EV Powertrain Assembly With Angled Gearset for Compact Packaging
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Solution Overview
Problem
Existing electric vehicle powertrain designs are not compact enough, lacking in modularity and efficiency, which affects crash considerations and performance.
Innovation Solution
A drivetrain system with a compact design featuring two motors, A-shields, and a gearset with a unique bearing arrangement and modular inverter cores, allowing for a compact and cost-efficient package that can be oriented as both a front and rear drivetrain system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional powertrain arrangements are used, then component functionality is maintained, but the overall size and complexity of the powertrain assembly increases
Solution Approach 1:
The patent combines the motor housing and gearset housing into a single integrated housing structure. The motor is positioned such that its housing forms part of the gearset housing, eliminating the need for separate housings and reducing overall assembly size. This merging of components directly addresses the contradiction by reducing volume while managing complexity through integration.
Solution Approach 2:
The single housing structure serves multiple functions: it houses the motor, contains the gearset, provides mounting points for bearings, and forms structural support elements. This multi-functionality reduces the number of separate components needed, thereby reducing overall assembly size while maintaining necessary functionality.
2Power
If larger motors are installed to improve performance, then power output increases, but the powertrain assembly size increases
Solution Approach 1:
The patent utilizes a three-dimensional spatial arrangement where the motor shaft is angled relative to the drive shaft, creating a non-linear power transmission path. This angular arrangement allows the motor to be positioned more efficiently within the housing, maximizing power output while minimizing the axial length and overall volume of the assembly. The gearset is arranged to accommodate this angular relationship, optimizing space utilization.
Solution Approach 2:
The gearset is nested within the motor housing structure, with gears and shafts arranged to fit within the available space around the motor. The intermediate shaft and drive shaft are positioned to utilize the internal volume of the housing efficiently, allowing larger motors to be accommodated without proportionally increasing overall assembly size.
3Ease of manufacture
If modular inverter cores are used, then manufacturing efficiency and adaptability improve, but assembly complexity increases
Solution Approach 1:
The inverter is divided into multiple modular cores that can be manufactured separately and then assembled into the complete inverter unit. Each core contains specific power electronic components and can be produced using standardized manufacturing processes, improving manufacturing efficiency and allowing for easier assembly and maintenance.
Solution Approach 2:
The modular inverter cores are designed with standardized interfaces and mounting configurations that allow them to be used in different drivetrain configurations. The same core design can be adapted for front or rear drivetrain applications, reducing the number of unique components needed and simplifying the overall assembly process despite the modular architecture.
Data Source
AI summary
The drivetrain system includes an I shield, two motors, two A-shields, and a gearset. Each A-shield is affixed to a respective one of the two motors, and each A-shield is also affixed to the I-shield. The gearset includes a motor shaft of one of the motors and a motor gear affixed to the motor shaft. Three motor bearings are arranged co-linearly and coupled to the motor shaft. The gearset also includes an intermediate shaft and a wheel gear affixed to the intermediate shaft and engaged with the first motor gear. A pinion gear is also affixed to the intermediate shaft. Two intermediate bearings are arranged co-linearly and coupled to the intermediate shaft. The gearset also includes a drive shaft and a drive gear affixed to the drive shaft and engaged with the first pinion gear. The motor shaft, intermediate shaft and drive shaft form a shaft angle that may allow compactness.