Controller for battery-operated vehicle

• US 6,441,509 B1
• Filed: 05/16/2000
• Issued: 08/27/2002
• Est. Priority Date: 11/20/1997
• Status: Expired due to Fees

• Current Assignee: Sevcon Limited (BorgWarner Incorporated)
• Original Assignee: Sevcon Limited (BorgWarner Incorporated)
• Inventors: Miller, David
• Primary Examiner(s): FLEMING, FRITZ M
• Application Number:
  US09/571,224
• Time in Patent Office: 833 Days
• Field of Search: 307/9.1, 307/10.1, 307/147, 361/709-711, 361/717-720, 361/783, 361/760, 361/781, 361/777
• US Class Current: 307/9.1
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: H02J 7/345 using capacitors as storage or buffering devices
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/10015 Non-printed capacitor
• CPC Class Codes: H05K 2201/10166 Transistor
• CPC Class Codes: H05K 2201/10174 Diode
• CPC Class Codes: H05K 2203/1572 Processing both sides of a PCB by the same process; Providing a similar arrangement of components on both sides; Making interlayer connections from two sides
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A controller, for a battery-operated vehicle or the like, comprises a plurality of mosfet/diode/capacitor circuits. A printed circuit board (PCB) has the mosfet/diode/capacitor circuits arranged in four sets, one set along each side of the board, and with the inner areas of the board on both sides and the outer area on at least one side being substantially solid tracking areas forming the connections to the circuits. The connectors (A, B+, B−) to circuits are located substantially along a diagonal of the board, with the connectors (A and B+) to the two sides of the diodes located at opposite corners of the inner areas of the board. The inner tracking areas are divided by isolating lines into separate fingers for the respective circuits. The mosfet and diode of each circuit are mounted on one side of the board and the capacitor on the other, with a heat sink bar located between the mosfet and diode with the mosfet and diode clamped to it by a nut and bolt passing through lugs on the mosfet and diode each a matching hole in the bar.

Claims

1. A power controller having a switching circuit comprising a first switching element, a second switching element, and a capacitor, mounted on a printed circuit board with the first and second switching elements mounted adjacent each other on one face of the board and the capacitor on the other face of the board.

2. A controller according to claim 1, wherein the capacitor is mounted between the first and second switching elements.

3. A controller according to claim 1 including a heat sink located between the switching elements to receive heat therefrom.

4. A controller according to claim 3 comprising means mechanically fixing the switching elements to each other via the heat sink.

5. A controller according to claim 4 wherein each switching element has a lug with a hole in it and the fixing means passes through those holes and a matching hole in the heat sink.

6. A controller according to claim 3 wherein there are a plurality of switching circuits arranged in a row with a common heat sink.

7. A controller according to claim 3 wherein the heat sink is a bar.

8. A controller according to claim 3 including a heat dissipating element extending from the heat sink substantially parallel to the printed circuit board.

9. A controller according to claim 1 wherein the first switching element is a mosfet and the second switching element is a diode.

10. A controller according to claim 1 wherein all the switching elements are mosfets.

11. The controller as claimed in claim 1 in combination with a low voltage high current motor for a battery powered vehicle.

12. A power controller according to claim 1 having a plurality of said switching circuits arranged around an inner area of the printed circuit board in a partial or complete loop, the inner area of the board and the outer area of the board outside the loop being substantially solid tracking areas forming the sole connections for electrical current to the switching circuits.

13. A power controller, having a plurality of switching circuits each comprising a first switching element, a second switching element, and a capacitor, and a printed circuit board having the switching circuits arranged around an inner area of the board in a partial or complete loop, the inner area of the board and the outer area of the board outside the loop being substantially solid tracking areas forming the sole connections for electrical current to the switching circuits.

14. A controller according to claim 13 wherein the inner area on both sides of the board and the outer area on at least one side form the connections to the switching circuits.

15. A controller according to claim 13 wherein the switching circuits are arranged in four sets, each set parallel to a respective edge of the board.

16. A controller according to claim 15 wherein the connectors to switching circuits are located substantially along a diagonal of the board.

17. A controller according to claim 16 wherein the connectors to the terminals of the second switching elements are located at opposite corners of the inner areas of the board.

18. A controller according to claim 13 wherein parts of at least one of the tracking areas adjacent to the switching circuits are divided by isolating lines into separate fingers for the respective switching circuits.

19. A controller according to claim 13 wherein the first and second switching elements are mounted adjacent each other on one face of the board and the capacitor is mounted on the other face of the board.

20. A controller according to claim 13 wherein each first switching element is a mosfet and each second switching element is a diode.

21. A controller according to claim 13 wherein all the switching elements are mosfets.

22. The controller as claimed in claim 13, in combination with a low voltage high current motor for a battery powered vehicle.