Electric Motorcycle Battery Case With Integrated Motor Junction Box
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Solution Overview
Problem
Existing electric motorcycles lack an efficient and integrated electrical connection system that ensures durability and optimized tension in the drive system while accommodating a wide range of suspension travel without a gearbox.
Innovation Solution
The electric motorcycle integrates the battery case and electric motor with a unified frame, utilizing a high pole count motor and concealed electrical connections within a motor flange and junction box, which secures the motor and battery case together, providing a sealed passage for all electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric motor and battery case are integrated with a unified frame structure, then the durability and tension optimization of the drive system is improved, but the device complexity increases due to the need for sealed passages and integrated electrical connections
Solution Approach 1:
The battery case and motor mounting portion are merged into a unified frame structure, creating an integrated assembly that enhances durability and optimizes tension distribution. The battery case serves dual functions as both energy storage housing and structural frame component, while the motor mounting portion integrates the electric motor securely into the frame.
Solution Approach 2:
A sealed passage is provided within the battery case to serve as an intermediary pathway for electrical connections between the battery pack and power electronics, and between the power electronics and electric motor. This sealed passage protects electrical connections while maintaining the integrated structure.
2Reliability
If the electrical connections are concealed within the motor mounting portion and sealed passage, then the protection and organization of electrical connections is improved, but the ease of manufacture decreases due to the need for integrated sealed structures
Solution Approach 1:
The junction box is integrated into the battery case structure, combining the functions of electrical connection housing and structural support. This integration protects electrical connections while organizing them within a unified structure that is manufactured as a single component or pre-assembled unit.
Solution Approach 2:
The sealed passage acts as an intermediary structure that routes and protects electrical connections between components. By providing a dedicated sealed pathway within the battery case, the design protects connections from environmental factors while maintaining organized routing.
3Weight of moving object
If the battery case serves as both structural frame and electrical housing, then the weight reduction and space optimization are improved, but the manufacturing precision requirements increase to ensure proper sealing and integration
Solution Approach 1:
The battery case is designed with multi-functionality, serving simultaneously as the housing for the battery pack, the structural frame component, and the mounting structure for the electric motor. This eliminates the need for separate frame members and electrical housings, reducing overall weight and optimizing space utilization.
Solution Approach 2:
Multiple functional elements are merged into the battery case structure: the electrical housing, structural frame, and motor mounting provisions are combined into a single integrated component, reducing part count and weight while optimizing the use of available space.
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 integration enhances durability and optimizes tension in the drive system, allowing for a wide range of suspension travel without a gearbox, while ensuring efficient and concealed electrical connections.
Implementation Method 1
A battery pack includes a plurality of rechargeable electrochemical cells received within an internal cell cavity of a battery case
Data Source
AI summary
An electric motorcycle includes an electric motor configured to provide propulsion of the motorcycle, and a battery pack with a battery case. The electric motor and the battery case are coupled together to define an overlapping area. In the overlapping area, the battery case includes an integrated junction box for one or more electrical connections to the electric motor.