Motor Controller Radiator Cooling Inverter and Capacitor Modules

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Solution Overview

Problem

Existing motor controllers for electric vehicles are bulky, inefficient in heat dissipation, fail to cool laminated busbars and AC copper bars, and have complex connections, leading to high costs.

Innovation Solution

A compact motor controller design featuring a radiator with a cooling waterway that cools both the inverter and capacitor modules, with direct heat transfer methods for AC copper bars and laminated busbars, and simplified connections using a box body with strategically placed components and filters for improved electromagnetic compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the motor controller uses dispersed assembly of inverse module and capacitor module, then the installation flexibility is improved, but the heat dissipation efficiency deteriorates

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidheat dissipation efficiency

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The patent merges the inverse module and capacitor module into a unified assembly structure where both modules are mounted on the same radiator housing. The inverse module is positioned on the upper surface of the radiator while the capacitor module is positioned on the lower surface, creating an integrated heat dissipation system that improves thermal efficiency while maintaining installation flexibility through modular design.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the motor controller includes bunched wires for connections, then the electrical connectivity is improved, but the device complexity and cost increase

Engineering Contradiction:

Improveelectrical connectivityVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the bunched wire connection system by implementing direct mechanical and electrical connections between modules. The inverse module and capacitor module are directly mounted on the radiator housing with integrated terminals, removing the need for separate wire harnesses and reducing connection complexity while maintaining reliable electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Device complexity

If the motor controller uses traditional cooling methods, then the cooling simplicity is maintained, but the cooling effectiveness for laminated busbar and AC copper bar deteriorates

Engineering Contradiction:

Improvecooling system simplicityVSAvoidcooling effectiveness

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The radiator housing serves multiple functions simultaneously: it provides structural support for both inverse and capacitor modules, acts as a heat dissipation component through integrated cooling waterways, and serves as an mounting structure for the laminated busbar and AC copper bar. This multi-functional design achieves effective cooling for all components without increasing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Temperature

If the motor controller increases the volume for better cooling, then the cooling effectiveness is improved, but the installation space occupancy increases

Engineering Contradiction:

Improvecooling effectivenessVSAvoidinstallation space

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The patent implements a nested arrangement where the inverse module and capacitor module are positioned within the same radiator housing structure. The inverse module is mounted on the upper surface of the radiator while the capacitor module is mounted on the lower surface, creating a compact nested configuration that maximizes cooling effectiveness within a minimized volume, reducing installation space occupancy.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution results in a smaller, more efficient, and cost-effective motor controller with enhanced heat dissipation and electromagnetic compatibility, ensuring stable and reliable operation.

Implementation Method 1

the cooling waterway is adapted to cool the capacitor module and the inverse module

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a cooling waterway, a water inlet and a water outlet that communicate with the cooling waterway

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

A needle bed stretches downwards from a bottom of the IGBT module. The upper surface of the radiator is provided with the inverse module and grooves, and the needle bed on the IGBT module stretches into the grooves on the upper surface of the radiator

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9769962B2Motor controller

Publication Date: 2017.09.19 ZHONGSHAN BROAD OCEAN

AI summary

A motor controller, including: a box body, a capacitor module, and an inverse module. The box body includes a chamber, and a radiator is disposed in the chamber. The radiator divides the chamber to yield a first chamber and a second chamber. The inverse module is disposed on an upper surface of the radiator in the first chamber. The capacitor module is disposed on a lower surface of the radiator in the second chamber. The radiator includes a cooling waterway, and a water inlet and a water outlet that communicate with the cooling waterway. The cooling waterway is adapted to cool the capacitor module and the inverse module.