An integrated traction inverter current distribution and thermal management system

Abstract

The present disclosure relates to an integrated traction inverter current distribution and thermal management system (100). The system (100) features a motor (101) housed within a motor enclosure (103), with motor windings (113) to drive the motor. A power board (105) is disposed within the motor enclosure (103), including an inverter unit that convert DC power into three-phase AC power for the motor (101). A series of bus bars (111a, 111b, 112) delivers the AC power to the motor windings (113). To manage heat, a heat sink (106) is positioned in the vicinity of the inverter unit to dissipate heat through natural air convection, ensuring optimal performance and thermal management. This integrated configuration minimizes energy losses and enhances overall system reliability in electric motor-driven applications.

Description

[0001] AN INTEGRATED TRACTION INVERTER CURRENT DISTRIBUTION AND THERMAE MANAGEMENT SYSTEM

[0002] FIELD

[0003] The present disclosure relates to the field of electric vehicle powertrain systems, more particularly focusing on integrated traction inverter systems.

[0004] BACKGROUND

[0005] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0006] Electric motors are integral to various applications, including electric vehicles, industrial machinery, and renewable energy systems. A key component in these systems is the traction inverter, which converts direct current (DC) from a battery into three-phase alternating current (AC) required to drive the motor. Existing traction inverter systems often encounter challenges such as excessive heat generation, electromagnetic interference, and limited scalability, which can reduce efficiency and reliability. Traditional systems also necessitate complex cooling mechanisms and are not optimized for compact, modular configurations, making them less suitable for modem, high-performance applications.

[0007] Furthermore, precise control and monitoring of the inverter system are essential to ensure optimal performance and longevity of the electric motor and associated components. This includes real-time management of phase currents, thermal performance, and system efficiency.

[0008] Therefore, there is a need for an integrated traction inverter current distribution and thermal management system that alleviates the aforementioned drawbacks.

[0009] OBJECTS

[0010] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

[0011] It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative. An object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system.

[0012] Another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that ensures efficient power conversion with efficient heat dissipation.

[0013] Still, another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that enhances reliability and operational performance under extreme conditions.

[0014] Yet another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that optimizes cooling without the need for liquid cooling systems.

[0015] Still, another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that allows easy maintenance, upgrades, and adaptation to different power levels or vehicle types.

[0016] Yet another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that implements real-time control, monitoring, and fault detection mechanisms to ensure continuous and safe operation of the inverter system.

[0017] Still another object of the present disclosure is to provide an integrated traction inverter current distribution and thermal management system that improves the durability and longevity of the inverter system by incorporating a reinforced mechanical structure and failsafe mechanisms.

[0018] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

[0019] SUMMARY

[0020] The present disclosure envisages a traction inverter system. The system is configured to facilitate three-phase alternating current (AC) distribution and thermal management in an operative configuration of a motor. The system, comprises a motor enclosure, a motor, a power board, and a control board.

[0021] The motor is housed in the motor enclosure, the motor comprising motor windings.

[0022] The power board configured to be disposed within the motor enclosure. The power board includes an inverter unit, a plurality of bus bars, and a heat sink.

[0023] The inverter unit is configured to convert a direct current (DC) power received from a power source to a three-phase alternating current (AC) power.

[0024] The plurality of bus bars is configured to distribute the three-phase alternating current from the inverter unit to the motor windings of the motor.

[0025] The heat sink is configured to be disposed in the vicinity of the inverter unit to dissipate heat generated by the inverter unit during operation.

[0026] The control board configured to be disposed within the motor enclosure, and operatively coupled with the power board . The control board configured to control control switching sequences of the inverter unit and is further configured to manage motor phase currents in real-time. The power board, the control board, and said motor windings are integrated within said motor enclosure in a compact architecture to facilitate distribution of the three-phase alternating current, and thermal management of the inverter unit in an operative configuration.

[0027] In an embodiment, the inverter unit includes a plurality of metal oxide semiconductor field effect transistors (MOSFETs).

[0028] In an embodiment, the system further includes a polymeric cover, configured to be disposed on the operative top of said power board, said polymeric cover having an insulating layer configured to thermally isolate said control board from said power board.

