Integrated Electric Drive Layout for Compact EV Packaging
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Solution Overview
Problem
Existing electric drive systems in electric vehicles suffer from low integration level and large accommodation space, leading to high weight, increased costs, and complex wiring harness connections.
Innovation Solution
An integrated electric drive system with a housing that accommodates a controller, motor, and speed reducer in balanced spaces, eliminating large hanging spaces and integrating components like an air conditioning compressor and water pump, while optimizing component arrangement for reduced size and improved noise, vibration, and harshness (NVH).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the controller, motor, and speed reducer are integrated in a traditional arrangement, then the system can function as an electric drive system, but the overall weight increases and the integration level remains low
Solution Approach 1:
The controller, motor, and speed reducer are merged into a single integrated housing structure. The controller is mounted in the first accommodation space, the motor in the second accommodation space, and the speed reducer in the third accommodation space, all within one housing. This merging reduces the number of separate components and connections, thereby reducing overall weight while achieving high integration level.
2Volume of stationary object
If traditional arrangement methods are used, then components can be accommodated, but the accommodation space becomes large
Solution Approach 1:
The housing is designed with three distinct accommodation spaces arranged in different spatial dimensions. The controller is in the first accommodation space, the motor in the second accommodation space, and the speed reducer in the third accommodation space. This spatial arrangement optimizes the use of available space, reducing the overall accommodation volume while maintaining proper component separation and connectivity.
3Volume of stationary object
If components are integrated closely, then accommodation space is reduced, but noise, vibration, and harshness (NVH) problems increase
Solution Approach 1:
The housing is segmented into three distinct accommodation spaces that closely integrate the controller, motor, and speed reducer. This segmentation allows for compact arrangement reducing mounting space, while the separate enclosed spaces for each component help isolate vibration and noise sources, thereby controlling NVH issues despite the close integration.
4Device complexity
If complex wiring harness connections are included, then system functionality is complete, but device complexity and costs increase
Solution Approach 1:
The controller is directly integrated with the motor within the same housing structure, eliminating the need for complex external wiring harnesses. The controller can directly control the motor through internal connections, simplifying the overall system architecture, reducing manufacturing complexity, and lowering costs while maintaining complete system functionality.
Data Source
AI summary
A drive system includes a motor, a speed reducer, a controller, and a housing. The housing includes: a first accommodation space for accommodating the controller; a second accommodation space configured for accommodating the motor; and a third accommodation space configured for accommodating the speed reducer. The controller is connected with the motor, and an output shaft of the motor is connected with the speed reducer. In a length direction of the output shaft, an absolute value of a difference between a mounting width and a width of the first accommodation space is no greater than a first difference threshold. In a direction perpendicular to the length direction of the output shaft and parallel to a horizontal plane, an absolute value of a difference between a length of the first accommodation space and a length of the third accommodation space is no greater than a second difference threshold.