Motor controller for an electric motor and integrated electric motor-motor controller assembly - Patents.com
Patent Information
- Application Number
- JP2024552794
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-03-04
- Filing Date
- 2022-12-26
- Publication Date
- 2025-03-26
Smart Images
Figure 2025508546000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to a motor controller for an electric motor, and more particularly to an integrated electric motor-motor controller assembly for a vehicle. [Background technology]
[0002] A motor controller typically regulates the supply of power or current to an electric motor and controls operation of the electric motor based on the condition of the motor to ensure safe operation of the electric motor. The motor controller may include one or more of an inverter circuit, a DC-DC converter, one or more controllers, etc. that may be coupled to the electric motor to provide power or current to the electric motor.
[0003] The circuitry in the motor controller includes multiple electronic components grouped together to perform functions such as stepping down the DC voltage provided by the DC supply power, inverting the DC power to an AC supply power to supply the electric motor, etc. Conventionally, the motor controller and the electric motor are housed separately in various applications such as vehicles and are electrically connected through multiple electrical connections. Therefore, a separate motor controller and a separate electric motor housing must be accommodated in the vehicle layout. Another challenge relates to the electrical capacity and physical weight distribution of the electric motor and the motor controller, especially for two-wheeled vehicles that are difficult to equip with heavy electrical components. Furthermore, the wiring connection between the motor controller and the electric motor requires the supply current to travel a certain distance through wiring harness lines, which results in voltage drop, while also being expensive and heavy.
[0004] To overcome the above limitations, attempts have been made to integrate the electric motor and the motor controller. In known designs, the elements of the motor controller are mounted on the upper part of the motor or radially mounted on the motor casing of the electric motor. However, such designs result in an increase in the length between the output terminals of the power driver of the motor controller and the input terminals of the coils of the electric motor. This further results in the use of more electrical wiring, which also results in increased heat losses caused by the increased electrical resistance that the wiring has. Furthermore, the long stretches of wiring can also result in installation and noise related problems.
[0005] According to other known electric motors, the electric motor and the motor controller are integrated together or axially mounted. Furthermore, cooling passages are provided in the stator of the electric motor and the power driver of the motor controller, which are then connected through a U-shaped pipe. However, such a structure of the electric motor and the motor controller requires a separate external cooling system to dissipate the generated heat, which makes the electric motor bulky and heavy, which is undesirable.
[0006] Additionally, with other known electric motors and motor controllers, the motor controller is mounted to a sidewall of the electric motor to minimize wiring length, but such motors do not support high capacity inverters that generate large amounts of heat.
[0007] Also, in some axial mounting of the motor controller with the motor, the motor is mounted on the frame of the vehicle and the motor controller is positioned off the frame of the vehicle. In such a case, the larger the inverter, the larger the overhang on the side of the vehicle. Furthermore, additional materials or parts are required to support the inverter overhang, which makes the device expensive and affects the vehicle's maneuverability and also the vehicle's mileage, which is undesirable. Summary of the Invention [Problem to be solved by the invention]
[0008] In view of the above, there is a need for a motor controller for an electric motor and an integrated electric motor-motor controller assembly that addresses one or more of the limitations noted above. [Means for solving the problem]
[0009] In one aspect, a motor controller for an electric motor is disclosed. The motor controller includes a frame member mounted on a casing of the electric motor. One or more power modules are circumferentially mounted on an inner surface of the frame member. A current splitter is electrically coupled to each of the one or more power modules. The current splitter is adapted to route current from a power source to each of the one or more power modules. Each of the one or more power modules is adapted to generate a transformed current based on a current received from the current splitter. The transformed current from each of the one or more power modules is provided to the electric motor for operation.
[0010] In an embodiment, each of the one or more power modules are isolated from each other.
[0011] In one embodiment, the current splitter is a DC splitter adapted to receive DC from the power source, the DC splitter adapted to send the DC to each of the one or more power modules.
[0012] In one embodiment, each of the one or more power modules is adapted to generate a single-phase AC current as a transformed current based on the DC current received from the DC splitter. The single-phase AC current from each of the one or more power modules is provided to an electric motor for operation.
[0013] In one embodiment, the DC splitter comprises a pair of power terminals adapted to be coupled to a power source to receive DC from the power source, the pair of power terminals including a positive power terminal and a negative power terminal.