[0029] In an embodiment, the control board is configured with at least one microcontroller, at least one gate driver, and at least one power management unit to control switching sequence of said inverter unit and manage motor phase currents in real-time, wherein said control board is connected to said power board (105) through board-to-board connectors. In an embodiment, the motor enclosure integrates built-in airflow channels that facilitate natural air convection cooling, wherein the heat sink is configured to dissipate heat by natural air convection within the motor enclosure.

[0030] In an embodiment, the power board is formed from a single-layer metal-clad architecture and coated with a thermally conductive, electrically insulating material for improved heat dissipation and protection from environmental contaminants.

[0031] In an embodiment, the MOSFETs are arranged in a symmetrical three-phase configuration, each phase comprising three top and three bottom MOSFETs arranged in parallel, the arrangement ensuring uniform current distribution and heat dissipation.

[0032] In an embodiment, the plurality of bus bars is formed from copper and configured to supply the DC power to the power board, distribute the DC power evenly across all phase MOSFETs, and deliver three-phase AC power to the motor windings.

[0033] In an embodiment, the power board includes direct current (DC) link capacitors positioned close to the MOSFETs to reduce inductive losses and enhance ripple current handling capabilities.

[0034] In an embodiment, the power board includes thermal vias to channel heat from the MOSFETs to the heat sink, improving the thermal performance of the system.

[0035] In an embodiment, the control board includes an integrated fault detection mechanism that monitors thermal performance and triggers protective responses to prevent overheating.

[0036] In an embodiment, the control board includes a Controller Area Network (CAN) communication module enabling remote monitoring and diagnostics of the system.

[0037] In an embodiment, the control board includes an electromagnetic shielding layer to protect the low-voltage components from electromagnetic interference (EMI) generated by high- power components of the system.

[0038] In an embodiment, the motor enclosure is constructed from a composite material that combines lightweight properties with high thermal conductivity for improved thermal management and reduced system weight. In an embodiment, the polymeric cover includes an insulating layer mounted on top of the power board to prevent heat transfer from the power board to the control board.

[0039] In an embodiment, the motor enclosure is incorporated with a phase change material to absorb and release heat during operation, enhancing overall thermal management of the system.

[0040] In an embodiment, the control board includes a real-time clock (RTC) module to synchronize the operation of the inverter unit with other vehicle systems for improved performance timing.

[0041] In an embodiment, the power board further includes surge protection circuitry to shield the system from voltage spikes caused by sudden load changes or external disturbances, ensuring the longevity and safety of the inverter components.

[0042] In an embodiment, the inverter unit includes a noise reduction mechanism to minimize electromagnetic interference generated during operation and ensure compliance with automotive industry standards for electromagnetic compatibility (EMC).

[0043] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0044] An integrated traction inverter current distribution and thermal management system, of the present disclosure will now be described with the help of the accompanying drawing in which:

[0045] Figure 1 illustrates an integrated traction inverter current distribution and thermal management system, in accordance with an embodiment of the present disclosure;

[0046] Figure 2 illustrates a power board of the system, in accordance with an embodiment of the present disclosure;

[0047] Figure 3 illustrates the power board inside a motor enclosure in accordance with an embodiment of the present disclosure; and

[0048] Figure 4 illustrates the power board, a polymeric cover, and a control board of the system, in accordance with an embodiment of the present disclosure.

[0049] LIST OF REFERENCE NUMERALS 100 Traction inverter system

[0050] 101 Motor

[0051] 103 Motor enclosure

[0052] 105 Power board

[0053] 106 Heat sink

[0054] 107 Control board

[0055] I l la, U lb, 112 Bus bars

[0056] 113 Motor windings

[0057] 114 Metal oxide semiconductor field effect transistors (MOSFETs)

[0058] 115 Direct Current (De) Links Capacitors

[0059] 117 Polymeric Cover

[0060] 121 Motor Housing

[0061] 138 Nuts and Bolts

[0062] 140 Power Supply Wires

[0063] DETAILED DESCRIPTION

[0064] The present disclosure relates to an integrated traction inverter system developed for controlling electric motors. It is particularly useful in applications requiring efficient power conversion, advanced thermal management, and enhanced reliability, such as electric vehicles.

