Motor Controller Size Reduction via Segmented Circuit Boards

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Solution Overview

Problem

Current motor controller configurations are costly and large due to the form factor driven by power control components, which limits size reduction and increases heat generation, affecting efficiency and cost-effectiveness.

Innovation Solution

The implementation of a separate motor management circuit board with an insulated metal substrate for driver components and a power supply circuit board made from composite material, where the motor management circuit board uses surface mount components for heat sinking and the power supply circuit board uses through-hole components, allowing for size reduction and improved thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If power control components are mounted on a single circuit board, then the motor controller can be manufactured with a simple structure, but the form factor of the power control components drives the form factor of the remainder of the components, resulting in increased overall size and heat generation

Engineering Contradiction:

Improvecircuit board structureVSAvoidmotor controller size

Core Design Contradiction:

Device complexityVSVolume of moving object

Solution Approach 1:

The motor controller is divided into two separate circuit boards: a power supply circuit board and a motor management circuit board. This segmentation allows each board to be optimized independently for its specific function, enabling better thermal management and size reduction while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If power control components are mounted on a single circuit board, then the structure remains simple, but heat generation increases affecting efficiency

Engineering Contradiction:

Improvecircuit board structureVSAvoidheat generation

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

By separating power control components on the power supply circuit board from other components on the motor management circuit board, heat generation is reduced through improved thermal management and reduced thermal interference between components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Power control components that generate significant heat are extracted from the motor management circuit board and placed on a separate power supply circuit board, allowing for dedicated thermal management of high-power components.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If a single circuit board configuration is used, then manufacturing is simpler, but the overall size and cost of the motor controller increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmotor controller size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The controller is segmented into two functionally distinct circuit boards that can be manufactured separately using standardized processes, then assembled together. This approach maintains manufacturing simplicity while reducing overall size through optimized component placement and thermal management.

Inventive Principle:

Principle #1Segmentation

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

This configuration reduces the overall size and cost of the motor controller, enhances heat dissipation, and simplifies manufacturing by standardizing components, leading to improved process yield and reduced development time for new products.

Implementation Method 1

an insulated metal substrate for a plurality of driver components

Methodology Applied

Scientific EffectHeat sinking: Heat Sink

Implementation Method 2

insulated metal substrate operable as a heat sink for a plurality of components mounted thereon

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a plurality of power processing components operably attached to the printed circuit card and operable to convert an input voltage into at least one output voltage

Methodology Applied

Scientific EffectElectrical energy conversion:

Data Source

PatentUS8878470B2Methods and apparatus for reducing size and costs of motor controllers for electric motors

Publication Date: 2014.11.04 REGAL BELOIT AMERICA INC

AI summary

An electric motor that includes an electronic motor controller is described. The electronic motor controller includes a motor management circuit and a power supply circuit physically separate from the motor management circuit. The motor management circuit includes an insulated metal substrate, driver components operably attached to the insulated metal substrate and operable to provide output signals for application to windings of the electric motor, at least one current sensor operable for sensing an amount of current applied to the windings of and electric motor, and at least one control device operably attached to the insulated metal substrate for controlling operation of the driver components. The power supply circuit includes a composite circuit card and power processing components operably attached to the circuit card and operable to convert an input voltage into at least one output voltage to be supplied to the motor management circuit.