Integrated EV Drive Controller With Shared High-Voltage Interface
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Solution Overview
Problem
Existing electric drive assemblies in vehicles require high-voltage wiring harnesses, occupy significant space, and are costly due to physical integration of modules without effective reuse of components, leading to slow signal interaction transmission.
Innovation Solution
An integrated controller that combines a control unit and charging/discharging converter within a single box, reducing the need for high-voltage wiring harnesses and distribution boxes, and integrates motor controllers and DC converters to share a common interface and digital signal processing chips, thereby minimizing the use of structural parts and wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If physical integration of multiple modules (motor controller, DC/DC converter, OBC, PDU) is implemented, then costs in wiring harness and support are reduced, but device complexity increases and signal transmission speed decreases
Solution Approach 1:
The patent merges multiple control modules (motor controller, DC/DC converter, OBC, PDU) and the high-voltage distribution box into a single integrated controller. This consolidation eliminates the need for separate wiring harnesses connecting these modules, directly reducing the quantity of wiring harness material while managing complexity through unified module design.
Solution Approach 2:
The integrated controller is designed as a multi-functional unit that performs high-voltage distribution, motor control, DC/DC conversion, and onboard charging functions simultaneously. This universal design allows a single device to replace multiple specialized components, reducing overall system complexity despite the increased functionality within the unified structure.
2Quantity of substance
If physical integration of modules is implemented, then wiring harness costs are reduced, but space occupation increases
Solution Approach 1:
By merging multiple modules into one integrated controller, the patent eliminates the space required for separate module housings and their interconnections. Although the integrated controller itself occupies space, the total volume is reduced compared to distributed modules with extensive wiring harnesses connecting them throughout the vehicle.
3Reliability
If extensive high-voltage wiring harnesses are used, then module connectivity is ensured, but costs and space occupation increase
Solution Approach 1:
The patent merges all high-voltage distribution functions into the integrated controller, eliminating the need for separate high-voltage distribution boxes and their associated wiring harnesses. Module connectivity is maintained through internal connections within the integrated controller, ensuring reliable signal and power transmission while dramatically reducing the quantity of high-voltage wiring harness required.
4Ease of manufacture
If separate high-voltage distribution box is arranged, then power distribution is simplified, but device complexity and costs increase
Solution Approach 1:
The patent merges the high-voltage distribution box functions into the integrated controller, eliminating the need for a separate distribution box. Power distribution is simplified by having the integrated controller directly manage high-voltage output to various modules, reducing device complexity while maintaining ease of manufacture through a unified power management architecture.
Data Source
AI summary
An integrated controller includes: a box; a controller and a charging/discharging converter disposed in the box; and a high-voltage interface assembly including a high-voltage interface disposed on the box and a high-voltage connector disposed in the box. The high-voltage connector is connected with the high-voltage interface, the controller, and the charging/discharging converter to receive and distribute a high-voltage battery signal.