Drive Device Control Unit Single Base Design
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Solution Overview
Problem
Existing drive device control units face challenges in achieving reduced size, weight, and part count while ensuring vibration resistance and reliability, particularly due to the need for rigid brackets that increase weight and complexity.
Innovation Solution
A drive device control unit design featuring a single base with the switching element module and smoothing capacitor fixed to one surface, and the control substrate fixed to the opposite surface, supported by the same base, reducing the number of parts and weight while maintaining vibration resistance through a simplified structural arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate brackets (capacitor bracket and control substrate bracket) are provided to fix the smoothing capacitor and control substrate, then vibration resistance is improved, but the number of parts and weight increase
Solution Approach 1:
The patent combines the capacitor bracket and control substrate bracket into a single integrated bracket structure. This single bracket simultaneously supports both the smoothing capacitor and the control substrate, eliminating the need for separate brackets while maintaining the required vibration resistance through proper structural design and fixing mechanisms.
Solution Approach 2:
The integrated bracket serves multiple functions: it acts as both the capacitor bracket for mounting the smoothing capacitor and the control substrate bracket for mounting the control substrate. This multi-functional design reduces the overall number of parts while ensuring that both components are securely fixed with adequate vibration resistance.
2Reliability
If rigid brackets are used to ensure vibration resistance, then reliability is improved, but weight increases
Solution Approach 1:
By merging the capacitor bracket and control substrate bracket into a single integrated structure, the total weight of bracket components is reduced compared to using two separate rigid brackets. The integrated design allows for optimized material distribution and structural efficiency.
Solution Approach 2:
The patent employs a bracket design that achieves sufficient rigidity and vibration resistance without requiring excessive material thickness or weight. The structural design optimizes the balance between rigidity for vibration resistance and minimal weight through efficient geometry and support arrangements.
3Reliability
If separate brackets with complicated convexo-concave shapes are provided, then fixing portions are secured, but manufacturing complexity increases
Solution Approach 1:
The integration of two separate brackets into one unified bracket structure simplifies the manufacturing process. Instead of producing and assembling two complex brackets with different shapes, a single bracket can be manufactured as one piece or fewer components, reducing manufacturing complexity while providing all necessary fixing portions.
Solution Approach 2:
The integrated bracket is designed to perform multiple mounting functions within a single structural element. It includes appropriate fixing portions for both the smoothing capacitor and the control substrate, eliminating the need for separate specialized brackets and simplifying both manufacturing and assembly processes.
Data Source
AI summary
A drive device control unit that controls a drive device including a rotating electrical machine, the drive device control unit includes a control substrate that controls the drive device; a switching element module that forms an inverter that drives the rotating electrical machine; a smoothing capacitor that smoothes an input power supply of the inverter; a first base having the switching element module fixed thereto; and a second base supported by the first base and having the smoothing capacitor fixed to a first surface of the second base, wherein the control substrate is fixed to a second surface of the second base opposite to the first surface having the smoothing capacitor fixed thereto.