Surrounded Capacitor Busbar Layout for Compact Motor Controllers
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Solution Overview
Problem
Existing motor controllers in new energy vehicles face challenges in optimizing the connection structures, layout, cooling, and assembly efficiency of integrated motor and motor controllers, particularly in terms of circuit wiring and capacitor positioning, which affect space utilization and stability.
Innovation Solution
A laminated busbar assembly with capacitors is introduced, featuring a main circuit board, positive and negative electrode connection plates, and a mounting shell with collision avoidance holes and positioning posts, allowing for centralized terminal arrangement and stable capacitor support, optimizing circuit layout and reducing axial dimension.
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 heat dissipation becomes more challenging
Solution Approach 1:
The motor and motor controller are integrated into a single drive assembly with a unified housing, merging two separate components into one compact unit. This reduces the overall footprint while incorporating shared cooling resources.
Solution Approach 2:
The liquid cooling system serves dual purposes: it cools both the motor controller electronics and the motor simultaneously through a shared cooling channel system, making the cooling infrastructure multi-functional and efficient.
2Temperature
If power transistors are annularly arranged around the circuit board, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The power transistors are arranged in an annular (circular) pattern around the circuit board instead of a linear or grid layout. This curved arrangement optimizes heat dissipation by distributing heat sources evenly around the cooling channel while maintaining compactness.
3Temperature
If integrated liquid cooling is implemented, then heat dissipation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The motor cooling groove and controller cooling groove are merged into a single integrated liquid cooling system with shared coolant flow paths, allowing one cooling infrastructure to serve multiple heat-generating components.
Solution Approach 2:
The cooling system is segmented into distinct cooling grooves for different components (motor cooling groove, controller cooling groove) that are independently designed but hydraulically connected, allowing modular manufacturing and assembly.
4Volume of moving object
If the controller is mounted at the rear end in axial direction, then space utilization is improved, but connection structure complexity increases
Solution Approach 1:
The controller mounting position is moved to the rear end in the axial direction, utilizing previously unused space in the axial dimension rather than radial or lateral directions, thereby optimizing the overall spatial arrangement.
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 solution enhances circuit wiring efficiency, improves assembly ease, and achieves a compact, stable, and highly integrated drive assembly by centralizing terminal connections and supporting capacitors, thus optimizing space utilization and operational stability.
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
Implementation Method 2
The waste heat of the power transistors can be efficiently conducted to the interconnected controller cooling groove and motor cooling groove, realizing integrated liquid cooling
Data Source
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AI summary
The present disclosure relates to the field of new energy, and provides a motor controller with capacitors surrounded, a drive assembly, and a vehicle. The motor controller includes multiple capacitors, a main circuit board, a positive electrode connection plate in a form of a bottomed cylinder, and a negative electrode connection plate, wherein the main circuit board is provided with positioning posts with different diameters on a bottom, and outer edges of the positive and the negative electrode connection plates are each circumferentially provided with multiple pins. The multiple capacitors are arranged in a device accommodating space, the positioning posts and the negative electrode connection plate facilitate a stable connection of the capacitors, and the laminated assembly is simple.