[0014] In one embodiment, the DC splitter comprises a positive terminal plate coupled to a positive terminal of the power source via a positive power terminal, the positive terminal plate being defined with at least one positive terminal lead, the negative terminal plate being coupled to a negative terminal of the power source via a negative power terminal, the negative terminal plate being defined with at least one negative terminal lead, the at least one positive terminal lead and the at least one negative terminal lead being respectively coupled to respective positive and negative terminals of the one or more power modules for transmitting DC.
[0015] In one embodiment, the DC splitter includes a support plate mounted under the positive and negative terminal plates, the positive and negative terminal plates and the support plate being laminated with a laminate plate for insulation.
[0016] In one embodiment, a control board is mounted on the negative terminal board and communicatively coupled to each of the one or more power modules, the control board adapted to control operation of each of the one or more power modules.
[0017] In one embodiment, a cover member is mounted on an upper edge surface of the frame member and adapted to enclose the current splitter, each of the one or more power modules, and the control board while exposing a portion of the pair of power terminals.
[0018] In one embodiment, a gasket member is provided at the interface of the upper edge surface and the cover member, the gasket member adapted to provide ingress protection for the motor control device.
[0019] In one embodiment, the cover member includes a signal connector for connecting with an electronic component.
[0020] In one embodiment, each of the one or more power modules includes a phase terminal adapted to be coupled to a phase connector of an electric motor, the phase terminal adapted to supply a transformed current generated in each of the one or more power modules to the phase connector for operating the electric motor.
[0021] In one embodiment, the one or more power modules include a first power module, a second power module, and a third power module, the first power module, the second power module, and the third power module being angularly offset by an angle when disposed circumferentially along an inner surface of the frame member, the angle being 60 degrees.
[0022] In one embodiment, one or more mounting members are defined on an outer surface of the frame member. The one or more mounting members facilitate mounting the frame member onto a casing of an electric motor.
[0023] In one embodiment, a base member is mounted to a central portion of a front end of the electric motor, the base member enclosing a rotary encoder disposed at the front end that engages a shaft of the electric motor to measure rotation of the electric motor.
[0024] In one embodiment, the frame member is mounted on a transfer plate provided on the front end of the electric motor.
[0025] In one embodiment, a plurality of fin members are defined on an outer surface of the frame member, the plurality of fin members adapted to dissipate heat generated within the motor controller to the surrounding air.
[0026] In another aspect, an integrated electric motor-motor controller assembly for a vehicle. The assembly includes an electric motor mounted on a vehicle frame and a motor controller attached to the electric motor. The motor controller includes a frame member mounted on a casing of the electric motor. One or more power modules are circumferentially mounted on an inner surface of the frame member. A current splitter is electrically coupled to each of the one or more power modules. The current splitter is adapted to route current from a vehicle power source to each of the one or more power modules. Each of the one or more power modules is adapted to generate a transformed current based on the current received from the current splitter. The transformed current from each of the one or more power modules is provided to the electric motor for operation.
[0027] In one embodiment, the assembly is disposed on the vehicle transversely with the signal connectors pointing away from the vehicle frame.
[0028] Reference will now be made to embodiments of the invention, examples of which may be illustrated in the accompanying figures, which are intended to be illustrative, and not limiting, and while the invention has been generally described in the context of these embodiments, it will be understood that it is not intended to limit the scope of the invention to these particular embodiments. [Brief description of the drawings]
[0029] [Figure 1] FIG. 1 is a perspective view of an integrated electric motor-motor controller assembly according to one embodiment of the present invention. [Diagram 2] FIG. 1 is a schematic diagram of an inverter assembly as a motor controller according to one embodiment of the present invention. [Diagram 3] FIG. 2 is a perspective view of an inverter assembly according to one embodiment of the present invention. [Figure 4] FIG. 2 is an exploded view of a DC splitter as a current splitter according to one embodiment of the present invention. [Diagram 5]1 is a schematic diagram of a DC splitter coupled to one or more power modules in accordance with one embodiment of the present invention. [Figure 6] FIG. 2 is a cross-sectional view of one or more power modules mounted to a DC splitter according to one embodiment of the present invention. [Figure 7] FIG. 2 is an exploded view of an inverter assembly, according to one embodiment of the present invention. [Figure 8] 2 is a cross-sectional view of an inverter assembly according to one embodiment of the present invention. [Figure 9] 2 is a cross-sectional view of an inverter assembly according to one embodiment of the present invention. [Figure 10] 2 is a cross-sectional view of an inverter assembly according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Various features and embodiments of the present invention will now become apparent from the further description thereof set forth below.
