GB2463916A - Electronic machine with power electronics - Google Patents

Electronic machine with power electronics Download PDF

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Publication number
GB2463916A
GB2463916A GB0817860A GB0817860A GB2463916A GB 2463916 A GB2463916 A GB 2463916A GB 0817860 A GB0817860 A GB 0817860A GB 0817860 A GB0817860 A GB 0817860A GB 2463916 A GB2463916 A GB 2463916A
Authority
GB
United Kingdom
Prior art keywords
electric machine
circuit board
housing
solid state
switching devices
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0817860A
Other versions
GB0817860D0 (en
GB2463916A8 (en
GB2463916B (en
Inventor
David R Mulligan
Ian Forster
Jonathan Eric Hostler
Paul Jonathan Bloore
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Visteon Global Technologies Inc
Original Assignee
Visteon Global Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Visteon Global Technologies Inc filed Critical Visteon Global Technologies Inc
Priority to GB0817860.0A priority Critical patent/GB2463916B/en
Publication of GB0817860D0 publication Critical patent/GB0817860D0/en
Priority to DE102009045218A priority patent/DE102009045218A1/en
Publication of GB2463916A publication Critical patent/GB2463916A/en
Publication of GB2463916A8 publication Critical patent/GB2463916A8/en
Application granted granted Critical
Publication of GB2463916B publication Critical patent/GB2463916B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0201Thermal arrangements, e.g. for cooling, heating or preventing overheating
    • H05K1/0203Cooling of mounted components
    • H05K1/0204Cooling of mounted components using means for thermal conduction connection in the thickness direction of the substrate
    • H05K1/0206Cooling of mounted components using means for thermal conduction connection in the thickness direction of the substrate by printed thermal vias
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K5/00Casings; Enclosures; Supports
    • H02K5/04Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H02K5/207Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium with openings in the casing specially adapted for ambient air
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K11/00Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30Structural association with control circuits or drive circuits
    • H02K11/33Drive circuits, e.g. power electronics
    • H02K11/0073
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K11/00Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/04Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for rectification
    • H02K11/049Rectifiers associated with stationary parts, e.g. stator cores
    • H02K11/05Rectifiers associated with casings, enclosures or brackets
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K5/00Casings; Enclosures; Supports
    • H02K5/04Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K9/00Arrangements for cooling or ventilating
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0201Thermal arrangements, e.g. for cooling, heating or preventing overheating
    • H05K1/0203Cooling of mounted components
    • H05K1/0204Cooling of mounted components using means for thermal conduction connection in the thickness direction of the substrate
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K5/00Casings; Enclosures; Supports
    • H02K5/04Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/22Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225Terminal boxes or connection arrangements
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K9/00Arrangements for cooling or ventilating
    • H02K9/22Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
    • H02K9/223Heat bridges
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K9/00Arrangements for cooling or ventilating
    • H02K9/22Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
    • H02K9/227Heat sinks
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0272Adaptations for fluid transport, e.g. channels, holes
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09Shape and layout
    • H05K2201/09009Substrate related
    • H05K2201/09027Non-rectangular flat PCB, e.g. circular
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007Types of components
    • H05K2201/10166Transistor
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10431Details of mounted components
    • H05K2201/10439Position of a single component
    • H05K2201/10446Mounted on an edge
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/0058Laminating printed circuit boards onto other substrates, e.g. metallic substrates
    • H05K3/0061Laminating printed circuit boards onto other substrates, e.g. metallic substrates onto a metallic substrate, e.g. a heat sink

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)

Abstract

An electric motor or generator assembly comprises an electric machine assembly 1 including a housing 2, an electric machine 6 housed within the housing, and a power electronics assembly 12 including one or more solid state power switching devices 18 for switching the electric current supplied to or drawn from the electric machine. The electric machine 6 is electrically connected to a plurality of electrical connections 24 that extend through the housing 2 for making external electrical connection to the electric machine, and the power electronics assembly 12 including a circuit board 14 on a first side 15 of which the solid state power switching devices 18 are mounted, the second side 16 of which is joined to an external portion 10 of the housing 2 so that the housing acts as a heat sink for the solid state power switching devices 18. The switching devices 18 are mounted in a peripheral portion of the circuit board 14 and the plurality of electrical connections 24 are electrically connected to a central portion of the circuit board 14.

