Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-01-29
2001-01-23
Ramirez, Nestor (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S064000, C310S089000
Reexamination Certificate
active
06177740
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to electrical motors. More specifically, the present invention relates to an integrated motor and motor drive unit.
BACKGROUND OF THE INVENTION
Electric motors are used in many industries. On automobiles, motors are used in various locations. For example, motors may be used to drive a pump.
Commonly, these motors generally comprise two main components; a motor assembly and a drive assembly. The motor assembly includes the actual rotating motor. The drive assembly includes the drive electronics for controlling the operation of the motor. Commonly, the motor and the drive assembly are two separate components connected by an external cable assembly. There are several disadvantages to a separate drive assembly and motor assembly.
One disadvantage of a separate motor assembly is the external cable assembly. An external cable assembly increases electrical resistance for the system, and may act as an antenna which may both receive and radiate unwanted electromagnetic interference. In fact, the FCC has regulated the electromagnetic radiation emitted from a motor. To prevent electromagnetic interference, a more expensive shielded wire must be used if electromagnetic interference exceeds the FCC regulation.
Another disadvantage to providing a separate drive assembly and motor assembly is the integration of the two separate units into the finished product. Having two separate assemblies increases the space required for a motor and drive unit. Also, the assembly complexity for mounting two components is relatively high.
For automotive applications, motors use a relatively low voltage and draw high currents. This causes the motors to dissipate more power. Some industrial integrated drive motors operate at 110 volts. The high voltage motors draw little current and dissipate small amounts of power. Because of the low power dissipation, organic-based circuit boards for power distribution may be used in such applications. However, in low voltage automotive applications, organic-based circuit boards cannot be used.
SUMMARY OF THE INVENTION
It is therefore one object of the invention to provide an integrated motor and drive unit. It is a further object of the invention to provide an easily assemblable motor and drive unit.
In one aspect of the invention, a motor and motor drive unit assembly includes a motor assembly having a housing and a motor rotatably coupled within the housing. A power distribution bus is coupled to the housing. In a preferred embodiment, the power distribution bus is coupled to an end cap of the motor. A plurality of semiconductor switches are coupled to the power distribution bus. The motor and drive assembly further includes a drive assembly having a case or housing coupled to the power distribution bus. The case is preferably electrically isolated from, and is in thermal communication with, the power distribution bus. The case or housing has a plurality of openings therethrough. An interconnect circuit board is disposed within the case and is electrically coupled to the power distribution bus through the plurality of openings. A system control board is disposed within the case and is electrically coupled to the interconnect board.
One advantage of the invention is the high heat dissipation capabilities. Because the power distribution bus is located between the case and the motor housing, both the motor housing and the case may act as a heat sink. Another advantage of the invention is that the semiconductor switches are coupled directly on the motor eliminating interconnecting wires. Another advantage of the invention is that the shaft position sensors may be mounted directly to the system control board within the case which results in a lower cost assembly.
In a further aspect of the invention, the present invention may be used for more than just a motor. For example, the teachings of the present invention may be applied to a power supply or other power intensive application. In this manner, a power distribution bus such as that described above is coupled between a first thermally conductive member and a second thermally conductive member. The power distribution bus has a plurality of semiconductor switches mounted thereto. The first and second thermally conductive members may, for example, be a heat sink, a circuit board housing for housing electronic control circuitry or other type of housing. The power distribution bus is electrically isolated from the first thermally conductive member and the second thermally conductive member. The power distribution bus is thermally coupled to the first thermally conductive member and the second thermally conductive member to allow heat to be dissipated from the power distribution bus through the first thermally conductive member and the second thermally conductive member.
These and other features and advantages of the present invention will become apparent from the following description of the invention, when viewed in accordance with the accompanying drawings and appended claims.
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patent: 5491370 (1996-02-01), Schneider et al.
patent: 5640062 (1997-06-01), Yockey
patent: 5814909 (1998-09-01), Yamada et al.
patent: 5939807 (1999-08-01), Patyk et al.
Delphi Technologies Inc.
Funke Jimmy L.
Perez Guillermo
Ramirez Nestor
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