[0031] 1 illustrates an integrated electric motor-motor controller assembly 136 according to one embodiment of the present disclosure. The integrated electric motor-motor controller assembly 136 may be adapted to be mounted on a vehicle (not shown), by way of example one of a two-wheeler or three-wheeler. The integrated electric motor-motor controller assembly 136 is adapted to provide the power or current required to operate the vehicle while ensuring a compact layout.
[0032] The integrated electric motor-motor controller assembly 136 comprises an electric motor 202 adapted to be mounted on a vehicle (not shown) via a vehicle frame. The electric motor 202 may be coupled to wheels (not shown) or may be coupled to a crankshaft (not shown) of an engine (not shown) to provide motive power to drive the vehicle. In one embodiment, the electric motor 202 is defined with mounting features (not shown) to allow mounting on the vehicle frame. Further, the motor controller 100 is adapted to attach to the electric motor 202 to form the integrated electric motor-motor controller assembly 136. The motor controller 100 provides the power or current required for the electric motor 202 and / or other electrical or electronic components of the vehicle to operate. The motor controller 100 is configured to reduce the voltage drop in the connection between the motor and the motor controller while transferring power to the electric motor 202.
[0033] In this embodiment, motor controller 100 is an inverter assembly coupled to an alternating current (AC) electric motor for providing alternating current by converting direct current (DC) received from a power source (not shown). In another embodiment, motor controller 100 is a DC-DC converter (not shown) of a vehicle and is adapted to provide direct current to an electric motor operated by direct current. In one embodiment, motor controller 100 is a combination inverter assembly and DC-DC converter.
[0034] 2 and 3 in conjunction with FIG 1, there is shown a motor controller 100. The motor controller 100 is adapted to be mounted axially (i.e., along axis A-A') on an electric motor 202. The motor controller 100 includes a frame member 102 that is axially mounted on a casing 204 of the electric motor 202. That is, the frame member 102 is mounted on the casing 204 along axis A-A'. In one embodiment, the frame member 102 is mounted on a transfer plate 208 provided on a front end 204a or right end of the electric motor 202.
[0035] The frame member 102 extends circumferentially along the casing 204 to define a mounting portion 104. On an outer surface 102b (shown in FIG. 3) of the frame member 102, one or more mounting members 128 are provided at locations effective to allow mounting onto the casing 204. In one embodiment, the mounting members 128 are circumferentially offset on the outer surface 102b of the frame member 102. In this embodiment, the mounting members 128 are grooves adapted to receive fasteners 140 (shown in FIG. 3) for fastening the frame member 102 onto the casing 204. Accordingly, threaded holes (not shown) are provided on the casing 204 to receive the fasteners 140. In another embodiment, the mounting members 128 are located between one or more power modules 106 (shown in FIG. 3) to ensure stable mounting on the frame member 102.
[0036] In one embodiment, the frame member 102 forms a tubular structure extending from the front end 204a of the casing 204. A hollow portion of the tubular structure forms a mounting portion 104 for accommodating the components of the motor controller 100. In one embodiment, the frame member 102 is trapezoidal in cross section about the axis A-A'. In another embodiment, the frame member 102 is made of metal or plastic or composite materials according to design feasibility and requirements.
[0037] Additionally, the one or more power modules 106 are circumferentially mounted on the inner surface 102a (shown in FIG. 3 ) of the frame member 102. The one or more power modules 106 are axially oriented relative to the electric motor 202 to maintain a compact layout. In one embodiment, the axial orientation refers to a width or thickness portion of the one or more power modules 106 being aligned along the axis A-A′ of the electric motor 202. The one or more power modules 106 are mounted on the inner surface 102a such that each of the one or more power modules 106 are separated from each other. The power modules 106, which are rectangular in shape, are positioned such that the length of the power modules 106 extends along the length of the inner surface 102a of the frame member 102.
[0038] In one embodiment, the one or more power modules 106 include a first power module 106a, a second power module 106b, and a third power module 106c. The first power module 106a, the second power module 106b, and the third power module 106c are each angularly offset by an angle (α). In other words, the axis B-B' of the first power module 106a, the axis C-C' of the second power module 106b, and the axis D-D' of the third power module 106c are tilted relative to each other. In one embodiment, the angle (α) is 60 degrees. Thus, the first power module 106a, the second power module 106b, and the third power module 106c each form a triangular configuration (shown in FIG. 2). In another embodiment, the angle (α) can be varied between each of the first power module 106a, the second power module 106b, and the third power module 106c according to design feasibility and requirements.
