Axial Drive Apparatus Motor Power Module Integration
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Solution Overview
Problem
Conventional drive apparatuses with electronic control units are bulky due to the parallel arrangement of semiconductor switching elements, making it difficult to reduce the size of the apparatus.
Innovation Solution
The drive apparatus is designed with a power module and control wiring part arranged in an axial direction, where the power module is positioned along the heat receiving surface of a heat sink, and the motor leads are connected to the power module opposite to the motor case, allowing for a compact stack structure that separates the motor and electronic control unit, reducing the radial size and enabling easier replacement or repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semiconductor switching elements are mounted with wide surface parallel to power circuit substrate, then electrical connection is improved, but device size increases
Solution Approach 1:
The patent changes the mounting orientation of semiconductor switching elements from parallel to perpendicular relative to the power circuit substrate. This dimensional change allows the wide surface of the switching elements to face the motor case direction, reducing the radial area occupied on the substrate while maintaining electrical connection through the perpendicular mounting structure.
Solution Approach 2:
The patent employs asymmetric mounting where the semiconductor switching elements are positioned at different orientations and locations on the power circuit substrate. Specifically, some elements are mounted perpendicular to the substrate with their wide surfaces facing different directions, creating an asymmetric layout that optimizes space utilization while ensuring proper electrical connections.
2Device complexity
If electronic control unit is located near electric motor, then integration is improved, but device size increases
Solution Approach 1:
The patent implements a nested structure where the electronic control unit components (power circuit substrate, control circuit substrate, heat sink) are stacked axially near the motor case. The power module is mounted on the heat sink, which is positioned on the motor case, creating a compact nested arrangement that integrates the electronic control unit within the motor assembly without significantly increasing overall volume.
Solution Approach 2:
The patent transitions from a planar arrangement to a three-dimensional axial stacking configuration. The electronic control unit components are arranged in the axial direction rather than spreading out radially, utilizing the vertical space near the motor case to achieve integration while minimizing the device's radial footprint.
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
This configuration reduces the overall size of the drive apparatus, allows for efficient heat dissipation, and simplifies manufacturing and repair processes by separating the motor and electronic control unit, while maintaining effective operation.
Implementation Method 1
The heat sink includes a heat receiving surface located in a rising direction from an end surface wall of the motor case
Implementation Method 2
The power module is arranged along the heat receiving surface of the heat sink
Data Source
AI summary
A heat sink of a drive apparatus includes a heat receiving surface located in a rising direction from an end surface wall of a motor case formed in an axial direction of the motor case. A power module includes a mold part and is arranged along the heat receiving surface of the heat sink. Motor leads are taken out from the motor case and electrically connected to the power module and winding wires. The drive apparatus has the motor case, a control circuit substrate, the heat sink, the power module and a power circuit substrate arranged in this order in the axial direction. The motor leads are connected to the power module at an opposite side of the motor case relative to the mold part in the axial direction.