electric drive unit

Abstract

A vehicle (100) has an electric drive unit (102) having an elongate axis (110), a gear box (104), an electric motor (106) mounted to the gear box (104) and configured to provide drive to the gear box (104), and an inverter (108) mounted to the gear box (104) and configured to provide drive current to the electric motor (106). The elongate axis (110) is orthogonal to the input and output rotational axes of the gear box (104). The electric drive unit (102) has a first mount (134), a second mount (135), and a third mount (140) that connect the electric drive unit (102) to a body of the vehicle (100) at respective first, second, and third mounting points such that the elongate axis (110) of the electric drive unit is at a pitch angle of greater than 45°.

Description

TECHNICAL FIELD

[0001] The present invention relates to an electric vehicle having an electric drive unit (EDU). BACKGROUND

[0002] Electric and hybrid electric vehicles are becoming increasingly common. One such vehicle can comprise at least one electric drive unit (EDU), each electric drive unit (EDU) driving a corresponding pair of wheels. The EDU can comprise a gear box and an electric motor. The electric motor can be provided with drive current by an inverter.

[0003] It would be desirable to provide an electric vehicle having an improved mounting arrangement for at least one electric drive unit, preferably having improved packaging and / or safety characteristics, and / or reduced manufacturing cost and / or complexity. SUMMARY

[0004] The present invention provides a vehicle comprising an electric drive unit, the electric drive unit having an elongate axis and comprising:

[0005] a gear box;

[0006] an electric motor mounted to the gear box and configured to provide drive to the gear box;

[0007] an inverter mounted to the gear box and configured to provide drive current to the electric motor;

[0008] wherein the elongate axis is orthogonal to input and output rotational axes of the gear box, and the electric drive unit comprises a first mount, a second mount and a third mount, the first, second and third mounts connecting the electric drive unit to a main body of the vehicle at respective first, second and third mounting points, such that the elongate axis of the electric drive unit is at a pitch angle, the pitch angle being greater than 45°.

[0009] The pitch angle is measured relative to a lower surface of the main body of the vehicle, the lower surface being substantially parallel to a surface on which the vehicle is disposed in use.

[0010] The use of three mounts and a pitch angle greater than 45° can result in an improved mounting arrangement for the at least one electric drive unit. Depending on the specific implementation, these features can provide improved packaging and / or safety characteristics, and / or reduced cost and / or complexity.

[0011] The first and second mounting points can carry most or substantially all of the weight of the electric drive unit via the respective first and second mounts, which can result in reduced manufacturing cost and / or complexity, and / or improved distribution of various forces acting on the electric drive unit in use.

[0012] The third mounting point can be a torque reaction point, which can result in reduced manufacturing costs and / or complexity. This can also provide an improved distribution of forces acting on the electric drive unit in use.

[0013] The electric drive unit can be mounted such that its elongate axis is substantially vertical. The additional longitudinal space provided by this arrangement can provide improved packaging characteristics, for example compared to a horizontal electric drive unit arrangement, as well as the option to provide improved safety characteristics by increasing the folding zone of the vehicle. Vertical here will be understood to not refer to strict vertical, but to encompass a range of angles, for example between 70-110 degrees.

[0014] The first mounting member and the second mounting member can be positioned higher than the third mounting member. This can provide a stable mounting of the electric drive unit, reduce costs and / or complexity, and / or improve the distribution of various forces acting on the electric drive unit in use.

[0015] The inverter can be mounted to a first lateral side of the gearbox, and the electric motor can be mounted to a second lateral side of the gearbox opposite the first lateral side. This can provide a relatively compact and balanced arrangement.

[0016] The first mounting member can form part of or be attached to the inverter. This can provide a convenient and compact mounting arrangement on the inverter side of the electric drive unit.

[0017] The second mounting member can form part of or be attached to the electric motor. This can provide a convenient and compact mounting arrangement on the electric motor side of the electric drive unit.

[0018] The electric drive unit is substantially T-shaped in a front view, with the first mounting member and the second mounting member positioned at opposite ends of a lateral portion of the T-shape, and the gearbox forming a vertical portion of the T-shape. This can provide a convenient and compact mounting arrangement. The elongate axis extends longitudinally through the vertical portion of the T-shape.

[0019] The third mounting member can be disposed forward of a lower portion of the vertical portion. This can provide a convenient and compact mounting arrangement, and / or an improved distribution of various forces acting on the electric drive unit in use.

