Modular Electric Motor Axial Plug Connections
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Solution Overview
Problem
Electric vehicles face challenges in achieving durability, wide temperature usability, simplicity, and cost-effectiveness while accommodating various performance classes and allowing for easy product variants, with existing solutions not adequately addressing assembly efficiency and repairability.
Innovation Solution
The electric vehicle design features a plug connection system between electric motor modules with axial movement, separating live parts from fluid-carrying components for enhanced safety, and includes a modular structure with regulated cooling and power connections, allowing for easy assembly and repair, with the motor and battery positioned to optimize weight distribution and road holding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric motor modules are connected using traditional connection methods, then structural stability is maintained, but assembly time increases and repairability decreases
Solution Approach 1:
The electric motor is divided into modular electric motor modules that can be independently assembled and disconnected. Each module contains complete functional elements (stator, rotor, housing), enabling rapid assembly through plug connections while maintaining full functionality of individual units for repair purposes.
Solution Approach 2:
The connection system transitions from static permanent connections to dynamic reversible plug connections. The axial plug connectors allow modules to be quickly connected and disconnected along the axial direction, enabling both rapid assembly and easy replacement of failed modules without complex disassembly procedures.
2Reliability
If live parts and fluid-carrying parts are integrated in the same connector, then device complexity is reduced, but operational safety decreases
Solution Approach 1:
Live electrical parts and fluid-carrying parts are extracted and separated into different axial plug connectors. The first axial plug connector handles cooling medium connections while the second axial plug connector handles power connections, eliminating the risk of electrical shocks during coolant maintenance and preventing fluid contamination of electrical components.
Solution Approach 2:
Different types of connections (coolant and power) are mediated through separate axial plug connectors positioned at different locations. This intermediary separation ensures that coolant connections and electrical connections are handled independently, with appropriate sealing and protection for each type of connection.
3Productivity
If motor modules are designed for easy assembly, then productivity increases, but manufacturing precision requirements worsen
Solution Approach 1:
The axial plug connectors are designed with asymmetric coupling features including coupling projections and coupling recesses. This asymmetric design provides automatic alignment guidance during assembly, ensuring precise positioning of modules along the axial direction while maintaining simple assembly operations through the unidirectional coupling mechanism.
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 results in a quick and efficient assembly process, improved operational safety, and enhanced durability, enabling the production of various performance models with optimized weight distribution and driving characteristics.
Implementation Method 1
the cooling medium connection (188) is connected to a cooling channel (184) which runs through the rotor shaft (40)
Implementation Method 2
the first axial plug connector (200) and the second axial plug connector (202) can be coupled to one another by moving the electric motor modules (38.1, 38.2) towards one another in a coupling direction (K)
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
The invention relates to an electric vehicle (10), in particular an electric car, comprising (a) a first axle (12), (b) a second axle (14), (c) an electric motor (18) for driving at least one of the axles and (d) a battery (22) for supplying the electric motor (18) with electrical energy. According to the invention, the electric motor (18) is composed of a first electric motor module (38.1) and at least one second electric motor module (38.2, 38.3), (f) wherein the electric motor modules (38.1, 38.2, 38.3) are arranged one behind the other with respect to a motor rotation axis (D18) and have a common rotor shaft (40) or coupled rotor shafts (41), and (g) the first electric motor module (38.1) and the second electric motor module (38.2) are connected to each other by means of a plug connection (204) which has at least one cooling medium connection (208) for cooling medium and at least one current connection (210) for power current.