Motor-Integrated Inverter Layout for Cooled Power Switch Mounting
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Solution Overview
Problem
Existing inverter designs for electric motors lack efficient cooling and integration with the motor, leading to potential thermal issues and reduced performance, especially at high voltage levels.
Innovation Solution
An integrated inverter and motor design where the inverter is housed separately with coolant channels connecting both parts, featuring a printed circuit board, power switches mounted outside for thermal dissipation, and a spring mechanism to ensure contact with coolant channels, along with high-voltage and signal terminals for efficient power transmission and rotation speed sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power switches are integrated close to the PCB, then electrical connection is simplified, but thermal dissipation becomes insufficient
Solution Approach 1:
The power switch assembly is segmented from the PCB and mounted on the housing structure instead. This allows the power switches to be physically separated from the PCB while maintaining electrical connection through terminals, while simultaneously enabling independent thermal management through direct coolant contact with the power switch housing.
2Volume of stationary object
If inverter and motor are integrated in same housing, then space is reduced, but cooling efficiency decreases
Solution Approach 1:
The housing is designed with differentiated local qualities: the inverter housing portion includes dedicated coolant channels with high thermal conductivity materials and optimized flow paths for electronic component cooling, while the motor housing portion has separate cooling arrangements. This allows each subsystem to be cooled according to its specific thermal requirements while maintaining a compact integrated structure.
3Reliability
If power switches are mounted on opposing face away from coolant channel, then electrical isolation is improved, but thermal contact is reduced
Solution Approach 1:
A flexible thermal interface material or thermal paste is introduced as an intermediary between the power switches and the housing coolant channel. This intermediary maintains effective thermal contact while allowing for manufacturing tolerances and assembly variations, ensuring consistent thermal transfer from the power switches to the coolant without compromising electrical isolation.
4Area of stationary object
If high voltage terminals are placed close to signal terminals, then connector size is reduced, but electrical interference increases
Solution Approach 1:
The terminal arrangement within the connector employs asymmetric positioning and shielding strategies. High voltage terminals are positioned with unequal spacing relative to signal terminals, with increased clearance in critical directions. Asymmetric shielding structures are implemented to direct electromagnetic interference away from sensitive signal lines while maintaining a compact overall connector footprint.
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 enhances cooling efficiency, maintains thermal contact, and allows for precise rotation speed monitoring, improving the performance and reliability of electric motors operating at high voltages.
Implementation Method 1
A spring may be affixed to the opposing face or a lid of the second part, and the spring may apply a force to the power switches in the direction of the coolant channel. The force may be configured to press the power switches against the opposing face.
Implementation Method 2
Coolant may enter a coolant channel of the second part of the housing and may be therefrom directed to the first part for cooling the electric motor.
Implementation Method 3
Coolant may enter a coolant channel of the second part of the housing and may be therefrom directed to the first part for cooling the electric motor.
Implementation Method 4
The PCB may include a sensor thereon configured to sense the fiducial mark and produce a signal related to a rotational speed of the shaft. For example, the sensor may be an optical sensor, a proximity sensor, or a magnetic sensor.
Implementation Method 5
The PCB may include a sensor thereon configured to sense the fiducial mark and produce a signal related to a rotational speed of the shaft. For example, the sensor may be an optical sensor, a proximity sensor, or a magnetic sensor.
Data Source
AI summary
An inverter may be integrated with an electric motor in a single housing. Coolant may enter a coolant channel of the housing and be directed to the electric motor. The inverter may include a printed circuit board (PCB) and power switches. The PCB may be located in the center of the housing. The power switches may be located outside of the PCB on an opposing face of the coolant channel. A spring may apply a force to the power switches to maintain thermal contact between the power switches and the coolant channel. Flexible leads may connect between the power switches and the PCB. The electric motor may include a shaft that is located adjacent to the PCB. The shaft may include a fiducial mark, and the PCB may include a sensor configured to detect the fiducial mark to determine a rotational speed of the shaft.