Integrated Drive System Assembly for Electric Vehicles
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Solution Overview
Problem
Conventional hybrid vehicles have complex and expensive drive systems due to the combination of combustion engines and electric motors, limiting fuel efficiency and pollution control, and all-electric vehicles face challenges with separate and complex component mounting and cooling systems.
Innovation Solution
An integrated drive system assembly that combines an electric motor, power inverter, and gearbox into a single unit with a common thermal management system, using short, rigid bus bars for electrical connections and optimizing coolant distribution to manage temperature across components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate component mounting is used for electric motor, power inverter, and gearbox, then ease of manufacturing is improved, but device complexity increases and weight increases
Solution Approach 1:
The patent combines the electric motor, power inverter, and gearbox into a single integrated drive assembly. The motor housing serves as a common structural element that houses both the motor and inverter components, eliminating the need for separate mounting structures and reducing overall system complexity while maintaining ease of manufacture as a modular unit.
Solution Approach 2:
The motor housing performs multiple functions: it serves as the structural housing for the electric motor, provides mounting structure for the power inverter, and acts as a common thermal management component. This multi-functionality reduces the number of separate components needed and simplifies the overall system architecture.
2Temperature
If separate cooling systems are used for motor and inverter, then thermal management effectiveness is improved, but device complexity and weight increase
Solution Approach 1:
The patent implements a unified thermal management system where a single coolant circulation system serves both the motor and inverter. The motor housing contains integrated coolant channels that provide cooling to both components through a common coolant flow path, eliminating the need for separate cooling systems and reducing overall complexity.
Solution Approach 2:
The coolant circulation system performs multiple cooling functions simultaneously. The same coolant flow provides thermal management for both the electric motor stator and winding, as well as for the power inverter, making the cooling system highly efficient and reducing the number of separate cooling circuits needed.
3Adaptability or versatility
If flexible cables are used for electrical connections, then adaptability is improved, but electrical efficiency decreases due to longer connection lengths
Solution Approach 1:
The patent integrates the power inverter directly within the motor housing, placing the inverter circuit board in close proximity to the motor windings. This integration dramatically reduces the length of electrical connections required, minimizing resistive energy losses while the rigid mounting structure provides sufficient mechanical stability for the electrical connections.
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
This design simplifies the system, reduces weight and manufacturing costs, improves electrical efficiency, and streamlines thermal management, while balancing vehicle weight and minimizing noise and vibration.
Implementation Method 1
The motor housing includes a stator coolant inlet and stator coolant outlet for receiving and discharging coolant to cool the stator and inverter
Implementation Method 2
coolant circulation system used to cool the motor, inverter, and gearbox
Implementation Method 3
An integrated drive system assembly includes an electric motor, a power inverter, and a gearbox
Data Source
AI summary
An electric vehicle includes an energy storage system, an integrated drive system assembly having a gearbox, a power inverter, and an electric motor, wherein the gearbox, the electric motor and the power inverter are assembled into a single unit with a multi-piece housing. The electric vehicle may also include two half shafts for respective wheels of the electric vehicle. The gearbox, the electric motor and the power inverter may be oriented such that the gearbox extends along a center line of the electric vehicle and the electric motor and the power inverter extend from the gearbox in opposite directions. The electric vehicle may also include a mutual thermal management system coupled to the integrated drive system assembly and having at least one liquid coolant loop that is thermally coupled to the electric motor, the power inverter, the gearbox, a cooling system, a refrigeration system, and an HVAC system.