[0065] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

[0066] Embodiments are provided to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0067] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and / or components, but do not forbid the presence or addition of one or more other features, elements, components, and / or groups thereof.

[0068] When an element is referred to as being “engaged to,” "connected to," or "coupled to" another element, it may be directly engaged, connected, or coupled to the other element. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements.

[0069] Therefore, the present disclosure is an integrated traction inverter current distribution and thermal management system (herein after referred as traction inverter system or system 100). The present disclosure is explained in Figure 1- Figure 4.

[0070] The system (100) comprises a motor enclosure (103), a motor (101), a power board (105), a polymeric cover (117), and a control board (107).

[0071] The motor (101) is housed in the motor enclosure (103), the motor (101) comprises motor windings (113).

[0072] The power board (105) configured to be disposed within the motor enclosure (103), the power board (105) including an inverter unit, a plurality of bus bars (I l la, 111b, 112), and a heat sink (106).

[0073] In an embodiment, the power board (105) is integrated within the motor enclosure. The inverter unit has a plurality of metal oxide semiconductor field effect transistors (MOSFETs) (114) to convert a direct current (DC) power received from a power source to a three-phase alternating current (AC) power.

[0074] The plurality of bus bars (I l la, 111b, 112) is configured to deliver the AC power from the MOSFETs (114) to the motor windings (113) of the motor (101).

[0075] The heat sink (106) is configured to disposed on the power board (105) in the vicinity of the MOSFETs (114) to dissipate heat generated by the MOSFETs (114) through natural air convection.

[0076] The polymeric cover (117) is configured to be disposed within the motor enclosure (103) and mounted on top of the power board (105) to prevent heat transfer from the power board (105).

[0077] In an polymeric cover (117) is integrated within the motor enclosure (103).

[0078] The control board (107) is configured within the motor enclosure (103), mounted on top of the polymeric cover (117), and connected to the power board PCB (105) via board-to-board connectors. The control board (107) includes low-voltage components including at least one micro-controller (124), at least one gate driver, and at least one integrated power management unit, for controlling the operation of the inverter unit to control switching sequences of the inverter unit and manage motor phase currents in real-time.

[0079] In an embodiment, the motor enclosure (103) integrates built-in airflow channels that facilitate natural air convection cooling.

[0080] In an embodiment, the power board (105) is formed from a single-layer metal-clad architecture and coated with a thermally conductive, electrically insulating material for improved heat dissipation and protection from environmental contaminants.

[0081] In an embodiment, the MOSFETs (114) are arranged in a symmetrical three-phase configuration, each phase comprising three top and three bottom MOSFETs arranged in parallel, the arrangement ensuring uniform current distribution and heat dissipation.

[0082] In an embodiment, the plurality of bus bars (I l la, 111b, 112) are formed from copper and configured to supply the DC power to the power board (105), distribute the DC power evenly across all phase MOSFETs (114), and deliver three-phase AC power to the motor windings (113).

[0083] In an embodiment, the power board (105) includes a direct current (DC) links capacitors (115) positioned close to the MOSFETs (114) to reduce inductive losses and enhance ripple current handling capabilities.

[0084] In an embodiment, the power board (105) includes thermal vias to channel heat from the MOSFETs (114) to the heat sink (106), improving the thermal performance of the system (100).

[0085] In an embodiment, the control board (107) includes an integrated fault detection mechanism (123) that monitors thermal performance and triggers protective responses to prevent overheating.

[0086] In an embodiment, the control board (107) includes a Controller Area Network (CAN) communication module enabling remote monitoring and diagnostics of the system (100).

[0087] In an embodiment, the control board (107) includes an electromagnetic shielding layer to protect the low-voltage components from electromagnetic interference (EMI) generated by high-power components of the system (100).

[0088] In an embodiment, the motor enclosure (103) is constructed from a composite material that combines lightweight properties with high thermal conductivity for improved thermal management and reduced system weight.

[0089] In an embodiment, the polymeric cover (117) includes an insulating layer mounted on top of the power board (105) to prevent heat transfer from the power board (105) to the control board (107).

[0090] In an embodiment, the motor enclosure (103) is incorporated with a phase change material to absorb and release heat during operation, enhancing the overall thermal management of the system (100).

