Single-Piece E-Drive Enclosure for Compact EV Packaging
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Solution Overview
Problem
Existing integrated electric drive systems for electric vehicles have low integration levels and large enclosure spaces, leading to increased weight, costs, and noise, vibration, and harshness (NVH) issues.
Innovation Solution
An integrated electric drive system with a single-piece enclosure that houses a motor, speed reducer, controller, and air conditioning compressor, with balanced mounting spaces and a high integration level, reducing the need for complex wiring harness connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are mounted separately on motor stator enclosure and transmission, then each component has its own mounting space, but the overall enclosure space increases and integration level decreases
Solution Approach 1:
The patent merges the controller mounting space with the motor enclosure by recessing the controller into the motor's stator enclosure. This integration eliminates the need for separate mounting structures for the controller while maintaining all necessary functions, thereby improving integration level and reducing overall enclosure space.
Solution Approach 2:
The controller is nested within the motor enclosure by creating a recessed space in the stator enclosure that accommodates the controller. This nesting approach allows the controller to be housed within the existing motor structure without increasing the external dimensions of the motor assembly.
2Area of stationary object
If multiple components are integrated into a single enclosure, then integration level increases and space is reduced, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The patent applies local quality by creating a specifically designed recessed space within the motor stator enclosure that is optimized for controller mounting. This localized modification provides precise mounting dimensions and positioning for the controller without requiring the entire motor enclosure to meet high precision standards, thus balancing integration benefits with manufacturing feasibility.
3Device complexity
If components are distributed across multiple mounting locations, then each component has adequate space, but wiring harness complexity and connection points increase
Solution Approach 1:
By merging the controller mounting location with the motor enclosure, the patent reduces the number of separate mounting locations to a single integrated unit. This consolidation significantly reduces wiring harness complexity by minimizing the number of connection points and cable routes required, while the recessed design ensures the controller still has adequate space for heat dissipation and access.
Data Source
AI summary
An integrated electric drive system and an electric vehicle are provided. The integrated electric drive system includes a motor, a speed reducer, a controller, and a single-piece enclosure. A first enclosure space is formed on the single-piece enclosure, and a second enclosure space and a third enclosure space configured for the speed reducer to be mounted are arranged on the single-piece enclosure. The motor controller is connected with the motor. An output shaft of the motor is connected with the speed reducer. An absolute value of a difference between a preset mounting width value and a width value of the first enclosure space is less than or equal to a first difference threshold. An absolute value of a difference between a length value of the first enclosure space and a length value of the third enclosure space is less than or equal to a second difference threshold.