Vehicle Integrated Controller Layout for Thermal and EMC Isolation
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Solution Overview
Problem
The increasing functional requirements in new energy vehicles lead to an increase in the number and types of electronic control assemblies, occupying more space and requiring additional wiring harnesses, which compromises the safety and reliability of these systems.
Innovation Solution
An integrated controller is developed with high-voltage power modules and low-voltage control modules separately integrated into distinct assemblies, reducing thermal and electromagnetic interference while minimizing space occupancy, thereby enhancing safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple electronic control assemblies are integrated into one piece, then wiring harnesses and space are reduced, but thermal interference and reliability risks increase
Solution Approach 1:
The integrated controller is segmented into distinct high-voltage power modules and low-voltage control modules that are integrally arranged together. This segmentation allows different voltage modules to share a common housing and mounting structure while maintaining electrical and thermal separation, thereby reducing wiring complexity without compromising reliability.
Solution Approach 2:
The patent introduces a common housing structure and integrated mounting bracket as intermediary elements that physically connect the high-voltage and low-voltage modules while providing thermal isolation. This intermediary structure enables the modules to be integrated spatially while maintaining the reliability needed for separate voltage system operation.
2Volume of stationary object
If high-voltage power modules and low-voltage control modules are integrated together, then space is reduced, but thermal energy impact on control modules increases
Solution Approach 1:
The controller is divided into spatially distinct high-voltage power modules and low-voltage control modules within a common housing. The high-voltage modules generating thermal energy are separated from the low-voltage control modules through physical arrangement and structural design, allowing compact integration while minimizing thermal coupling between modules.
Solution Approach 2:
Different regions of the integrated controller are designed with different thermal management characteristics. The high-voltage module regions incorporate thermal dissipation structures and materials, while the low-voltage control module regions are positioned and designed to minimize thermal exposure, creating local quality differences that protect sensitive control electronics.
3Adaptability or versatility
If more electronic control assemblies are added to meet functional requirements, then functionality increases, but space occupancy and system complexity increase
Solution Approach 1:
Multiple electronic control assemblies are merged into a single integrated controller housing that accommodates both high-voltage power modules and low-voltage control modules. This consolidation combines previously separate control functions into one unified structure, increasing adaptability while reducing the total space occupied by multiple discrete assemblies.
Solution Approach 2:
The integrated controller is designed as a universal platform that can accommodate multiple types of high-voltage power modules and low-voltage control modules through standardized mounting structures and interfaces. This multi-functional design allows the same housing structure to support various functional configurations without requiring additional space for each specific module type.
Data Source
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AI summary
The present disclosure discloses an integrated controller for a vehicle, an integrated control system, and a vehicle. The integrated controller of the present disclosure includes a driving assembly and a control assembly. The driving assembly includes multiple high-voltage power modules integrally arranged. The control assembly includes multiple low-voltage control modules integrally arranged. Each of the low-voltage control modules is configurable to control each of the high-voltage power modules to operate. In the integrated controller of the present disclosure, a high-power assembly that implements a high-voltage function is integrated into the driving assembly, and a low-voltage control assembly is integrated into the control module. In this way, differentiated integration of the high-voltage power module that generates a relatively large amount of thermal energy and the low-voltage control module is achieved, impact of thermal energy of the high-voltage power module on the low-voltage control module is reduced, and stability and an electromagnetic compatibility level of a circuit are improved while reducing an occupied space, which helps improve usage safety and reliability of the integrated controller.