[0091] In an embodiment, the control board (107) includes a real-time clock (RTC) module to synchronize the operation of the inverter unit with other vehicle systems for improved performance timing. In an embodiment, the power board (105) further includes a surge protection circuitry to shield the system (100) from voltage spikes caused by sudden load changes or external disturbances, ensuring the longevity and safety of the inverter components.

[0092] In an embodiment, the inverter unit includes a noise reduction mechanism to minimize electromagnetic interference generated during operation and ensure compliance with automotive industry standards for electromagnetic compatibility (EMC).

[0093] Therefore, the power board (105), the control board (107), and the motor windings (113) are integrated within the motor enclosure (103) in a compact architecture to facilitate distribution of three-phase alternating current, and thermal management of the inverter unit in an operative configuration.

[0094] Figure 1 illustrates an integrated motor assembly. Figure 1 shows the integrated traction inverter system (100) in an exploded view, highlighting the assembly of its critical components. At the heart of the system is the motor (101), which is housed within the motor enclosure (103). The enclosure not only protects the motor but also integrates the inverter unit that is responsible for converting DC power into three-phase AC power to drive the motor. Inside the motor enclosure, the power board PCB (105) is positioned, and equipped with phase MOSFETs (114) that play a crucial role in the power conversion process. To manage the heat generated by these MOSFETs, a heat sink (106) is attached to the power board, ensuring effective thermal dissipation through natural convection. Adjacent to the power board PCB is the control board PCB (107), which manages the operation of the inverter unit. This control board includes key components such as the micro-controller (124), power management unit, and an electromagnetic shielding layer (109) to protect against electromagnetic interference. The system also features copper bus bars (I l la) that supply DC power from the control board to the power board, and three-phase copper bus bars (112) that deliver the converted AC power to the motor windings (113). The motor windings are essential for generating motion within the motor. The entire assembly is supported by a motor housing (121), which also serves as an additional heat sink and shield against EMI, enhancing the system's overall thermal management. The components are securely fastened together using various nuts and bolts (138), ensuring the structural integrity of the system. Finally, power supply wires (140) provide the necessary electrical connections to ensure efficient power and signal transfer between the different components of the system. Figure 2 illustrates a power board metal-clad PCB, in accordance with the present disclosure. Figure 2 shows a detailed view of the Power Board PCB (105) within the integrated traction inverter system (100). The figure highlights the arrangement of critical components that play a vital role in the system's power conversion and thermal management. Central to the configuration are the three-phase copper bus bars (112), which are strategically positioned to deliver three-phase AC power to the motor windings (113). These bus bars are configured to minimize heat dissipation and ensure balanced impedance, which is crucial for efficient power transmission. Also prominently featured in this figure are the DC link capacitors (115). These capacitors are mounted on the Power Board PCB (105) and are positioned close to the three-phase copper bus bars (112) to minimize inductive losses and enhance ripple current handling capabilities. The proximity of the DC link capacitors to the phase MOSFETs (not labelled in this figure but present on the PCB) improves the overall stability and performance of the inverter system. The layout of the components on the Power Board PCB (105) is carefully configuration to optimize the system’s thermal management. The PCB's structure and component placement ensure effective heat dissipation, contributing to the longevity and reliability of the traction inverter system.

[0095] Figure 3 illustrates a power board with a heat sink assembly in accordance with the present disclosure. Figure 3 shows the integrated assembly of the Power Board PCB (105) within the motor enclosure, providing a three-dimensional perspective of the key components and their spatial arrangement. The Power Board PCB (105) is centrally mounted, with several critical components organized to optimize both electrical performance and thermal management. The figure prominently displays the phase MOSFETs (114) arranged on either side of the PCB, which is essential for converting DC power to three-phase AC power. These MOSFETs are positioned to ensure even current distribution and efficient heat dissipation. The three-phase copper bus bars (112) are also visible, connecting the phase MOSFETs (114) and delivering AC power to the motor windings. Their arrangement minimizes impedance and heat generation, contributing to the overall efficiency of the system. Additionally, the DC link capacitors (115) are strategically placed close to the phase MOSFETs and bus bars to reduce inductive losses and improve power stability. A key feature of the assembly is the polymeric cover (117), which provides an insulating barrier, protecting the sensitive low-voltage components on the control board from the heat generated by the high-power components on the power board. This cover (117) helps to maintain thermal integrity and prevent potential overheating. Moreover, figure 3 shows the copper bus bars (l l la,l l lb,112), which are configured to supply DC power from the control board PCB to the power board PCB. The bus bars are robustly constructed to handle high currents with minimal resistance. The entire assembly is carefully engineered to ensure reliable operation and efficient thermal management, with all components securely housed within the motor enclosure.

