Powertrain Inverter Housing Layout for Low Height and EMI Control
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Solution Overview
Problem
Existing vehicle powertrain structures face challenges in reducing the upper surface height of the power converter while minimizing the horizontal occupied area, leading to potential interference with peripheral devices and increased risk of damage during collisions.
Innovation Solution
A vehicle powertrain structure with a drive system housing and converter housing that includes a downward protruding portion, where secondary circuit components are aligned in the overlapping area, and a conductive member connects the circuit section and power supply connection portion, utilizing a ferrite core and Y capacitor for noise filtration and compact arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the power converter is arranged above the drive system to reduce space occupation, then the horizontal occupied area is reduced, but the upper surface height increases causing interference with peripheral devices
Solution Approach 1:
The patent utilizes the vertical dimension by creating a downward protruding portion in the converter housing. This allows secondary circuit components to be arranged below the main housing plane, effectively using three-dimensional space rather than expanding horizontally or vertically in a single direction. The downward protruding portion extends in the vertical direction while accommodating components that would otherwise increase horizontal footprint.
Solution Approach 2:
The secondary circuit components are nested within the downward protruding portion of the converter housing. This nesting arrangement allows the components to be contained within the existing housing structure's vertical envelope, rather than requiring additional horizontal space. The conductive member is also nested within this protruding portion, connecting the battery to the circuit section through the downward extension.
2Length of stationary object
If the upper surface height of the power converter is suppressed to be low, then interference with peripheral devices is avoided, but the horizontal occupied area increases
Solution Approach 1:
Instead of expanding horizontally to accommodate all components within a low height constraint, the patent transitions to utilizing the vertical dimension through the downward protruding portion. This dimensional shift allows components to be arranged in the vertical direction below the main housing, maintaining a low upper surface height while avoiding horizontal expansion.
3Length of stationary object
If components are arranged flat to reduce upper surface height, then the power converter height is reduced, but the occupied area in horizontal direction increases
Solution Approach 1:
The patent abandons the flat two-dimensional arrangement in favor of a three-dimensional configuration with the downward protruding portion. This allows components to be distributed in the vertical direction rather than being constrained to a flat plane, thereby reducing the upper surface height without requiring increased horizontal occupied area.
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
The structure effectively suppresses the upper surface height and horizontal expansion of the power converter, preventing noise leakage and electromagnetic interference, enhancing safety and reducing damage during collisions.
Implementation Method 1
utilizing a ferrite core and Y capacitor for noise filtration and compact arrangement
Data Source
AI summary
A vehicle includes: a drive system having a motor; an inverter arranged in an upper portion of the drive system; and a DC bus bar connecting a circuit section of the inverter and a DC connector. An inverter housing has: a housing main portion extending in a front-rear direction along the drive system; and a downward protruding portion protruding downward from a front end portion of the housing main portion. The circuit section includes: a main circuit component arranged other than in a rear end area overlapping the downward protruding portion in a plan view; and a secondary circuit component arranged in the rear end area, and the DC bus bar is connected to the circuit section in the downward protruding portion.