Motor Assembly Connector Protection via Segmented Covers
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Solution Overview
Problem
Conventional motor assemblies for vehicles face challenges in protecting electrical components from flying stones and road surface water due to their placement near the road surface, which restricts the arrangement of components and increases the risk of damage during operation.
Innovation Solution
The motor assembly design includes a side connector cover and a lower connector cover that protect the connectors and cooling water hose from lateral impacts and road debris, while also reducing the axial length of the assembly and improving workability by routing the cooling water hose between the side connector cover and the inverter case, thus enhancing protection and reducing the risk of disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are disposed in the lower portion of the motor assembly facing the road surface, then the arrangement of components is restricted and the risk of contact with flying stones and road surface water increases, but this placement allows for direct access and simpler routing of connections
Solution Approach 1:
The invention divides the connector protection function into separate components: a side connector cover and a lower connector cover. The side connector cover protects connectors on the lateral side, while the lower connector cover protects connectors in the lower portion facing the road surface. This segmentation allows each cover to be optimized for its specific protective function without restricting overall component arrangement.
Solution Approach 2:
The connector covers act as intermediary protective elements between the electrical connectors and the harmful external environment (flying stones, water). These covers shield the connectors while allowing the wire harness to pass through designated openings, thus protecting the electrical components without complicating the routing arrangement.
2Reliability
If connectors and wire harnesses are exposed in the lower portion of the motor assembly, then installation and maintenance are easier, but the risk of disconnection due to impacts from flying stones increases
Solution Approach 1:
The connector covers are designed as shell structures that enclose the connectors and wire harnesses in the lower portion. These covers feature openings that allow the wire harness to pass through while providing protective enclosure. This design protects connections from impacts while maintaining accessibility for installation and maintenance operations.
Solution Approach 2:
The invention adds a vertical dimension to connector protection by introducing the lower connector cover that shields connectors from below. This dimensional approach allows the wire harness to be routed through the cover structure, protecting the connection point from lateral and vertical impacts while maintaining operational accessibility.
3Reliability
If the cooling water hose is routed externally without protection, then routing is simpler, but the hose is vulnerable to disconnection from lateral impacts
Solution Approach 1:
The side connector cover and lower connector cover are merged into an integrated protective structure. This combined cover system simultaneously protects both the electrical connectors and the cooling water hose routing, eliminating the need for separate protective elements and simplifying the overall design while providing comprehensive protection against lateral and vertical impacts.
Data Source
AI summary
A motor assembly includes a motor, a housing that accommodates the motor, an inverter electrically connected to the motor, an inverter case that accommodates the inverter, an auxiliary device provided in a lower portion of the housing to oppose a road surface, a wire harness that includes a first connector connected to a connector provided in the inverter case, a second connector connected to a connector provided in the auxiliary device, and an electric wire connecting the first connector and the second connector, and a lower connector cover provided in the lower portion of the housing and covering the second connector from a lower side.