Stacked Motor Controller Module Layout for Compact EV Packaging
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Solution Overview
Problem
The existing motor controllers in electric vehicles have a complex arrangement of multiple power assemblies, leading to high space requirements, low space utilization, and increased production costs due to the tiled configuration of power assemblies, which hinders miniaturization and integration.
Innovation Solution
A motor controller integrated module is designed with a bus capacitor, heat sink, and two power assemblies integrated together, where the bus capacitor and power assemblies are stacked in a specific orientation to minimize space usage, and a heat dissipation plate is used to cool the power assemblies efficiently, reducing the overall size of the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two power assemblies are tiled in the motor controller, then the motor controller can be configured to electrically connect to the motor and generator, but the space utilization is low and the size is large
Solution Approach 1:
The patent transitions from a two-dimensional tiled arrangement to a three-dimensional stacked arrangement. The power assemblies are stacked in the vertical direction with the heat dissipation plate positioned between them,充分利用 spatial dimensions to reduce the horizontal footprint while maintaining electrical connection capabilities to both motor and generator
Solution Approach 2:
The patent combines multiple components into an integrated module: the power assemblies, heat dissipation plate, and housing are merged into a single compact unit. The housing simultaneously provides structural support, electrical connection terminals, and mounting interfaces, reducing the overall number of separate components and optimizing space utilization
2Adaptability or versatility
If two power assemblies are tiled in the motor controller, then the motor controller can function with dual power conversion capability, but the production and processing procedures become complex and costs increase
Solution Approach 1:
The patent divides the dual power assembly into two separate but identical modular units, each capable of independent power conversion. This segmentation allows for standardized manufacturing of individual power assembly modules that can be produced using the same processes and then assembled together, simplifying production while maintaining dual functionality
Solution Approach 2:
The housing structure is designed with universal features that serve multiple functions: it provides mechanical support, electrical connection terminals for both power assemblies, mounting interfaces for the heat dissipation plate, and structural protection. This multi-functionality reduces the need for additional specialized components and simplifies the overall manufacturing process
3Reliability
If the capacitor core package is arranged in the motor controller integrated module, then electrical connection is achieved, but space occupation in the width direction increases
Solution Approach 1:
The capacitor core package is repositioned from a horizontal arrangement to a vertical arrangement in the stacking direction. This dimensional change allows the capacitor to maintain its electrical connection function while occupying minimal space in the width direction, as its primary extent is now in the vertical dimension where space is more abundant
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
The integrated design results in a compact motor controller module with reduced size, optimizing the layout of the power supply apparatus and the entire vehicle, while enhancing cooling efficiency and reducing production costs.
Implementation Method 1
the heat sink is configured to cool the two power assemblies
Data Source
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AI summary
This application provides a motor controller integrated module, a power supply apparatus, and an electric vehicle. A bus capacitor, a heat sink, and two power assemblies are integrated into the motor controller integrated module. The bus capacitor includes a housing and a capacitor core package. The housing includes an accommodating groove. The accommodating groove is configured to accommodate the capacitor core package. A length of the capacitor core package in a width direction of the capacitor core package is less than a length of the capacitor core package in a length direction of the capacitor core package. A peripheral groove wall of the accommodating groove includes two first side walls that are opposite in the width direction of the capacitor core package. The two power assemblies and a heat dissipation plate of the heat sink are stacked in the width direction of the capacitor core package and arranged on a side that is of one first side wall and that is away from the other first side wall. Each power assembly includes three power modules. A thickness direction of each power module is parallel to the width direction of the capacitor core package. The arrangement manner in which the bus capacitor and the two power assemblies are stacked reduces a size of the motor controller integrated module, thereby reducing a size of the power supply apparatus, and optimizing a layout of the entire vehicle.