[0020] The gearbox can comprise an output shaft for driving a wheel of the vehicle, wherein the centre of gravity of the first electric drive unit is above the output shaft. This can provide a convenient and compact mounting arrangement.

[0021] The electric drive unit can be configured to drive a pair of front wheels of the vehicle.

[0022] Each of the first mounting member, the second mounting member, and the third mounting member can comprise a respective resilient mounting member and / or a respective mounting bracket.

[0023] The vehicle can comprise a further electric drive unit having a further elongate axis, and the further electric drive unit comprises:

[0024] a further gear box;

[0025] a further electric motor mounted to the further gear box and configured to provide drive to the further gear box; and

[0026] a further inverter mounted to the further gear box and configured to provide drive current to the further electric motor;

[0027] wherein the further elongate axis is orthogonal to the input and output rotational axes of the further gear box, and the further electric drive unit is mounted with the further elongate axis at a further pitch angle, the further pitch angle being less than the pitch angle.

[0028] The further electric drive unit can be mounted such that its elongate axis is substantially horizontal. Horizontal mounting can allow for greater space to be provided above the electric drive unit, which can be particularly useful when the further electric drive unit is positioned beneath a load space of the vehicle. Horizontal here will be understood to not mean strictly horizontal, but to encompass a range of angles, for example between 0-30 degrees.

[0029] The further electric drive unit can be configured to drive a pair of rear wheels of the vehicle.

[0030] The further electric drive unit can comprise a plurality of combined load bearing and torque reaction mounts which connect the further electric drive unit to a body of the vehicle at their respective mounting points. This can provide a convenient and compact alternative mounting arrangement, which can be particularly useful when the further electric drive unit is positioned beneath a load space of the vehicle.

[0031] The further electric drive unit can comprise fourth, fifth, sixth and seventh mounts which mount the further electric drive unit to the body of the vehicle at their respective fourth, fifth, sixth and seventh mounting points. This can provide a convenient and compact alternative mounting arrangement, which can be particularly useful when the further electric drive unit is positioned beneath a load space of the vehicle.

[0032] All of the mounts of the further electric drive unit can bear a portion of the weight of the further electric drive unit. This can provide a convenient and compact alternative mounting arrangement, which can be particularly useful when the further electric drive unit is positioned beneath a load space of the vehicle.

[0033] Each of the fourth, fifth, sixth and seventh mounts can comprise a respective resilient mount and / or mounting bracket. At least two of the fourth, fifth, sixth and seventh mounts can comprise a common bracket.

[0034] The fourth, fifth, sixth and seventh mounts can be disposed in substantially the same plane.

[0035] The electric drive unit can be a front electric drive unit having one mount on each of the inverter, electric machine and gear box. Alternatively or additionally, the other electric drive unit can be a rear electric drive unit having one mount on each of the electric machine and inverter and two mounts on the gear box. These can provide a convenient and compact mounting arrangement.

[0036] Any of the mounts can comprise or take the form of a bracket attached to the electric drive unit. Alternatively, any of the mounts can form part of the electric drive unit, for example forming part of the electric machine, inverter or gear box. BRIEF DESCRIPTION OF DRAWINGS

[0037] So that the application can be more readily understood, embodiments of the application will now be described, by way of example, with reference to the drawings, in which:

[0038] Figure 1 is a partial perspective side view of a vehicle including a front electric drive unit (EDU) and another rear EDU;

[0039] Figure 2 is a partial perspective front view of the vehicle of Figure 1 showing the Figure 1 front EDU;

[0040] Figure 3 is a partial perspective rear view of the vehicle of Figure 1 showing the other EDU of Figure 1 ;

[0041] Figure 4 is a left view of the front EDU;

[0042] Figure 5 is a right view of the front EDU;

[0043] Figure 6 is a perspective view of the front EDU with the mounts omitted for clarity;

[0044] Figure 7 is another perspective view of the front EDU;

[0045] Figure 8 is a perspective view of the front EDU showing attachment of the EDU to a front subframe of the vehicle;

[0046] Figure 9 is a left view of the other EDU;

[0047] Figure 10 is a right view of the other EDU of Figure 9 ;

[0048] ​Figure 11 This is a perspective view of another EDU, in which the mounting components are omitted for clarity;

[0049] Figure 12 This is another perspective view of another EDU;

[0050] Figure 13 This is a floor plan of another EDU;

[0051] Figure 14 Is it installed to Figure 1 A plan view of another EDU on the rear subframe of the vehicle. Detailed Implementation

[0052] Referring to the accompanying drawings, vehicle 100 includes an electric drive unit (EDU) in the form of an EDU 102. The EDU 102 includes a gearbox 104. An electric motor 106 is mounted to the gearbox 104 and configured to provide drive to an input shaft (not shown) of the gearbox 104. An inverter in the form of an inverter 108 is mounted to the gearbox 104 and configured to provide drive current to the electric motor 106.

