Motor control device

Abstract

A motor controller comprising an inverter module including an inverter circuit coupled to a baseplate, wherein the baseplate includes cooling features; a cooling channel configured to receive a cooling fluid, wherein the cooling features extend into the cooling channel; a capacitor; and a laminated bus electrically coupling the capacitor to the inverter circuit and thermally coupling the capacitor to the cooling channel.

We claim: 
     
         1 . A motor controller comprising:
 a case base comprising a first and second wall extending along a normal vector relative to a first broad face of the case base;   an inverter circuit mounted to an end of the first and second wall, the inverter circuit comprising a broad face;   a baseplate comprising:
 a first broad face coupled to the broad face of the inverter circuit; 
 a second broad face opposing the first broad face of the baseplate; and 
 a set of cooling features extending from the second broad face of the baseplate; 
   a cooling channel that is configured to receive a cooling fluid, the cooling channel cooperatively defined by the first and second wall of the case base and the second broad face of the baseplate, wherein the cooling features extend into the cooling channel such that the cooling fluid flows across the cooling features; and   a capacitor thermally connected to the cooling channel;   a set of DC power connectors; and   a set of bus bars thermally connected to the cooling channel and electrically connecting the set of DC power connectors to the inverter circuit.   
     
     
         2 . The motor controller of  claim 1 , wherein the set of bus bars extend between the capacitor and the case base, and thermally and electrically connect the capacitor to the cooling channel. 
     
     
         3 . The motor controller of  claim 2 , wherein the second set of bus bars form a laminated bus. 
     
     
         4 . The motor controller of  claim 1 , further comprising:
 an AC connector; and   a first bus bar thermally connected to the cooling channel and electrically coupling the AC connector to the inverter circuit.   
     
     
         5 . The motor controller of  claim 1 , further comprising power electronics coupled to the first broad face of the case base. 
     
     
         6 . A motor controller comprising:
 a case base comprising a first and second wall extending along a normal vector relative to a first broad face of the case base;   an inverter circuit mounted to an end of the first and second wall, the inverter circuit comprising a broad face;   a baseplate comprising:
 a first broad face coupled to the broad face of the inverter circuit; 
 a second broad face opposing the first broad face of the baseplate; and 
 a set of cooling features extending from the second broad face of the baseplate; 
   a cooling channel that is configured to receive a cooling fluid, the cooling channel cooperatively defined by the first and second wall of the case base and the second broad face of the baseplate, wherein the cooling features extend into the cooling channel such that the cooling fluid flows across the cooling features; and   a capacitor thermally connected to the cooling channel;   a set of AC power connectors; and   a set of bus bars thermally connected to the cooling channel and electrically connecting the set of AC power connectors to the inverter circuit.   
     
     
         7 . The motor controller of  claim 6 , further comprising:
 a DC connector; and   a second bus electrically coupling the DC connector to the inverter circuit and thermally coupling the capacitor to the cooling channel.   
     
     
         8 . The motor controller of  claim 7 , wherein the second bus comprises a laminated bus that extends along the first wall and between the capacitor and the case base. 
     
     
         9 . The motor controller of  claim 8 , wherein the set of bus bars extends along and is thermally connected to the second wall, wherein the second wall opposes the first wall in parallel. 
     
     
         10 . The motor controller of  claim 6 , wherein the capacitor is thermally connected to the cooling channel along the first wall. 
     
     
         11 . The motor controller of  claim 10 , wherein the cooling channel terminates at the first wall. 
     
     
         12 . The motor controller of  claim 6 , further comprising power electronics coupled to the first broad face of the case base. 
     
     
         13 . A motor controller comprising:
 an inverter circuit comprising a broad face;   a baseplate comprising:
 a first broad face coupled to the broad face of the inverter circuit; 
 a second broad face opposing the first broad face of the baseplate; and 
 a set of cooling features extending from the second broad face of the baseplate; 
   a case base comprising a first and second wall extending relative to a first broad case base face, wherein the baseplate is mounted to the first and second wall;   a cooling channel that is configured to receive a cooling fluid, the cooling channel cooperatively defined by the first and second wall and the second broad face of the baseplate, wherein the cooling features extend into the cooling channel such that the cooling fluid flows across the cooling features; and   a capacitor thermally connected to the cooling channel along the first wall.   
     
     
         14 . The motor controller of  claim 13 , wherein the capacitor is electrically connected to the inverter circuit by a laminated bus. 
     
     
         15 . The motor controller of  claim 13 , further comprising power electronics coupled to the case base. 
     
     
         16 . The motor controller of  claim 15 , wherein the power electronics are coupled to the first broad face of the case base. 
     
     
         17 . The motor controller of  claim 16 , wherein the power electronics comprise a control circuit. 
     
     
         18 . The motor controller of  claim 13 , wherein the inverter circuit comprises an insulated-gate bipolar transistor and secondary electronics. 
     
     
         19 . The motor controller of  claim 18 , wherein the secondary electronics are coupled to the first broad face of the baseplate. 
     
     
         20 . The motor controller of  claim 1 , wherein the cooling channel comprises a reservoir that terminates at the first and second walls.