Laminated Busbar Layout for Compact Integrated Motor Controllers
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Solution Overview
Problem
Existing drive assemblies in new energy vehicles face challenges in achieving efficient integration, optimal connection structures, cooling, and assembly ease, particularly in integrating the motor and motor controller, while maintaining a compact footprint.
Innovation Solution
A laminated busbar assembly with circular main circuit board, fan-shaped or arcuate single-phase connection plates, and collision avoidance grooves, combined with a motor controller and drive assembly design that utilizes space at the motor's rear end for efficient component placement, including a partition wall and bearing to separate rotor and controller chambers, optimizing wiring and heat conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor and motor controller are integrated to reduce footprint, then space utilization is improved, but the connection structures and cooling systems become more complex
Solution Approach 1:
The patent integrates the motor controller directly into the motor housing, merging two previously separate components into a unified assembly. The controller is positioned within the motor housing space, and the cooling system is integrated to serve both the motor and controller simultaneously, reducing the overall footprint while maintaining functional independence
Solution Approach 2:
The cooling system is designed with multi-functionality to serve dual purposes: cooling the motor windings and cooling the power transistors in the controller. The liquid cooling channels are routed to contact both the motor stator and the controller housing, allowing a single cooling system to handle thermal management for both components
2Temperature
If power transistors are annularly arranged around the circuit board, then heat dissipation efficiency is improved, but the controller structure becomes more complex
Solution Approach 1:
The power transistors are arranged in an annular (circular) pattern around the central circuit board instead of a linear or grid arrangement. This curved, radial layout maximizes the surface area available for heat dissipation while maintaining compact dimensions. The annular array allows heat to be distributed across a larger perimeter area, improving thermal management
Solution Approach 2:
The controller structure is segmented into distinct functional zones: a central circuit board area for control electronics, an annular region for power transistors, and an outer region for heat dissipation surfaces. This segmentation allows each zone to be optimized independently while maintaining overall structural integrity
3Temperature
If liquid cooling channels are integrated into the housing, then cooling efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs liquid cooling channels integrated into the motor housing and controller housing structures. These channels form a closed-loop hydraulic system that circulates coolant to absorb heat from the motor stator and power transistors. The housing itself serves as part of the cooling system, with embedded channels that maximize thermal contact area while maintaining structural integrity
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
The design reduces occupied space, improves space utilization, and achieves high integration with efficient assembly and heat conduction, optimizing circuit wiring and layout.
Implementation Method 1
an outer wall of the housing is provided with a liquid cooling channel which includes a motor cooling groove and a controller cooling groove that communicate with each other
Implementation Method 2
The waste heat of the power transistors can be efficiently conducted to the interconnected controller cooling groove and motor cooling groove, realizing integrated liquid cooling
Implementation Method 3
The waste heat of the power transistors can be efficiently conducted to the interconnected controller cooling groove and motor cooling groove
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present disclosure relates to the field of new energy, and provides a laminated busbar assembly, a motor controller, a drive assembly, and a vehicle. The laminated busbar assembly includes a main circuit board, a positive and a negative electrode connection plates, and a three-phase connection plate assembly, which are laminated in sequence. The positive and the negative electrode connection plates, and the three-phase connection plate assembly are each provided with pins arranged circumferentially. The present disclosure designs a laminated arrangement and an annular arrangement of pins, thereby improving the device integration and space utilization, effectively reducing the occupied space, and realizing high integration of the motor controller and the drive assembly.