Power Electronics Module Direct Contact E-Motor Connection
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Solution Overview
Problem
Existing hybrid drive systems for vehicles with both internal combustion engines and electric motors face challenges in reducing costs and assembly complexity while enhancing reliability, particularly in the design and functionality of clutch devices and power transmission systems.
Innovation Solution
A power electronics module with direct contact devices for connecting to an E-motor power connection, eliminating the need for high-voltage cables, which simplifies assembly, reduces costs, and increases safety by providing a secure and stable galvanic connection between the power electronics module and the hybrid module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage cables are used to connect the power electronics module and hybrid module, then electrical connection is achieved, but costs increase and safety decreases
Solution Approach 1:
The patent removes the high-voltage cable from the system by implementing direct contact devices that establish electrical connection without intermediate cable components. This extraction of the cable eliminates safety risks associated with cable malfunction and reduces overall system complexity.
Solution Approach 2:
The contact device integrates both mechanical connection and electrical conduction functions into a single component. The contact device merges the previously separate functions of cable connection and electrical contact, eliminating the need for separate cable assemblies and reducing system complexity.
2Ease of manufacture
If high-voltage cables are used for E-motor power connection, then electrical power transmission is achieved, but assembly expense increases
Solution Approach 1:
The high-voltage cable is completely removed from the assembly process. The direct contact devices establish electrical power transmission through integrated contact points, eliminating the need to manufacture, supply, and assemble separate cable components.
Solution Approach 2:
The contact devices are pre-integrated into the power electronics module and hybrid module assemblies respectively. This preliminary integration of contact points eliminates the need for separate cable assembly steps during final assembly, reducing assembly expense and complexity.
3Reliability
If direct contact devices are used for E-motor power connection, then safety and reliability are improved, but manufacturing precision requirements increase
Solution Approach 1:
The contact devices are designed with self-aligning features that ensure reliable electrical contact through form-fitting geometric relationships. The contact surfaces are configured to automatically align during assembly, reducing the impact of manufacturing tolerances and ensuring consistent electrical connection without requiring extremely tight precision controls.
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 solution reduces costs and enhances safety by eliminating high-voltage cables, improving the reliability of the hybrid drive system through secure and stable electrical connections, while also simplifying the assembly process.
Implementation Method 1
providing a secure and stable galvanic connection between the power electronics module and the hybrid module
Data Source
AI summary
The invention relates to a power electronics module for operating a hybrid module for a hybrid drive unit, said hybrid module includes an E-motor which can produce a drive torque of the hybrid drive unit. The power electronics module includes an E-motor connection on the power electronics module side which has a contact device on the power electronics module side which is connected to the power electronics module for directly connecting to a contact device on the hybrid module side provided on the hybrid module, of a hybrid module-sided E-motor power connection. The invention also relates to a hybrid module for a hybrid drive unit and to a method for mounting and/or assembling a hybrid module for a hybrid drive unit.