Motor Controller PCB Layout With Buried Copper Bars
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Solution Overview
Problem
Existing high-power motor control units face challenges in cost control, rational layout, and size reduction due to fixed power device modules and limited layout on power circuit boards, making it difficult to select the appropriate module based on system power level.
Innovation Solution
A motor control unit design that integrates copper bars and circuit boards, allowing flexible control of parallel-connected power devices, rational layout, and size reduction by pre-burying copper bars in the circuit board, enhancing electrical connections and shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-power motor control unit uses fixed power device modules with parallel-connected power devices, then the power handling capability is improved, but the adaptability to different system power levels deteriorates and cost control becomes difficult
Solution Approach 1:
The power device module is segmented into individual power devices that can be independently selected and connected in parallel. Instead of using a fixed module with predetermined number of parallel devices, the invention allows selecting different quantities of individual power devices based on system power requirements, enabling flexible adaptation to different power levels while maintaining cost control.
2Ease of manufacture
If a fixed shape power device module is used, then the manufacturing process is simplified, but the layout flexibility on power circuit board deteriorates and size reduction becomes difficult
Solution Approach 1:
The fixed power device module is divided into individual power devices that can be independently laid out on the power circuit board. This segmentation allows flexible arrangement of power devices according to electrical connection requirements and space constraints, improving layout flexibility and enabling size reduction while maintaining manufacturing simplicity through standardized individual device mounting.
Solution Approach 2:
The invention transitions from a fixed two-dimensional module shape to a flexible two-dimensional layout on the circuit board. By abandoning the rigid module boundary and allowing power devices to be distributed across the board according to electrical requirements, the design achieves adaptive layout that optimizes both manufacturing and size.
3Productivity
If copper bars are not pre-buried in the circuit board, then the assembly process is simpler, but the electrical connection quality and shock resistance deteriorate
Solution Approach 1:
Copper bars are pre-buried in the circuit board during board manufacturing before final assembly. This preliminary action creates ready-made electrical connection pathways within the board structure, ensuring high-quality electrical connections and improved shock resistance. The pre-buried copper bars eliminate the need for separate connection steps, maintaining assembly efficiency while significantly enhancing connection reliability.
Data Source
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AI summary
Disclosed in embodiments of the disclosure are a motor control unit and a vehicle. The motor control unit includes a power circuit board, where the power circuit board includes a circuit board and a plurality of bridge arms; the circuit board includes a mounting surface and a non-mounting surface that are arranged oppositely, and the plurality of bridge arms are arranged on a plane where the mounting surface is located; each of the bridge arms includes an upper bridge arm and a lower bridge arm, and each of the upper bridge arms and the lower bridge arms includes a plurality of discrete power tubes; the power circuit board further includes a plurality of first copper bars and a plurality of second copper bars that are buried in the circuit board; the first copper bars correspond to the upper bridge arms one to one, and the plurality of power tubes in the same upper bridge arm are connected in parallel by the first copper bar; the second copper bars correspond to the lower bridge arms one to one, and the plurality of power tubes in the same lower bridge arm are connected in parallel by the second copper bar; and the power circuit board further includes a U-phase copper bar, a V-phase copper bar and a W-phase copper bar that are buried in the circuit board and configured to output a three-phase alternating current.