Integrated Motor-Transmission Box Assembly for Compact EV Packaging
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Solution Overview
Problem
Existing vehicle motor and transmission assemblies in vehicles have bulky components, large space occupation, high loss, and complex structures, leading to increased costs and reduced endurance capabilities.
Innovation Solution
An integrated electric assembly design where a motor and transmission share a box assembly, with a mounting plate dividing the space into motor and transmission holding cavities, and a cooling lubricating liquid cools the assembly, enhancing integration, compactness, and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If motor assembly and transmission assembly are individually disposed and connected through bolts, then each assembly can be manufactured independently, but the structure becomes bulky, occupies large space, and increases overall weight
Solution Approach 1:
The patent merges the motor assembly and transmission assembly into a single integrated electric assembly. The motor, transmission, and controller are housed together within one box assembly, eliminating the need for separate bolted connections between motor and transmission boxes. This integration directly reduces the total volume and space occupation while maintaining manufacturability through modular sub-assemblies.
2Strength
If box assemblies at connection locations have large wall thicknesses, then structural strength is improved, but space is wasted and the structure becomes less compact
Solution Approach 1:
The patent applies local quality by providing reinforcement ribs at specific critical locations within the box assembly where structural strength is needed, rather than uniformly increasing wall thickness throughout. The reinforcement ribs are strategically positioned to strengthen the box assembly at connection points and load-bearing areas while keeping other areas compact and space-efficient.
3Volume of moving object
If motor and transmission are directly integrated through box assembly, then structure becomes compact and space is reduced, but mounting and maintenance become difficult
Solution Approach 1:
The patent segments the electric assembly into distinct functional modules: motor assembly, transmission assembly, and controller assembly, all housed within the integrated box assembly. Each module can be independently manufactured, tested, and replaced. The mounting plate with through-holes allows for easy installation and removal of the transmission assembly from the motor assembly, facilitating maintenance while maintaining compact integration.
4Temperature
If cooling lubricating liquid is used to cool the box assembly, then cooling effect is improved, but system complexity increases
Solution Approach 1:
The patent uses cooling lubricating liquid that serves multiple functions simultaneously: it cools the box assembly and transmission components, lubricates moving parts, and provides protection against corrosion. This multi-functional approach improves cooling efficiency without significantly increasing system complexity, as the same fluid performs multiple essential functions within the integrated assembly.
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 design achieves a compact structure with improved cooling, reduced weight, and enhanced reliability, facilitating assembly and maintenance, while lowering costs and energy loss.
Implementation Method 1
the cooling lubricating liquid cools the box assembly through the mounting plate
Data Source
AI summary
An electric assembly includes a box assembly, a motor, and a transmission. A mounting plate is disposed in the box assembly, and the mounting plate divides a space within the box assembly into a motor holding cavity and a transmission holding cavity. The motor is disposed in the motor holding cavity. The transmission is disposed in the transmission holding cavity, and the motor is power-coupled to the transmission such that the motor and the transmission are directly integrated through the box assembly without external connection of the motor and the transmission. The mounting plate is a monolithically integral part of the box assembly.