Electric Motor Inverter PCB Layout for Reduced Cable Complexity
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Solution Overview
Problem
The complex setup resulting from numerous cable connections between a central control unit and power components in electric motors with a large number of field conductors complicates the design and increases wiring effort.
Innovation Solution
An electric motor design featuring a stator with rod conductors and inverters with parallel power sections, where output stages are arranged on multiple printed circuit boards forming circular or ring-shaped structures, connected via connecting boards that replace multiple cables with a single board per phase, simplifying the connection method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a large number of field conductors (48, 72, or 120) are used with individual power components for each conductor, then the electric motor can be designed compactly with each field conductor driven by its own power components and phase, but the cable connections between the central control unit and the large number of power components become very complex
Solution Approach 1:
The patent divides the power components into multiple modular units, with each unit controlling a specific phase or group of field conductors. These modular power component units are distributed around the motor periphery rather than centralized, which reduces the complexity of cable connections while maintaining compact motor design. Each modular unit can be independently connected to the control unit, simplifying the overall wiring architecture.
Solution Approach 2:
The patent transitions from a centralized control architecture to a distributed spatial arrangement of power components around the motor periphery. By organizing power components in a radial or circumferential pattern corresponding to the field conductors, the system reduces cable complexity through spatial optimization. This dimensional reorganization allows shorter, more efficient connections between control units and power components.
2Adaptability or versatility
If individual power components are assigned to each field conductor to enable compact motor design, then each field conductor can be driven by its own phase, but the number of cable connections between the central control unit and power components increases significantly
Solution Approach 1:
The patent combines multiple power components into integrated modular units that can handle multiple phases or groups of field conductors. By merging related power components into single modular packages, the system reduces the total number of separate cable connections required while maintaining the capability to independently control each field conductor phase.
Solution Approach 2:
The patent designs universal modular power component units that can serve multiple functions - each unit is capable of controlling multiple phases or groups of field conductors. This multi-functionality reduces the overall number of cable connections needed, as a single modular unit can replace what would otherwise require multiple separate power components and their associated cable connections.
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 design simplifies the connection of electronic components, reduces wiring complexity, and allows for a more compact and modular electric motor with efficient heat dissipation and reduced cable connections.
Implementation Method 1
Each circuit board has one or more connectors for contacting the output stages. A connecting board is plugged into connectors on circuit boards of various circular or ring-shaped structures that are azimuthally aligned with respect to the central axis.
Data Source
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AI summary
An electric motor having stator-side bar windings comprises a plurality of inverters for controlling the bars, wherein: the power components of the inverters are arranged on one or more circuit boards, and the circuit boards form at least two circular or annular structures that are axially off-set from each other; the circuit boards are electrically connected by means of a connecting printed circuit board; the connecting printed circuit boards extend axially and are plugged onto the circuit boards on the outer circumference and the inner diameter of the circular and annular structures, respectively.