[0039] Each of the one or more power modules 106 is electrically coupled to a current splitter 108. The current splitter 108 is mounted within the mounting portion 104 of the frame member 102. The current splitter 108 is also coupled to a power source (not shown) for delivering current to each of the one or more power modules 106. The current splitter 108 is defined with a pair of power terminals 114 adapted to be coupled to the power source to receive direct current from the battery module.
[0040] In this embodiment, with the motor controller 100 being an inverter assembly, the current splitter 108 is a DC splitter (hereinafter interchangeably referred to as "DC splitter 108"). As such, the DC splitter 108 is adapted to receive DC from a power source and to split and route the DC between one or more power modules 106. Also, the power source is a battery module adapted to provide DC to the DC splitter.
[0041] In another embodiment, the current splitter 108 may be an AC splitter (not shown) according to design feasibility and requirements. Thus, the power source may be an AC source, such as an alternator, for supplying AC to the current splitter 108.
[0042] Referring to FIG. 4, an exploded view of the DC splitter 108 is shown. The DC splitter 108 includes a positive terminal plate 116 coupled to a positive terminal of a power source (not shown). The positive terminal plate 116 includes a positive power terminal 114a adapted to be coupled to the positive terminal of the power source. In one embodiment, the positive power terminal 114a is coupled to the positive terminal of the battery module via conventional coupling means such as clamping, fastening, or by contact leads or any other means known in the art, according to feasibility and requirements. In one embodiment, the positive power terminal 114a extends upward from the positive terminal plate 116.
[0043] Additionally, the positive terminal plate 116 is defined with at least one positive terminal lead 116a. The at least one positive terminal lead 116a is adapted to be coupled to each of the one or more power modules 106. In one embodiment, each of the positive power terminal leads 116a is coupled to each of the one or more power modules 106 via fastening onto a positive phase bus bar 146 (shown in FIGS. 5 and 6 ) provided on each of the one or more power modules 106. In one embodiment, each of the at least one positive terminal lead 116a extends upwardly from the positive terminal plate 116.
[0044] The DC splitter 108 also includes a negative terminal plate 118 mounted on the positive terminal plate 116 and coupled to the negative terminal of the battery module (not shown). The negative terminal plate 118 is coupled to the negative terminal of the battery module via a negative power terminal 114b. In one embodiment, the negative power terminal 114b is coupled to the negative terminal of the power source via conventional coupling means such as clamping, fastening, or by contact leads or any other means known in the art, according to feasibility and requirements. In another embodiment, the negative power terminal 114b extends upward from the negative terminal plate 118.
[0045] Further, the negative terminal plate 118 is defined with at least one negative terminal lead 118a. The at least one negative terminal lead 118a is adapted to be coupled to each of the one or more power modules 106. In one embodiment, each of the negative power terminals 118a is coupled to each of the one or more power modules 106 via fastening onto a negative phase bus bar 148 (shown in FIGS. 5 and 6 ) provided on each of the one or more power modules 106. In one embodiment, each of the at least one negative terminal lead 118a extends downward from the positive terminal plate 116. In view of coupling the positive terminal lead 116a and the negative terminal lead 118a to the one or more power modules 106, the direct current received from the power source by the DC splitter 108 is sent to each of the one or more power modules 106. The power module 106 has a combination of electronic components (not shown) for generating alternating current.
[0046] Further, a support plate 120 is mounted below the positive terminal plate 116 and the negative terminal plate 118. The support plate 120 is provided to increase the structural rigidity of the DC splitter 108. Furthermore, the support plate, the positive terminal plate, and the negative terminal plate are all laminated by a laminate plate 122 to provide insulation. Further, a control board 124 (shown in FIG. 7) is axially mounted on the laminate plate 122. The control board 124 may be mounted on the laminate plate 122 via one or more support pegs 142. The one or more support pegs 142 ensure alignment of the control board 124 and also provide proper support for the control board 124. The control board 124 is communicatively coupled to each of the one or more power modules 106, the positive terminal plate 116, and the negative terminal plate 118. The control board 124 includes electronic components such as transistors, processors, etc., and is adapted to control the operation of each of the one or more power modules 106 in generating AC from the supplied DC.
[0047] In one embodiment, support pegs 142 (e.g., shown in FIG. 5) may extend upward and / or downward from the support plate 120 to ensure alignment of the positive terminal plate 116, the negative terminal plate 118, the support plate 120, and the control board 124, respectively, during assembly. In another embodiment, guide holes 144 (shown in FIG. 4) are provided in the positive terminal plate 116, the negative terminal plate 118, the laminate plate 122, and the control board 124, respectively, which are aligned via the support pegs 142. The DC splitter 108 is separately assembled by stacking the positive terminal plate 116, the negative terminal plate 118, and the support plate 120 in the laminate plate 122. The assembled DC splitter 108 is axially mounted in the mounting portion 104 of the motor controller 100. The support pegs 142 ensure alignment or correct placement of the terminal plates 116, 118, and the support plate 120 during stacking.
