Power Conversion Device Connector Top Access for Compact Drive Units
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Solution Overview
Problem
Existing drive units for electric vehicles, which directly fix a power conversion device to a rotating electric machine, face challenges in downsizing due to the requirement of a large tool space for connector access, limiting layout flexibility and increasing the height dimension.
Innovation Solution
A drive unit design where the power conversion device is arranged on one side of the rotating electric machine in an orthogonal direction, with a first connector portion on the upper portion facing the horizontal direction, allowing access from above, eliminating the need for a large tool space within the power conversion device and enabling size reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a large tool space is secured inside the power conversion device for tool access during connection work, then the ease of repair is improved, but the volume of the power conversion device increases
Solution Approach 1:
The connector portion is repositioned from the traditional side-access configuration to the upper surface of the power conversion device. This dimensional change allows tool access from the top direction rather than requiring internal tool space, enabling connection work from a different spatial dimension and eliminating the need for large internal tool spaces.
Solution Approach 2:
The tool access function is extracted from the internal structure of the power conversion device. By placing the connector portion on the upper surface, the tool access requirement is separated from the device's internal volume, allowing the device to be compact while still providing adequate access space for connection work.
2Volume of moving object
If the power conversion device is downsized by reducing tool space, then the volume of the power conversion device is reduced, but the ease of repair deteriorates due to limited tool access
Solution Approach 1:
The connector portion is positioned on the upper surface of the power conversion device, changing the access direction from horizontal (side access) to vertical (top access). This dimensional reconfiguration enables tool access without requiring large internal tool spaces, achieving device downsizing while maintaining ease of repair.
Solution Approach 2:
The upper surface of the power conversion device serves as an intermediary access point. Instead of requiring direct internal access through large openings, the connector portion on the upper surface acts as a mediator that provides tool access while maintaining a compact device structure.
Data Source
AI summary
A drive unit includes: a rotating electric machine having a rotation axis extending in a horizontal direction; a rotating electric machine case which accommodates the rotating electric machine; and a power conversion device converting electric power supplied to the rotating electric machine and electric power supplied from the rotating electric machine. The power conversion device is arranged on one side of the rotating electric machine. A first connector portion, to which a power line connected to a battery is connected, is provided on an upper portion of the power conversion device to face the horizontal direction. The first connector portion includes an internal connection portion connected to a conductive member arranged inside the power conversion device, and the first connector portion has a configuration in which the internal connection portion permits access from an upper side of the power conversion device.