Electric Drive Module With Vibration Decoupling
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Solution Overview
Problem
Existing drive modules for commercial vehicles with electric and hybrid drives require components to be tested functionally only after installation, which is inefficient and does not account for vibration protection during operation.
Innovation Solution
Assembling the drive module components into a fully functional unit externally, with a support frame using rubber-elastic bearings for vibration decoupling and a liquid cooling system, allowing pre-installation testing and improved protection against vibrations and collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If components are assembled separately and mounted individually on the longitudinal frame, then installation flexibility is improved, but functional testing cannot be performed before installation and vibration protection is insufficient
Solution Approach 1:
The drive module is segmented into a self-contained unit with its own support frame, separate from the vehicle's longitudinal frame. This allows the module to be assembled, tested, and installed as a complete functional unit, enabling pre-installation functional testing while maintaining installation flexibility through the modular design
Solution Approach 2:
A support frame acts as an intermediary structure between the drive module components and the vehicle's longitudinal frame. This intermediate structure enables the module to be mounted as a complete unit for functional testing, while also providing integration points for vibration protection through rubber-elastic bearings
2Stability of the object's composition
If components are mounted directly on the longitudinal frame, then structural integration is improved, but vibration protection during operation deteriorates
Solution Approach 1:
The support frame serves as an intermediary structure that provides both structural integration and vibration protection. It integrates the drive module components into a stable unit while incorporating rubber-elastic bearings as intermediaries between the module and vehicle frame to filter vibrations
Solution Approach 2:
The support frame is designed with integrated vibration protection features, including rubber-elastic bearings, that are built into the structure before the module is installed in the vehicle. This beforehand cushioning ensures vibration protection is already in place when the module begins operation
3Strength
If the support frame is rigidly connected to the longitudinal frame, then structural strength is improved, but vibration decoupling capability deteriorates
Solution Approach 1:
The support frame uses rubber-elastic bearings as intermediary elements between itself and the longitudinal frame. These bearings provide the necessary mechanical strength to support the drive module while simultaneously decoupling vibrations through their elastic properties
Solution Approach 2:
The support frame combines rigid structural elements (for strength) with rubber-elastic bearing materials (for vibration decoupling). This composite approach allows the same support structure to provide both structural strength and vibration protection
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
Enables pre-functional testing of the drive module components, reduces vibration impact, and provides enhanced protection and accessibility during installation and operation, ensuring efficient and reliable performance.
Implementation Method 1
the support frame is attached to the structure with the interposition of rubber-elastic bearings, whereby the drive module and in particular the battery packs are mounted in a vibration-decoupled manner
Implementation Method 2
rubber-elastic bearings
Implementation Method 3
The cooling system can be a liquid system with at least one air-water heat exchanger and a geodetically high coolant expansion tank
Implementation Method 4
liquid cooling system
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electric drive module for a vehicle, in particular a commercial vehicle, with an electric or hybrid drive, comprising at least one battery pack (25) rechargeable via an inverter (27), a support frame (19) accommodating the battery pack (25) and attachable to the vehicle body, and a cooling device for temperature control of the electrical components. According to the invention, the drive module (3) is arranged as a self-contained unit in the support frame (19), which can be attached to the vehicle body (8) (1), together with the battery pack (25), the electrical converters, such as the inverter (27) and DC converter (28), at least one electrical connection interface, and a cooling system with at least one heat exchanger (30), coolant lines (33, 34, 35, 36), and a pump (31).