Modular Motor Controller With Shared Cooling And Oscillation Damping
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Solution Overview
Problem
Electric vehicle traction systems face challenges due to the weight, bulk, and complexity of motor-controller assemblies, as well as safety concerns from high current losses and wiring issues, and the lack of damping in electric vehicles leads to oscillatory behavior and increased noise.
Innovation Solution
A modular motor-controller assembly with symmetrically arranged components and a shared cooling system reduces weight and complexity, and an oscillation damping system modifies torque demand signals to damp motor speed oscillations, improving safety and vehicle responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate cooling systems are provided for each motor-controller, then each system can be optimized independently, but the overall weight, bulk, and complexity increase significantly
Solution Approach 1:
The patent combines multiple separate cooling systems into a single shared cooling system that serves multiple motor-controllers. This is achieved by integrating common coolant distribution manifolds and heat exchangers that can dissipate heat from multiple controllers simultaneously, thereby reducing the total weight and complexity while maintaining effective cooling capacity.
Solution Approach 2:
The cooling system is designed with universal components that can serve multiple functions and multiple controllers. The shared coolant loops and heat dissipation apparatus are configured to handle thermal loads from different motor-controllers, making the cooling infrastructure multi-functional and reducing redundancy.
2Adaptability or versatility
If high current is transmitted through long wires to spaced-apart motors and controllers, then system layout flexibility increases, but current losses and safety risks increase
Solution Approach 1:
The patent merges the motor and controller into a closely integrated modular assembly, minimizing the distance between high-current components. This integration reduces the length of high-current wiring required, thereby reducing I²R losses and voltage drops while maintaining system layout flexibility through standardized modular units.
Solution Approach 2:
The patent introduces intermediate bus bars and low-inductance connection structures as mediators between the controller and motor terminals. These intermediaries provide low-impedance current paths that reduce energy losses compared to long wire connections, while still allowing flexible system configuration through standardized interfaces.
3Device complexity
If electric vehicles lack oscillation damping, then the system remains simple, but oscillatory behavior and noise increase
Solution Approach 1:
The patent implements a feedback-based oscillation damping control system that monitors motor speed and torque signals to detect oscillatory behavior. When oscillations are detected, the controller adjusts the torque demand signal in real-time to counteract the oscillations, thereby reducing noise and vibration while maintaining relatively simple system architecture.
Solution Approach 2:
The patent modifies control parameters such as torque demand signals and current references dynamically to dampen oscillations. By adjusting these parameters based on detected oscillation frequency and amplitude, the system can suppress harmful oscillatory behavior without requiring complex mechanical damping structures.
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 modular design simplifies assembly and reduces weight and volume, while the damping system enhances vehicle stability and reduces noise and oscillations, improving the driving experience.
Implementation Method 1
Heat is also generated in the motor due to ohmic (I2R) heating in the windings, eddy currents and due to friction
Implementation Method 2
cooling is achieved by running fluid coolant past a heat sink or manifold to absorb thermal energy
Implementation Method 3
the controller has an inverter for converting the DC supply to AC for the motor
Implementation Method 4
The controller is configured to perform inversion, filtering and conditioning processing on the DC output of the power source to provide the motor with the required AC power source
Data Source
AI summary
An electric motor controller having a front face and a rear face, the front face carrying a plurality of AC output couplings and the controller carrying a converter configured to convert a received DC supply into an output AC supply for controlling an electric motor, the AC output couplings being disposed symmetrically about an axis of symmetry of the controller on the front face of the controller. Also described is an apparatus comprising: a DC series motor; and a first current supply configured to supply a first current to an armature of the DC series motor; a second current supply configured to supply a second current to a field winding of the DC series motor; and a controller configured to control the first current supply to supply the first current based on a required torque output for the motor, and to control the second current supply to supply the second current based on the first current.