Rotary Electric Machine Controller Layout for Heat and Space Efficiency
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Solution Overview
Problem
Existing controllers for rotary electric machines face challenges in efficiently arranging power modules and smoothing capacitors, leading to space inefficiencies and potential thermal interference, which affects energy efficiency and overall size.
Innovation Solution
A controller design that arranges power modules at intervals in the circumferential direction of a cylindrical casing, with a smoothing capacitor continuously along the inner surfaces of the modules, optimizing space utilization and reducing thermal influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the capacity of the smoothing capacitor is increased to protect the power modules, then the reliability is improved, but the volume of the controller increases
Solution Approach 1:
The patent transitions from conventional linear or discrete arrangement of power modules and smoothing capacitor to a three-dimensional radial arrangement around a central shaft. The power modules are positioned at different radial distances from the shaft, with the smoothing capacitor located in the central region. This spatial reconfiguration in multiple dimensions allows compact packaging of larger capacity capacitors without increasing the overall controller volume.
Solution Approach 2:
The patent implements a nested arrangement where the smoothing capacitor is positioned in the central region and power modules are arranged around it at different radial distances. This nested configuration allows the components to occupy overlapping spatial zones efficiently, maximizing space utilization and accommodating larger capacity capacitors within the same controller volume.
2Volume of stationary object
If the power modules and smoothing capacitor are arranged densely to improve space efficiency, then the volume is reduced, but thermal interference increases
Solution Approach 1:
The patent applies local quality by assigning different thermal management characteristics to different regions. The power modules positioned at larger radial distances experience better natural convection cooling due to their proximity to the outer casing surface, while the smoothing capacitor in the central region is thermally isolated from direct contact with heat-generating components. This localized thermal management allows dense packing while controlling thermal interference.
Solution Approach 2:
The patent introduces thermal management intermediaries including heat sinks attached to power modules and thermally conductive yet electrically insulating materials between components. These intermediaries facilitate heat dissipation from power modules while preventing excessive thermal coupling between the smoothing capacitor and power modules, enabling dense arrangement without excessive thermal interference.
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
Improves space efficiency, reduces thermal interference, and enhances heat radiation, resulting in a smaller, lighter, and more energy-efficient controller for rotary electric machines.
Implementation Method 1
the plurality of power modules contacts with the inner circumferential surface of the cylindrical casing that has high heat radiation, so that the heat radiation of the plurality of power modules as heat generating components can be improved
Implementation Method 2
a smoothing capacitor (79) configured to smooth an electric current input to the plurality of power modules
Data Source
AI summary
A controller is integrated with a rotary electric machine and configured to control driving of the rotary electric machine. The controller of the rotary electric machine includes a plurality of power modules each including a switching element that is a component of a power conversion circuit, a smoothing capacitor configured to smooth an electric current input to the plurality of power modules, and a cylindrical casing configured to accommodate the plurality of power modules and the smoothing capacitor. The plurality of power modules is arranged at an interval in a circumferential direction of the casing and contacts with an inner circumferential surface of the casing, and the smoothing capacitor is continuously arranged along inner surfaces of the plurality of power modules.