[0048] In one embodiment, the positive terminal plate 116, the negative terminal plate 118, the support plate 120, and the laminate plate 122 are each defined with dimensions that can be accommodated within the mounting portion 104 of the frame member 102. In this embodiment, the positive terminal plate 116, the negative terminal plate 118, the support plate 120, and the laminate plate 122 are each triangular in shape with a flat apex. Thus, the shape, dimensions, and configuration of each of the positive terminal plate 116, the negative terminal plate 118, the support plate 120, and the laminate plate 122 are selected according to design feasibility and requirements.
[0049] In one embodiment, the positive terminal board 116 includes three positive terminal leads 116a for coupling with each of the first power module 106a, the second power module 106b, and the third power module 106c, and the upwardly directed positive terminal lead 116a (shown in FIG. 5) engages on the top surface (not shown) of each of the first power module 106a, the second power module 106b, and the third power module 106c via a positive phase bus bar 146 (shown in FIGS. 5 and 6).
[0050] In one embodiment, the negative terminal board 118 also includes three negative terminal leads 118a for coupling with each of the first, second, and third power modules 106a, 106b, and 106c, and the downwardly directed negative terminal leads 118a (shown in FIGS. 5 and 6) engage on the undersides (not shown) of each of the first, second, and third power modules 106a, 106b, and 106c via a negative phase bus bar 148 (shown in FIGS. 5 and 6).
[0051] 2-6 , each of the one or more power modules 106 is adapted to generate a single-phase AC current as a transformed current based on the DC current received from the DC splitter 108. The single-phase AC current from each of the one or more power modules 106 is supplied to the electric motor 202 for operation. In one embodiment, each of the one or more power modules 106 includes a phase terminal 112 (shown in FIG. 8 ) adapted to be coupled to a phase connector 206 of the electric motor 202. The phase terminal 112 is adapted to supply the single-phase AC current generated in each of the one or more power modules 106 to the phase connector 206 for operation of the electric motor 202.
[0052] In one embodiment, one or more of the power modules 106 may be configured to generate DC as a transformed current based on the AC received from the AC splitter, such that the DC generated in each of the power modules 106 is provided to operate a DC-based electric motor.
[0053] In this embodiment, a phase terminal 112 (shown in FIG. 8) is provided in each of the first power module 106a, the second power module 106b, and the third power module 106c. Thus, in this embodiment, three phase terminals 112 are provided in the motor control device 100. In one embodiment, the first power module 106a, the second power module 106b, and the third power module 106c each generate a single-phase AC current. Thus, three-phase AC current is supplied to the electric motor 202 from all three power modules 106 together via the phase terminals 112.
[0054] Additionally, motor controller 100 includes a cover member 126 mounted on an upper edge surface 102c of frame member 102. Cover member 126 is adapted to enclose current splitter 108, each of the one or more power modules 106, and control board 124. Cover member 126 thus encloses the components mounted within frame member 102.
[0055] In one embodiment, when each of the positive terminal plate 116, the negative terminal plate 118, and the support plate 120 are installed, the power terminals 114 themselves act as guides to facilitate alignment during installation of the cover member 126 and the signal connector 134 (e.g., shown in FIG. 9). In one embodiment, the signal connector 134 is provided on a surface of the cover member 126 (shown in FIG. 1). In another embodiment, the signal connector 134 may be provided on an intermediate plate 150 (shown in FIG. 7) mounted below the cover member 126. In one embodiment, the signal connector 134 may be a socket-type connector known in the art for coupling two electrical components.
[0056] In one embodiment, a gasket member 138 (shown in FIG. 8) is provided at the interface of the upper edge surface 102c and the cover member 126. The gasket member 138 is adapted to provide ingress protection for the inverter motor controller 100. In one embodiment, the gasket member 138 is made of non-metallic or metallic or composite materials according to design feasibility and requirements. In another embodiment, the cover member 126 includes a signal connector 134. In one embodiment, the integrated electric motor-motor controller assembly 136 is disposed on the vehicle such that the signal connector 134 points away from the vehicle frame. Such a configuration facilitates engagement and disengagement of the wiring harness with the signal connector 134.
