Integrated Motor Inverter Layout for Compact Cooling and Wiring
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Solution Overview
Problem
Conventional electric power units face challenges in compact packaging due to the mismatched shapes of inverter housings and AC electric motors, leading to increased size and inefficient cooling, along with the need for numerous connectors and cables.
Innovation Solution
The electric power unit integrates a power assembly and control assembly within a common enclosure on the longitudinal side and end of the AC electric motor housing, with a cooling jacket surrounding the stator, reducing the overall size and eliminating the need for extensive wiring by using AC power busbars and integrated sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the inverter housing is mounted on the AC electric motor to integrate both electronic units, then the device complexity is reduced, but the volume of the electric power unit increases due to shape mismatch between rectangular inverter housing and cylindrical motor
Solution Approach 1:
The inverter housing is positioned inside the cylindrical housing of the AC electric motor, nesting the rectangular inverter within the circular motor housing. This allows both components to occupy the same spatial envelope, reducing the overall volume of the electric power unit while maintaining integration of the electronic units.
Solution Approach 2:
The inverter housing is oriented with its longitudinal axis perpendicular to the rotor shaft axis, positioning it in a different dimensional orientation within the housing space. This perpendicular arrangement allows efficient use of the cylindrical housing volume and reduces the external dimensions of the combined unit.
2Ease of operation
If the inverter is mounted on the AC electric motor with extensive wiring, then the control function is achieved, but the number of connectors and cables increases leading to higher device complexity
Solution Approach 1:
The power assembly and control assembly are merged into a single integrated inverter unit mounted within the motor housing. This consolidation eliminates the need for separate wiring harnesses, connectors, and cables between discrete inverter and motor components, reducing device complexity while maintaining full control functionality.
3Temperature
If conventional cooling methods are used for the inverter and motor, then the cooling function is provided, but the cooling efficiency is insufficient
Solution Approach 1:
The cooling jacket is positioned concentrically around the stator, nesting the cooling system within the motor structure. This allows the coolant to flow in direct thermal contact with the stator windings, maximizing heat transfer efficiency and improving the cooling function while minimizing energy loss.
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 results in a more compact design with improved cooling efficiency and reduced wiring complexity, enabling precise monitoring and operation close to maximum power without failure risks.
Implementation Method 1
a power assembly configured to receive direct current (DC) power from a DC power source and to convert the DC power into AC power
Implementation Method 2
a cooling jacket surrounding the stator
Data Source
AI summary
An electric power unit comprises an AC electric motor, a power assembly, and a control assembly. The AC electric motor has a housing and an output shaft supported in the housing, the housing having a first end and a second end opposite the first end, the output shaft protruding from the first end. A combination of the power assembly and of the control assembly forms a DC to AC inverter. The power assembly receives DC power from a DC power source and converts the DC power into AC power. The control assembly controls a transmission of the AC power from the power assembly to the AC electric motor. The power assembly is disposed on a longitudinal side of the housing, the longitudinal side extending between the first and second ends of the housing. The control assembly is mounted on the second end of the housing.