Hybrid powertrain

Abstract

A hybrid system is a hybrid power system installed in a vehicle. It includes a drive unit with a motor that drives the wheels, and a generator unit with an engine and a generator driven by the engine, located adjacent to the drive unit in a separate state. One of the drive unit and the generator unit is mounted to the vehicle body via a first mounting member at its lower portion. The other of the drive unit and the generator unit is mounted to the vehicle body via a second mounting member at its upper portion.

Description

Technical Field

[0001] The present invention relates to a hybrid power system for a vehicle. Background Art

[0002] WO2018 / 047224 discloses a hybrid system that is an example of a system for a hybrid vehicle and includes: a drive unit having a driving motor; and a power generation unit having an engine and a generator for power generation. Summary of the Invention

[0003] In the technology disclosed in WO2018 / 047224, the gear train on the drive unit side and the gear train on the power generation unit side are integrated. However, this structure increases the size of the housing. Therefore, if the gear train produces abnormal noise such as gear rattling due to vibrations from the power generation unit engine, this noise may resonate with the housing wall and propagate outside the housing.

[0004] Therefore, research is underway to miniaturize the housings of hybrid systems. For example, by installing the drive unit and power unit in a separate structure on the vehicle body, each housing can be miniaturized, reducing the overall installation space. Furthermore, by miniaturizing the walls of the drive unit and power unit housings, the noise propagating from these walls is reduced, thereby reducing noise propagating outside the housings.

[0005] However, when the drive unit and generator unit are mounted on the vehicle body in a separate structure, the vibration modes of the motor-driven drive unit and the engine-driven generator unit differ, potentially causing the drive unit and generator unit to swing toward each other. Therefore, to prevent contact between the drive unit and generator unit, the separation distance between them must be increased, potentially increasing the installation space required for the hybrid system.

[0006] A hybrid system according to one embodiment of the present invention is a hybrid system installed in a vehicle. The hybrid system includes a drive unit having a motor that drives wheels; and a power generation unit having an engine and a generator driven by the engine, the power generation unit being disposed adjacent to the drive unit in a separated state. One of the drive unit and the power generation unit is mounted to the vehicle body via a first mounting member at the bottom of the unit. The other of the drive unit and the power generation unit is mounted to the vehicle body via a second mounting member at the top of the other unit.

[0007] According to one embodiment of the hybrid system of the present invention, one of the drive unit and the power generation unit is mounted on the vehicle body at the bottom, while the other is mounted on the vehicle body at the top. This allows the hybrid system layout to be designed with consideration given to the swinging motion of either the drive unit or the power generation unit, both at the top and bottom. This further reduces the separation between the drive unit and the power generation unit, thereby reducing the installation space required for the hybrid system. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is a perspective view of the hybrid system according to this embodiment.

[0009] Figure 2 It is another oblique view of the hybrid system.

[0010] Figure 3 It is a left side view of the hybrid system.

[0011] Figure 4 yes Figure 3 An enlarged view of a portion of .

[0012] Figure 5 This is an enlarged oblique view of the generator viewed from the front right. DETAILED DESCRIPTION

[0013] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[0014] Figure 1 and Figure 2 It is a perspective view of a hybrid system according to an embodiment of the present invention.

[0015] The hybrid system 1 is mounted on a body of a hybrid vehicle and is a driving source for causing the vehicle to travel. Figure 1 and Figure 2 Each of the figures shows the hybrid system 1 as viewed from the left front, and is an oblique view from different angles. In the figures, arrows indicate the front (Fr), rear (Rr), right (R), and left (L) directions relative to the vehicle's travel direction. In the following description, the front-back, left-right, and up-down directions are relative to the vehicle's travel direction.

[0016] The hybrid system 1 includes a drive unit 10 disposed at the rear and a power generation unit 20 disposed adjacent to the drive unit 10 in a separated state. The drive unit 10 is disposed at the rear of the power generation unit 20 with its upper portion tilted toward the power generation unit 20 in the front.