Description

Electric Machine with Power Electronics
BACKGROUND
a. Field of the Invention
The present invention relates to an electric motor or generator assembly, and in particular to an electric motor or generator having a power electronics package for proving an electric current to drive the motor or for drawing an electrical current from the generator.
*.:. b. RelatedArt S.. S * I *S..
The use of high power electric motors is becoming ever more common in motor vehicles, owing to advances in semiconductor technology and the need to improve *...S.
* fuel economy and vehicle performance. Examples include the use of electric motors in hybrid vehicle to power road going wheels, and the use of high power engine starter motors in vehicles where the engine is turned off whenever the vehicle is stationary. Typical power consumption of such high power electric motors is in the range of 2 kW to 20 kW. The electric power to run such electric motors may be provided at 12 to 400 volts dc.
A vehicle starter motor will usually also serve as an engine driven generator.
Similarly, in a hybrid vehicle, the wheel electric motors will serve as electric generators when the vehicle is braking. The term "electric machine" as used in this specification refers to both electric motors and generators.
There is a need in the drive electronics at each high power electric machine to switch high currents in the machine's coils in a suitable sequence in order to power the machine. The solid state power switches that are normally used to switch the high currents are normally mounted directly onto a heat sink in order to dissipate heat generated within the solid state power switches. Control electronics for controlling the switching of the solid state power switches is mounted on a separate circuit board which may be connected to the solid state power switches by means of a rigid connector or flex circuit board connector.
Although this arrangement provides ready access to the various circuit boards and components if it is ever necessary to repair or replace the power electronics, the assembly of the power converter, control electronics and heat sink is relatively expensive.
It is an object of the present invention to provide a more convenient and economical electric machine assembly including an electric motor or generator **..* and power electronics for driving the electric motor or generator. S... * . S...
SUMMARY OF THE INVENTION * S *5**
* According to the invention, there is provided an electric machine assembly including a housing, an electric machine housed within the housing, and a power electronics assembly including one or more solid state power switching devices for switching the electric current supplied to or drawn from the electric machine, the electric machine being electrically connected to a plurality of electrical connections that extend through the housing for making external electrical connection to the power electronics assembly including a circuit board on a first side of which the solid state power switching devices are mounted, wherein: -the solid state power switching devices are mounted in a peripheral portion of the circuit board; -the plurality of electrical connections are electrically connected to a central portion of the circuit board; and -the second side of the circuit board is joined to an external portion of the housing so that the housing acts as a first heat sink to the solid state power switching devices.
The assembly provides a compact and robust arrangement of the electric machine and power electronics assembly and makes use of the material of the housing as a heat sink for the solid state power switching devices.
The circuit board may be formed with thermal paths between the first and second sides of the board to aid the conduction of heat from the first side of the board to the second side of the board. Areas of the board having these thermal paths preferentially conduct heat from one side of the board to another in comparison with other areas not having these paths. The thermal paths may be plated through holes in the circuit board.
The second side of the circuit board may be bonded to an external portion of the *.. housing by means of a thermal paste. This bonding ensures a secure assembly and also makes use of the thermal mass of the housing as a heat sink for the solid state power switching devices. * * **.. *15
***I** * The housing is substantially cylindrical in form extending along an axis of the electric machine, and the circuit board is joined to an external end face of the *:" housing extending transverse to said axis. In this case, the circuit board is preferably round. * 20
The solid state power switching devices are preferably mounted in an annular peripheral portion of the circuit board. This helps to keep the devices as far apart as possible and maximises the area of the assembly from which heat may be drawn by one or more heat sinks.
The housing may include one or more channels for conveying a coolant within the assembly including at least one channel in proximity with the external portion of the housing to which the circuit board is joined. The coolant may then serve to cool both the electric machine as well as the power electronics assembly.
A second heat sink may also be used in contact with the solid state power switching devices on the first side of the circuit board. This may be a passive heat sink having a large surface area provided by fins from which excess heat may be convected into the air.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described, by way of example, and with reference to the accompanying drawings, in which: io Figure 1 is a schematic view of an electrical machine assembly according to * a preferred embodiment of the invention having an electric machine housed within a housing, and a power electronics assembly mounted externally at * ** . one end of the housing; and * * I *...
:415 Figure 2 is a cross section through a part of the power electronics assembly and housing of Figure 1. * * * S..
DETAILED DESCRIPTION
Figures 1 and 2 show an electric machine assembly 1, which is in this example is a generator/starter motor assembly for a motor vehicle. The assembly is based around a housing 2, part of which is shown cut away to reveal the windings 4 of an electric machine 6 held within the housing. The electric machine 6 serves as a generator to generate electric current to charge a battery (not shown), and as a starter motor for an internal combustion engine (not shown).
The housing 2 is generally cylindrical in shape, extending along an axis 8. The housing 2 has one substantially flat end surface 10 that extends transverse to the axis 8, on which a power electronics assembly 12 is mounted. The power electronics assembly is based on a printed circuit board 14 that has a central dielectric layer that is sandwiched between a pair of patterned conductive layers 15, 16 that include circuit traces (not shown) for conveying electrical current.
A number of solid state power switching devices 18 are mounted around the circular periphery of the board 14 and together with other circuit elements including a microcontroller 20 in a central portion of the board serve as a controller for current generated by or supplied to the electric machine 6. The power and control semiconductor devices 18, 20 are preferably surface mount devices electrically connected to just the outer side 15 of the board 14.
The layers 15, 16 are joined together in separate grid arrays 22 beneath each one of the power switching devices 18 so that heat generated by the devices is * conducted efficiently from the layer 15 on which the devices are mounted to the * opposite layer 16 that faces towards the housing end surface 10. *... * I *I*.
The electric machine 6 inc'udes a plurality of electrical connections 24 that extend S...
through the housing 2. At least some of these connections 24 are electrically connected a central portion of the circuit board 14, but some may stand proud of the board for making external electrical connections
SSSSS * S
The inner side 16 of the circuit board is joined to the external surface 10 of the housing so that the housing acts as a first heat sink to the solid state power switching devices 18.
The conductive layers 15, 16 plated on the opposite sides of the board 14 are separated by an intervening insulator 28. The thickness of each of the plated layers 15, 16 is greater than the thickness of the intervening insulating layer 28.
This helps to maximise the ability of the board to convey heat away from the semiconductor device 18 and towards the housing 2.
The power electronics assembly 12 is thermally bonded to the housing end surface 10 by means of a thin layer thermally conductive paste 30. The housing may also be secured by means of one or more screws 32.
Figure 2 shows a cross section through a part of the power electronics assembly 12 and housing 2. Also shown in Figure 2 is a channel 34 for conveying a coolant within the assembly, in proximity with the external portion 10 of the housing to which the circuit board 14 is joined. The coolant channel 34 therefore serves to carry excess heat away from both the electrical machine 6 and the circuit board 14.
Optionally, a passive heat sink including cooling fins (not shown) may be in physical contact with upper sides 36 of the semiconductor devices 18, 20.
The arrangement described above is particularly compact, as both the controland *:*:: power electronics are on the same board, together with the electrical connections * *** to the electrical machine. A grid array of through-plated vias is provided to preferentially conduct heat from beneath each power semiconductor device into the heat sink provided by the housing. The invention therefore provides a a.....
0 convenient and economical electric machine assembly including an electric motor or generator and power electronics for driving the electric motor or generator.
S
*....S * S

