Drive Unit Connector Angling for Maintenance Access
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Solution Overview
Problem
Existing drive units for electric vehicles, where the power conversion device is fixed orthogonal to the rotating electric machine, face challenges in maintainability due to limited workspace, especially when connecting or disconnecting power lines, leading to decreased accessibility and increased complexity.
Innovation Solution
The drive unit design includes a power conversion device with a first connector that protrudes at a predetermined angle away from the rotating electric machine in the orthogonal direction, allowing for improved workspace security and maintainability by offsetting the connector's position relative to the power conversion device's ends and the electric motor case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the power conversion device is fixed to one side of the rotating electric machine in the orthogonal direction, then the degree of freedom in layout is improved, but the work space for connecting or disconnecting power lines becomes small
Solution Approach 1:
The first connector is designed to protrude from the power conversion device at a predetermined angle in the rotation axis direction, creating a three-dimensional offset that provides adequate work space for power line connections while maintaining the compact orthogonal layout between the power conversion device and rotating electric machine
2Volume of moving object
If the power conversion device is fixed to one side of the rotating electric machine in the orthogonal direction, then the layout compactness is improved, but the maintainability decreases
Solution Approach 1:
The connector protrudes at an angle in the rotation axis direction, utilizing the third dimension to create sufficient access space for maintenance operations without increasing the two-dimensional footprint of the drive unit, thereby maintaining layout compactness while improving maintainability
3Reliability
If the connector is positioned on the power conversion device, then the electrical connection is achieved, but the accessibility for connection and disconnection becomes difficult
Solution Approach 1:
The connector protrudes from the power conversion device at a predetermined angle in the rotation axis direction, creating spatial separation between the connector and the power conversion device body, which provides adequate work space for connecting or disconnecting power lines while maintaining reliable electrical connection
Solution Approach 2:
The protruding connector structure acts as an intermediary element that extends the connection interface away from the power conversion device, providing accessible connection points for power lines without compromising the integrated design of the drive unit
Data Source
AI summary
A drive unit includes: a rotating electric machine having a rotation axis extending in a horizontal direction; a rotating electric machine case; and a power conversion device. The power conversion device is arranged on one side of the rotating electric machine in an orthogonal direction. The power conversion device includes a first connector to which a first electric power line through which electric power supplied to the rotating electric machine and electric power supplied from the rotating electric machine flow are connected. The first connector is provided on a first end side and is arranged to protrude from the power conversion device at a predetermined angle in a direction away from the rotating electric machine in the orthogonal direction, as the first connector goes away from the power conversion device in the rotation axis direction, when viewed from above.