Integrated EV Powertrain Layout With Shorter Wire Harness Routing
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Solution Overview
Problem
Existing powertrain systems have a large and inefficient layout due to separate components, which occupy significant space in vehicles and require long wire harnesses, affecting the vehicle's appearance and increasing protection needs.
Innovation Solution
The powertrain integrates an electric motor, transmission, and controller, with the controller mounted in an angled space defined by the electric motor and transmission, creating a compact structure and simplifying wire harness connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the controller, transmission, and electric motor are arranged separately and fixed by mold assembly bolts, then each component can be independently manufactured and maintained, but the overall structure occupies a large space and increases device complexity
Solution Approach 1:
The controller is integrated into the transmission housing, with the controller mounting plate formed as an integral part of the transmission case. This merging of components eliminates the need for separate mounting structures and reduces the overall space required for the powertrain assembly.
Solution Approach 2:
The controller is nested within the transmission housing structure. The controller mounting plate is positioned inside the transmission case, utilizing the existing transmission housing space to accommodate the controller, thereby reducing the external dimensions of the powertrain.
2Reliability
If the controller is mounted separately above the transmission and electric motor, then the controller has independent mounting and cooling, but it occupies a large space and increases the powertrain height
Solution Approach 1:
The controller mounting plate is integrated with the transmission case, creating a unified structure that reduces the vertical space required. The controller is mounted within the transmission housing rather than above it, thereby reducing the overall powertrain height.
Solution Approach 2:
The controller is repositioned from a vertical arrangement (above the transmission) to a horizontal arrangement (within the transmission housing). This dimensional change allows the controller to be accommodated within the existing transmission footprint without increasing the powertrain height.
3Reliability
If a long three-phase wire is used to connect the controller and electric motor, then electrical connection is achieved, but the wire harness occupies large space and requires high protection level
Solution Approach 1:
The three-phase wire connection is extracted from the external wire harness and integrated directly into the transmission housing structure. The wire is routed through the transmission case to connect the controller and electric motor, eliminating the need for long external wire harnesses.
Solution Approach 2:
The electrical connection structure is merged with the transmission housing. The wire routing channels and mounting structures are integrated into the transmission case, consolidating the wire harness within the existing transmission boundaries and reducing external space requirements.
Data Source
AI summary
A powertrain includes an electric motor; a transmission mounted to the electric motor; and a controller mounted to at least one of the electric motor and the transmission and electrically connected to the electric motor. The controller, the transmission, and the electric motor are integrated together. The controller includes a controller body, a controller support, and a wire harness rack. The controller body is disposed on the controller support, and the controller support is mounted to at least one of the electric motor and the transmission. The wire harness rack is connected to the controller support and the electric motor and having a wire arrangement groove. A connecting wire harness between the controller and the electric motor is disposed in the wire arrangement groove.