Integrated Oil Module Layout for Flexible Motor Mounting

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Solution Overview

Problem

The existing oil module designs for electric motors require separate connections for the conveying device and heat exchanger, leading to complex assembly and reduced mounting options due to the need for an oil pan, which occupies installation space and limits orientation flexibility.

Innovation Solution

A compact oil module design featuring a main body with integrated fluidic connections on both sides, eliminating the need for an oil pan and allowing for variable mounting orientations, incorporating a conveying device and heat exchanger with fluidic pathways that can be oriented freely between inlet, pump, and cooler openings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate connections are provided for the conveying device and heat exchanger on the motor, then the components can be independently connected, but the assembly complexity increases and production becomes more complex

Engineering Contradiction:
Improveconnection flexibilityVSAvoidassembly complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the conveying device and heat exchanger into a single integrated oil module that attaches to the motor as one unit. The module includes a common mounting plate with integrated fluidic connections, where the conveying device inlet and heat exchanger inlet are connected to a common inlet, and outlets are similarly integrated. This merging reduces the number of separate connections required on the motor from four (individual connections for each component) to two (common inlet and outlet connections), thereby reducing assembly complexity while maintaining connection flexibility.

Inventive Principle:
Principle #5Merging (Combining)

2Reliability

If an oil pan is included in the oil module, then oil can be collected and fed back to the flow path, but the installation space requirement increases and mounting options are reduced

Engineering Contradiction:
Improveoil circulation reliabilityVSAvoidinstallation space
Core Design Contradiction:
ReliabilityVSArea of stationary object

Solution Approach 1:

The patent extracts and eliminates the oil pan component from the traditional oil module design. Instead of collecting oil in a pan and using gravity for feedback, the system uses a compact conveying device that directly pumps oil from the motor area back through the heat exchanger and into the flow path. This extraction of the oil pan reduces the installation space requirement and removes the constraint that required the module to be mounted in specific orientations, while the conveying device maintains reliable oil circulation through active pumping.

Inventive Principle:
Principle #2Taking out (Extraction)

3Reliability

If the oil module is designed with an oil pan forming the lowest point, then oil can be properly collected, but the mounting orientation is restricted and variability is reduced

Engineering Contradiction:
Improveoil collection efficiencyVSAvoidmounting orientation flexibility
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the gravity-based passive oil collection system (which required the oil pan to be at the lowest point) with an active pumping system. The conveying device uses mechanical pumping action to collect and circulate oil, eliminating the dependency on gravitational force and orientation. This substitution allows the oil module to be mounted in various orientations without compromising oil collection efficiency, thereby increasing mounting orientation flexibility while maintaining reliable oil circulation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 assembly, reduces installation space requirements, and enhances mounting flexibility while maintaining efficient oil circulation and temperature control, thereby improving the overall system's efficiency and ease of production.

Implementation Method 1

a conveying device (8), in particular an oil pump (10), which, during the operation, conveys the oil along a flow path (9)

Methodology Applied
Scientific EffectFluid transport through pump: Pump

Implementation Method 2

a heat exchanger (11), in particular an oil cooler (12), through which, for temperature-controlling, in particular for cooling, of the oil, the oil flows

Methodology Applied
Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS11906032B2Oil module
Publication Date: 2024.02.20 MAHLE INT GMBH
  • US11906032B2 patent drawing
  • US11906032B2 patent drawing
  • US11906032B2 patent drawing

AI summary

An oil module may include a conveying device for conveying oil along a flow path, a heat exchanger for temperature-controlling the oil, and a main body having a front side and a back side. The front side may include (i) an inlet opening and (ii) an outlet opening. The back side may include (i) at least one pump opening fluidically connected with the inlet opening, (ii) a first cooler opening fluidically connected with the at least one pump opening, and (iii) a second cooler opening fluidically connected with the outlet opening. The conveying device may be arranged on the back side and fluidically connected with the at least one pump opening. The heat exchanger may be arranged on the back side and fluidically connected with the first cooler opening and the second cooler opening.