Electric Drive Layout With Around-Shaft Power Electronics Cooling
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Solution Overview
Problem
Existing integrated electric drive systems waste space and hinder heat dissipation due to the fixed layout of the power electronics module, which limits the dimensions and arrangement of electronic devices and inefficiently uses available space.
Innovation Solution
The power electronics module is arranged around the drive shaft of the transmission, forming a hollow structure with the drive shaft passing through, allowing for a compact design that integrates the electric machine, transmission, and power electronics module on the same side, with connected cooling circuits for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the power electronics module is arranged at one side of the transmission drive shaft, then the structure is simplified and space between transmission and wheel is utilized, but the dimensions of the power electronics module are limited and heat dissipation is affected
Solution Approach 1:
The power electronics module transitions from a two-dimensional side arrangement to a three-dimensional arrangement around the drive shaft, utilizing the radial space in multiple directions. This dimensional change allows the module to wrap around the drive shaft circumferentially, effectively using the available space between the transmission housing and wheel assembly while providing sufficient volume for heat dissipation.
Solution Approach 2:
The power electronics module is nested around the drive shaft, with the drive shaft passing through the center of the module. This nested configuration allows the module to utilize the space around the drive shaft while maintaining a compact overall structure, effectively integrating the power electronics module within the existing transmission assembly footprint.
2Area of stationary object
If the power electronics module is arranged at one side of the transmission drive shaft, then space is utilized, but space at the other side remains unused causing waste
Solution Approach 1:
The power electronics module transitions from a one-sided two-dimensional arrangement to a three-dimensional arrangement that utilizes space around the drive shaft in multiple directions including top, bottom, left, and right sides. This dimensional change enables comprehensive utilization of the available space between the transmission housing and wheel assembly, eliminating unused space on the opposite side.
Solution Approach 2:
The space around the drive shaft is utilized for multiple functions: the power electronics module is arranged around the drive shaft, cooling circuits are configured to pass through or around the drive shaft area, and the drive shaft itself serves as a structural element that the module surrounds. This multi-functional use of the same spatial region maximizes space efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration maximizes space usage, reduces installation space, and improves heat dissipation capabilities, resulting in a more compact and efficient integrated electric drive system for electric vehicles.
Implementation Method 1
at least one of the first housing, the second housing and the third housing is provided with a cooling circuit
Data Source
AI summary
An integrated electric drive system includes an electric machine having a first housing and an output shaft, a transmission having a second housing and a drive shaft, and a power electronics module with a third housing and an electronic device configured to provide electric power for the electric machine. The transmission receives an input torque of the output shaft and outputs the same via the drive shaft. The power electronics module is configured to be arranged around the drive shaft. The integrated electric drive system can be installed on an electric vehicle. The integrated electric drive system has a more compact structure with a higher degree of integration, and better heat dissipation capability, facilitating spatial optimization and lightweight design of the electric vehicle.