EV Powertrain Layout Along Power Flow for Compact High-Density Integration
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Solution Overview
Problem
Existing electric vehicle powertrains face challenges in miniaturization, heat dissipation, power density, reliability, and energy conversion efficiency due to suboptimal layout and structure designs of components, which affect energy transmission paths and overall performance.
Innovation Solution
A powertrain layout is designed along a power flow, integrating a motor and motor controller within an integrated housing, with specific orientations and non-overlapping projections of components to minimize energy loss and optimize space utilization, while ensuring compact and efficient energy transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If components are integrated into a compact powertrain, then space utilization is improved and costs are reduced, but heat dissipation performance deteriorates
Solution Approach 1:
The patent arranges components in a three-dimensional space with overlapping projections in certain directions while maintaining separation in critical directions. The motor and motor controller are positioned with their projections overlapping in the third direction but separated in the first direction, allowing compact integration while maintaining thermal management pathways.
2Power
If components are arranged compactly, then power density is improved, but energy conversion efficiency deteriorates due to suboptimal layout
Solution Approach 1:
The patent optimizes the local arrangement of components by positioning the motor controller and motor with specific projection overlaps and separations. The controller accommodating cavity and motor accommodating cavity have overlapping projections in the third direction, while maintaining separation in the first direction, creating optimal local conditions for both compactness and energy efficiency.
3Volume of moving object
If components are integrated closely, then miniaturization is achieved, but reliability deteriorates due to increased interference and energy loss
Solution Approach 1:
The patent employs asymmetric arrangement of components where the motor and motor controller are positioned with non-uniform spacing and orientation. The projections of the component cavities overlap partially in the third direction while maintaining separation in the first direction, creating an asymmetric layout that achieves miniaturization while managing interference through directional separation.
Data Source
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AI summary
Embodiments of this application provide a powertrain arranged along a power flow. The powertrain includes an integrated housing, a motor, and a motor controller. The integrated housing includes a motor accommodating cavity, a controller accommodating cavity, a direct-current input interface mounting hole, and an alternating-current output interface mounting hole. The motor includes a motor shaft and a motor winding. The direct-current input interface mounting hole and the alternating-current output interface mounting hole are arranged relative to each other along a first direction. The alternating-current output interface mounting hole and a wiring terminal of the motor winding are arranged on one side along the first direction. The direct-current input interface mounting hole and an output end of the motor shaft are arranged on the other side along the first direction. A projection of the controller accommodating cavity partially overlaps a projection of the motor accommodating cavity along a second direction. A projection of the direct-current input interface mounting hole, a projection of the alternating-current output interface mounting hole, and a projection of the motor shaft do not overlap along a third direction. The powertrain provided in this application has a compact layout and complies with a flow direction of a power flow, to help implement miniaturization and high power density of the powertrain.