Integrated Motor Controller Housing for Compact Powertrain Assembly
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Solution Overview
Problem
The motor controller in electric vehicles has a large number of parts, leading to complex assembly processes, significant size, and poor integration, which hinders compactness and vehicle layout.
Innovation Solution
An integrated component with an integrated housing that includes supporting and fastening columns to secure a circuit board and liquid cooling heat sink, along with Hall magnetic cores and a filter cavity, enhancing integration and compactness by reducing the number of components and facilitating miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional motor controller design with multiple separate parts is used, then each component can be independently manufactured and assembled, but the overall size of the motor controller becomes large and integration is poor
Solution Approach 1:
The patent merges multiple separate components (circuit board, heat sink, power modules, capacitor, filter, housing) into a single integrated motor controller assembly. The integrated housing contains all these components arranged in a compact configuration, eliminating the need for separate mounting brackets, fasteners, and assembly steps that would be required if these components were manufactured and assembled separately. This directly resolves the contradiction by combining multiple parts into one unified structure.
Solution Approach 2:
The integrated housing serves multiple functions simultaneously: it provides structural support, thermal management pathways, electrical isolation, and mechanical mounting for all internal components. The housing design incorporates features for circuit board mounting, heat sink attachment, power module installation, capacitor placement, and filter integration, making it a multi-functional component that replaces what would traditionally require multiple separate parts.
2Productivity
If multiple separate components are used in motor controller, then each component can be optimized independently, but the assembly process becomes complex and time-consuming
Solution Approach 1:
By combining multiple components into a pre-integrated housing assembly, the patent reduces the number of discrete assembly steps required. Instead of separately mounting the circuit board, heat sink, power modules, capacitor, and filter onto a controller chassis, all these components are already positioned and secured within the integrated housing, significantly simplifying the final assembly process and improving productivity.
Solution Approach 2:
The integrated housing is prepared in advance with all necessary mounting features, positioning elements, and internal arrangements configured before final installation. This preliminary integration of components within the housing eliminates the need for complex on-site assembly operations, allowing for faster and simpler installation in the final application.
3Volume of moving object
If components are arranged with large gaps for assembly and cooling, then manufacturing and heat dissipation are easier, but the overall compactness and size increase
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of components to a three-dimensional spatial configuration within the integrated housing. Components are stacked and positioned in multiple layers and directions, utilizing vertical space and internal volume efficiently. This dimensional transition allows for compact packaging while maintaining adequate spacing for heat dissipation pathways and assembly access through strategically placed openings and channels.
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 integrated design reduces the size of the motor controller, improves assembly efficiency, and enhances heat dissipation through coolant through holes, resulting in a more compact and efficient motor controller.
Implementation Method 1
The liquid cooling heat sink and the circuit board are respectively fastened to the integrated housing by using the supporting columns and the fastening columns
Data Source
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AI summary
Embodiments of this application provide an integrated component, a motor controller, and a powertrain. The integrated component includes an integrated housing and a capacitor core. The integrated housing is configured to accommodate the capacitor core. The integrated housing includes a first surface and a second surface that are opposite to each other in a first direction. The first surface includes two rows of fastening columns and two rows of supporting columns. Each row of the fastening columns includes a plurality of fastening columns, and each row of the supporting columns includes a plurality of supporting columns. In a second direction, the plurality of fastening columns in each row of the fastening columns are arranged at intervals, and the plurality of supporting columns in each row of the supporting columns are arranged at intervals. In a third direction, the two rows of supporting columns are arranged at an interval, and the two rows of fastening columns are arranged between the two rows of supporting columns at an interval. The integrated component provided in this application has high integration and high compactness, and can reduce components and parts of the motor controller, so that a size of the motor controller is reduced.