Rear-Axial Motor Controller Layout for Compact EV Drive Assemblies
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Solution Overview
Problem
Existing drive assemblies in new energy vehicles face challenges in optimizing the integration of the motor and motor controller, particularly in terms of space utilization, cooling efficiency, and ease of assembly, while maintaining operational stability.
Innovation Solution
A drive assembly design that integrates a motor controller at the rear end in the axial direction, utilizing a cylindrical housing with a partition wall to separate motor and controller chambers, featuring a bearing, rotor, stator, and three-phase terminals, along with liquid cooling channels and collision avoidance grooves to enhance space utilization and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor and motor controller are integrated to reduce footprint, then space utilization is improved, but the complexity of connection structures and layout optimization increases
Solution Approach 1:
The housing is divided into a motor chamber and a controller chamber by a partition wall, allowing the motor and controller to be spatially separated while maintaining integration within a single housing structure. This segmentation simplifies the connection structures by providing dedicated mounting areas and reducing interference between components.
Solution Approach 2:
The partition wall is arranged in the radial direction of the housing, creating a radial segmentation rather than axial or longitudinal division. This radial arrangement optimizes the layout of connection structures and electrical components by utilizing the circumferential space efficiently, reducing the complexity of wiring and mechanical connections.
2Volume of moving object
If the motor and motor controller are integrated, then space for passengers and batteries is increased, but the cooling system design becomes more challenging
Solution Approach 1:
The partition wall not only separates the motor and controller chambers but also serves as a thermal management boundary. This segmentation allows for independent cooling channel design in each chamber, simplifying the overall cooling system by treating heat dissipation zones separately rather than managing a complex integrated thermal field.
Solution Approach 2:
The partition wall performs multiple functions: structural separation of chambers, mounting support for electrical connection pins, and thermal management boundary. This multi-functionality reduces the need for separate cooling components, simplifying the cooling system design while maintaining effective heat dissipation for both motor and controller.
3Ease of manufacture
If electrical connection pins are disposed through the partition wall, then electrical connection is achieved, but the reliability of electrical connection may be affected by misalignment or collision
Solution Approach 1:
Collision avoidance grooves are pre-formed in the partition wall at the locations where electrical connection pins pass through. These grooves provide predetermined clearance paths that prevent misalignment and collision between the pins and the partition wall during assembly and operation, thereby ensuring reliable electrical connection without requiring complex alignment mechanisms.
4Ease of manufacture
If the projection planes of single-phase terminals are located between bearing and stator, then assembly is simplified, but the space for terminal arrangement is constrained
Solution Approach 1:
The single-phase terminals are arranged in the radial direction of the housing, with their projection planes positioned between the bearing and stator in the radial dimension. This radial arrangement utilizes the available circumferential space efficiently, allowing for simplified assembly along the axial direction while maintaining adequate terminal arrangement space through optimal radial positioning.
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 design effectively reduces occupied space, improves integration, enhances operational stability, and optimizes heat dissipation through efficient heat conduction and liquid cooling, facilitating easy assembly and disassembly.
Implementation Method 1
optimizes heat dissipation through efficient heat conduction and liquid cooling
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present disclosure relates to the field of new energy, and provides a drive assembly with a motor controller and a vehicle including the same. A cylindrical housing is provided therein with a chamber, a partition wall provided on an inner wall of the housing divides the chamber into a motor mounting chamber and a controller mounting chamber. The present disclosure utilizes a space at a rear end in an axial direction of a motor, and designs a partition wall and a bearing, such that a rotor is rotatably provided in a motor mounting chamber and a motor controller is provided in a controller mounting chamber. The present disclosure designs a drive assembly with a motor controller at a rear end in the axial direction, thereby improving the device integration and space utilization, effectively reducing the occupied space, and realizing high integration of the motor controller and the drive assembly.