Shared Motor Casing Layout for Front and Rear EV Drive Units
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Solution Overview
Problem
The manufacturing of high-performance electric vehicles with all-wheel drive systems requires multiple high-pressure die-cast aluminum exterior case parts for front and rear drive units, leading to increased costs and space requirements due to the need for dedicated tooling and machining for each unit.
Innovation Solution
A multi-motor electric-vehicle drive unit system is designed with identical motor casings for both front and rear drive units, allowing for shared manufacturing equipment and reduced tooling requirements. The system includes a first drive unit with a first motor casing, oil reservoir, and inverter, and a second drive unit with an identical motor casing, a differently shaped oil reservoir, and an inverter with a different orientation, all controlled by specific software configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated factory assembly lines and high pressure die-cast aluminum exterior case parts are used for front and rear drive units, then manufacturing precision and reliability are improved, but manufacturing cost and space requirements increase
Solution Approach 1:
The motor casing is designed as a universal component that can serve both front and rear drive units. The casing includes multiple mounting locations and features that allow it to be adapted to different drive unit configurations, eliminating the need for separate dedicated casings for front and rear applications.
Solution Approach 2:
The motor casing is segmented into standardized modular sections with consistent interfaces. This segmentation allows the same casing design to be used across different drive units by selectively activating or deactivating certain features through software configuration, rather than creating entirely different casing designs.
2Manufacturing precision
If multiple high pressure die-cast aluminum exterior case parts are used for front and rear drive units, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
A single high pressure die-cast aluminum motor casing design is used for both front and rear drive units. This universal casing maintains manufacturing precision through standardized tooling while reducing costs by eliminating the need for multiple dedicated tooling sets and reducing setup changes between production runs.
Solution Approach 2:
The motor casing design incorporates parameter variations (such as mounting hole positions, reinforcement ribs, or sensor locations) that can be activated or deactivated based on the specific application. This allows the same basic casing geometry to serve multiple functions while maintaining precision through consistent manufacturing processes.
3Manufacturing precision
If dedicated machining and tooling are used for front and rear drive units, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The motor casing is designed with universal machining features and tooling interfaces that work for both front and rear drive units. Standardized locating features, mounting interfaces, and machining patterns allow the same tooling setup to produce casings for different applications, reducing tooling complexity while maintaining precision.
4Adaptability or versatility
If significantly different front and rear drive units are designed, then adaptability to specific applications is improved, but manufacturing cost and space requirements increase
Solution Approach 1:
The motor casing incorporates universal design features that allow it to adapt to both front and rear drive unit applications. This includes standardized mounting interfaces, flexible cooling channel configurations, and modular component arrangements that can be configured for different performance requirements while using the same base casing design.
Solution Approach 2:
The motor casing design allows for dynamic configuration through software-controlled features. Certain physical features in the casing (such as oil flow paths, mounting positions, or cooling channels) can be selectively activated or deactivated based on the specific application requirements, providing adaptability without requiring physically different casing designs.
Data Source
AI summary
A multi-motor electric-vehicle drive unit system comprises: a first drive unit comprising: a first motor casing; a first oil reservoir mounted to a bottom of the first motor casing; and a first inverter mounted to the first motor casing, wherein the first drive unit is installed so that the first inverter has a first orientation; and a second drive unit comprising: a second motor casing, wherein the second motor casing is identical to the first motor casing; a second oil reservoir mounted to a bottom of the second motor casing, wherein the second oil reservoir has a different shape than the first oil reservoir; and a second inverter mounted to the second motor casing, wherein the second drive unit is installed so that the second inverter has a second orientation, the second orientation different from the first orientation.