Integrated Dual-Motor Controller Design for Compact Packaging
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Solution Overview
Problem
Existing dual-motor controllers have complex internal connections, low space utilization, and large size due to scattered components like power modules, capacitors, and current sensors, leading to inefficient packaging and increased structural complexity.
Innovation Solution
An integrated dual-motor controller design that integrates a bus magnetic ring component, an all-in-one module, control plate, isolation plate, and drive plate within a controller housing, along with a modular layout that includes a water-cooling plate, power module, boost inductors, current sensor, and relay, facilitating reduced size and improved space utilization through direct soldering and copper bus bar connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components (power module, capacitor, current sensor) are scattered inside the controller, then each component can be independently designed and replaced, but the internal connections become complex and space utilization decreases
Solution Approach 1:
The patent combines multiple components (power module, capacitor, current sensor, cooling plate) into an integrated controller housing with a unified structure. The components are arranged and connected through integrated bus bars and mounting structures within the housing, reducing the number of separate connection elements and simplifying the overall assembly while maintaining component functionality and replaceability
2Adaptability or versatility
If two separate power modules are used, then each motor can be controlled independently, but the controller size increases and structural complexity increases
Solution Approach 1:
The patent integrates two power module functions into a single unified controller housing with shared components. The capacitor, current sensor, and cooling plate serve both motor control functions, while the housing and mounting structures provide unified support. This integration maintains independent control capability for both motors while significantly reducing the overall controller volume compared to using two separate power modules
Solution Approach 2:
The controller housing and internal components are designed to perform multiple functions simultaneously. The cooling plate provides thermal management for both power modules, the capacitor bank supports both motor control circuits, and the bus bar structure distributes power to both motors. This multi-functionality approach enables dual motor independent control within a single compact unit
3Ease of operation
If components are scattered inside the controller, then each component can be individually accessed, but space utilization and packaging efficiency decrease
Solution Approach 1:
The patent arranges components within a compact integrated housing where the power module, capacitor, current sensor, and cooling plate are positioned in close proximity with optimized spacing. The housing structure provides unified access points and mounting interfaces that enable individual component access while maximizing the use of internal space. The integrated design achieves high space utilization through efficient component layout and shared structural elements
Data Source
AI summary
The integrated dual-motor controller includes a controller housing, a bus magnetic ring component, an all-in-one module, a control plate, an isolation plate and a drive plate. The bus magnetic ring component, the all-in-one module, the control plate, the isolation plate and the drive plate are all integrated in the controller housing. The integrated dual-motor controller is designed to achieve a high level of integration, and a modular design is used inside to facilitate mounting and reduce the size.