Claims (10)

  1. CLAIMS1. An electric machine assembly including a housing, an electric machine housed within the housing, and a power electronics assembly inc'uding one or more solid state power switching devices for switching the electric current supplied to or drawn from the electric machine, the electric machine being electrically connected to a plurality of electrical connections that extend through the housing for making external electrical connection to the power electronics assembly including a circuit board on a first side of which the solid state power switching devices are mounted, wherein: -the solid state power transforming devices are mounted in a peripheral portion of the circuit board; -the plurality of electrical connections are electrically connected to a central portion of the circuit board; and -the second side of the circuit board is joined to an external portion of the S. s. S* * housing so that the housing acts as a first heat sink to the solid state power switching devices.S *...* * S
  2. 2. An electric machine assembly as claimed in Claim 1, in which the circuit board is formed with thermal paths between the first and second sides of the board to aid the conduction of heat from the first side of the board to the second side of the board.
  3. 3. An electric machine assembly as claimed in Claimi or Claim 2, ih which the second side of the circuit board is bonded to an external portion of the housing by means of a thermal paste.
  4. 4. An electric machine assembly as claimed in which the housing is substantially cylindrical in form extending along an axis of the electric machine, and the circuit board is joined to an external end face of the housing extending transverse to said axis.
  5. 5. An electric machine assembly as claimed in any preceding claim, in which the solid state power switching devices are mounted in an annular peripheral portion of the circuit board.
  6. 6. An electric machine assembly as claimed in any preceding claim, in which the housing includes one or more channels for conveying a coolant within the assembly including at least one channel in proximity with the external portion of the housing to which the circuit board is joined.
  7. 7. An electric machine assembly as claimed in any preceding claim, comprising additionally a second heat sink, the second heat sink being in contact with the solid state power switching devices on the first side of the circuit board. * S *
  8. 8. An electric machine as claimed in any preceding claim, in which the circuit board is circular in outline, the solid state power switching devices being mounted in a circular pattern around the outside of the circuit board.
  9. 9. An electric machine as claimed in any preceding claim, in which the circuit board has a conductive layer plated on the first and second sides, and an intervening insulator layer between said plated layers, the thickness of each of said plated layers being greater than the thickness of the intervening insulating layer.
  10. 10. An electric machine assembly, substantially as herein described, with reference to or as shown in the accompanying drawings.
GB0817860.0A 2008-09-30 2008-09-30 Electronic machine with power electronics Expired - Fee Related GB2463916B (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB0817860.0A GB2463916B (en) 2008-09-30 2008-09-30 Electronic machine with power electronics
DE102009045218A DE102009045218A1 (en) 2008-09-30 2009-09-30 Electric machine with power electronics

