support structure to resiliently bias the printed circuit board toward the support structure; a boss attached to a surface of one of the printed circuit board and the support structure, wherein the spring clip engages the boss to retain the printed circuit board on the support structure; and Guide pins are rigidly attached to the support structure and pass through apertures in the printed circuit board such that lateral movement of the printed circuit board relative to the support structure is restricted.

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