Powertrain Housing Layout for EMC Shielding and Collision Safety
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Solution Overview
Problem
Existing vehicle powertrain structures face challenges in ensuring electromagnetic compatibility (EMC) and safety during vehicle collisions, particularly due to potential damage to direct current (DC) wires and increased electromagnetic interference, as well as issues with wire length and placement of noise filters.
Innovation Solution
A vehicle powertrain structure with a drive system housing that accommodates a motor and a power converter, where the DC connector is integrated into the wall portion, and a noise filter is inserted in the DC wire, ensuring the DC wire is housed within a conductive material to prevent electromagnetic interference and protect against collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the DC wire is arranged outside the case or in a separate inverter case, then the DC wire can be easily connected between the battery and power converter, but the DC wire may be damaged during vehicle collision and electromagnetic interference may occur
Solution Approach 1:
The patent merges the DC wire routing with the drive system housing structure by providing a dedicated accommodation space within the housing. The DC wire is routed through the conductive housing material itself, combining the protective function of the housing with the wiring function, thereby protecting the DC wire during collisions while maintaining connection ease.
Solution Approach 2:
The conductive housing material acts as an intermediary between the DC wire and the external environment. The housing serves as both a structural element and a protective conduit for the DC wire, mediating the connection between the battery and power converter while providing collision protection and electromagnetic shielding.
2Adaptability or versatility
If the DC wire is made longer to reach the battery from the power converter, then the battery can be placed in different positions, but the wire length increases and electromagnetic interference risk increases
Solution Approach 1:
The conductive housing material serves as an intermediary shielding layer between the DC wire and external electromagnetic sources. By routing the DC wire through the housing structure, the housing material provides electromagnetic shielding that reduces interference risk even when the wire length increases to accommodate flexible battery placement.
Solution Approach 2:
The patent extracts the DC wire from the traditional separate wiring harness and integrates it into the drive system housing structure. The housing itself becomes the conduit, separating the wiring function from the traditional flexible harness and providing rigid protection against electromagnetic interference.
3Device complexity
If the noise filter is not provided in the DC wire, then the device complexity is reduced, but electromagnetic compatibility measures cannot be established
Solution Approach 1:
The patent merges the noise filter with the DC wire assembly by providing a dedicated mounting position within the housing structure. The filter is integrated into the housing-wire assembly rather than being a separate external component, reducing overall device complexity while maintaining electromagnetic compatibility.
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 structure establishes EMC measures, prevents electromagnetic interference, and ensures safety during collisions by protecting the DC wire and power converter, allowing for a compact design while maintaining reliability and ease of assembly.
Implementation Method 1
a drive system housing formed by using a conductive material and accommodating at least the motor; and a converter housing formed by using a conductive material and accommodating the circuit section
Implementation Method 2
a noise filter inserted in the DC wire are accommodated
Data Source
AI summary
To provide a vehicle powertrain structure capable of establishing an electromagnetic compatibility (EMC) measure and ensuring safety during a vehicle collision at the same time, a vehicle includes a drive system, a battery, and an inverter. The drive system includes a motor for vehicle travel and a motor housing made of a conductive material. The battery is a power source of the motor. The inverter has a circuit section and an inverter housing. The inverter housing is tightly joined to the motor housing. The motor housing has a direct current (DC) connector that is disposed in a rear wall portion, and has a DC bus bar and a ferrite core accommodated in a housing inner space. The DC bus bar connects the circuit section of the inverter and the DC connector. The ferrite core is a noise filter that is inserted in the DC bus bar.