Pre-Assembled Inverter Assembly for Clean Motor-Gearbox Integration

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Solution Overview

Problem

The integration of inverter assemblies with electric motors and gearboxes in vehicles poses challenges due to technical cleanliness issues and handling difficulties caused by the heavy and oil-filled components, making it hard to test and handle the combined system effectively.

Innovation Solution

A pre-assembled inverter assembly with a support structure, integrated cooling channel, and separate compartmentalization, allowing for independent testing and protection from debris, reducing the need for a dedicated housing and enabling easier attachment to electric motors or gearboxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the inverter assembly is integrated in the motor housing with the gearbox, then the system is more compact, but handling and testing becomes difficult and technical cleanliness is compromised

Engineering Contradiction:

Improvesystem compactnessVSAvoidhandling and testing ease

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The inverter assembly is separated from the motor and gearbox, allowing it to be manufactured, tested, and handled independently before final installation. This segmentation enables the inverter to be pre-assembled on a carrier plate and tested separately, improving handling and testing ease while maintaining system compactness through modular integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inverter assembly is pre-assembled and tested before being installed in the motor housing. This preliminary action allows quality control and functional testing to be performed on the inverter independently, avoiding the need to disassemble the entire motor-gearbox-inverter system for testing.

Inventive Principle:

Principle #10Preliminary action

2Volume of moving object

If the inverter assembly is integrated with the gearbox, then space is optimized, but protection against oil and debris is reduced

Engineering Contradiction:

Improvespace utilizationVSAvoidcontamination from oil and debris

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A separate inverter compartment is introduced as an intermediary space between the inverter assembly and the oil-filled gearbox. This compartment provides physical separation and protection, preventing direct contact between the inverter and harmful factors like oil and debris, while still allowing compact integration within the motor housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If a separate inverter housing is used, then protection is improved, but mass and manufacturing costs increase

Engineering Contradiction:

Improveprotection against contaminationVSAvoidinverter assembly mass

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The inverter assembly is integrated with the motor housing structure, combining the housing functions. The motor housing serves dual purposes: protecting the motor and providing a mounting structure for the inverter compartment. This merging eliminates the need for a separate inverter housing, reducing mass and manufacturing costs while maintaining protection against contamination.

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If the inverter assembly is manufactured as a complete integrated system, then assembly is simplified, but testing and quality control become more difficult

Engineering Contradiction:

Improveassembly complexityVSAvoidtesting and quality control ease

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The manufacturing process is segmented into two stages: first, the inverter assembly is manufactured and tested as a separate module on a carrier plate; second, the tested inverter assembly is installed in the motor housing. This segmentation enables quality control and functional testing to be performed on the inverter independently, improving manufacturing precision while keeping assembly simple through modular integration.

Inventive Principle:

Principle #1Segmentation

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 configuration reduces the mass and manufacturing costs of the inverter assembly, provides better protection against contamination, and simplifies handling and testing by allowing separate assembly and testing of the inverter module before integration.

Implementation Method 1

the opposite side is directly attached to the cooling channel, in order to dissipate heat from the power electronics efficiently

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A cooling fluid can be pumped in a circuit through the cooling channel in order to dissipate heat from the inverter assembly

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4333270A1Inverter assembly for an electric motor or for a gearbox

Publication Date: 2024.03.06 VALEO ELECTRIFICATION

Figure 1

AI summary

Inverter assembly (10) for an electric motor (4) or for a gearbox, comprising a support structure, power electronics (15), a cooling channel (14), a DC-link capacitor (12) and a printed circuit board (PCB) (16), wherein the inverter assembly (10) is configured as a pre-assembled component, which is attachable to the electric motor (4) or to the gearbox. In addition, an electric motor or a gearbox assembly (1) and a method for assembling an electric motor (1) or a gearbox assembly are proposed.