Integrated Motor Controller Partitioning for Thermal Isolation
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Solution Overview
Problem
Existing electric drive devices face challenges in managing thermal influences between structural components of a rotary electric machine and electronic components of a controller, as well as between different electronic components, leading to potential heat damage and reduced energy efficiency.
Innovation Solution
The implementation of a heat insulation component with a partition portion that separates structural components of the rotary electric machine from electronic components and separates electronic components within the controller, utilizing a resin layer with lower thermal conductivity to face components with greater heat generation and a metal layer for electromagnetic noise shielding, while allowing ventilation to enhance cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electronic components are integrated in a compact controller, then device complexity is reduced, but thermal management becomes more difficult due to proximity of heat-generating and heat-sensitive components
Solution Approach 1:
The controller's internal space is segmented into multiple regions by the second heat insulation portion, creating distinct thermal zones. This allows heat-generating components like power modules to be separated from heat-sensitive components like smoothing capacitors, enabling compact integration while maintaining thermal management.
Solution Approach 2:
The second heat insulation portion acts as an intermediary barrier between electronic components with different thermal characteristics. This intermediary structure enables close integration of components while preventing direct thermal interaction, resolving the conflict between compactness and thermal management.
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 effectively suppresses thermal influences, protects vulnerable components from heat damage, improves heat radiation, and enhances cooling performance for both the rotary electric machine and the controller, leading to improved energy efficiency and simplified device configuration.
Implementation Method 1
utilizing a resin layer with lower thermal conductivity to face components with greater heat generation
Implementation Method 2
and a metal layer for electromagnetic noise shielding
Implementation Method 3
while allowing ventilation to enhance cooling performance
Data Source
AI summary
An electric drive device includes a rotary electric machine, and a controller integrated with the rotary electric machine and configured to control driving of the rotary electric machine. The rotary electric machine includes a plurality of structural components, and a housing that accommodates the plurality of structural components, the controller includes a plurality of electronic components, and a casing that is adjacent to the housing and accommodates the plurality of electronic components, and a heat insulation component separates the plurality of structural components from the plurality of electronic components, and the heat insulation component includes a partition portion that separates the plurality of electronic components.