Integrated E-Mobility Drive Motor Layout for Compact High Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric mobility systems face challenges in optimizing the packaging of inverters, motors, and reducers, requiring a robust and easy-to-assemble connection structure for high-output driving systems, particularly in small vehicles like electric bicycles and e-cargos, to accommodate increased luggage capacity and improve mass productivity.
Innovation Solution
A driving motor system with an inverter, motor, and reducer configuration that includes a coaxial input and output gear structure, multiple planetary gears, and a robust bearing system, integrated with a compact design and easy assembly features, such as a three-phase bus bar and sensor connector connection, to optimize packaging and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-output driving system is applied to increase luggage capacity, then the power output is improved, but the packaging space and system size increase
Solution Approach 1:
The patent merges the motor and reducer into a single integrated housing structure, eliminating the need for separate mounting spaces. The inverter is positioned to share space with other components, creating a compact three-component integration that achieves high power output without proportionally increasing packaging volume.
Solution Approach 2:
The patent employs a nested arrangement where the inverter is positioned within the space envelope defined by the motor-reducer assembly. The control unit is integrated into the housing structure, creating a nested configuration that maximizes component density while maintaining accessibility for maintenance.
2Reliability
If a robust gear structure is designed for power transmission, then the transmission reliability is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent segments the gear train into modular planetary gear sets that can be pre-assembled and tested as independent units. The input shaft, planetary gears, and output shaft are designed as separable components that can be manufactured independently and then assembled using standardized fastening mechanisms, reducing overall manufacturing complexity.
Solution Approach 2:
The patent introduces standardized intermediate components such as bearing assemblies and shaft couplings that facilitate the connection between gear elements. These intermediary components serve as universal interfaces that simplify the assembly process while maintaining the structural integrity and reliability of the power transmission system.
3Device complexity
If multiple components are integrated to optimize packaging, then the packaging efficiency is improved, but the ease of repair and maintenance deteriorates
Solution Approach 1:
The integrated housing is designed with segmented access points and removable panels that allow technicians to access specific components (inverter, control unit, or gear elements) without disassembling the entire assembly. Each major component has dedicated access pathways that maintain packaging efficiency while enabling targeted maintenance operations.
Solution Approach 2:
The patent designs the inverter and control unit with extraction capabilities, allowing these electronic components to be removed as complete units for replacement or repair. The electrical connections are designed with quick-disconnect features that enable component extraction without affecting the mechanical integrity of the motor-reducer assembly.
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
The system achieves optimized packaging, reduced size and weight, and simplified assembly, enhancing the robustness and efficiency of power transmission while accommodating increased luggage capacity in electric mobility vehicles.
Implementation Method 1
an inverter configured to receive DC power and convert the DC power into AC power
Implementation Method 2
a motor configured to provide driving force
Implementation Method 3
the at least one planetary gear may be engaged with the input gear and the output gear to receive the driving force from the input gear and transmit the driving force to the output gear
Implementation Method 4
a reducer configured to increase the driving force provided by the motor and transmit the driving force
Data Source
AI summary
A driving motor system and a driving system of an electric mobility are provided. The driving motor system may comprise: an inverter configured to receive DC power and convert the DC power into AC power; a motor configured to provide driving force; and a reducer configured to increase the driving force provided by the motor and transmit the driving force to a wheel of the electric mobility, wherein the motor and the reducer are installed inside a motor housing.