[0017] The drive unit 10 receives power from a battery (not shown) and rotates an axle (not shown). Specifically, the drive unit 10 includes a motor 11 whose rotating shaft is connected to the axle, and an inverter 12 disposed above the motor 11. The inverter 12 converts the DC power supplied from the battery into the desired AC power and supplies it to the motor 11. As described later, the inverter 12 is also connected to the power generation unit 20. The drive unit 10 may further include a gear train (not shown) that connects the rotating shaft of the motor 11 to the axle.

[0018] The drive unit 10 is fixed to a frame member, which is part of the vehicle body, at its lower portion via first mounting members 13 and 14. Specifically, the drive unit 10 is fixed to the vehicle body from the rear using first mounting member 13 and from the left using first mounting member 14. The drive unit 10 is also fixed to the vehicle body from the right via a first mounting member (not shown). Therefore, the drive unit 10 is fixed to the vehicle body at its lower portion via three first mounting members.

[0019] The power generation unit 20 supplies the generated electricity to the battery and the motor 11 via the inverter 12 of the drive unit 10. The power generation unit 20 includes an engine 21, which is installed on the right side and is driven by gasoline or the like; a generator 22, which is installed on the left side; and a gear train 23, which is installed between the engine 21 and the generator 22 and connects them.

[0020] The driving force of the engine 21 is transmitted to the generator 22 via the gear train 23. This generates electricity, which is then converted to AC power by the inverter 12 and supplied to the battery and drive unit 10. Furthermore, the power generation unit 20 is secured to a frame member, which is part of the vehicle body, from its upper portion via second mounting members 24 and 25. Specifically, the power generation unit 20 is secured to the vehicle body from the left side using the second mounting member 24 and from the right side using the second mounting member 25.

[0021] In this manner, the inverter 12 is connected to the motor 11 at the drive unit 10 and to the power generation unit 20. Specifically, the inverter 12 is configured as a device capable of performing two power conversion systems: a system for converting the power stored in the battery from DC to AC and then supplying it to the motor 11; and a system for converting the power generated by the generator 22 from AC to DC and then supplying it to the battery and motor 11.

[0022] In addition, Figure 1 In FIG. 1 , shock absorbers 26 and 27 connected to the vehicle body are shown on the left and right sides of the drive unit 10. Figure 2 For the sake of readability, the description of the shock absorbers 26 and 27 is omitted.

[0023] Figure 3This is a side view of the lower portion of the hybrid system 1 as viewed from the left side.

[0024] As shown in the figure, the drive unit 10, which is fixed at the bottom, is positioned adjacent to the power generation unit 20, which is fixed at the top, by first mounting members 13 and 14, and the second mounting members 24 and 25. Specifically, the motor 11 of the drive unit 10 and the generator 22 of the power generation unit 20 are positioned adjacent to each other with a predetermined distance in the front-to-back direction.

[0025] In addition, the drive unit 10 is configured so that the upper portion is tilted toward the power generation unit 20, and the power generation unit 20 is arranged upright without tilting. In addition, the inverter 12 and the generator 22 are electrically connected via a wiring harness 31. The inverter 12 is also electrically connected to the motor 11 via a wiring harness not shown. In this embodiment, the motor 11 and the generator 22 are driven by three-phase electricity, and three cables are accommodated in the wiring harness 31. The wiring harness 31 is arranged in a gap formed between the drive unit 10 and the power generation unit 20, and the middle portion of the wiring harness 31 between the connection portions of the inverter 12 and the generator 22 is supported by a first support member 32 connected to the motor 11.

[0026] Figure 4 yes Figure 3 In this figure, the first support area 33 where the wire harness 31 is supported by the first support member 32 is enlarged.

[0027] The first support member 32 includes a main body 34 in a plate-like shape with multiple curved portions. The main body 34 is formed along its longitudinal direction by the multiple curved portions, thereby forming a recessed portion near the center of the longitudinal direction. Bolts 35 secure the recessed portion of the main body 34 to the motor 11 at the point where the drive unit 10 and the power generation unit 20 are closest. The main body 34 is positioned so that its longitudinal direction is perpendicular to the vehicle width direction and does not tilt in the vehicle width direction.

