Integrated Motor Controller Housing for Compact Cooling Layout
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Solution Overview
Problem
The motor controller in electric vehicles has a large number of components, leading to complex assembly processes, significant size, and poor compactness, which is not conducive to vehicle layout and maintenance.
Innovation Solution
An integrated component with a housing that accommodates a capacitor core, fastening and supporting columns, and a liquid cooling heat sink, along with a compact layout of power modules and circuit boards, reduces the number of components and enhances integration, allowing for miniaturization and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional motor controller design with multiple separate components is used, then each component can be independently manufactured and assembled, but the overall device size becomes large and assembly process becomes complex
Solution Approach 1:
The patent combines multiple functional components (power module, capacitor, circuit board, heat sink) into a single integrated housing structure. The housing simultaneously serves as structural support, mounting platform, and thermal management system, eliminating the need for separate component housings and reducing overall controller volume.
Solution Approach 2:
The integrated housing performs multiple functions: it provides structural support, mounts all internal components, facilitates heat dissipation through integrated heat sink channels, and enables liquid cooling circulation. This multi-functionality reduces the number of separate parts needed.
2Adaptability or versatility
If multiple separate components are used in motor controller, then functional modularity is maintained, but assembly process becomes complex and compactness deteriorates
Solution Approach 1:
Multiple components are merged into a single integrated assembly where the housing contains and supports all functional elements. This reduces the number of assembly steps from assembling multiple separate components to installing a single integrated unit.
3Ease of operation
If components are arranged with large gaps for assembly and maintenance, then accessibility is improved, but compactness and space utilization deteriorate
Solution Approach 1:
The patent transitions from planar component arrangement to three-dimensional spatial utilization. Components are stacked and arranged vertically and depth-wise within the housing, allowing efficient space utilization while maintaining access pathways for maintenance operations.
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, simplifies assembly and maintenance, and enhances compactness while maintaining effective heat dissipation and signal transmission.
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
Implementation Method 2
improved heat dissipation
Data Source
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. 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.