Inverter-Integrated Driving Module Axial Arrangement
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Solution Overview
Problem
Conventional power module-integrated motors face increased copper loss and complex connecting work due to long wiring lengths and numerous connections between phase coils, leading to higher costs and efficiency losses.
Innovation Solution
The inverter-integrated driving module configures phase coils as concentrated windings on circumferentially consecutive tooth portions and positions inverter units in close proximity to the motor, reducing wiring lengths and the number of connections between phase coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If output wires are led around the end surface of the stator to connect to the power module, then the power module can be inserted into and fixed to the power module mount portion, but the wiring length between the power module and the motor is increased, increasing copper loss
Solution Approach 1:
The patent changes the spatial arrangement by positioning the power module axially adjacent to the stator core rather than radially outward. The output wires connect to the power module through the axial direction by having the power module disposed adjacent to the stator core in the axial direction, with output wires extending from the stator coil through the stator core to the power module. This dimensional reconfiguration significantly shortens the wiring length compared to leading wires around the end surface, thereby reducing copper loss while maintaining ease of assembly.
2Adaptability or versatility
If twelve phase coils are arranged in order of U phase, V phase, W phase through the V phase and W phase, then the motor winding can be constituted by two three-phase alternating current windings, but the number of connections between the phase coils is extremely large, increasing complicated connecting work and cost
Solution Approach 1:
The patent merges adjacent phase coils of the same phase into concentrated windings. Specifically, it configures the motor winding such that U-phase coils, V-phase coils, and W-phase coils are formed by concentrated windings on adjacent tooth portions. This merging reduces the number of separate coil connections required, as adjacent coils of the same phase are electrically connected in series through the winding structure itself, thereby simplifying the connecting work and reducing assembly complexity while maintaining the two three-phase alternating current winding configuration.
3Loss of energy
If the inverter module is disposed in close proximity to the motor with inverter units facing phase coils axially, then wiring length is shortened and copper loss is reduced, but the structural configuration becomes more complex
Solution Approach 1:
The patent integrates the inverter module structure to serve multiple functions simultaneously. The inverter module housing provides both mechanical support and electrical insulation, while the circuit board serves as both the mounting substrate for switching elements and the structural framework for the entire inverter module. The output terminals are positioned to directly receive connections from stator coils, eliminating the need for separate connection structures. This multi-functional design achieves the compact axial arrangement that shortens wiring length without proportionally increasing structural complexity.
Data Source
AI summary
Phase coils are each configured by winding a conductor wire in a concentrated winding consecutively on three circumferentially consecutive tooth portions, six inverter units of an inverter module are each disposed in close proximity to a motor so as to face each of the phase coils axially, and the motor and the inverter module are electrically connected by connecting an alternating-current output terminals of each of the plurality of inverter units to output wires of the phase coils that face the inverter units axially.