Modular Electric Drive Control PCBs for Variant Reduction

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Solution Overview

Problem

Existing electric drive technologies face challenges in reducing the number of variants while maintaining flexibility and functionality for power electronics systems across different electric motors, particularly in industrial applications.

Innovation Solution

A modular control unit with at least two printed circuit boards, one equipped with basic power electronics and another with supplementary functions, allows for adaptable interface functions across a set of electric motors of the same power class, enabling modular assembly and separation of functional units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If all required interface functions are implemented on a single power electronics system for each specific electric motor, then full functionality is achieved, but the number of power electronics variants increases

Engineering Contradiction:

ImprovefunctionalityVSAvoidnumber of variants

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The power electronics system is divided into a basic printed circuit board containing core power electronics and additional printed circuit boards containing specific interface functions. This segmentation allows the basic board to remain standardized while interface functions are added modularly, reducing the number of variants needed to serve multiple motor applications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The basic printed circuit board is designed with universal power electronics that can serve multiple electric motor applications. Specific interface functions are then added through additional printed circuit boards, allowing a single basic design to be adapted universally across different motor types and cable classes while maintaining full functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a single power electronics system is designed to handle all interface functions for various electric motors, then adaptability across motor types is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveadaptability across motor typesVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system is segmented into a standardized basic printed circuit board that can be manufactured in high volumes with consistent quality, and additional interface boards that are manufactured separately and assembled. This segmentation simplifies manufacturing by allowing the basic board to be produced efficiently while interface functions are added as needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The basic printed circuit board with universal power electronics is merged with additional printed circuit boards containing specific interface functions. This combining approach allows standardized components to be manufactured separately and then assembled into complete systems, reducing overall manufacturing complexity while maintaining adaptability.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple variants of power electronics are produced to cover all cable classes and motor types, then full functionality is maintained, but production costs increase

Engineering Contradiction:

Improvefunctionality coverageVSAvoidcost-effective production

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The power electronics system is segmented into a basic printed circuit board that can be produced in high volumes at low cost, and additional interface boards that are produced separately. This allows the basic board to benefit from economies of scale while interface functions are added modularly, reducing total production costs while maintaining functionality coverage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal basic printed circuit board design serves multiple cable classes and motor types, eliminating the need to produce separate variants for each application. This universality increases production efficiency and reduces costs while maintaining the ability to adapt to different motor requirements through additional interface boards.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12388333B2Modular interface concept for an electric drive

Publication Date: 2025.08.12 EBM PAPST MULFINGEN GMBH & CO KG

AI summary

A modular control unit (100) is adaptable, in terms of interface functions, for an electric motor selected from a predetermined number i of electric motors, in particular electric motors of the same power class. The control unit (100) has at least two printed circuit boards (L1, L2), selected from a set of N different printed circuit boards (L1, L2, . . . , LN). Interface functions, electrical components, electronic components or control units for the operation of the electric motor are located on the printed circuit boards.