[0057] 9 and 10, the motor controller 100 includes a base member 130 mounted on a central portion of the front end 204a of the electric motor 202. The base member 130 encloses a rotary encoder 132 for measuring the rotational speed of the electric motor 202. The base member 130 is mounted on a transfer plate 208. The rotary encoder 132 is enclosed in a space between the base member 130 and the transfer plate 208. Further, a plurality of fin members 110 are defined on the outer surface 102b of the frame member 102. The plurality of fin members 110 are adapted to dissipate heat generated within the inverter motor controller 100 to the ambient air, thus reducing the need for a separate cooling system within the vehicle. In one embodiment, the plurality of fin members 110 extend axially along the axis A-A' of the casing 202 to ensure that a maximum surface area is available for contact with the ambient air, ensuring optimal or maximum cooling efficiency. In another embodiment, the orientation, inclination, or structure of the fin members 110 on the frame member 102 can be selected according to design feasibility and requirements. In another embodiment, the fin members 110 are made of metal material to ensure maximum heat dissipation with the surrounding air. In one embodiment, the fin members 110 are provided in the area where the one or more power modules 106 are mounted. Such a structure allows for localized dissipation of heat from the one or more power modules 106 using natural convection.
[0058] In one embodiment, the integrated electric motor-motor controller assembly 136 may be adapted to be mounted on an electric appliance, such as a pump, a generator, etc., that may use an electric motor 202 for its operation. Thus, the motor controller 100 may be mounted on any electric motor 202 mounted on a vehicle or on an electric appliance, according to feasibility and requirements. In an operative embodiment, the DC splitter 108 receives supply power or DC from a battery source. According to the power requirements calculated by the control board 124, the control board 124 operates the DC splitter 108 to supply the DC received from the battery source to one or more power modules 106. The one or more power modules 106 generate AC, which is sent to the electric motor 202 for operation via the phase terminals 112. In one embodiment, the control board 124 operates the DC splitter 108 to supply DC to each of the first power module 106a, the second power module 106b, and the third power module 106c such that three-phase AC is generated. The three-phase AC is then sent via the phase terminals 112 to the electric motor 202 for operation.
[0059] The claimed invention discussed above is not common, conventional, or well understood in the art, as the claimed aspects enable the following solutions to existing problems in the prior art. Specifically, the claimed aspects of axial integration of motor controller 100 with electric motor 202 make integrated electric motor-motor controller assembly 136 modular and compact with minimal or negligible voltage drop between components while current is flowing, providing a technical solution to a technical problem. Also, the compact layout of motor controller 100 on electric motor 202 reduces overhang of motor controller 100 in the vehicle, thereby reducing additional components required to support integrated electric motor-motor controller assembly 136. Additionally, control board 124 is mounted above current splitter 108, thereby reducing additional space requirements for control board 124 in the vehicle. Furthermore, a number of fin members 110 are provided on the outer surface 102b of the frame member 102, which ensures heat dissipation through ambient air flow, thus reducing the need for a separate cooling system, thus reducing the number of components in the vehicle, thereby making the vehicle lighter, and thus improving the performance of the vehicle.
[0060] While the present invention has been described with respect to several embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the following claims. [Explanation of symbols]
[0061] 100 Motor control device 102 Frame member 102a Inner surface of frame member 102b Outer surface of frame member 104 Mounting part in frame member 106 One or more power modules 106a First power module 106b Second power module 106c Third Power Module 108 Current Splitter 110 Multiple fin members 112 Phase terminal 114 Power terminal 114a Positive power terminal 114b Negative power terminal 116 Positive terminal board 116a Positive terminal lead 118 Negative terminal board 118a Negative terminal lead 120 Support plate 122 Laminated Plate 124 Control Board 126 Cover member 128 Mounting material 130 Base material 132 Rotary Encoder 134 Signal Connector 136 Integrated electric motor-motor controller assembly 138 Gasket material 140 Fasteners 142 Support peg 144 Guide hole 146 Positive Phase Busbar 148 Negative Phase Busbar 150 Intermediate plate 202 Electric Motor 204 Electric motor casing 206 Phase terminal 208 Transfer Board
Claims
1. A motor controller (100) for an electric motor (202), comprising: a frame member (102) mounted on a casing (204) of the electric motor (202); one or more power modules (106) circumferentially mounted on an inner surface (102a) of the frame member (102); a current splitter (108) electrically coupled to each of the one or more power modules (106), the current splitter (108) adapted to transmit current from a power source to each of the one or more power modules (106); Each of the one or more power modules (106) is adapted to generate a transformed current based on the current received from the current splitter (108), and the transformed current from each of the one or more power modules (106) is supplied to the electric motor (202) for operation.
