Integrated Inverter Module for E-Axle Drive and Transmission
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power electronics for electric motors in electric and hybrid vehicles are complex to produce and difficult to compact due to numerous electronic components, and require separate chambers for semiconductor switching elements, making them inefficient and costly.
Innovation Solution
A power module with semiconductor switching elements on a shared substrate and control unit, integrated with a single printed circuit board and heatsink, which also serves for the transmission, allowing for a combined power electronics solution that simplifies production and reduces chamber size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate power electronics are used for electric motor and transmission, then each component can be independently controlled, but the device complexity and number of electronic components increase
Solution Approach 1:
The patent combines the power electronics for the electric motor and the power electronics for the transmission into a single integrated power module. This merging reduces the total number of electronic components and simplifies the overall device complexity while maintaining the ability to independently control both the motor and transmission through separate control circuits within the unified module.
Solution Approach 2:
The integrated power module serves multiple functions: it acts as the power electronics for the electric motor and simultaneously serves as the power electronics for the transmission. This multi-functionality allows a single device to replace what would traditionally require two separate devices, reducing complexity while preserving independent control capabilities through dedicated control circuits for each function.
2Adaptability or versatility
If multiple separate electronic components are used, then each component can be optimized for its specific function, but the chamber size and overall module volume increase
Solution Approach 1:
The patent merges the previously separate power electronics components into a single integrated power module, significantly reducing the chamber size required to house all electronic components. The unified structure eliminates the need for multiple separate chambers while maintaining functional optimization through dedicated control circuits for both the electric motor and transmission.
3Reliability
If separate chambers are used for semiconductor switching elements, then each chamber can be independently sealed and cooled, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent integrates the semiconductor switching elements for both the electric motor and transmission into a single shared chamber within the unified power module. This approach maintains reliable sealing through a single integrated sealing structure and simplifies manufacturing by reducing the number of separate chambers and sealing interfaces that would need to be assembled, thereby decreasing assembly difficulty while preserving reliability.
4Adaptability or versatility
If numerous separate electronic components are used, then each component can perform its specific function, but the production cost and manufacturing time increase
Solution Approach 1:
The patent combines multiple separate electronic components into a single integrated power module, significantly improving production efficiency. By manufacturing one unified component rather than assembling multiple separate components, the production process is simplified, manufacturing time is reduced, and production costs are lowered, while the integrated module retains full functional capability for controlling both the electric motor and transmission.
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 approach results in a more compact, cost-effective power module with simplified production processes and improved reliability, enabling efficient power conversion for both the electric drive and transmission with reduced component count and chamber size.
Implementation Method 1
These inverters normally comprise semiconductor switching elements, typically formed by transistors
Implementation Method 2
integrated with a single printed circuit board and heatsink
Data Source
AI summary
A power module for an electric axle drive may include a plurality of semiconductor switching elements, where the semiconductor switching elements are attached to a substrate. The power module may also include a control unit electrically connected to the plurality of semiconductor switching elements, where the plurality of semiconductor switching elements includes a first set of semiconductor switching elements dedicated to the electric axle drive. The plurality of semiconductor switching elements may also include a second set of second set of semiconductor switching elements dedicated to a transmission connected to the electric axle drive.