Powertrain Sensor Layout With Integrated Rotor and Control Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing powertrain assembly design in vehicles is inefficient in optimizing spatial layout and cost due to the axial space occupied by the motor position sensor and the need for long wiring harnesses between the sensor and electronic control assembly, leading to increased size and weight.
Innovation Solution
The powertrain assembly integrates the sensor rotor into the first rotary shaft and the sensor stator into the electronic control assembly, eliminating the need for additional axial space and reducing the axial size, while also eliminating the need for long wiring harnesses by integrating the motor position sensor components into existing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor position sensor is arranged at the opposite side of the motor from the electronic control assembly, then the sensor can be connected through a wiring harness, but the axial size of the drive assembly expands and occupies additional axial mounting space
Solution Approach 1:
The patent merges the motor position sensor with the electronic control assembly by integrating the sensor stator into the control assembly housing and routing the sensor rotor shaft through the same assembly. This consolidation eliminates the need for separate mounting space on the opposite side of the motor, thereby reducing the axial size of the drive assembly while maintaining reliable electrical connections through integrated wiring.
2Length of moving object
If the motor position sensor is integrated into the powertrain assembly, then the axial size is reduced, but the sensor components require additional mounting space and structural integration
Solution Approach 1:
The electronic control assembly is designed to serve multiple functions: it houses the control electronics and simultaneously integrates the motor position sensor components. The control assembly housing acts as a multi-functional structure that accommodates both the sensor stator and the wiring harness connections, eliminating the need for separate dedicated sensor mounting structures and reducing overall integration complexity.
3Adaptability or versatility
If a long wiring harness is used to connect the motor position sensor and electronic control assembly, then the components can be positioned at opposite sides, but electromagnetic interference and shielding costs increase
Solution Approach 1:
The patent extracts the sensor signal transmission function from a long external wiring harness by integrating the sensor stator directly into the electronic control assembly. This extraction eliminates the need for long wiring harnesses that would extend between opposite sides of the motor, thereby removing the source of electromagnetic interference and the associated shielding requirements while maintaining the necessary electrical connections.
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 integration reduces the overall weight and size of the powertrain assembly, improves spatial layout, and avoids electromagnetic interference and shielding costs, enhancing cost-effectiveness.
Implementation Method 1
the sensor stator is a coil structure arranged on the circuit board... one of the first induction coil etching layer and the second induction coil etching layer is configured to induce a sinusoidal signal, and an other one... is configured to induce a cosinoidal signal
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The disclosure relates to a powertrain assembly, a chassis and a vehicle. The powertrain assembly includes a motor (1), a motor position sensor (4), a first rotary shaft (2) and an electronic control assembly (3), where the motor position sensor (4) is configured to monitor a position of the motor and includes a sensor rotor (41) and a sensor stator (42); a first end of the first rotary shaft (2) is connected to the motor (1), and the sensor rotor (41) is arranged at a second end of the first rotary shaft (2); and the sensor stator (42) is arranged in the electronic control assembly,(3) and the second end of the first rotary shaft (2) is in the electronic control assembly (3).