[0053] In the illustrated embodiment, the motor 106 is mounted to the first lateral side of the gearbox 104, and the inverter 108 is mounted to the second lateral side of the gearbox 104 opposite to the first lateral side.

[0054] EDU102 has an elongated shaft 110 that extends substantially through the gearbox 104. For example... Figure 2 and Figures 4 to 7 As best shown in the diagram, the elongated axis 110 in this embodiment is defined as an axis orthogonal to the input and output rotation axes of the gearbox 104. The elongated axis 110 generally extends through the centerline passing through the gearbox 104. Figure 2 As shown in the best view, the EDU is basically T-shaped in the front view, and the elongated axis 110 extends roughly along the vertical portion of the T-shape.

[0055] In the illustrated embodiment, EDU102 includes a first mounting bracket 134, which is secured by screwing bolts 142 into corresponding threaded bosses 144 on inverter 108 (see [link]). Figure 6 In this manner, the first mounting bracket 134 is directly bolted to the first inverter 108. The EDU 102 includes a second mounting bracket 135, which is secured by screwing bolts 152 into corresponding threaded bosses 153 on the motor 106 (see [link to EDU 102]). Figure 7 In this manner, the second mounting bracket 135 is directly bolted to the motor 106. The first mounting bracket 134 and the second mounting bracket 135 are positioned at opposite ends of the transverse portion of the T-shape, and the gearbox 104 forms the vertical portion of the T-shape.

[0056] like Figure 4, Figure 5 and Figure 8 The third mounting bracket 140 is bolted to the lower end of the gear case 104 by way of bolts 145 threaded into corresponding threaded bosses 147, as best shown in

[0057] In the illustrated embodiment, the first mounting bracket 134 is attached to the inverter 108. In other embodiments, the first mounting bracket 134 can comprise the inverter 108 itself, or can be attached to or form part of the gear case 104. The first mounting bracket 134 has a resilient mounting portion 131.

[0058] Similarly, in the illustrated embodiment, the second mounting bracket 135 is attached to the electric motor 106. In other embodiments, the second mounting bracket 135 can comprise the electric motor itself, or can be attached to or form part of the gear case 104. The second mounting bracket 135 has a resilient mounting portion 136.

[0059] In the illustrated embodiment, the third mounting bracket 140 is attached to the gear case 104. In other embodiments, the third mounting bracket 140 can comprise the gear case 104 itself, or can be attached to or form part of another part of the EDU 102. The third mounting bracket 140 has a resilient mounting portion 146.

[0060] The vehicle 100 includes a cross member 141 that extends between the front shock towers 138 of the vehicle 100. The first mounting bracket 134 is connected to the vehicle 100 at mounting points 137 of the cross member 141 by way of its resilient mounting portion 131, and the second mounting 135 is connected to the vehicle 100 at mounting points 139 of the cross member 141 by way of its resilient mounting portion 136. In the illustrated embodiment, the mounting points 137 and 139 bear substantially all of the weight of the EDU through the first and second mounting brackets 134 and 135.

[0061] The vehicle 100 includes a front subframe 133. The third mounting bracket 140 is connected to a third mounting point 143 on the subframe 133 at a location lower than the first and second mounting points 134 and 135 by way of its resilient mounting portion 146 (see Figure 8 ). In the illustrated embodiment, the third mounting point 143 is a torque reaction mounting point that bears substantially no weight of the EDU. As can be seen in Figure 8 , the resilient mounting portion 146 of the third mounting bracket 140 is bolted to the subframe 133 at both ends of the resilient mounting portion 146.

[0062] The EDU 102 is mounted with its axis 110 at a pitch angle of greater than 45°. In the illustrated embodiment, the pitch angle is substantially vertical. In this context, the word "vertical" is used in its ordinary meaning and is not necessarily limited to a strict 90°.

