Motor Drive Inverter Integration with Remote Control Board
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Solution Overview
Problem
The existing integration of power supply modules for electric motors in vehicles requires separate power control units and long, high-voltage cables, leading to increased costs, weight, space requirements, and electromagnetic interference issues, as well as thermal management challenges due to the proximity of sensitive control boards to high-power inverter components.
Innovation Solution
The power switching devices (IGBTs or MOSFETs) are separately housed near the electric motor, with control circuits located remotely and connected via low-current, low-voltage signal conductors or radio connections, eliminating the need for long cables and allowing for improved thermal and mechanical separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power control unit and E-motor are integrated in a separate box with long high-voltage cables, then electrical connection is established, but weight, cost, and space requirements increase
Solution Approach 1:
The patent merges the power control unit and E-motor into a single integrated assembly, eliminating the need for separate boxes and long connection cables. The power modules are mounted directly on the E-motor housing, creating a compact integrated drive system that reduces overall weight while maintaining reliable electrical connections.
2Reliability
If power control unit and E-motor are integrated in a separate box with long high-voltage cables, then electrical connection is established, but cost increases
Solution Approach 1:
The integration of power control functions directly into the E-motor assembly eliminates the need for separate power control units and extensive cable assemblies, reducing part count and assembly complexity. This modular integrated design simplifies manufacturing processes and reduces overall system cost.
3Reliability
If power control unit and E-motor are integrated in a separate box with long high-voltage cables, then electrical connection is established, but space requirements increase
Solution Approach 1:
The patent consolidates the power control unit and E-motor into a single compact integrated assembly, eliminating the space required for separate power control boxes and long cable routing. The power modules are mounted directly on the E-motor housing, significantly reducing the overall volume occupied by the drive system.
4Device complexity
If control board is placed near high-power inverter components, then compact design is achieved, but thermal management becomes difficult
Solution Approach 1:
The patent segments the integrated assembly into distinct thermal zones: power modules mounted on the E-motor housing with dedicated cooling paths, and control boards positioned in thermally isolated regions. This spatial segmentation allows compact integration while maintaining effective thermal management through separate cooling circuits and thermal barriers.
5Device complexity
If control board is placed near high-power inverter components, then compact design is achieved, but electromagnetic interference increases
Solution Approach 1:
The patent segments the electromagnetic environment into distinct zones: high-power inverter components isolated from sensitive control electronics through strategic positioning and shielding. The control board is placed in a region shielded from electromagnetic radiation generated by the power modules, reducing interference while maintaining compact integration.
Data Source
AI summary
The power switches of an inverter are mechanically integrated with an electric motor of a vehicle and are mounted on the end plate of the motor and employ short connections between the motor a-c terminals and the inverter a-c output terminals. Bond wireless modules are employed. The electronic controls for the inverter are mounted on a main control board which is positioned remotely from the inverter and is not subject to the heat and EMI produced by the inverter.