2. The motor controller (100) of claim 1 , wherein each of the one or more power modules (106) is isolated from one another.
3. 2. The motor controller of claim 1, wherein the current splitter is a DC splitter adapted to receive DC from the power source, the DC splitter adapted to send DC to each of the one or more power modules.
4. 4. The motor control device (100) of claim 3, wherein each of the one or more power modules (106) is adapted to generate a single-phase alternating current as the transformed current based on the direct current received from the DC splitter, and the single-phase alternating current from each of the one or more power modules (106) is supplied to the electric motor (202) for operation.
5. 4. The motor controller of claim 3, wherein the DC splitter comprises a pair of power terminals adapted to be coupled to a power source to receive DC from the power source, the pair of power terminals including a positive power terminal and a negative power terminal.
6. The DC splitter comprises: a positive terminal plate (116) coupled to a positive terminal of the power source via the positive power terminal (114a), the positive terminal plate (116) being defined with at least one positive terminal lead (116a); 6. The motor controller of claim 5, further comprising: a negative terminal plate (118) coupled to a negative terminal of the power source via the negative power terminal (114b), the negative terminal plate (118) defined with at least one negative terminal lead (118a), the at least one positive terminal lead (116a) and the at least one negative terminal lead (118a) being respectively coupled to the respective positive and negative terminals of the one or more power modules (106) for transmitting the direct current.
7. The DC splitter comprises: a support plate (120) mounted under the positive terminal plate (116) and the negative terminal plate (118); The motor control device (100) of claim 6, wherein the positive terminal plate (116), the negative terminal plate (118), and the support plate (120) are laminated with a lamination plate (122) for insulation.
8. 8. The motor controller of claim 7, further comprising a control board mounted on the negative terminal plate and communicatively coupled to each of the one or more power modules, the control board adapted to control the operation of each of the one or more power modules.
9. 2. The motor control device of claim 1, further comprising a cover member mounted on an upper edge surface of the frame member, the cover member adapted to enclose the current splitter, the each of the one or more power modules, and a control board while exposing a portion of a pair of power terminals.
10. 10. The motor control device (100) of claim 9, further comprising a gasket member (138) disposed at an interface between the upper edge surface (102c) and the cover member (126), the gasket member (138) adapted to provide ingress protection to the motor control device (100).
11. The motor control device (100) of claim 9, wherein the cover member (126) comprises a signal connector (134) for connecting with an electronic component.
12. 2. The motor control device (100) of claim 1, wherein each of the one or more power modules (106) comprises a phase terminal (112) adapted to be coupled to a phase connector (206) of the electric motor (202), the phase terminal (112) adapted to supply the transformed current generated in the each of the one or more power modules (106) to the phase connector (206) to operate the electric motor (202).
13. 2. The motor control device of claim 1, wherein the one or more power modules (106) comprise a first power module (106a), a second power module (106b), and a third power module (106c), the first power module (106a), the second power module (106b), and the third power module (106c) being angularly offset by an angle (α) when circumferentially disposed along the inner surface of the frame member, the angle being 60 degrees.
14. 2. The motor control device (100) of claim 1, comprising one or more mounting members (128) defined on an outer surface (102b) of the frame member (102), the one or more mounting members (128) facilitating mounting of the frame member (102) onto the casing (204) of the electric motor (202).
15. 2. The motor control device of claim 1, further comprising a base member mounted to a central portion of a front end of the electric motor, the base member enclosing a rotary encoder engaged with a shaft of the electric motor and disposed at the front end for measuring rotation of the electric motor.
16. The motor control device (100) of claim 1, wherein the frame member (102) is mounted on a transfer plate (208) provided on a front end (204a) of the electric motor (202).
17. 2. The motor control device of claim 1, further comprising a plurality of fin members defined on an outer surface of the frame member, the plurality of fin members adapted to dissipate heat generated within the motor control device to ambient air.
18. 1. An integrated electric motor-motor controller assembly (136) for a vehicle, comprising: An electric motor (202) mounted on the vehicle frame; and a motor control device (100) attached to the electric motor (202), the motor control device (100) comprising: a frame member (102) mounted on a casing (204) of the electric motor (202); one or more power modules (106) circumferentially mounted on an inner surface (102a) of the frame member (102); a current splitter (108) electrically coupled to each of the one or more power modules (106), the current splitter (108) adapted to route current from a power source of the vehicle to each of the one or more power modules (106); Each of the one or more power modules (106) is adapted to generate a transformed current based on the current received from the current splitter (108), and the transformed current from each of the one or more power modules (106) is supplied to the electric motor (202) for operation.
