Electric Drive Control Device ECU Packaging and Thermal Management
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Solution Overview
Problem
In electric drive systems, particularly in vehicle EPS systems, the integration of redundant electronic control units (ECUs) poses challenges in packaging efficiency, size reduction, and assembly due to identical hardware structures, leading to potential mixing and assembly failures, and requires separate management of unique IDs in mass production.
Innovation Solution
An electric drive control device is designed with a first and second electronic control unit positioned on opposite sides of the motor housing, each with a unique hardware ID assigned through connection terminals, and a heat dissipating member to enhance heat dissipation, allowing for efficient packaging and production management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two identical ECUs are mounted in a package for redundancy design, then safety and reliability are improved, but the package size increases and arrangement efficiency decreases
Solution Approach 1:
The patent merges two separate ECU packages into a single integrated package by positioning both ECUs within the same motor housing structure. The first ECU is mounted on the motor housing, and the second ECU is positioned opposite to it, both within the same package boundary. This merging approach maintains redundancy for safety while reducing the overall package volume compared to using two separate packages.
2Reliability
If two ECUs with same hardware structure are used for redundancy, then reliability is improved, but assembly difficulty increases due to inability to distinguish between them
Solution Approach 1:
The patent applies local quality differentiation by giving each ECU a distinct spatial position within the package. The first ECU is mounted on a specific location of the motor housing, while the second ECU is positioned opposite to it. This spatial differentiation allows assembly workers to distinguish between the two identical ECUs based on their positions, preventing mixing during assembly while maintaining hardware redundancy.
3Temperature
If ECUs are disposed along the drive shaft for heat dissipation, then heat dissipation is improved, but the package size increases
Solution Approach 1:
Instead of disposing ECUs along the drive shaft axis (one-dimensional arrangement), the patent utilizes the radial dimension of the motor housing by positioning the two ECUs opposite to each other across the housing. This two-dimensional spatial arrangement allows both ECUs to be accommodated within the same package footprint without extending the package length, thereby maintaining heat dissipation effectiveness while minimizing package volume.
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 improves packaging efficiency, reduces package size, ensures effective heat dissipation, and prevents assembly failures by uniquely identifying and managing ECUs in hardware, facilitating efficient production and assembly.
Implementation Method 1
a heat dissipating member disposed on the side opposite to the drive shaft of the electric motor among both sides of the motor housing in the direction of the drive shaft and configured to dissipate heat generated in the first electronic control unit and the second electronic control unit
Data Source
AI summary
According to an embodiment of the present invention, an electric drive control device of the present invention, which is for controlling an electric motor that generates a drive force, includes a first electronic control unit disposed on a side opposite to a drive shaft of the electric motor among both sides of a motor housing in which the electric motor is accommodated in a direction of the drive shaft and configured to control the electric motor, and a second electronic control unit disposed opposite to the first electronic control unit in the direction of the drive shaft and configured to control the electric motor.