Integrated EV Propulsion Layout for Lower Mass and Complexity
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Solution Overview
Problem
Incorporating an electrified propulsion system into vehicles often increases mass and system complexity, which can negatively impact reliability and acceptance.
Innovation Solution
An integrated electrified vehicle propulsion system (IEPS) that includes a single electric machine, mechanical geartrain, rechargeable energy storage device, integrated cooling system, and power electronics system, all housed in a single unit, with a centralized layout to reduce mass and complexity, and features a multi-phase rotary electric motor/generator, torque transmission device, and fluidic heat exchange for efficient power transfer and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an electrified propulsion system is incorporated into a vehicle, then propulsion capability is improved, but mass increases
Solution Approach 1:
The patent combines the electric machine, power electronics system, cooling system, and energy storage device into a single integrated propulsion system housing. This consolidation reduces the overall mass by eliminating redundant structural components and interconnections between separate systems, while maintaining full propulsion functionality.
2Power
If an electrified propulsion system is incorporated into a vehicle, then propulsion capability is improved, but system complexity increases
Solution Approach 1:
The patent integrates multiple complex subsystems (electric machine, power electronics, cooling, energy storage) into a single unified housing with shared structural and thermal management components. This consolidation reduces the number of separate connections and interfaces, thereby reducing overall system complexity despite maintaining advanced propulsion capabilities.
3Weight of moving object
If components are consolidated into a single housing, then mass and complexity are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The integrated housing is designed as a modular structure with distinct compartments for the electric machine, power electronics system, cooling system, and energy storage device. This segmentation allows each subsystem to be manufactured and tested independently before final assembly, reducing the overall manufacturing precision requirements while maintaining the benefits of integration.
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 IEPS reduces mass, complexity, and enhances reliability by consolidating components, improving power transfer efficiency, and facilitating flexible integration into various vehicle configurations with minimal interconnections, thereby improving the overall acceptability of EV systems.
Implementation Method 1
The single electric machine being a multi-phase rotary electric motor/generator
Implementation Method 2
an integrated cooling system... fluidic heat exchange for efficient power transfer and heat management
Data Source
AI summary
An integrated electrified propulsion system for a vehicle includes a single electric machine, a mechanical geartrain, a rechargeable energy storage device, an integrated cooling system, and a power electronics system. The single electric machine, the mechanical geartrain, the integrated cooling system, the rechargeable energy storage device, and the power electronics system are arranged in a single housing. The single electric machine is rotatably coupled to the mechanical geartrain to transfer mechanical power therebetween.