Annular Motor Controller Layout for Compact Drive Assembly Integration
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Solution Overview
Problem
Existing motor and motor controller integration in new energy vehicles faces challenges in optimizing connection structures, cooling, and electrical connection layouts, which hinders efficient integration and assembly.
Innovation Solution
A motor controller with an annular circuit layout featuring a laminated busbar assembly, including a circular main circuit board, positive and negative electrode connection plates, and arcuate single-phase connection plates, optimized for compactness and ease of assembly, with capacitors positioned between the connection plates and power transistors arranged circumferentially around the main circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor and motor controller are integrated to reduce footprint, then space utilization is improved, but connection structures and cooling systems become more complex
Solution Approach 1:
The patent integrates the motor controller directly onto the motor shaft, merging two previously separate components into a single unified assembly. This reduces the overall footprint while the standardized connection interfaces and integrated cooling channels simplify the connection structures and cooling systems, resolving the complexity issue
Solution Approach 2:
The drive assembly is designed with universal connection structures that serve multiple functions: electrical connections, mechanical mounting, and cooling fluid pathways all through integrated interfaces. This multi-functionality reduces the number of separate connection structures needed, simplifying the overall system while maintaining compact integration
2Temperature
If power transistors are arranged annularly with integrated liquid cooling, then heat dissipation efficiency is improved, but device structure becomes more complex
Solution Approach 1:
The power transistors are arranged in an annular (circular) pattern around the motor shaft rather than in a linear or rectangular configuration. This curved arrangement optimizes heat dissipation by distributing thermal loads evenly around the cooling channels and improves thermal conductivity pathways, while the rotational symmetry actually simplifies the overall structural design
Solution Approach 2:
The cooling channels are nested within the motor shaft structure, with power transistors mounted on the outer surface of the shaft. The cooling fluid flows through hollow channels inside the shaft, creating a nested configuration where the cooling system is embedded within the structural component, improving heat dissipation without adding external complexity
3Volume of moving object
If the controller is positioned at the rear end in axial direction, then space utilization is improved, but wiring layout becomes more complex
Solution Approach 1:
The controller is segmented into modular circuit boards that are mounted on the rear end of the motor shaft. This segmentation allows for compact arrangement of electrical components in a standardized pattern, simplifying the wiring layout by creating clear signal paths and power distribution routes from the motor windings to the control electronics
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The annular circuit layout reduces axial dimension, optimizes wiring and connection efficiency, and enhances assembly ease, resulting in a compact, high-integration drive assembly suitable for new energy vehicles.
Implementation Method 1
an outer wall of the housing is provided with a liquid cooling channel which includes a motor cooling groove and a controller cooling groove that communicate with each other
Data Source
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AI summary
The present disclosure relates to the field of new energy, and provides a motor controller with an annular circuit layout, a drive assembly, and a vehicle. The motor controller includes a laminated busbar assembly and multiple power transistors, wherein the laminated busbar assembly a main circuit board, a positive electrode connection plate, a negative electrode connection plate, and a three-phase connection plate assembly. In the present disclosure, the main circuit board is provided with a connection position in a center thereof, and a control circuit position, a first soldering position, and a second soldering position, which are each annular and arranged around the connection position in sequence, so that connection terminals are centrally arranged, and the central control circuit has a relatively large space. The annular circuit layout improves the structural coordination with the drive assembly.