U-Shaped Electric Drive Assembly for Compact Four-Wheel Packaging
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Solution Overview
Problem
The large volume and mass of existing electric drive assembly housings pose challenges in arranging and designing vehicles, reducing trunk space and increasing difficulty in chassis design due to the need for high-power and high-torque electric motors and improved NVH performance.
Innovation Solution
The electric drive assembly is configured with two electric motors and speed reducers arranged in a U-shape to form a compact structure, integrating the electric motor controller, which reduces the overall height and increases trunk space, while enhancing strength and NVH performance by integrating the motors and controller within a single housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-power and high-torque electric motors are used to improve vehicle dynamics, then power and torque are improved, but volume and mass of the electric motor and controller increase
Solution Approach 1:
The patent combines two electric motors, two speed reducers, and an electric motor controller into a single integrated housing structure. The first electric motor and second electric motor are disposed in the housing along with their respective speed reducers and the controller, merging multiple separate components into one unified assembly. This reduces the overall volume and mass compared to having separate housings for each component while maintaining the required high power and torque output.
2Reliability
If the housing is strengthened to improve NVH and durability performance, then durability and NVH performance are improved, but volume and mass of the housing increase
Solution Approach 1:
The patent integrates multiple components (electric motors, speed reducers, controller) into a single housing, which distributes and shares the structural load. This allows the housing to achieve improved NVH and durability performance through the combined structural integrity of the integrated assembly rather than requiring excessive strengthening of individual component housings, thereby avoiding unnecessary volume and mass increase.
3Volume of moving object
If the housing volume is reduced to improve vehicle arrangement and trunk space, then space utilization is improved, but device complexity increases due to integration requirements
Solution Approach 1:
The patent segments the housing into distinct functional regions: a first electric motor disposed in the housing, a second electric motor disposed in the housing, speed reducers connected to each motor, and an electric motor controller mounted in the housing. This segmentation allows each component to be independently designed and positioned within the integrated housing, reducing the overall volume while managing complexity through organized spatial arrangement.
4Length of moving object
If electric motors and controller are integrated to reduce height and increase trunk space, then height is reduced, but manufacturing and assembly complexity increases
Solution Approach 1:
The patent segments the integrated assembly into clearly defined components (first electric motor, second electric motor, speed reducers, controller) with specific mounting positions in the housing. This segmentation facilitates modular manufacturing and assembly, where each component can be prepared separately and then integrated into the final compact arrangement, reducing height while managing manufacturing complexity through standardized interfaces and positions.
Data Source
AI summary
An electric drive assembly includes a first electric motor, a second electric motor, a first speed reducer, a second speed reducer, and an electric motor controller. The first speed reducer is connected between the first electric motor and a first wheel, the second speed reducer is connected between the second electric motor and a second wheel, one of the first wheel and the second wheel is a left wheel, and the other one of the first wheel and the second wheel is a right wheel. The first electric motor, the second electric motor, the first speed reducer, and the second speed reducer are disposed in a U-shape, and form an electric motor controller mounting space configured to mount the electric motor controller.