[0096] Figure 4 illustrates a power board and control board assembly, in accordance with the present disclosure. Figure 4 shows, on the operative left side of the figure, the Power Board PCB (105) with the phase MOSFETs (114) mounted on it. These MOSFETs are essential for the conversion of DC to three-phase AC power. The three-phase copper bus bars (112) are connected to the MOSFETs, efficiently delivering the AC power to the motor windings. The DC link capacitors (115) are strategically placed near the bus bars to minimize inductive losses and stabilize power flow. The heat sink (106) is visible and attached to the Power Board PCB (105), facilitating heat dissipation from the MOSFETs to maintain optimal operating temperatures. The central portion of the figure shows the polymeric cover (117), which acts as an insulating barrier between the Power Board PCB (105) and the Control Board PCB (107), protecting the low-voltage control components from heat generated by the power components. The copper bus bars (11 la, 11 lb, 112) that supply DC power from the control board to the power board are also depicted, ensuring efficient and stable power delivery. On the operative right side of the figure, the Control Board PCB (107) is detailed, showing the arrangement of control elements and low-voltage components responsible for managing the operation of the inverter system. The nuts and bolts (138) used to securely fasten the entire assembly are clearly shown, emphasizing the structural integrity of the system.

[0097] In an embodiment, the traction inverter system (100) within the motor enclosure (103), is configured to dynamically adjust its speed based on real-time thermal data. This active cooling mechanism can enhance thermal management, particularly during high-power operations, and can work in conjunction with natural air convection cooling to maintain optimal operating temperatures.

[0098] In an embodiment, the system (100) is configured with a multi -phase power stage that includes more than three phases, such as a five-phase or six-phase configuration. This advanced configuration allows for finer control over the motor's operation, reducing torque ripple, and improving overall efficiency and smoothness of motor performance. In an embodiment, the inverter unit incorporates a self-diagnostic module (139) that periodically checks the health of the power components, including MOSFETs (114), capacitors (115), and bus bars (I l la, 111b, 112). The diagnostic results may be stored in onboard memory and communicated to external diagnostic tools via the wireless communication module for predictive maintenance.

[0099] In an embodiment, the system (100) includes a regenerative braking feature, which allows the inverter to convert the kinetic energy of the motor (101) back into electrical energy during deceleration. This energy can be stored in the vehicle's battery system, thereby improving the overall efficiency of the vehicle by recovering otherwise wasted energy.

[0100] In an embodiment, the motor enclosure (103) is constructed from a composite material that combines lightweight properties with high thermal conductivity. This construction reduces the overall mass of the system (100) while enhancing its thermal management capabilities, making it particularly suitable for applications in electric vehicles where weight is a critical factor.

[0101] In an embodiment, the control board (107) is equipped with an advanced sensor fusion technique that integrates data from multiple sensors, such as current sensors, temperature sensors, and vibration sensors. This technique can provide a more comprehensive understanding of the system's operational state, enabling more precise control and adjustments to enhance performance and reliability.

[0102] In an embodiment, the power board (105) includes a built-in surge protection circuit that shields the system (100) from voltage spikes, which can occur due to sudden load changes or external disturbances. This protection ensures the longevity and safety of the components within the inverter unit.

[0103] In an embodiment, the system (100) features an energy- efficient standby mode that significantly reduces power consumption when the motor (101) is not in active use. This mode can be automatically activated when the vehicle is stationary, contributing to overall energy savings and extending the vehicle's range.

