EV Driving Unit Connector Layout for Compact Motor-PDU Packaging
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Solution Overview
Problem
The existing driving units for electric vehicles are too large, which reduces the space available in the passenger and luggage compartments, necessitating a reduction in size without compromising performance or increasing the unit's height.
Innovation Solution
The driving unit is designed with the first and second connecting portions between the rotary electric machine and the electric power conversion device in the orthogonal direction, with coolant introduction and discharge pipes positioned to minimize exposure to coolant leaks and optimize space usage, allowing for a compact design while maintaining effective cooling and connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electric power conversion device is directly fixed to the rotary electric machine, then the integration is improved, but the height dimension increases leading to layout constraints
Solution Approach 1:
The patent transitions from a vertical stacking arrangement (increasing height) to a horizontal side-by-side arrangement (increasing width) of the electric power conversion device relative to the rotary electric machine. This dimensional change allows integration without increasing the height dimension, thereby resolving the layout constraints while maintaining integration benefits.
2Volume of moving object
If the driving unit size is reduced, then the passenger compartment or luggage compartment space increases, but the space between components for connecting portions decreases
Solution Approach 1:
The patent merges the first connecting portion (electric power connection) and the second connecting portion (sensor connection) into a shared spatial region between the rotary electric machine and the electric power conversion device. This consolidation allows both connections to coexist in a compact arrangement, enabling driving unit size reduction while maintaining necessary connection spaces.
3Ease of manufacture
If the first connector is positioned above the rotation axis, then the electrical connection is optimized, but the connector may be exposed to coolant leaks
Solution Approach 1:
The patent introduces a protective structure (such as a protective cover or housing) as an intermediary element that shields the first connector positioned above the rotation axis from coolant leaks. This mediator allows the connector to maintain its optimized electrical connection position while protecting it from the harmful effects of coolant exposure.
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 configuration effectively reduces the size of the driving unit by utilizing available space between the rotary electric machine and the electric power conversion device, preventing coolant exposure and ensuring efficient cooling and maintainability, thus addressing the space constraints while maintaining performance.
Implementation Method 1
at least a part of the first connecting portion is immersed in the first coolant stored in the rotary electric machine accommodating portion of the rotary electric machine case
Data Source
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AI summary
A driving unit (30) includes a rotary electric machine MOT which has a rotation axis CL extending in a horizontal direction, a rotary electric machine case (40), and an electric power conversion device PDU. The electric power conversion device PDU is disposed on one side of the rotary electric machine MOT in an orthogonal direction. A first coolant LB is stored in a rotary electric machine accommodating portion (41) of the rotary electric machine case (40). The driving unit (30) has a first connecting portion (70) electrically connecting the rotary electric machine MOT and the electric power conversion device PDU and a second connecting portion (60) electrically connecting a sensor provided to the rotary electric machine MOT and the electric power conversion device PDU. The first connecting portion (70) and the second connecting portion (60) are disposed between the rotary electric machine MOT and the electric power conversion device PDU in the orthogonal direction.