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0817860.0A GB2463916B (en) 2008-09-30 2008-09-30 Electronic machine with power electronics

Publications (4)

Publication Number Publication Date
GB0817860D0 GB0817860D0 (en) 2008-11-05
GB2463916A true GB2463916A (en) 2010-03-31
GB2463916A8 GB2463916A8 (en) 2010-07-28
GB2463916B GB2463916B (en) 2012-01-18

Family

ID=40019781

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0817860.0A Expired - Fee Related GB2463916B (en) 2008-09-30 2008-09-30 Electronic machine with power electronics

Country Status (2)

Country Link
DE (1) DE102009045218A1 (en)
GB (1) GB2463916B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016156022A1 (en) * 2015-03-30 2016-10-06 Danfoss Silicon Power Gmbh Apparatus comprising a power module attached through an isolation layer to an electric machine and corresponding manufacturing method

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013111774A1 (en) * 2013-10-25 2015-04-30 Zf Lenksysteme Gmbh ELECTRIC SERVO MOTOR FOR A STEERING SYSTEM
DE102019201292A1 (en) 2019-02-01 2020-08-06 Zf Friedrichshafen Ag Power electronics arrangement for a vehicle, in particular an electric and / or hybrid vehicle, and method for producing such a power electronics arrangement

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5119466A (en) * 1989-05-24 1992-06-02 Asmo Co., Ltd. Control motor integrated with a direct current motor and a speed control circuit
WO1999000887A1 (en) * 1997-06-26 1999-01-07 Robert Bosch Gmbh Electric drive motor
US20040042180A1 (en) * 2002-08-29 2004-03-04 Atsushi Yamaguchi Electronic circuit device including heat-generating element mounted on circuit board
US20060158049A1 (en) * 2005-01-18 2006-07-20 Seiki Suzuki Integrated electric motor and drive, optimized for high-temperature operation
GB2426386A (en) * 2005-05-13 2006-11-22 Lear Corp Cooling a component mounted on a PCB
JP2007295639A (en) * 2006-04-20 2007-11-08 Denso Corp Motor drive for vehicle

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5119466A (en) * 1989-05-24 1992-06-02 Asmo Co., Ltd. Control motor integrated with a direct current motor and a speed control circuit
WO1999000887A1 (en) * 1997-06-26 1999-01-07 Robert Bosch Gmbh Electric drive motor
US20040042180A1 (en) * 2002-08-29 2004-03-04 Atsushi Yamaguchi Electronic circuit device including heat-generating element mounted on circuit board
US20060158049A1 (en) * 2005-01-18 2006-07-20 Seiki Suzuki Integrated electric motor and drive, optimized for high-temperature operation
GB2426386A (en) * 2005-05-13 2006-11-22 Lear Corp Cooling a component mounted on a PCB
JP2007295639A (en) * 2006-04-20 2007-11-08 Denso Corp Motor drive for vehicle

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016156022A1 (en) * 2015-03-30 2016-10-06 Danfoss Silicon Power Gmbh Apparatus comprising a power module attached through an isolation layer to an electric machine and corresponding manufacturing method

Also Published As

Publication number Publication date
DE102009045218A1 (en) 2010-05-06
GB0817860D0 (en) 2008-11-05
GB2463916A8 (en) 2010-07-28
GB2463916B (en) 2012-01-18

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Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20120930