Electric Vehicle Powertrain Assembly Integration
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Solution Overview
Problem
Current powertrain assemblies for electric vehicles, particularly microcars, are mechanically complex and costly due to their derivation from internal-combustion engine designs, leading to high production costs and limited adoption of electric traction in microcars.
Innovation Solution
A compact powertrain assembly with a housing containing a permanent-magnet synchronous electric motor and a transmission system that includes a first and second reduction stage, eliminating the need for belt-tensioning jockey wheels, integrated into the vehicle's suspension arm for reduced weight and cost, using a housing with hinging and fastening points for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powertrain assemblies are derived from internal-combustion engine designs, then mechanical functionality is achieved, but device complexity and production cost increase
Solution Approach 1:
The powertrain assembly is divided into modular components: electric motor unit, transmission unit with reduction stages, and suspension arm integration. Each module can be independently manufactured and assembled, reducing overall complexity and production cost compared to adapting complex internal-combustion engine designs.
Solution Approach 2:
The powertrain assembly merges the electric motor, transmission system, and suspension arm into a single integrated unit. This combination eliminates the need for separate mounting structures and reduces the number of parts, thereby simplifying the overall mechanical system and lowering production costs.
2Reliability
If traditional transmission systems are used with belt-tensioning jockey wheels, then reliable power transmission is achieved, but device complexity and component count increase
Solution Approach 1:
The design extracts and eliminates the belt-tensioning jockey wheels from the transmission system. Instead of using traditional tensioning mechanisms, the patent employs a simplified transmission arrangement that maintains reliable power transmission without these additional components, thereby reducing device complexity.
Solution Approach 2:
The transmission system is designed to self-adjust and maintain proper belt tension through its inherent mechanical structure, eliminating the need for separate tensioning devices. The transmission components work together to automatically maintain optimal operating conditions without additional active elements.
3Reliability
If complete powertrain assemblies are manufactured and assembled on the finished vehicle, then functional integration is achieved, but assembly time and maintenance complexity increase
Solution Approach 1:
The powertrain is segmented into the suspension arm-integrated unit that can be pre-assembled and tested independently, then installed as a module on the finished vehicle. This segmentation allows for easier maintenance and repair, as the entire powertrain-suspension assembly can be replaced or serviced as a single unit without disassembling the entire vehicle.
Solution Approach 2:
The integrated powertrain assembly serves multiple functions: it provides both the suspension function and the powertrain function simultaneously. This multi-functionality reduces the number of separate assemblies needed and simplifies both initial assembly and subsequent maintenance operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces production costs and allows for rapid assembly and maintenance of electric vehicles, enhancing mechanical compactness and efficiency while utilizing small-size motors for effective traction, making electric microcars more attractive by lowering the purchase cost and improving performance.
Implementation Method 1
at least one electric motor provided with a stator rigidly associated with the housing and a rotor which can be rotationally driven with respect to said stator
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
Powertrain assembly (1), which is unusually compact and light, for an electric vehicle, comprising a housing (2) which contains: at least one electric motor (3) provided with a stator (30) which is rigidly associated with the housing (2) and a rotor (31) which can be rotationally driven with respect to said stator (30); and a transmission (5) designed to transmit the movement of the rotor (31) to a traction shaft (6); said traction shaft (6) comprising an outer portion (60) which projects from the housing (2) and to which a wheel hub (61) is rigidly coupled. The housing (2) comprises at least one hinging point (20) and at least one fastening point (21) for connecting it, as an individually movable unit, to the chassis (102) and to a shock-absorber group (101) of said electric vehicle (100), respectively.