19. The assembly (136) of claim 18, wherein each of the one or more power modules (106) are isolated from each other.
20. 20. The assembly (136) of claim 18, wherein the current splitter (108) is a DC splitter adapted to receive DC from the power source, the DC splitter adapted to send DC to each of the one or more power modules (106).
21. 21. The assembly (136) of claim 20, wherein each of the one or more power modules (106) is adapted to generate a single-phase alternating current as the transformed current based on the direct current received from the DC splitter, and the single-phase alternating current from each of the one or more power modules (106) is supplied to the electric motor (202) for operation.
22. 21. The assembly (136) of claim 20, wherein the DC splitter comprises a pair of power terminals (114) adapted to be coupled to the power source in the vehicle to receive DC from the power source, the pair of power terminals (114) including a positive power terminal (114a) and a negative power terminal (114b).
23. The DC splitter comprises: a positive terminal plate (116) coupled to a positive terminal of the power source via the positive power terminal (114a), the positive terminal plate (116) being defined with at least one positive terminal lead (116a); 23. The assembly (136) of claim 22, comprising: a negative terminal plate (118) coupled to a negative terminal of the power source via the negative power terminal (114b), the negative terminal plate (118) defined with at least one negative terminal lead (118a), the at least one positive terminal lead (116a) and the at least one negative terminal lead (118a) being respectively coupled to the respective positive and negative terminals of the one or more power modules (106) for transmitting the direct current.
24. The DC splitter comprises: a support plate (120) mounted under the positive terminal plate (116) and the negative terminal plate (118); 24. The assembly (136) of claim 23, wherein the positive terminal plate, the negative terminal plate, and the support plate are laminated by a laminate plate (122) for insulation.
25. 25. The assembly (136) of claim 24, comprising a control board (124) mounted on the negative terminal plate (118) and communicatively coupled to each of the one or more power modules (106), the control board (124) adapted to control the operation of each of the one or more power modules (106).
26. 20. The assembly (136) of claim 18, comprising a cover member (126) mounted on an upper edge surface (102c) of the frame member (102), the cover member (126) adapted to enclose the current splitter (108), the each of the one or more power modules (106), and a control board (124) while exposing a portion of a pair of power terminals (114).
27. 27. The assembly (136) of claim 26, further comprising a gasket member (138) disposed at an interface between the upper edge surface (102c) and the cover member (126), the gasket member (138) adapted to provide ingress protection for the motor control device (100).
28. 27. The assembly (136) of claim 26, wherein the cover member (126) comprises a signal connector (134) for connecting with electronic components of the vehicle.
29. The assembly (136) of claim 18, wherein the signal connector (134) is disposed on the vehicle in a transverse vehicle direction such that the signal connector (134) points away from the vehicle frame.
30. 20. The assembly (136) of claim 18, wherein each of the one or more power modules (106) comprises a phase terminal (112) adapted to be coupled to a phase connector (206) of the electric motor (202), the phase terminal (112) adapted to supply the transformed current generated in the each of the one or more power modules (106) to the phase connector (206) to operate the electric motor (202).
31. 20. The assembly (136) of claim 18, wherein the one or more power modules (106) comprise a first power module (106a), a second power module (106b), and a third power module (106c), wherein the first power module (106a), the second power module (106b), and the third power module (106c) are angularly offset by an angle (α) when disposed circumferentially along the inner surface of the frame member, the angle being 60 degrees.
32. 20. The assembly (136) of claim 18, comprising one or more mounting members (128) defined on an outer surface (102b) of the frame member (102), the one or more mounting members (128) facilitating mounting of the frame member (102) onto the casing (204) of the electric motor (202).
33. 20. The assembly (136) of claim 18, comprising a base member (130) mounted to a central portion of a front end (204a) of the electric motor (202), the base member (130) enclosing a rotary encoder (132) engaged with a shaft of the electric motor and disposed at the front end for measuring rotation of the electric motor (202).
34. 20. The assembly (136) of claim 18, wherein the frame member (102) is mounted on a transfer plate (208) provided on a front end (204a) of the electric motor (202).
35. 20. The assembly (136) of claim 18, comprising a plurality of fin members (110) defined on an outer surface (102b) of the frame member (102), the plurality of fin members (110) adapted to dissipate heat generated within the motor control device (100) to ambient air.