Integrated EV Powertrain Layout for Compact Controller Packaging
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Solution Overview
Problem
Existing powertrain designs occupy excessive space due to separate and elevated controller placement, long wire harnesses, and inadequate height for rear drive vehicles, affecting vehicle appearance and functionality.
Innovation Solution
Integration of the controller, transmission, and electric motor with the controller mounted in an angled space between the transmission and electric motor, reducing the need for long wire harnesses and optimizing the powertrain's compact structure and reduced height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the controller is mounted separately on the frame above the transmission and electric motor, then the controller can be easily installed and maintained, but the powertrain occupies excessive space and has increased height
Solution Approach 1:
The controller is integrated with the transmission and electric motor to form a unified powertrain assembly. The controller is positioned in the angled space between the transmission and electric motor, merging previously separate components into a compact integrated structure that reduces overall mounting space while maintaining accessibility for installation and maintenance.
2Ease of repair
If the controller is mounted separately on the frame, then the controller can be independently replaced and serviced, but the wire harness becomes long and occupies excessive space
Solution Approach 1:
By integrating the controller with the transmission and electric motor assembly, the wire harness length is significantly reduced as the controller is now positioned adjacent to the electric motor it controls. The integrated design allows the controller to remain serviceable while eliminating the need for long wire harnesses that would occupy excessive vehicle space.
3Temperature
If the controller is mounted above the transmission and electric motor, then the controller has adequate cooling space, but the powertrain height increases affecting rear drive vehicle requirements
Solution Approach 1:
Instead of positioning the controller vertically above the transmission and electric motor (increasing height in the vertical dimension), the controller is placed in the angled horizontal space between these components. This dimensional repositioning maintains adequate spacing for cooling while keeping the powertrain height within requirements for rear drive vehicles.
4Volume of moving object
If the controller, transmission, and electric motor are integrated, then the powertrain structure becomes compact, but the controller mounting position becomes more complex
Solution Approach 1:
The integrated powertrain assembly is divided into modular components with the controller, transmission, and electric motor maintaining their functional independence. The controller is mounted on the transmission case in the angled space, creating a standardized mounting interface that simplifies assembly despite the integrated configuration. This segmentation approach enables compact volume while preserving manufacturing ease through modular assembly procedures.
Data Source
AI summary
A powertrain and a vehicle including the powertrain are provided. The powertrain includes: an electric motor; a transmission mounted to the electric motor and defining, together with the electric motor, an angled space for helping a half shaft of the transmission to extend along an axial direction of the transmission; a controller mounted to at least one of the electric motor and the transmission and electrically connected to the electric motor, where the controller, the transmission, and the electric motor are integrated together, at least one part of the controller being located in the angled space.