[0104] In an embodiment, the system (100) includes a noise reduction technique implemented within the micro-controller (124) that actively cancels out audible noise generated by the inverter’s switching operations. This feature is particularly useful in applications where noise reduction is critical, such as in passenger electric vehicles. In an embodiment, the control board (107) is configured to interface with an external AI- based optimization system that learns from driving patterns and environmental conditions to continuously improve the efficiency and performance of the inverter system (100) over time. This interface allows the system to adapt dynamically to changing conditions, providing a more intelligent and responsive driving experience.

[0105] In an operative configuration, the integrated traction inverter current distribution and thermal management system (100) is configured to efficiently convert direct current (DC) power from a power source into three-phase alternating current (AC) power for driving an electric motor (101). The system integrates key components within a motor enclosure (103), including a power board (105), which houses an inverter unit comprising metal oxide semiconductor field effect transistors (MOSFETs) (114). The MOSFETs convert DC power into AC power, which is then delivered to the motor windings (113) via bus bars (I l la, 111b, 112). To ensure proper thermal management, a heat sink (106) is integrated on the power board (105), and natural air convection is facilitated by built-in airflow channels within the motor enclosure (103). The control board (107), which includes low-voltage components such as a microcontroller (124), a gate driver, and an integrated power management unit, is mounted above a polymeric cover (117) and connected to the power board (105) via board-to-board connectors. The control board regulates inverter switching sequences and manages motor phase currents in real time, ensuring efficient motor operation. Thermal vias and phase change materials enhance the system’s thermal performance, and the motor enclosure is constructed from a lightweight composite material for optimal heat dissipation and reduced system weight.

[0106] Advantageously, the integrated traction inverter system (100) combines power conversion, current distribution, and thermal management into a single compact unit, reducing the overall size, weight, and complexity of the electric drivetrain. The use of MOSFETs (114) area arranged in a symmetrical three-phase configuration ensures uniform current distribution and improved heat dissipation, thereby enhancing system efficiency and reliability. Natural air convection cooling through built-in airflow channels and the use of thermal vias and phase change materials provide effective thermal management, reducing the risk of overheating and extending the lifespan of critical components. Additionally, the integrated fault detection mechanism and noise reduction system further ensure the system’s safe and reliable operation. The composite motor enclosure and polymeric cover (117) not only improve thermal insulation but also contribute to reducing the overall system weight, making it ideal for use in electric vehicles where efficiency and performance are paramount. The system also includes advanced features such as a Controller Area Network (CAN) module for remote diagnostics, enhancing its operability and maintainability in real-world applications.

[0107] The functions described herein may be implemented in hardware, executed by a processor, firmware, or any combination thereof. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. The nature of the disclosure can be implemented by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.

[0108] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

[0109] TECHNICAL ADVANCEMENTS

[0110] The present disclosure described hereinabove has several technical advantages including, but not limited to, an integrated traction inverter current distribution and thermal management system, which;

[0111] • ensures efficient power conversion with minimal heat dissipation;

[0112] • enhances reliability and operational performance under extreme conditions;

[0113] • reduces the weight of long cables, reduces losses, it makes the system compact and efficient;

[0114] • optimizes cooling without the need for liquid cooling systems;

[0115] • allows for easy maintenance, upgrades, and adaptation to different power levels or vehicle types;

[0116] • implements real-time control, monitoring, and fault detection mechanisms to ensure continuous and safe operation of the inverter system; • improves the durability and longevity of the inverter system by incorporating a reinforced mechanical structure and fail-safe mechanisms; and

[0117] • reduces electromagnetic interference (EMI) and ensures compliance with automotive industry standards for electromagnetic compatibility (EMC).

[0118] The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

[0119] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0120] The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0121] Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application. While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

[0122] 77

Claims

CLAIMS:

1. A traction inverter system (100), said system (100) configured to facilitate three-phase alternating current (AC) distribution and thermal management in an operative configuration of a motor, said system comprising:• a motor enclosure (103);• a motor (101) housed in the motor enclosure (103), said motor (101) comprising motor windings (113);• a power board (105) configured to be disposed within the motor enclosure (103), said power board (105) comprising: o an inverter unit configured to convert a direct current (DC) power received from a power source to a three-phase alternating current (AC) power; o a plurality of bus bars (Illa, 111b, 112) configured to distribute said three- phase alternating current from said inverter unit to said motor windings (113); and o a heat sink (106) configured to be disposed in the vicinity of said inverter unit to dissipate heat generated by said inverter unit during operation,• a control board (107) configured to be disposed within the motor enclosure (103), and operatively coupled with said power board (105), said control board (107) configured to control switching sequence of said inverter unit and further configured to manage motor phase currents in real-time, wherein said power board (105), said control board (107), and said motor windings (113) are integrated within said motor enclosure (103) in a compact architecture to facilitate distribution of said three-phase alternating current, and thermal management of said inverter unit in an operative configuration.

