L-Shaped E-Drive Layout for Motor Power and Weight Balance
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Solution Overview
Problem
The existing layouts of electrical drive units in electric vehicles, such as the 'T-shaped' architecture, limit the size and type of motors that can be used, leading to reduced power output, weight balance issues, and increased space requirements, along with potential failure points in modular housing designs under high torque and stress.
Innovation Solution
An improved electrical drive unit layout with a transversely arranged motor and an L-shaped gearbox configuration, where the gearbox is offset from the centerline, allowing for longer, more powerful motors and reducing the size of the power inverter housing, combined with a single integrated housing to enhance stiffness and reduce failure points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the gearbox is positioned on the centerline with motor and power inverter on opposite sides (T-shaped layout), then the assembly is compact in transverse direction, but the motor length is limited and maximum power output is reduced
Solution Approach 1:
The patent transitions from a T-shaped layout (motor and inverter on opposite sides of centerline) to an L-shaped layout where both motor and inverter are positioned on the same side of the centerline. This dimensional reconfiguration allows the motor to extend further in the transverse direction without increasing the overall assembly width, thereby maximizing motor length and power output while maintaining compact transverse footprint.
2Area of stationary object
If the motor is positioned on one side of the centerline, then the assembly width is reduced, but the weight balance is offset and vehicle handling is negatively impacted
Solution Approach 1:
The patent employs asymmetric positioning of components within the L-shaped layout. The motor, being the heaviest component, is positioned closer to the centerline while the lighter power inverter is positioned further away on the same side. This asymmetric arrangement reduces the overall assembly width compared to centered configurations, while the strategic positioning of the heavy motor minimizes weight balance offset and maintains acceptable vehicle handling characteristics.
3Ease of manufacture
If a multi-piece housing with separate motor and gearbox housings is used, then manufacturing and assembly flexibility is improved, but the number of connection points increases and reliability decreases under high torque and stress
Solution Approach 1:
The patent integrates the motor housing and gearbox housing into a single unified housing structure. This merging eliminates the interface between separate housings, thereby removing potential failure points caused by bolts and connections under high torque and stress conditions. The single housing design maintains manufacturing flexibility through modular internal component arrangement while significantly improving reliability by eliminating connection interfaces that are susceptible to vibration, noise, and leakage issues.
4Power
If the motor is larger than the power inverter, then more space is required for the assembly, but the power output is increased
Solution Approach 1:
The L-shaped layout repositions both the motor and power inverter on the same side of the centerline, allowing the larger motor to extend further in the transverse direction without proportionally increasing the overall assembly width. This spatial optimization enables accommodation of a larger, more powerful motor while minimizing the increase in assembly footprint, as both components share the same transverse space efficiently.
Data Source
AI summary
An electrical drive unit includes an electric motor having a first transverse end and an opposite second transverse end, and a gearbox including a main gearbox portion and a transverse projection portion. The motor is attached to the gearbox at the second transverse end of the motor and is located on a first transverse side of the main gearbox portion in a first transverse direction. The transverse projection portion of the gearbox includes at least one gear of the gearbox and extends from the first transverse side of the main gearbox portion such that the transverse projection portion and at least a portion of the at least one gear extends in the first transverse direction beyond the second transverse end of the motor.