Electric Drive System Axial Power Supply Integration
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Solution Overview
Problem
Existing electric drive systems for vehicles face challenges in achieving compactness and reducing the distance between energy supply and motor while meeting insulation requirements and cost constraints, particularly due to high voltage levels that necessitate large conductor cross-sections and increased weight.
Innovation Solution
The energy supply is arranged axially adjacent to the electric motor within a cylindrical housing, divided into disk elements with logical/electrical segmentation, allowing for efficient energy distribution and operation with lower voltages, reducing the need for extensive insulation and cable lengths, and enabling modular redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high voltage levels (>400V) are used in the drive system, then the current-carrying cable cross-sections and motor windings can be reduced, but the insulation requirements and electrical safety costs increase significantly
Solution Approach 1:
The patent changes the voltage parameter from conventional high voltage (>400V) to low voltage (≤60V phase voltage). This parameter change fundamentally alters the system requirements: lower voltage allows for reduced insulation thickness and simpler electrical safety measures, while the compact arrangement compensates for the increased current by minimizing conductor lengths
2Object-affected harmful factors
If the energy supply is arranged remotely from the electric motor, then insulation distances can be maintained for high voltage systems, but the system volume increases and power density decreases
Solution Approach 1:
The patent merges the energy supply unit with the motor housing, integrating both components into a single compact assembly. The energy supply is positioned in the hollow cylindrical space within the motor housing, eliminating the need for separate mounting and reducing overall system volume. This integration is enabled by the low voltage design, which allows components to be placed in close proximity without requiring extensive insulation clearances
3Object-affected harmful factors
If low voltage levels (≤60V) are used in the drive system, then insulation requirements and costs are minimized, but the current increases requiring larger conductor cross-sections
Solution Approach 1:
The patent performs preliminary action by minimizing conductor lengths through strategic component placement before the system operates. The energy supply is positioned axially adjacent to the motor, and control electronics are integrated into the housing, pre-establishing short current paths. This preliminary arrangement of components ensures that even though low voltage requires higher currents, the conductor cross-section increase is minimized by keeping conductor lengths as short as possible
4Productivity
If the energy supply and motor are integrated in a compact arrangement, then power density increases and distances are reduced, but insulation requirements for high voltage systems become more difficult to meet
Solution Approach 1:
The patent changes the voltage parameter from high voltage to low voltage (≤60V phase voltage), which fundamentally resolves the contradiction between compact integration and insulation requirements. At low voltage, the insulation distances required by safety standards are minimal, allowing the energy supply, control electronics, and motor to be integrated in a compact arrangement with high power density without compromising electrical safety
Data Source
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AI summary
The invention relates to an electric drive system, particularly for vehicles, comprising an electric motor (1) and a power supply (6), wherein said power supply (6) is arranged to be axially adjacent to the electric motor (1) and directed peripherally around the rotational axis of said electric motor (1), particularly with an angle extension of 360 degrees.