[0028] The first support member 32 further includes first retaining members 36A and 36B provided at both ends outside the recessed portion of the main body 34. The first retaining member 36A is provided below the point where the bolt 35 fastens the main body 34, while the first retaining member 36B is provided above it. The first retaining members 36A and 36B have insertion holes for inserting the wire harness 31 and are configured to retain the outer periphery of the wire harness 31.

[0029] Thus, the middle portion of the wire harness 31 is fixed by the first support member 32 at the first support area 33 of the drive unit 10, which includes the position closest to the power generation unit 20. This configuration reduces the possibility of the wire harness 31 contacting the generator 22 when the drive unit 10 and the power generation unit 20 swing.

[0030] Furthermore, the midway portion of the wire harness 31 is supported by the first holding member 36A of the first support member 32, which is located below the fastening portion with the bolts 35. Here, regarding the case where the wire harness 31 is routed upward from the bottom between the drive unit 10 and the power generation unit 20, a comparison is made between this embodiment and a comparative example in which the wire harness 31 is secured at the fastening portion with the bolts 35.

[0031] In the comparative example, the wire harness 31 is not guided by any component until it is routed near the fastening point of the bolt 35. In contrast, in the present embodiment, the wire harness 31 is guided by the first retaining member 36A and then routed near the fastening point of the bolt 35, which is the shortest distance from the power generation unit 20. Therefore, in the present embodiment, the guidance of the first retaining member 36A facilitates the routing of the wire harness 31. Furthermore, in the present embodiment, the wire harness 31 is guided by two retaining members, the first retaining members 36A and 36B, arranged side by side in the vertical direction, during routing. This facilitates routing the wire harness 31 above and below the first support area 33, which is closest to the drive unit 10 and the power generation unit 20.

[0032] Next, Figure 3 The part covered by the left side of the generator 22, which is not shown in detail, is described. In this part, the middle part of the wire harness 31 below the first holding member 36A is fixed to the generator 22 using the second support member 37. In addition, the wire harness 31 is connected to the connector 38 of the generator 22. Figure 5 The structure covered on the left side of the generator 22, i.e. Figure 3 Parts not shown are described in detail.

[0033] Figure 5 This is a perspective view as viewed from the front right side of the generator 22 .

[0034] The wire harness 31 is connected at its end to a connector 38 on the generator 22, and its midway portion is supported by a second support member 37 attached to the generator 22. Specifically, the wire harness 31 is connected to the connector 38 at its end and supported by the second support member 37 at a midway portion near the end. The second support member 37 includes a main body 37A fixed to the lower portion of the generator 22 and a retaining member 37B formed below the main body 37A. The retaining member 37B has an insertion hole for inserting the wire harness 31 and is configured to retain the outer periphery of the wire harness 31. The area where the wire harness 31 is secured by the second support member 37 is referred to as the second support area 39.

[0035] Here, as Figure 3As shown, connector 38 is located on the opposite side of generator 22 from drive unit 10. Specifically, connector 38 is positioned below generator 22, near the front. Wiring harness 31 is curved in a large arc and routed toward inverter 12, located upward and rearward. Therefore, even when wiring harness 31 is used to connect inverter 12 and generator 22, utilizing the gap between drive unit 10 and power generation unit 20, it is less likely to bend, resulting in improved durability.

[0036] Furthermore, the first support area 33 and the second support area 39 are arranged within the same plane perpendicular to the vehicle width direction (left-right direction) to prevent any misalignment. Consequently, the wire harness 31 between the first and second support areas 33 and 39 is less likely to misalign in the left-right direction and is routed in a straight line in the vertical direction, thus avoiding unnecessary extension of the wire harness 31. Furthermore, if the wire harness 31 is of the same length, when there is no left-right misalignment between the first and second support areas 33 and 39, the wire harness 31 is more likely to slack between the first and second support areas, resulting in excess space, compared to when there is misalignment.

