Electric Vehicle Axle Position Sensor Integration
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Solution Overview
Problem
The existing electric vehicle axle mechanisms require extensive cabling and multiple connections, leading to increased complexity, assembly costs, and potential error sources due to the separate positioning of position sensing devices and electric motors.
Innovation Solution
Integration of the position sensing device into the electronic power unit or evaluation device, eliminating the need for additional cabling and allowing direct connections via stamped grids or coil windings, thereby reducing the number of components and connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the position sensing device is embodied as a separate unit connected to the electronic power unit by cable, then the rotor position can be ascertained, but the cabling outlay and device complexity increase significantly
Solution Approach 1:
The patent combines the position sensing device with the electronic power unit into a single integrated housing. The position sensor is mounted inside the electronic power unit housing, eliminating the need for separate cabling and external connections. This merging of previously separate components directly reduces device complexity while maintaining position detection capability.
2Measurement precision
If the position sensing device is embodied as a separate unit, then the rotor position can be monitored, but the number of plug connectors and feedthroughs increases
Solution Approach 1:
By integrating the position sensing device within the electronic power unit housing, the patent eliminates multiple plug connectors and feedthroughs that would be required for separate units. This single housing configuration simplifies the assembly process and reduces the number of manufacturing steps required.
3Measurement precision
If the position sensing device is mounted separately on the electric motor, then position detection is achieved, but the thermal management system becomes more complex
Solution Approach 1:
The patent positions the position sensing device and electric motor within the same housing as the electronic power unit, creating a unified thermal management system. This integration allows for simplified cooling arrangements where a single cooling mechanism can serve all heat-generating components (electric motor, electronic power unit, and position sensor) rather than requiring separate cooling systems for each component.
Data Source
AI summary
An electric vehicle axle mechanism comprising: at least one vehicle axle; a gear mechanism connected to the vehicle axle; an electric motor that comprises a rotor and that is connected to the gear mechanism for transmitting a torque to the at least one vehicle axle; a position sensing device for ascertaining a rotor position of the rotor; an electronic power unit that is connected to the electric motor for supplying electrical energy to the electric motor, wherein the electronic power unit furthermore comprises an evaluating device for evaluating the signals of the position sensing device and is connected to an evaluating device that is embodied as a separate device, wherein the position sensing device is integrated at least in part in the electronic power unit or the evaluating unit.