Axially Stacked Motor Inverter Layout for Heat-Dense EV Packaging
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Solution Overview
Problem
Existing electric vehicle inverters face challenges in achieving high power density and efficiency within limited space and temperature constraints, necessitating improved heat dissipation and assembly efficiency.
Innovation Solution
The inverter and motor main body are axially stacked with annularly arranged power modules and bus bars, reducing volume and weight by integrating a multiphase control inverter with a multiphase AC electric motor, utilizing a two-phase system to replace a three-phase system, and enhancing heat dissipation through magnetic shields and annular circuit layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inverter and motor main body are integrated with annularly arranged power modules and bus bars, then the power density and assembly efficiency are improved, but the heat dissipation challenge increases
Solution Approach 1:
The inverter and motor main body are merged into an integrated structure where the inverter is axially stacked on the motor main body. The power modules are annularly arranged around the capacitor module, and the bus bars are radially arranged to connect the power modules, creating a compact integrated assembly that improves space utilization and assembly efficiency while managing heat through the distributed configuration.
Solution Approach 2:
The power modules are arranged in an annular pattern around the central capacitor module, transitioning from a linear or planar layout to a three-dimensional radial configuration. This dimensional change allows for better heat distribution and dissipation pathways while maintaining compact volume, as heat can radiate outward in multiple directions from the central heat-generating components.
2Volume of stationary object
If the inverter and motor main body are integrated axially stacked, then the volume is reduced, but the heat impact on electronic components increases
Solution Approach 1:
The integrated inverter structure is segmented into distinct functional zones: the power modules are annularly arranged around the central capacitor module, with the bus bars radially connecting them. This segmentation creates thermal zones that can be managed independently, allowing heat to be directed away from sensitive electronic components on the circuit board through the radial bus bar configuration and annular power module arrangement.
Solution Approach 2:
The capacitor module serves as a central intermediary structure around which the power modules are arranged. This central position allows the capacitor module to act as a thermal management hub, with the radially arranged bus bars providing thermal pathways that can conduct heat away from the capacitor and power modules toward the motor main body or external heat sinks, protecting the circuit board electronics from excessive heat.
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 configuration achieves a high power density inverter system with reduced volume and weight, improved heat dissipation, and simplified assembly, enhancing the overall efficiency and endurance of electric vehicles.
Implementation Method 1
The inverter converts the DC power supplied from the battery pack into AC power to drive the electric motor of the electric vehicle
Implementation Method 2
an appropriate heat dissipation method has to be designed to reduce the heat generated by the power switching components while the electric motor driving inverter is working
Data Source
AI summary
An electric motor includes a motor main body and an inverter. The inverter is axially stacked on one end of the motor main body, and the inverter includes a gate driver, a control circuit, a capacitor module, a DC bus bar, a plurality of power modules and a plurality of AC bus bars. The power module includes a plurality of AC output terminals, a plurality of DC input terminals and a plurality of signal terminals, and the AC bus bars are respectively connected to corresponding AC output terminals and extend downward to a motor coil of the motor main body. The power modules and the corresponding DC input terminals are annularly arranged around the capacitor module, the DC bus bar is extended and electrically connected to the corresponding DC input terminals and the capacitor module.