[0063] In the illustrated embodiment, the EDU 102 drives a set of front wheels 130 of the vehicle 100 through the respective output shafts 151 of the gearboxes 104. The center of gravity of the EDU 102 is above the output shafts.

[0064] In the illustrated embodiment, the vehicle 100 includes another EDU 112. The other EDU 112 includes another gearbox 114. Another electric motor 116 is mounted to the other gearbox 114 and is configured to provide drive to an input shaft (not shown) of the other gearbox 114. Another inverter, in the form of another inverter 118, is mounted to the other gearbox 114 and is configured to provide drive current to the other electric motor 116.

[0065] In the illustrated embodiment, the other electric motor 116 is mounted to a first lateral side of the other gearbox 114, and the other inverter 118 is mounted to a second lateral side of the other gearbox 114 opposite the first lateral side. As best shown in Figure 13 The other EDU is substantially T-shaped in plan.

[0066] The other EDU 112 has another elongate axis 120 that extends generally through the other gearbox 114. As best shown in Figure 9 and Figure 10 The elongate axis 120 is defined as an axis that is orthogonal to the input and output rotational axes of the other gearbox 114. The elongate axis 110 extends generally through the centerline through the gearbox 114.

[0067] The other EDU 112 is mounted with its other elongate axis 120 at another pitch angle, which can be less than 45°. In the illustrated embodiment, the other pitch angle is approximately horizontal. In this context, the word "horizontal" is used in its ordinary meaning and is not necessarily limited to a strict 0°.

[0068] In the illustrated embodiment, the other EDU includes a fourth mounting bracket 156, a fifth mounting bracket 158, and a sixth mounting bracket 160.

[0069] The bolts 164 (see Figure 9 , Figure 13 and Figure 14 ) are screwed into corresponding threaded bosses 166 (see Figure 11) in a manner similar to the first mounting bracket 152. The fourth mounting bracket 156 is attached by its resilient mounting portion 173 to a fourth mounting point 157 that is disposed on a rear subframe 150 (see Figure 14 ) of the vehicle 100.

[0070] The fourth mounting bracket 156 is bolted directly to the other inverter 118 by way of the bolts 168 (see Figure 10 ) being screwed into corresponding threaded bosses 170 (see Figure 12 ) on the other inverter 118. The fourth mounting bracket 156 is attached by its resilient mounting portion 173 to the fourth mounting point 157 that is disposed on the rear subframe 150 (see

[0071] The fourth mounting bracket 156 and the fifth mounting bracket 158 are positioned at opposite ends of a horizontal portion of a T-shape (see Figure 13 ) formed in a plane by the other EDU 112. The gear box 114 forms a vertical portion of the T-shape.

[0072] The sixth mounting bracket 160 is a common bracket for two resilient mounting portions 175, 176. The sixth mounting bracket 160 is bolted directly to the other gear box 114 by way of the threaded bolts 165 (see Figure 9 , Figure 10 , Figure 13 and Figure 14 ) being screwed into corresponding threaded bosses 161 (see Figure 11 and Figure 12 ). The sixth mounting bracket 160 is attached by its resilient mounting portions 175, 176 to a sixth mounting point 171 and a seventh mounting point 172 that are disposed on the rear subframe 150 of the vehicle 100.

[0073] Each of the fourth mounting bracket 156, the fifth mounting bracket 158, and the sixth mounting bracket 160 is a combined load bearing and torque reaction mount that connects the other EDU 112 to the vehicle 100 at its corresponding mounting point.

[0074] In the illustrated embodiment, the other EDU 112 is configured to drive a pair of rear wheels 132 of the vehicle.

[0075] The mounts for the front-mounted EDU 102 can consist of only the first, second, and third elastic mounts in the particular geometric relationship shown. Specific advantages are provided by having a first load-bearing mount on a first upper lateral side of the EDU, a second load-bearing mount on a second upper lateral side of the EDU opposite the first upper lateral side of the EDU, and a third torque reaction mount on a lower end of the EDU. These advantages include effectively mounting the EDU to a vehicle, particularly the front end of a vehicle, in a compact manner, thereby improving production and installation efficiency.

[0076] Similarly, the mounts for the rear-mounted EDU 112 can consist of only the first, second, third, and fourth mounts (corresponding to the fourth, fifth, sixth, and seventh elastic mounts in the illustrated embodiment) in the particular geometric relationship shown. Specific advantages are provided by having a first load-bearing and torque reaction mount on a first lateral side of the EDU, a second load-bearing and torque reaction mount on a second lateral side of the EDU opposite the first lateral side, and third and fourth load-bearing and torque reaction mounts on an end of the EDU opposite the locations of the first and second mounts. These advantages include effectively mounting the EDU to a vehicle, particularly the rear end of a vehicle, in a compact manner, thereby improving production and installation efficiency.

