Dual ECU Motor Controller with Shared Connector and Busbar
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Solution Overview
Problem
In vehicle electric power steering systems, the increasing number of electronic systems and stringent fail/safety regulations require redundancy designs, necessitating two electronic control units (ECUs) that pose challenges in space efficiency and wiring harness modifications, as conventional wiring is typically designed for a single ECU.
Innovation Solution
A motor controller design that uses a single connector to transmit power and control signals to two ECUs, with one ECU disposed opposite to the motor's output shaft, featuring a connection element like a busbar to connect the ECUs in a circuit, and a heat radiation member to manage heat generation, while maintaining space efficiency by optimizing substrate lengths and heat radiation configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two ECUs are disposed to control the motor for redundancy design, then reliability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines two separate ECUs (first ECU and second ECU) into a single integrated motor controller package. The first substrate and second substrate are disposed adjacent to each other, sharing common structural support and housing, thereby merging two separate control units into one compact assembly that maintains redundancy while reducing overall complexity.
Solution Approach 2:
The first substrate and second substrate share common functional components including a single connector for power and signal distribution, a shared heat radiation member for thermal management, and a common housing structure. This multi-functional design allows both ECUs to operate independently while sharing resources, improving space efficiency and reducing device complexity.
2Reliability
If two ECUs are disposed in the package, then redundancy control is achieved, but the package size increases
Solution Approach 1:
The patent implements a nested arrangement where the second substrate is positioned adjacent to and partially overlapping with the first substrate in the longitudinal direction. The heat radiation member is nested between the two substrates, and the connector is integrated into the housing structure, creating a compact nested configuration that minimizes package volume while accommodating both ECUs.
Solution Approach 2:
The patent transitions from a traditional side-by-side horizontal arrangement to a vertical stacking configuration where substrates are disposed in the longitudinal direction with overlapping surfaces. This dimensional change allows better space utilization and reduces the overall footprint of the motor controller package.
3Device complexity
If conventional wiring harness connected to single ECU is used, then wiring complexity is reduced, but signal transmission to two ECUs becomes difficult
Solution Approach 1:
The patent segments the signal distribution function by providing separate connection terminals on both the first substrate and second substrate that can be independently connected to the wiring harness. This segmentation allows the single wiring harness to distribute signals to both ECUs through their respective terminals without requiring complex internal wiring between the two substrates.
Solution Approach 2:
The connector serves as an intermediary component that receives power and control signals from the wiring harness and distributes them to both the first ECU and second ECU. This intermediary structure simplifies the wiring architecture by providing a single point of entry for signals while enabling dual ECU operation.
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
Enables simultaneous transmission of power and control signals to two ECUs through a single connector, minimizing package size and improving space efficiency, while effectively managing heat and maintaining system reliability.
Implementation Method 1
a heat radiation member disposed along the axis extending in the longitudinal direction of the motor and configured to radiate heat generated by the first ECU and the second ECU
Implementation Method 2
a connection element which is disposed to connect the first ECU and the second ECU in a circuit and transmits the power and the signal to the second ECU
Data Source
AI summary
A motor controller is disclosed. A motor controller according to one embodiment of the present invention comprises a first electronic control unit (ECU) which comprises a first substrate having a first length and controls a motor, a connector which is connected to one end portion of one longitudinal side of the first substrate to transmit power and a signal to the first ECU, a second ECU which comprises a second substrate having a second length shorter than the first length and including one surface facing one surface of the first substrate and controls the motor, and a connection element which is disposed to connect the first ECU and the second ECU in a circuit and transmits the power and the signal to the second ECU.