Integrated Vehicle Controller Layout to Replace HV Wire Harnesses
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Solution Overview
Problem
The high cost and increased assembly difficulty in vehicle systems due to independent controller modules connected through a wire harness in high-voltage systems, which complicates fault detection and replacement.
Innovation Solution
An integrated controller with a box body housing high-voltage power distribution and motor controllers connected via a switching copper bar, optimizing space and facilitating module replacement, and incorporating cooling channels for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If controller modules operate independently and are connected through a wire harness, then each module can function autonomously, but the input cost increases and assembly difficulty increases
Solution Approach 1:
The patent integrates multiple independent controller modules (HV power distribution module, motor controllers, DC-DC converter) into a single integrated controller housing. The modules are physically combined and electrically connected through a switching copper bar instead of external wire harnesses, reducing assembly complexity while maintaining module autonomy through internal modular architecture.
Solution Approach 2:
The integrated controller serves multiple functions simultaneously: high-voltage power distribution, motor control (left and right driving motors), air compressor control, steering control, and DC-DC voltage conversion. This multi-functional design reduces the need for separate independent controllers and their associated wire harnesses.
2Reliability
If controller modules are connected through a wire harness, then module independence is maintained, but fault detection cost increases
Solution Approach 1:
By integrating modules into a single controller with a unified switching copper bar connection system, the patent enables centralized monitoring and fault detection. The integrated architecture allows for easier identification of faulty modules through standardized connection points and reduced signal paths compared to distributed wire harness connections.
3Adaptability or versatility
If multiple controller modules are used, then functional coverage is comprehensive, but development cost increases
Solution Approach 1:
The integrated controller consolidates multiple functional modules (HV power distribution, dual motor control, air compressor control, steering control, DC-DC conversion) into a single device. This multi-functional design reduces development costs by eliminating the need for separate development, testing, and certification processes for multiple independent controllers while maintaining comprehensive functional coverage.
Solution Approach 2:
The patent combines multiple controller functions into a single integrated unit with shared housing, power distribution pathways, and control architecture. This merging reduces overall development cost through economies of scale in manufacturing, simplified supply chain management, and reduced installation complexity.
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 solution reduces development costs, simplifies module detection and replacement, and enables platformization of controllers across different vehicle types, while ensuring effective cooling and reduced assembly complexity.
Implementation Method 1
heat of the right driving motor controller, the air compressor motor controller, and the steering motor controller is dissipated through the first cooling water channel; and heat of the left driving motor controller and the DC-DC voltage converter is dissipated through the second cooling water channel
Implementation Method 2
a first cooling water channel and a second cooling water channel independent of each other are provided between the upper box body and the lower box body; heat of the right driving motor controller, the air compressor motor controller, and the steering motor controller is dissipated through the first cooling water channel
Data Source
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AI summary
An integrated controller (A) for a vehicle, and a vehicle (B), where the integrated controller (A) includes a box body (10), a high-voltage power distribution module (900) disposed in the box body (10), and a left driving motor controller (300), a right driving motor controller (400), an air compressor motor controller (500), a steering motor controller (600), and a DC-DC voltage converter (700) that are all connected to the high-voltage power distribution module (900); and the box body (10) is provided with a plurality of input/output interfaces corresponding to the high-voltage power distribution module (900), the left driving motor controller (300), the right driving motor controller (400), the air compressor motor controller (500), the steering motor controller (600), and the DC-DC voltage converter (700).