EV Integrated Drive Casing Layout for Cooling and Packaging
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Solution Overview
Problem
The installation of a mechanical-electrical integrated unit with a laminated structure in vehicles can be restricted by space and component limitations, leading to reduced cooling performance due to potential heat exposure from main power sources like engines or electric motors.
Innovation Solution
The electric vehicle design includes an electric motor, engine, and power transmission device, with the drive casing, first electrical casing, and second electrical casing arranged to allow for greater flexibility in installation while maintaining distance from heat sources, thereby reducing heat exposure and preserving cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the first electrical casing and second electrical casing are disposed on the upper side and one of opposite sides of the drive casing to increase installation flexibility, then the degree of freedom in installing the mechanical-electrical integrated unit is improved, but the electrical equipment may receive heat from the main power source, worsening the cooling performance
Solution Approach 1:
The patent transitions from a traditional laminated structure (arranged in vertical layers) to a three-dimensional spatial distribution arrangement. The drive casing, first electrical casing, and second electrical casing are positioned at different locations in space (drive casing at center, first electrical casing at upper side, second electrical casing at one of opposite sides), utilizing multiple dimensions (vertical and horizontal) simultaneously. This dimensional change enables better heat dissipation pathways while maintaining installation flexibility.
Solution Approach 2:
The patent employs an asymmetric arrangement where the first electrical casing and second electrical casing are positioned at different relative locations with respect to the drive casing and main power source. This asymmetric positioning allows optimization of each electrical casing's thermal environment independently, ensuring that electrical equipment does not receive excessive heat from the main power source while maintaining overall installation flexibility.
2Volume of moving object
If the mechanical-electrical integrated unit uses a laminated structure with drive casing, first electrical casing, and second electrical casing arranged vertically, then the structure is compact, but the degree of freedom in installing the unit is reduced
Solution Approach 1:
The patent moves away from a two-dimensional laminated (layered) structure to a three-dimensional spatial distribution. Instead of stacking casings vertically in fixed layers, the drive casing, first electrical casing, and second electrical casing are arranged in space utilizing both vertical and horizontal dimensions. This enables the unit to adapt to various installation spaces while maintaining compactness.
Solution Approach 2:
The patent introduces flexibility in the arrangement configuration. Rather than a fixed laminated structure, the casings can be positioned at different locations (upper side, opposite sides) depending on installation requirements. This dynamic positioning capability allows the mechanical-electrical integrated unit to adapt to different vehicle platforms and space constraints while maintaining structural compactness.
Data Source
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AI summary
An electric vehicle (10;300) includes: an electric motor (MG1,MG2;MGA); an engine (12;302); a power transmission device (16;304); a drive casing (100;340) that houses a drive apparatus (92;332) including the electric motor (MG1,MG2;MGA) and the power transmission device (16;304); a first electrical casing (102;342); and a second electrical casing (104;344). The drive casing (100;340), the first electrical casing (102;342) and the second electrical casing (104;344) cooperate to constitute a mechanical-electrical integrated unit (90;330). The drive casing (100;340) has a first wall surface (100a;340a), a second wall surface (100b;340b), a third wall surface (100c;340c), a fourth wall surface (100d;340d), a fifth wall surface (100e;340e) and a sixth wall surface (100f;340f). The engine (12;302) is disposed on the first wall surface (100a;340a), and is connected to an input shaft (22;308) of the power transmission device (16;304) on a side of the first wall surface (100a;340a). The first electrical casing (102;342) and the second electrical casing (104;344) are separately disposed on respective two of the second wall surface (100b;340b), the third wall surface (100c;340c), the fourth wall surface (100d;340d), the fifth wall surface (100e;340e) and the sixth wall surface (100f;340f).