Hybrid Drive Unit Coupling Segmentation
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Solution Overview
Problem
Existing integrated systems for hybrid vehicles lack a robust and efficient method for both electrical and mechanical coupling of control units and drive devices, leading to potential vibration issues and reduced stiffness in the drive unit casing.
Innovation Solution
The integration of a control unit and a drive unit is achieved through a combination of electrical coupling using an insertion/extraction bolt and mechanical coupling using bolts, ensuring secure and stable connections while allowing for relative movement to prevent interference between the coupling mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single coupling mechanism is used for both electrical and mechanical connection, then device complexity is reduced, but reliability of coupling and stiffness of drive unit casing deteriorates
Solution Approach 1:
The coupling mechanism is segmented into two independent parts: a fastening supporting member for electrical coupling and a fixing member for mechanical coupling. This segmentation allows each component to be optimized for its specific function, improving overall reliability while maintaining manageable complexity through functional separation.
2Strength
If rigid mechanical coupling is used to enhance stiffness, then drive unit casing stiffness is improved, but vibration and interference between coupling mechanisms increases
Solution Approach 1:
The fastening supporting member is designed with dynamic characteristics that allow it to flex and absorb vibrations while maintaining electrical coupling. This dynamic design prevents vibration transmission to the drive unit casing, allowing rigid mechanical coupling for stiffness without generating harmful vibrations.
3Ease of manufacture
If electrical coupling components are integrated with mechanical coupling components, then ease of manufacture is improved, but manufacturing precision and assembly accuracy deteriorate
Solution Approach 1:
By separating electrical coupling components from mechanical coupling components, each can be manufactured and assembled independently with appropriate precision requirements. This segmentation avoids the cumulative tolerance issues that would arise from integrating both functions into a single component, maintaining high manufacturing precision while still achieving overall integration.
Data Source
AI summary
An integrated system includes a controller, a drive device, a fastening supporting member, and a fixing member. The controller has a controller connector. The drive device has a drive device connector that is connected to the controller connector so that the drive device is electrically coupled to the controller. Via the fastening supporting member, the controller and the drive device are maintained in an electrically coupled state in which the drive device connector is connected to the controller connector. Via the fixing member, the controller and the drive device are maintained in a mechanically coupled state in which the drive device is mechanically coupled to the controller.