[0037] In addition, if Figure 3 As shown, the wire harness 31 is positioned radially outward of the generator 22 relative to a line connecting the first support region 33 and the second support region 39, for example, the dashed-dotted line connecting point A of the first retaining member 36A and point B of the retaining member 37B of the second support member 37. In other words, the wire harness 31 is positioned radially outward of the cylindrical generator 22, that is, radially outward of the generator 22 housing. This structure creates slack in the wire harness 31. As a result, when the drive unit 10 and the power generation unit 20 swing away from each other, the wire harness 31 is prevented from being stretched between the first support region 33 and the second support region 39.

[0038] According to the hybrid system 1 of this embodiment, the following effects can be obtained.

[0039] According to the hybrid system 1 of this embodiment, the drive unit 10 and the power generation unit 20 are arranged adjacent to each other in a separated state in a separate structure. Furthermore, the lower portion of the drive unit 10 is fixed to the vehicle body by first mounting members 13 and 14, and the upper portion of the power generation unit 20 is fixed to the vehicle body by second mounting members 24 and 25.

[0040] In this structure, the upper portion of the unit fixed by the first mounting members 13 and 14 swings around the lower mounting position. In addition, the lower portion of the unit fixed by the second mounting members 24 and 25 swings around the upper mounting position.

[0041] Therefore, in hybrid system 1, it is sufficient to provide a gap between drive unit 10 and power generation unit 20 by taking into account the swinging of the upper unit secured to the vehicle body by first mounting members 13 and 14, and the swinging of the lower unit secured to the vehicle body by second mounting members 24 and 25. This allows for a shorter gap than would be possible if the upper or lower portions of drive unit 10 and power generation unit 20 were assumed to swing toward each other, thus enabling a more compact hybrid system 1.

[0042] Furthermore, the gear train connected to the wheels included in the drive unit 10 and the gear train 23 of the power generation unit 20 are housed in separate units. Therefore, compared to a case where both gear trains are housed in a single unit, the walls of each unit's housing are miniaturized, reducing resonance and thus noise.

[0043] Furthermore, in this embodiment, the drive unit 10 is mounted on the lower portion and the power generation unit 20 is mounted on the upper portion, but this is not limiting. Alternatively, the drive unit 10 may be mounted on the upper portion and the power generation unit 20 may be mounted on the lower portion. In other words, one of the drive unit 10 and the power generation unit 20 may be mounted on the lower portion and the other on the upper portion.

[0044] Furthermore, the drive unit 10 can be installed at a position lower than the center of the vertical length of the drive unit 10. Furthermore, if the center of gravity of the drive unit 10 is located above the center, the installation position can be located above the center. Similarly, the power generation unit 20 can be installed at a position higher than the center of the vertical length of the power generation unit 20. Furthermore, if the center of gravity of the power generation unit 20 is located below the center, the installation position can be located below the center.

[0045] According to the hybrid system 1 of the present embodiment, the inverter 12 is arranged above the motor 11 in relation to the drive unit 10 mounted on the lower portion using the first mounting members 13 and 14 .

[0046] Here, the power generation unit 20 includes the engine 21 and is therefore heavier than the drive unit. If the inverter 12 is positioned above the generator 22 in the power generation unit 20 and the upper portion of the power generation unit 20 is mounted using the second mounting members 24 and 25, the lower portion of the heavier power generation unit 20 will swing more widely, necessitating a larger separation distance between the drive unit 10 and the power generation unit 20.

[0047] In contrast, in this embodiment, in the drive unit 10, the inverter 12 is arranged above the motor 11, and the lower portion of the drive unit 10 is mounted using the first mounting members 13 and 14. In this structure, the lightweight inverter 12, which is arranged above the lightweight drive unit 10, has a smaller swing amplitude, thereby shortening the separation distance between the motor 11 and the generator 22.

