Segmented Inverter Housing for Compact Drive Cooling and Assembly
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Solution Overview
Problem
Existing drive systems face challenges with insufficient installation space on circuit boards for power electronics, complex cable laying, and manual assembly, leading to inefficient production and cooling issues.
Innovation Solution
A compact drive unit design featuring a segmented inverter housing composed of extruded aluminum or aluminum alloy segments, with circuit boards arranged in a star-shaped configuration and connected via rigid-flex connections, allowing for automated assembly and efficient cooling through a closed housing arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If power electronics are mounted on circuit boards and inside cast housing, then installation space is utilized, but manufacturing complexity increases due to reworking requirements for heat dissipation and threaded bores
Solution Approach 1:
The housing is divided into multiple segments instead of using a single cast housing. This segmentation eliminates the need for complex reworking operations while maintaining structural integrity and heat dissipation capabilities. Each segment can be manufactured independently with standard processes.
Solution Approach 2:
Instead of mounting power electronics inside a cast housing and then providing cooling, the invention inverts the approach by integrating cooling channels directly into the housing structure during manufacturing. This eliminates the need for post-casting reworking operations.
2Ease of manufacture
If threaded bores are provided in cast housing for fastening components, then assembly is enabled, but processing complexity increases due to undercut locations requiring complex operations
Solution Approach 1:
The housing is segmented into multiple parts that can be assembled together using standard fastening methods. This eliminates the need for complex threaded bores in undercut locations, as segments can be joined at accessible locations with simple fastening operations.
3Ease of operation
If manual assembly is used for cable laying in confined space, then cable routing is achieved, but productivity decreases and automation becomes impossible
Solution Approach 1:
Cable routing paths are pre-planned and pre-positioned during the housing design and manufacturing phase. This preliminary action enables automated cable laying operations later, eliminating the need for manual assembly in confined spaces and significantly improving productivity.
4Ease of manufacture
If die casting process is used for housing production, then manufacturing is simplified, but dimensional accuracy and surface roughness cannot be guaranteed without reworking
Solution Approach 1:
The housing is divided into segments that are manufactured using processes better suited for achieving required dimensional accuracy and surface finish. This segmentation allows each part to be optimized for its specific manufacturing requirements without compromising overall production efficiency.
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
Enables automated production and testing of power electronics, reduces assembly costs, and enhances cooling efficiency by eliminating the need for manual assembly and die casting, resulting in a compact and thermally efficient drive system.
Implementation Method 1
each segment being in direct thermally conductive contact with at least one peripheral board
Implementation Method 2
at least one cooling unit, wherein these components of the drive are arranged axially one behind the other such that the electronic add-on part is arranged axially between the dynamoelectric rotary machine and the cooling unit wherein the electronic add-on part is cooled by a cooling air flow
Data Source
AI summary
In a method of producing an add-on part of a drive, one circuit board of multiple planar circuit boards, which have electrical conductor tracks with electrical connections, is provided with a centrally arranged opening for passage of a shaft. The circuit boards are populated with electrical and/or electronic components, and the populated electrical and/or electronic components and wiring are electrically tested. Segments made of a material with high thermal conductivity are arranged on at least two of the multiple circuit boards such that a bending process in a region of the electrical connections between the at least two circuit boards causes the segments to form an approximately peripherally closed cover. Lids are arranged on open sides of the cover to realize a closed housing arrangement.