EV Drive Unit Inverter Mounting to Prevent Collision Interference
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Solution Overview
Problem
In electric vehicles, when a large load is input during a collision, the side member can deform and interfere with the inverter unit, leading to potential insulation property issues.
Innovation Solution
A drive unit configuration is implemented where an upright wall is provided on the outer side of the inverter unit's fixing point in the vehicle width direction, and a mount bracket is fixed to the upright wall, preventing external interference with the inverter unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the inverter unit is fixed to the motor housing at an outer edge portion, then the device complexity is reduced, but the insulation property deteriorates when side member deforms during collision
Solution Approach 1:
The upright wall acts as an intermediary protective structure between the side member and the inverter unit. When the side member deforms during collision, the upright wall prevents direct contact with the inverter unit, thereby protecting the insulation property while maintaining a relatively simple mounting structure.
Solution Approach 2:
The upright wall is pre-formed as part of the motor housing structure before collision occurs. This preliminary structural arrangement ensures that when deformation happens during collision, the protective barrier is already in place to prevent interference with the inverter unit.
2Strength
If the mount bracket is fixed to the motor housing, then the drive unit is securely supported, but the side member can still deform and interfere with the inverter unit during large load input
Solution Approach 1:
The motor housing is segmented into functional zones: the upright wall serves as a protective barrier zone, while the motor housing proper provides structural support. This segmentation allows the support function and protection function to be separated, enabling secure mounting while preventing collision damage to the inverter unit.
3Device complexity
If no protective structure is added, then the device complexity remains low, but the insulation property deteriorates when side member deforms during collision
Solution Approach 1:
The upright wall serves multiple functions: it provides structural support for the motor housing, acts as a protective barrier against side member deformation, and defines the mounting location for the inverter unit. This multi-functionality achieves protection without significantly increasing device complexity.
Data Source
AI summary
A drive unit for an electric vehicle, comprising a drive unit including a rotary electric machine disposed in a motor room of the electric vehicle and an inverter unit electrically connected to the rotary electric machine and a mount bracket configured to support the drive unit in the motor room, is provided. The rotary electric machine includes a motor housing. The inverter unit is placed on an upper surface of the motor housing and fixed to the motor housing at a fixing point disposed at an outer edge portion of the inverter unit. The motor housing includes an upright wall that is upright above the motor housing on an outer side of the fixing point of the inverter unit in a vehicle width direction. One end of the mount bracket is fixed to an upper surface of the upright wall.