Rotary Electric Drive Unit Terminal Layout for Compact Transaxles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electrical connection structures in rotary electric drive units of hybrid vehicles result in a protruding case and increased size, which can lead to force application on the transaxle during collisions and compromise the compact layout of the engine room.
Innovation Solution
The proposed electrical connection structure involves housing two electric motors in a case and connecting them to electrical equipment via a connecting member, where the first electric motor is connected in parallel and the second in series with the electrical equipment terminals, allowing for a compact configuration by optimizing the arrangement of terminals and coupling members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the connecting portions between the electric motor and the power controller are grouped in the forward portion, then the case size reduction is achieved, but the transaxle protrudes forward and collision force increases
Solution Approach 1:
The patent changes the arrangement dimension of the connecting portions from the forward-rearward direction to the left-right direction. Specifically, the first and second three-phase terminals are arranged in series in the forward-rearward direction on the electrical equipment side, while the corresponding terminals on the case side are arranged in parallel in the left-right direction, thereby reducing forward protrusion while maintaining connection functionality.
2Object-affected harmful factors
If the connecting portions between the electric motor and the power controller are distributed to the left and right sides, then the collision force on transaxle is reduced, but the rotary electric drive unit size increases in the left-right direction
Solution Approach 1:
The patent utilizes the left-right dimension for terminal arrangement on the case side while keeping the electrical equipment side terminals arranged in the forward-rearward direction. This dimensional differentiation allows the connecting portions to be distributed left-right for safety while maintaining a compact forward-rearward profile.
Solution Approach 2:
The patent employs asymmetric arrangement of terminals between the electrical equipment side and the case side. The terminals are arranged in series on one side and in parallel on the other, creating an asymmetric configuration that optimizes both space utilization and collision resistance.
3Reliability
If the three-phase connector provided in the rearward portion of the electrical equipment side is connected to the three-phase connector provided in the rearward portion of the case side, then the electrical connection is achieved, but the case protrudes rearward and the size of the case increases rearward
Solution Approach 1:
Instead of connecting corresponding terminals in the same direction (rearward to rearward), the patent inverts the connection approach by arranging terminals in series on the electrical equipment side and in parallel on the case side, thereby connecting the rearward terminal to a laterally positioned terminal rather than a rearward-positioned terminal.
Data Source
AI summary
An electrical connection structure includes a case in which a first electric motor and a second electric motor are housed, and electrical equipment that controls the first electric motor or the second electric motor. The first electric motor is electrically connected to a first three-phase terminal of the electrical equipment via a connecting member. The second electric motor is electrically connected to a second three-phase terminal of the electrical equipment via the connecting member. On the electrical equipment side, the first three-phase terminal and the second three-phase terminal are arranged in series. On the case side, a first electric motor side three-phase terminal, which is connected to the first electric motor, in the connecting member, and a second electric motor side three-phase terminal, which is connected to the second electric motor, in the connecting member, are arranged in parallel.