Disconnecting Electric Drive Unit for Compact Driveline Packaging
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Solution Overview
Problem
The electrification of vehicle drivelines faces challenges related to cost, packaging space, and the robustness of electronics, which hinder their widespread adoption in vehicles.
Innovation Solution
A disconnecting electric drive unit comprising a housing, electric motor, transmission, differential assembly, and actuator mechanism that allows for selective coupling and decoupling of components, enabling efficient packaging and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrified drivelines are implemented in vehicles, then vehicle propulsion capability is improved, but cost increases
Solution Approach 1:
The driveline is divided into modular components (electric motor, transmission, differential assembly, axle shafts) that can be independently manufactured, tested, and assembled. This segmentation allows for standardized production of each module, reducing overall manufacturing cost while maintaining propulsion capability.
Solution Approach 2:
The electric drive unit is designed with universal mounting interfaces and standardized components that can be adapted to different vehicle platforms. The differential assembly serves multiple functions including power distribution and axial movement management, reducing the need for separate specialized components and lowering overall system cost.
2Power
If electrified drivelines are implemented in vehicles, then vehicle propulsion capability is improved, but packaging space requirements increase
Solution Approach 1:
Components are nested within each other to maximize space utilization. The electric motor is positioned centrally with the transmission nested around its output shaft. The differential assembly is nested within the transmission housing, and axle shafts are positioned within the differential case. This nested arrangement minimizes the overall volume of the driveline while maintaining all necessary propulsion functions.
Solution Approach 2:
The driveline components are arranged in a three-dimensional configuration rather than linear arrangement. The differential case utilizes vertical space with the pin apertures arranged circumferentially, and the second differential output member moves axially within the available space. This dimensional optimization allows efficient packaging within limited vehicle space.
3Ease of repair
If disconnecting mechanism is added to electric drive unit, then ease of maintenance and repair is improved, but device complexity increases
Solution Approach 1:
The second differential output member is designed to move dynamically between two axial positions (first and second positions) to achieve rotational coupling and decoupling. This dynamic positioning mechanism allows the component to be easily engaged or disengaged from the second side gear, facilitating maintenance and repair operations without requiring complete disassembly of the driveline.
Solution Approach 2:
The pins received in pin apertures serve as intermediary elements that facilitate the coupling and decoupling of the second differential output member with the second side gear. These pins can be easily inserted or removed through the apertures, providing a simple intermediary mechanism that enables maintenance access without complex fastening or unfastening procedures.
Data Source
AI summary
An electric drive unit having a disconnecting differential a multi-phase electric motor and an inverter that controls power to the electric motor. The inverter has an inverter mount, a plurality of power semiconductors that are mounted to the inverter mount, and a plurality of busbars. Each of the busbars has first and second busbar portions, each having a body and a plurality of fingers. The fingers on the first and second busbar portions are mechanically and electrically coupled to opposite sides of terminals on corresponding ones of the power semiconductors.