Board-level motor control system with integrated protection and control components

A motor control system for selectively controlling power from a power source to a load, the motor control system comprising:

• a printed circuit board (PCB) structure comprising at least one substrate and a plurality of conductive traces formed on the at least one substrate;
• a motor switching assembly integrated onto the PCB structure, the motor switching assembly comprising:
• a power converter operable to provide a controlled output power to the load;
• and
• a plurality of switching devices operable to selectively control power flow from the power source into the power converter and to bypass the power converter;
• and
• a controller coupled to the PCB structure and configured to control operation of the power converter and the plurality of switching devices;
• wherein the conductive traces form electrical connections within the motor switching assembly and electrically connect the motor switching assembly to the controller.

A method of manufacturing a board-level motor control system for controlling power from a power source to a load, the method comprising:

• providing a printed circuit board (PCB) structure comprising at least one substrate and a plurality of conductive traces formed on the at least one substrate;
• mounting a plurality of protection and control components onto the PCB structure, wherein mounting the plurality of protection and control components comprises one of:
• snapping respective plug-and-play components of the plurality of protection and control components onto the PCB structure;
• and
• soldering respective components of the plurality of protection and control components onto the PCB structure;
• electrically connecting the plurality of protection and control components via the plurality of conductive traces;
• and
• operatively connecting a controller to the plurality of protection and control components, with the plurality of conductive traces providing at least a portion of electrical connections between the controller and the plurality of protection and control components,
• mounting a power converter onto the PCB structure that is operable to provide a controlled output power to the load;
• and
• mounting one or more additional protection and control components onto the PCB structure, the one or more additional protection and control components comprising one or more of:
• an input relay positioned upstream of the power converter to control power flow into the power converter;
• an output relay positioned downstream of the power converter to control power flow output from the power converter;
• and
• a solid-state switching device comprising a plurality of solid-state switches that are selectively switchable to control and condition power flow therethrough, the solid-state switching device arranged upstream from the input relay or in parallel with the input relay.