Integrated Motor Controller Layout for Compact Low-NVH Assembly
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Solution Overview
Problem
Conventional motor controllers for new energy vehicles face challenges of complex assembly, large size, and heavy weight, which are not aligned with the industry's trend of small size, light weight, high power density, and good stability.
Innovation Solution
A motor controller design that integrates the input module assembly, output module assembly, and an integrated circuit board onto a cooling carrier with securing protrusion structures, simplifying assembly and reducing size and weight, while improving Noise, Vibration, and Harshness (NVH) performance by direct secure connections and optimized circuit configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components and parts are assembled using screw connections, then the motor controller can be manufactured with conventional methods, but the assembly becomes complex, size increases, and weight increases
Solution Approach 1:
The patent integrates multiple separate components (control board, drive board, input module, output module, power module) into a unified structure mounted on a single cooling carrier. The circuit board integrates both control and drive functions, while input and output modules are each consolidated into single components. This merging eliminates the need for multiple screw connections and separate housings, directly reducing assembly complexity while maintaining manufacturability through standardized mounting processes.
Solution Approach 2:
The cooling carrier serves multiple functions: it provides thermal management for all mounted components, acts as a structural mounting platform, and serves as the base for the integrated circuit board. This multi-functionality consolidates what would otherwise require separate components, reducing overall assembly complexity without compromising manufacturability.
2Ease of manufacture
If multiple separate components are assembled using screws, then conventional manufacturing methods can be used, but the motor controller size becomes large
Solution Approach 1:
By consolidating control and drive circuits onto a single integrated circuit board and mounting all modules on one cooling carrier, the patent dramatically reduces the overall volume required. The integrated design eliminates gaps and redundant structures between separate components, achieving compact size while remaining manufacturable through standard PCB and mounting techniques.
3Ease of manufacture
If multiple separate components are assembled using screws, then conventional manufacturing methods can be used, but the motor controller weight increases
Solution Approach 1:
The integration of multiple functional modules into a single assembled unit on the cooling carrier eliminates redundant housing materials and fastening components. The unified structure requires fewer screws and less structural material to hold components in place, directly reducing overall weight while maintaining ease of manufacture through standardized assembly processes.
4Ease of manufacture
If screw connections are used to mount components, then conventional assembly methods can be applied, but vibration transfer loops increase and NVH performance deteriorates
Solution Approach 1:
By mounting all critical components directly on the cooling carrier with the integrated circuit board as the central structure, the patent minimizes the number of connection points and potential vibration transfer paths. The direct mounting approach reduces intermediate fasteners and connection interfaces that would otherwise create vibration loops, improving NVH performance while keeping assembly straightforward.
Data Source
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AI summary
The disclosure relates to the technical field of controllers, and in particular to a motor controller, and an electric motor and a vehicle comprising the motor controller, in order to solve the problems of complex assembly, large size and heavy weight of conventional motor controllers. To this end, the motor controller of the disclosure comprises a cooling carrier, and an input module assembly, a power module, an output module assembly and an integrated circuit board that are electrically connected and mounted on the cooling carrier, wherein the input module assembly and the output module assembly are each separately integrated into one component, the integrated circuit board is a complete circuit board formed by integrating a control board and a drive board, the cooling carrier is provided with securing protrusion structures extending toward the integrated circuit board, and the integrated circuit board is directly securely connected to the securing protrusion structures. With such an arrangement, assembling steps of the motor controller can be simplified. By integrating a plurality of components into one component, the size and weight of the integrated component can be effectively reduced. By means of the securing protrusion structures, the NVH reducing effect of the integrated circuit board can be improved.