Electric Power Train Casing Integration for Volume Reduction
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Solution Overview
Problem
The existing power train configurations for vehicles with electric motorization are bulky due to multiple casings, which increase weight, complicate maintenance, and require extensive sealing and assembly areas, making them inefficient and difficult to handle.
Innovation Solution
A power train design where the power electronics system and electric motor are housed in separate casings that abut along a parallel interface direction, with an additional casing for the electric filter statically supported by the power electronics casing, reducing the number of assembly and sealing areas and forming a self-supporting structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple casings are superposed to house power electronics system, motor, and electric filter separately, then each component is protected and organized, but the overall volume and weight of the power train increase significantly
Solution Approach 1:
The patent merges the housing of the power electronics system and the electric filter into a single integrated casing structure. The power electronics casing and filter casing share common walls and mounting surfaces, eliminating the need for separate enclosed spaces for each component. This consolidation reduces the total volume occupied by multiple stacked casings while maintaining proper protection and organization of all components.
Solution Approach 2:
The integrated casing structure serves multiple functions simultaneously: it houses the power electronics system, accommodates the electric filter, provides structural support for mounting other components, and offers protection for all enclosed elements. This multi-functional design eliminates the need for dedicated single-purpose casings for each component.
2Reliability
If multiple casings are assembled in a parallelepiped shape on the motor casing, then all components are contained, but the number of sealing devices and assembly areas increases
Solution Approach 1:
The patent combines the power electronics casing and filter casing into a single integrated structure with shared walls and common mounting surfaces. This eliminates the need for separate sealing interfaces between multiple casings, reducing the total number of sealing devices required while maintaining proper containment of all components.
3Stability of the object's composition
If attachment areas are added to the cylindrical motor casing to support additional casings, then the structure becomes more stable, but the attachment areas become fragile and increase overall weight
Solution Approach 1:
The integrated casing structure eliminates the need for separate attachment areas on the motor casing by providing a unified mounting platform. The combined power electronics and filter housing acts as a single stable structure that distributes loads more effectively, reducing the need for additional reinforcement and attachment points on the cylindrical motor casing.
Solution Approach 2:
The patent transitions from adding material in the radial direction (attachment areas on the cylindrical casing) to utilizing the axial dimension for mounting. The integrated casing structure extends along the axis of the motor, providing stable mounting surfaces without requiring radial additions to the cylindrical casing, thereby maintaining structural integrity without increasing weight.
4Reliability
If multiple casings are used to house different components, then each component is protected, but maintenance operations become more difficult as several casings must be dismantled to access internal units
Solution Approach 1:
The patent integrates the power electronics and filter into a single housing structure with unified access points. Maintenance personnel can access both the power electronics system and the electric filter through the same casing opening, eliminating the need to dismantle multiple separate casings to reach different components.
5Reliability
If separate casings are used for power electronics system and motor, then each component is isolated and protected, but the overall assembly becomes more complex and harder to handle
Solution Approach 1:
The patent combines the power electronics system housing with the motor housing into a single integrated assembly. This unified structure maintains proper isolation and protection of internal components while reducing the number of separate parts that need to be handled during assembly and installation, thereby improving ease of operation.
Data Source
AI summary
An electric power train for an automotive vehicle includes an electric motor, a power electronics system, a first casing containing the power electronics system, a second distinct casing that contains the motor, and a third distinct casing. The first casing includes a bottom and an opening for access to the power electronics system. The second casing bears on an exterior wall of the first casing bottom. The opening is opposite the second casing. The third casing is assembled on the first casing and contains an electric filtering system. The first casing includes a platform, which juts out relative to at least one portion of the first casing and on a face of which platform an assembly contour for assembling the third casing on the first casing is defined. The assembly contour is substantially parallel to an axial direction of the motor. The platform overhangs the second casing.