Integrated Electric Scooter Power Assembly with Internal Wiring
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Solution Overview
Problem
Conventional electric scooters require significant space and have exposed, disordered wires for connecting independent motor, gearbox, and controller components, making them bulky and difficult to assemble and repair.
Innovation Solution
Integration of the motor, gearbox, and controller into a single case with internal wiring, utilizing a base with a separating layer to create distinct spaces for each component, reducing size and simplifying assembly by housing all connections within the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the motor, gearbox, and controller are mounted as three independent devices, then each component can be optimized independently, but the overall size increases and assembly becomes complex
Solution Approach 1:
The patent integrates the motor, gearbox, and controller into a single unified power assembly. The motor stator serves as the controller housing, the motor housing forms part of the gearbox structure, and wiring channels are built into the integrated body. This merging eliminates the need for separate mounting of three independent devices, reducing overall volume while maintaining individual component functionality and optimizability.
Solution Approach 2:
The integrated power assembly structure serves multiple functions simultaneously: the motor stator acts as both a magnetic component and controller housing, the motor housing provides both structural support and gearbox housing, and the integrated body serves as both structural framework and wiring conduit. This multi-functionality reduces the number of separate components needed, thereby reducing overall assembly size.
2Ease of repair
If the motor, gearbox, and controller are mounted as three independent devices, then each component can be serviced separately, but the number of exposed wires increases and assembly/repair difficulty increases
Solution Approach 1:
The patent extracts the wiring from the external environment and relocates it inside the integrated power assembly. Wiring channels are provided within the motor stator and housing to contain all electrical connections internally. This eliminates exposed wires while maintaining serviceability, as the integrated design allows for modular access to different components through the same housing structure.
3Adaptability or versatility
If three independent devices are used, then component independence is maintained, but the number of connecting wires increases and assembly becomes more difficult
Solution Approach 1:
The patent merges the three independent devices into a single integrated assembly where the motor, gearbox, and controller are structurally unified. The motor stator serves as the controller housing, and the motor housing forms part of the gearbox structure. This merging maintains functional independence of each component while dramatically simplifying assembly, as the integrated design eliminates the need to connect three separate devices with multiple wires and mounting operations.
Data Source
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AI summary
A power assembly of an electric scooter includes a case (10), in which an electric motor (40), a driven gear (50), and a controller (80) are received. The case (10) has a base (20), and the base (20) is provided with a separating layer (22) to divide a space in the base (20) into a first space (24) and a second space (26). The electric motor (40) has an output shaft (42) and a driving gear (44) connected to the output shaft (42). The driving gear (44) is received in the first space (24) of the base (20). The driven gear (50) is received in the first space (24) of the base (20) and meshed with the driving gear (44). A gear shaft (52) is connected to the driven gear, and the gear shaft (50) has an end extending out of the case (10). The controller (80) is provided in the second space (26) of the base (20) and electrically connected to the electric motor (40).