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Winding connection solution for an integrated synchronous motor drive

With increased demand in electric drives applications for higher power density, higher efficiency and higher temperature operation, integrated motor drives are gaining greater interest in automotive, aerospace and other specialist applications. Integrated drives not only physically integrate the various components of the drive (power electronic devices, filter components etc.) they must also integrate the various connections between these components. Although few articles report this integration it is nevertheless of equal importance to the integration of the active and passive parts. This paper presents three winding connection solutions, including two PCB (Printed Circuit Board) based solutions and a busbar solution for an integrated permanent magnet synchronous motor drive with fully integrated filter magnetics. Firstly, the design process and parameter selection considerations for two PCB solutions are presented demonstrating the requirement for extremely thick copper layers and extra connection wires. Afterwards, a busbar solution considering skin effect and litz wire connections is proposed. The total thickness, manufacturing difficulties and requirement of extra connection wires of different winding configurations are compared. Finally, the busbar solution is shown to be the optimum winding connection solution.