Electric Drive Assembly Layout With Drive-End Connection Cooling
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Solution Overview
Problem
Existing electric drive assembly systems face challenges with redesign requirements when electric machine length changes, low cooling efficiency due to air cooling, and increased length differences between left and right drive shafts, necessitating additional shafts for balance.
Innovation Solution
The electric connection assembly is relocated to the drive end of the rotor shaft, utilizing cooling oil from the gearbox assembly for improved cooling efficiency, and the system is designed to be more compact, reducing length differences between drive shafts without the need for additional shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric connection assembly is disposed at the non-drive end of the rotor shaft, then the connection between the electric machine and the inverter is established, but any change in electric machine length requires redesign of the electric connection assembly
Solution Approach 1:
The electric connection assembly is relocated from the non-drive end to the drive end of the rotor shaft, changing its spatial position. This dimensional repositioning allows the connection assembly to remain outside the electric machine's active length region, enabling electric machine length variations without affecting the connection assembly configuration.
Solution Approach 2:
The drive end of the rotor shaft serves as an intermediary location for the electric connection assembly. By positioning the connection assembly at this intermediary point that is external to the electric machine's length-determining region, the system decouples the connection assembly from electric machine length changes.
2Loss of energy
If the electric connection assembly is cooled by air, then the assembly is simple to implement, but the cooling efficiency is low
Solution Approach 1:
The cooling of the electric connection assembly is merged with the existing gearbox cooling system. The gearbox oil, which already circulates through the gearbox assembly, is utilized to cool the electric connection assembly, combining two cooling functions into a single integrated system.
Solution Approach 2:
The gearbox oil serves a dual function: it lubricates the gearbox components and simultaneously cools the electric connection assembly. The existing circulating oil from the gearbox automatically provides cooling to the connection assembly without requiring a separate cooling system.
3Length of moving object
If the electric drive assembly system has a large total length, then all components can be properly installed, but there is insufficient space and the system is disposed off-centre, requiring additional shafts
Solution Approach 1:
The electric connection assembly is repositioned to the drive end, which changes the spatial arrangement and allows for a more compact overall configuration. This repositioning enables better utilization of the available space and improves the centering of the electric drive assembly system within the vehicle.
Solution Approach 2:
The drive end of the rotor shaft serves multiple functions: it provides the mechanical connection for power transmission to the gearbox and simultaneously houses the electric connection assembly. This multi-functional use of the drive end eliminates the need for additional shafts and reduces the overall system length.
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 allows for flexible electric machine length adjustments without redesigning the connection assembly, enhances cooling efficiency, and reduces the length difference between left and right drive shafts, improving the overall integration and balance of the electric drive assembly system.
Implementation Method 1
the electric connection assembly in the electric drive assembly system is cooled by the cooling oil of the gearbox assembly
Data Source
AI summary
An electric drive assembly system includes a housing, including a body and a cover. Disposed in the housing is an electric machine including a rotor shaft, a gearbox assembly including a coaxially arranged gear input shaft connected to the rotor shaft to receive a torque from the electric machine. An electric machine control module is configured to control the electric machine, the electric machine control module being installed onto a first wall of the body by stacking over the electric machine and/or gearbox assembly in the direction transverse to the gear input shaft. An electric connection assembly is configured to electrically connect the electric machine control module to a stator of the electric machine. The electric connection assembly is provided to electrically connect to the stator of the electric machine near a drive end of the rotor shaft of the electric machine.