Motor Controller Cover Structure for Compact Power Module Cooling
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Solution Overview
Problem
The challenge is to create a compact and lightweight motor assembly that addresses the heat-generation issue in vehicle motors while allowing for simplified element placement and shared components, particularly in controllers with limited size constraints.
Innovation Solution
The solution involves a motor controller design where a power module generating significant heat is pressed against a metal controller cover, utilizing an insert injection method for the mold unit to reduce material and mold costs, and vertically disposing large elements to enhance heat dissipation, along with the use of a MOSFET on the substrate to prevent reverse power connections and improve stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the size of the substrate is increased to solve heat-generation problem, then heat dissipation performance is improved, but the size and weight of the motor assembly increase
Solution Approach 1:
The controller cover is integrated with a heat dissipation fin structure, merging the protective cover function with the heat dissipation function into a single component. This eliminates the need for a separate large substrate to dissipate heat, thereby improving heat dissipation performance without increasing the motor assembly's size and weight.
Solution Approach 2:
The heat dissipation solution transitions from a planar substrate approach to a three-dimensional fin structure extending from the controller cover. The fins create additional heat dissipation surface area in the vertical dimension, enabling effective heat dissipation without increasing the horizontal footprint or weight of the motor assembly.
2Temperature
If the size of the substrate is increased to solve heat-generation problem, then heat dissipation performance is improved, but the size and weight of the motor assembly increase
Solution Approach 1:
The controller cover is integrated with a heat dissipation fin structure, merging the protective cover function with the heat dissipation function into a single component. This eliminates the need for a separate large substrate to dissipate heat, thereby improving heat dissipation performance without increasing the motor assembly's size and weight.
Solution Approach 2:
The heat dissipation solution transitions from a planar substrate approach to a three-dimensional fin structure extending from the controller cover. The fins create additional heat dissipation surface area in the vertical dimension, enabling effective heat dissipation without increasing the horizontal footprint or weight of the motor assembly.
3Volume of moving object
If the size of the controller is limited, then user request is satisfied, but placement of elements and assembly becomes complex
Solution Approach 1:
The heat dissipation fins are integrated directly into the controller cover structure, merging two functions (protection and heat dissipation) into one component. This reduces the total number of parts and simplifies assembly, allowing the controller to remain compact while maintaining ease of manufacture.
Solution Approach 2:
The controller cover serves multiple functions: it protects internal components and simultaneously acts as a heat dissipation structure through its integrated fins. This multi-functionality reduces the number of separate components needed, simplifying element placement and assembly within the limited controller size.
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 design effectively reduces heat generation, allows for a compact motor assembly structure, and enables component sharing across different motor types by replacing only the substrate, thereby enhancing the motor's reliability and design flexibility.
Implementation Method 1
a heat-generation problem occurs in the substrate as the high current is applied thereto
Implementation Method 2
a power module generating a great amount of heat pressed against a controller cover made of a metal material
Data Source
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AI summary
An embodiment relates to a controller and a motor assembly comprising same, the controller comprising: a substrate; a controller housing disposed on the substrate; a CM filter unit disposed between the substrate and the controller housing; a DM filter unit disposed under the CM filter unit; a controller cover disposed between the substrate and the DM filter unit; a power module unit disposed between the substrate and the controller cover; and a connector unit coupled to the substrate, wherein the power module unit comprises a power module and a mold unit surrounding the power module. Accordingly, the heat generating problem of the power module unit can be resolved.