Integrated Power Conversion Housing for Electric Motor Height Reduction
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Solution Overview
Problem
Existing mechano-electrical integrated power conversion devices for electric automobiles have a large overall height due to the assembly of power drive units and voltage converters, which poses challenges in compactness and clearance issues when mounted on electric motors.
Innovation Solution
A mechano-electrical integrated power conversion device with a housing box design that disperses the power drive unit and voltage converter above and to the side of the electric motor, utilizing a single housing box with integrated die-cast molding and a cooling jacket to minimize height and weight, while ensuring efficient cooling and safety through internal wiring and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the power drive unit and voltage converter are assembled in a layered state with the high voltage electric module body disposed above the electric motor, then the power conversion device can be integrated, but the overall height becomes large and clearance with the hood becomes small
Solution Approach 1:
The housing box is divided into a box body main portion and a box body remainder portion, with the power drive unit and voltage converter housed in separate chambers (first housing chamber and second housing chamber respectively). This segmentation allows the components to be arranged in different spatial zones rather than stacked vertically, reducing the overall height while maintaining integration.
Solution Approach 2:
The patent transitions from a vertical stacking arrangement (layered state) to a horizontal/dispersed arrangement. The power drive unit is positioned above the electric motor while the voltage converter is disposed to the side, utilizing horizontal space instead of vertical space. This dimensional change effectively reduces the overall height of the integrated power conversion device.
2Length of stationary object
If the power drive unit and voltage converter are dispersed above and to the side of the electric motor, then the overall height is minimized, but the number of components and housing structures may increase
Solution Approach 1:
The patent merges the housing structures for the power drive unit and voltage converter into a single integrated housing box. The box body main portion and box body remainder portion form a unified structure that contains both components, eliminating the need for separate housing boxes and reducing the overall component count despite the dispersed arrangement of internal components.
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 solution minimizes the overall height of the power conversion device, suppresses the increase in components, enhances safety by internalizing high-voltage wires, and reduces weight and cost by eliminating fastening screws and waterproof couplers, while maintaining efficient cooling and compactness.
Implementation Method 1
a cooling jacket comprises the box body remainder portion and a heat-dissipating lid body mounted on the box body remainder portion so as to partition off part of the second housing chamber, and the voltage converter is housed within the second housing chamber so as to be in contact with the heat-dissipating lid body
Data Source
AI summary
A mechano-electrical integrated power conversion device includes power drive unit and voltage converter that are housed within a single housing box and formed as a module. The box includes box body, upper lid member, and side lid member. The box body includes: a box body main portion disposed above a casing of an electric motor; and a box body remainder portion connected integrally to a side wall of the box body main portion and extending downwardly to a side of the casing. The upper lid member is mounted on the box body main portion, a first housing chamber being defined therebetween and housing the power drive unit. The side lid member is mounted on a side open end part of the box body remainder portion, a second housing chamber being defined between the box body remainder portion and the side lid member and housing the voltage converter.