2. The system (100) as claimed in claim 1, wherein said inverter unit includes a plurality of metal oxide semiconductor field effect transistors (MOSFETs) (114).

3. The system (100) as claimed in claim 1, further includes a polymeric cover (117) configured to be disposed on the operative top of said power board (105), said polymeric cover (117) having an insulating layer configured to thermally isolate said control board (107) from said power board (105).

4. The system (100) as claimed in claim 1, wherein said control board (107) is configured with at least one microcontroller (124), at least one gate driver, and at least one power management unit to control switching sequence of said inverter unit and manage motor phase currents in real-time, wherein said control board (107) is connected to said power board (105) through board-to-board connectors.

5. The system (100) as claimed in claim 1, wherein the motor enclosure (103) integrates built-in airflow channels that facilitate natural air convection cooling, wherein said heat sink (106) is configured to dissipate heat by natural air convection within said motor enclosure (103).

6. The system (100) as claimed in claim 1, wherein the power board (105) is formed from a single-layer metal-clad architecture and coated with a thermally conductive, electrically insulating material for heat dissipation and protection from environmental contaminants.

7. The system (100) as claimed in claim 2, wherein the MOSFETs (114) are arranged in a symmetrical three-phase configuration, each phase comprising three top and three bottom MOSFETs arranged in parallel, the arrangement ensuring uniform current distribution and heat dissipation.

8. The system (100) as claimed in claim 7, wherein the plurality of bus bars (Illa, 111b, 112) are formed from copper and configured to supply DC power to the power board (105), distribute the DC power evenly across all MOSFETs (114), and deliver three-phase AC power to the motor windings (113).

9. The system (100) as claimed in claim 2, wherein the power board (105) includes direct current (DC) links capacitors (115) positioned close to the MOSFETs (114) to reduce inductive losses and enhance ripple current handling capabilities.

10. The system (100) as claimed in claim 2, wherein the power board (105) includes thermal vias to channel heat from the MOSFETs (114) to the heat sink (106), improving the thermal performance of the system (100).

11. The system (100) as claimed in claim 1, wherein the control board (107) includes an integrated fault detection mechanism (123) that monitors thermal performance and triggers protective responses to prevent overheating.

12. The system (100) as claimed in claim 1, wherein the control board (107) includes a Controller Area Network (CAN) communication module enabling remote monitoring and diagnostics of the system (100).

13. The system (100) as claimed in claim 1, wherein the control board (107) includes an electromagnetic shielding layer to protect the low-voltage components from electromagnetic interference (EMI) generated by high-power components of the system (100).

14. The system (100) as claimed in claim 1, wherein the motor enclosure (103) is constructed from a composite material that combines lightweight properties with high thermal conductivity for improved thermal management and reduced system weight.

15. The system (100) as claimed in claim 1, wherein the motor enclosure (103) is incorporated with a phase change material to absorb and release heat during operation, enhancing overall thermal management of the system (100).

16. The system (100) as claimed in claim 1, wherein the control board (107) includes a realtime clock (RTC) module to synchronize the operation of the inverter unit with other vehicle systems for improved performance timing.

17. The system (100) as claimed in claim 1, wherein the power board (105) further includes a surge protection circuitry to shield the system (100) from voltage spikes caused by sudden load changes or external disturbances, ensuring the longevity and safety of the inverter components.

18. The system (100) as claimed in claim 1, wherein the inverter unit includes a noise reduction mechanism to minimize electromagnetic interference generated duringoperation and ensure compliance with automotive industry standards for electromagnetic compatibility (EMC).27

Images