Motor Control Module Layout for Compact High-Power Inverters
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Solution Overview
Problem
Existing electric lawn mowers face challenges in providing a robust and efficient mechanism to control and mount motors, ensuring compactness, and maximizing runtime and cutting area, while effectively managing power distribution and regenerative energy.
Innovation Solution
The design incorporates a frame with a motor control panel that includes thermally-conductive mounting frames, circuit boards, inverter circuits, and controllers to regulate power to drive and deck motors, along with regenerative energy control modules to manage voltage thresholds and absorb regenerative energy, ensuring efficient power management and motor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motor control panel with multiple control modules is added to manage power distribution and regenerative energy, then power management efficiency and motor control capability are improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple control modules (drive motor controller, deck motor controller, regenerative energy control) into a single integrated motor control panel. This consolidation manages power distribution and regenerative energy absorption in one unified structure, improving power management efficiency while reducing overall system complexity compared to separate distributed control systems.
Solution Approach 2:
The motor control panel serves multiple functions simultaneously: it controls drive motors, controls deck motors, manages battery power distribution, and absorbs regenerative energy. This multi-functionality in a single component addresses the technical contradiction by improving comprehensive power management efficiency without proportionally increasing device complexity.
2Volume of moving object
If control modules are mounted on a plate extending parallel to the footrest platform, then space utilization and compactness are improved, but accessibility for maintenance and heat dissipation become more difficult
Solution Approach 1:
The control modules are mounted on a plate that extends in a dimension parallel to the footrest platform, utilizing previously underutilized space. This spatial arrangement improves compactness and space utilization by placing controls in a horizontal plane rather than vertical stacking, while the plate structure provides accessible surfaces for maintenance operations.
Solution Approach 2:
The plate structure serves as an intermediary mounting surface that facilitates both compact integration and maintenance accessibility. It provides a standardized interface for mounting control modules while maintaining clearance for heat dissipation and access for servicing, mediating between the conflicting requirements of compactness and maintainability.
3Loss of energy
If regenerative energy absorbing modules are integrated into the side pods, then energy recovery capability is improved, but structural complexity and weight increase
Solution Approach 1:
The regenerative energy absorbing modules are integrated directly into the existing side pod structures, merging the energy recovery function with the structural bodywork. This integration improves energy recovery capability while minimizing additional weight compared to separate mounted systems, as the control modules utilize the side pod framework as part of their mounting structure.
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 solution enhances the control and efficiency of motor operations, extends runtime, and optimizes cutting area coverage by effectively managing power distribution and regenerative energy, addressing the challenges of motor control and compactness in electric lawn mowers.
Implementation Method 1
a mounting frame made of thermally-conductive material
Data Source
AI summary
A control module for a high power motor includes a mounting frame made up of thermally-conductive material including a bottom wall and four side walls; a circuit board disposed within the side walls of the mounting frame; power switches configured as an inverter circuit oriented in two arrays mounted on opposite surfaces of the circuit board; an auxiliary circuit board extending substantially perpendicularly from the circuit board; capacitors mounted on the auxiliary circuit board with a long axis thereof extending parallel to the circuit board and away from the power switches; and connectors mounted between an edge of the circuit board and distal ends of the capacitors.