Controller-Integrated Rotating Machine Assembly

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Solution Overview

Problem

The existing controller-integrated rotating electric machines face challenges in integrating stator current switching circuit units due to low positional accuracy of signal-connection positions, leading to productivity issues and increased manufacturing costs.

Innovation Solution

The solution involves a controller-integrated rotating electric machine design with a rotor, stator, and stator current switching circuit units attached to an insulator cover, using a relaying connection member to facilitate assembly and improve positional accuracy, while maintaining heat sink integration and coolability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stator current switching circuit units are separately configured and fixed, then each unit can be independently manufactured, but the positional accuracies of signal-connection positions become low, causing positional displacement between pin and hole

Engineering Contradiction:

ImproveIndependent manufacturing of switching circuit unitsVSAvoidPositional accuracy of signal-connection positions

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent merges multiple stator current switching circuit units (U-phase, V-phase, W-phase) into a single integrated circuit board assembly. By combining these separately manufacturable units into one integrated structure with unified signal connection positions, the patent maintains ease of manufacture while achieving high positional accuracy for signal connections.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If separate heat sinks are used for each switching element, then heat dissipation is improved, but assembly complexity increases due to multiple separate components

Engineering Contradiction:

ImproveHeat dissipation capabilityVSAvoidNumber of separate heat sink components

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines multiple separate heat sinks into a single integrated heat sink structure that serves all switching elements (upper and lower arms of U-phase, V-phase, and W-phase). This integration maintains effective heat dissipation for all components while reducing assembly complexity by eliminating the need to install multiple separate heat sinks.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate stator current switching circuit units are integrated with rear cover and control circuit board, then controller integration is achieved, but productivity decreases due to difficulty in integration

Engineering Contradiction:

ImproveController integration capabilityVSAvoidAssembly productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple stator current switching circuit units into a single integrated circuit board assembly that can be installed as one unit. This integration maintains the controller integration capability while significantly improving productivity, as the integrated assembly requires fewer installation steps and reduces the complexity of integrating multiple separate units with the rear cover and control circuit board.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances assembly productivity, reduces manufacturing costs, and maintains the coolability of the rotating electric machine by using a relaying connection member to accurately position and integrate stator current switching circuit units.

Implementation Method 1

the drain terminals of the switching elements are connected with separate heat sinks

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS7999425B2Controller-integrated rotating electric machine

Publication Date: 2011.08.16 MITSUBISHI ELECTRIC MOBILITY CORP

AI summary

Assembly of a controller-integrated rotating electric machine is facilitated. In a controller-integrated rotating electric machine provided with a rotating electric machine unit having a rotor (2), a stator (3), and brackets (4, 5); a plurality of stator current switching circuit units (13) that are attached on an insulator cover (14) mounted on the brackets (4, 5); and a controller unit having a control circuit board (102), the stator current switching circuit unit (13) is provided with a plurality of switching elements (13a) and a plurality of switching elements (13b); a pair of heat sinks (13g, 13h) with which the drain terminals of the switching elements (13a, 13b) are connected; and a pair of electric connection members (17, 18) that pull out the terminals of the switching elements (13a, 13b) and that hold and integrate the pair of heat sinks (13g, 13h). Additionally, the plurality of stator current switching circuit units (13) is fixed to a relaying connection member (16), and electric connections between the stator current switching circuit units (13) and outside members are performed by the intermediary of the relaying connection member (16).