Motor Assembly Stacked ECU Configuration
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Solution Overview
Problem
Motor control assemblies with redundant controllers often fail together, minimizing the benefits of dual controllers, and pose packaging challenges due to their design.
Innovation Solution
A motor assembly with a stacked configuration featuring an outward ECU, an inward ECU, and a motor sensor board, where the inward ECU is between the motor and the outward ECU, and the motor sensor board is between the motor and the inward ECU, with electrical leads and potted seals to prevent moisture migration and optimize packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two independent motor controllers are used to improve control reliability, then redundancy is achieved, but the controllers may fail together due to common cause effects and packaging constraints prevent optimal placement
Solution Approach 1:
The patent divides the motor assembly into distinct spatial zones with controllers positioned at opposite ends of the motor housing, creating physically separated control zones that reduce common-cause failure risks while maintaining independent operation
Solution Approach 2:
The controllers are arranged in a distributed three-dimensional configuration rather than being stacked or placed adjacent to each other, utilizing the motor housing's length dimension to maximize spatial separation and minimize interference between redundant controllers
2Volume of stationary object
If redundant controllers are positioned close together for compact packaging, then packaging efficiency improves, but environmental contamination can affect both controllers simultaneously
Solution Approach 1:
The motor housing is segmented into multiple sealed compartments, each containing a controller, with physical barriers and sealing elements that prevent moisture and contaminants from migrating between zones while maintaining overall compact dimensions
Solution Approach 2:
Sealing elements and environmental barriers act as intermediary structures between the controllers and the external environment, preventing harmful factors from reaching the controllers while allowing the assembly to maintain a compact footprint
Data Source
AI summary
A motor assembly includes a motor, an outward electronic control unit (ECU), an inward ECU, and a motor sensor board unit. The inward ECU is disposed between the motor and the outward ECU. The motor sensor board unit is disposed between the motor and the inward ECU, and is attached to the inward ECU.