[0077] Those skilled in the art will appreciate that each mount can be attached to its respective mounting point by its respective elastic portion using a plurality of bolts. In the illustrated embodiment, the EDU 102 is attached to the vehicle at three attachment points by its three elastic mounting portions, and the EDU 112 is attached to the vehicle at four attachment points by its four elastic mounting portions.

[0078] In other embodiments, the mounting points 137 and 139 carry the majority of the weight of the EDU, with the third mounting point 143 carrying the remainder of the weight while still acting as a torque reaction point. It will be appreciated that other combinations of load-bearing and / or torque reaction mounts and mounting points can be employed, for example, depending on packaging and engineering requirements.

[0079] While the illustrated vehicle 100 is a sedan, the present application can be applied to other types of vehicles, such as trucks and vans.

[0080] While the present application has been described with reference to specific embodiments, it will be appreciated that the application can be embodied in many other forms.

Claims

1. A vehicle comprising an electric drive unit, the electric drive unit being substantially T-shaped in forward view, and comprising: A gearbox forming the vertical portion of the T-shape, wherein the elongated axis of the drive unit is orthogonal to the input and output rotation axes of the gearbox and extends longitudinally through the vertical portion of the T-shape; An electric motor is mounted to the gearbox and configured to provide drive to the gearbox; An inverter is mounted to the gearbox and configured to provide drive current to the motor; The electric drive unit includes a first mounting member, a second mounting member, and a third mounting member, which connect the electric drive unit to the body of the vehicle at their respective first mounting point, second mounting point, and third mounting point, such that the elongated axis is oriented at a pitch angle to the surface of the body, the surface being approximately parallel to a flat surface on which the vehicle is placed during use, and the pitch angle being greater than 45°. And wherein the first mounting member and the second mounting member are positioned at opposite ends of the transverse portion of the T-shape.

2. The vehicle as claimed in any of the preceding claims, wherein the electric drive unit is mounted such that its elongated axis is substantially vertical.

3. The vehicle as claimed in any of the preceding claims, wherein the first mounting member and the second mounting member are positioned above the third mounting member.

4. The vehicle as claimed in any of the preceding claims, wherein the inverter is mounted to a first lateral side of the gearbox, and the electric motor is mounted to a second lateral side of the gearbox opposite to the first lateral side.

5. The vehicle as claimed in any of the preceding claims, wherein the first mounting member forms part of or is attached to the inverter.

6. The vehicle as claimed in any of the preceding claims, wherein the second mounting member forms part of or is attached to the electric motor.

7. The vehicle as claimed in any of the preceding claims, comprising one or more output shafts for driving the wheels of the vehicle, wherein the center of gravity of the first electric drive unit is above the one or more output shafts.

8. The vehicle as claimed in any of the preceding claims, wherein the electric drive unit is configured to drive a pair of front wheels of the vehicle.

9. The vehicle as claimed in any of the preceding claims, further comprising another electric drive unit having an elongated shaft, and the other electric drive unit comprising: Another gearbox; Another electric motor, which is mounted to another gearbox and configured to provide drive to the other gearbox; as well as Another inverter is mounted to another gearbox and configured to provide drive current to another motor; The other electric drive unit is mounted such that its elongated axis is at another pitch angle, the other pitch angle of the other electric drive unit being smaller than the pitch angle of the electric drive unit.

10. The vehicle of claim 9, wherein the other electric drive unit is mounted such that its elongated axis is substantially horizontal.

11. The vehicle of claim 9 or 10, wherein the other electric drive unit is configured to drive a pair of rear wheels of the vehicle.

12. The vehicle of any one of claims 9 to 11, wherein the other electric drive unit comprises a plurality of combined load-bearing and torque-reaction mounting members, the plurality of combined load-bearing and torque-reaction mounting members connecting the other electric drive unit to the body of the vehicle at corresponding mounting points.

13. The vehicle of claim 12, wherein the other electric drive unit includes fourth, fifth, sixth, and seventh mounting members, the fourth, fifth, sixth, and seventh mounting members mounting the other electric drive unit to the body of the vehicle at their respective mounting points.

Images