[0048] In addition, a configuration in which the inverter 12 is mounted above the generator 22 and both the inverter 12 and the generator 22 are mounted above the generator 22 has been considered. However, this configuration complicates the installation components and the flow path for the refrigerant cooling the generator 22, making it undesirable. Therefore, if the inverter 12 is mounted above the generator 22, it becomes impossible to mount both the inverter 12 and the generator 22 above them, requiring only the inverter 12 to be mounted. Consequently, the swinging motion below the generator 20 increases, necessitating a greater separation distance between the drive unit 10 and the generator 20. Therefore, in a drive unit 10 mounted below, placing the inverter 12 above the motor 11 is the preferred configuration for the inverter 12, shortening the separation distance between the drive unit 10 and the generator 20.

[0049] According to the hybrid system 1 of the present embodiment, the drive unit 10 is fixed to the vehicle body by a first mounting member, and the power generation unit 20 is fixed to the vehicle body by second mounting members 24 and 25. In addition, the power generation unit 20 is arranged in front of the drive unit 10. Therefore, in the drive unit 10 provided at the rear, the inverter 12 is arranged on the upper part of the motor 11, so that the front part of the vehicle can be designed to be lower, thereby increasing the degree of freedom of design. In addition, the inverter 12 is not easily affected by external impacts during a frontal collision. In addition, the vibration of the engine 21 can be suppressed from being directly transmitted to the inverter 12, so that the durability of the inverter 12 can be improved.

[0050] The hybrid system 1 of this embodiment further includes a wiring harness 31, which is routed between the drive unit 10 and the power generation unit 20 and serves as wiring for connecting the generator 22 and the inverter 12. Furthermore, the generator 22 includes a connector 38 connected to the wiring harness 31 on the opposite side of the drive unit 10, that is, on the opposite side of the drive unit 10 relative to the rotor shaft of the generator 22 in the front-rear direction of the vehicle.

[0051] The connector 38, to which one end of the wire harness 31 is connected, is located on the opposite side of the generator 22 from the drive unit 10. This increases the overall length of the wire harness 31, whose other end is connected to the inverter 12, due to its increased bending radius. This reduces the likelihood of the wire harness 31 bending when the drive unit 10 and the generator unit 20 swing adjacent to each other, making it easier to maintain strength.

[0052] Furthermore, by ensuring a sufficient length for the harness 31 , it is possible to suppress the harness 31 from being stretched between the first support area 33 and the second support area 39 when the drive unit 10 and the power generation unit 20 swing toward each other.

[0053] According to hybrid system 1 of this embodiment, drive unit 10 is provided with first support member 32 for retaining the midway portion of wire harness 31 in first support region 33, located closest to power unit 20. This secures wire harness 31 at the location closest to power unit 20, thereby reducing the likelihood of wire harness 31, which is secured to drive unit 10, coming into contact with power unit 20 even when drive unit 10 and power unit 20 oscillate.

[0054] According to the hybrid system 1 of the present embodiment, the first support member 32 includes a plate-shaped main body portion 34 fastened to the motor 11 by bolts 35 , and first holding members 36A and 36B provided at both ends of the main body portion 34 .

[0055] In particular, the middle portion of the wire harness 31 is supported by the first retaining member 36A, which is located below the portion where the main body 34 is secured to the motor 11. This structure allows the wire harness 31 to be guided by the first retaining member 36A to a position closest to the power generation unit 20 when routed between the drive unit 10 and the power generation unit 20, compared to a case where the retaining member is located at the portion where the main body 34 is secured. This facilitates routing of the wire harness 31.

[0056] According to the hybrid system 1 of this embodiment, the mid-section of the wire harness 31 is supported by the second support member 37 fixed to the second support region 39 of the power generation unit 20. The second support region 39 is located below the first support member 32. This configuration supports the mid-section of the wire harness 31 at multiple locations, thereby reducing the possibility of the wire harness 31 contacting the drive unit 10 and the power generation unit 20.

[0057] According to the hybrid system 1 of this embodiment, the midway portion of the wire harness 31 is supported by the first support region 33 and the second support region 39 provided with the first support member 32. Furthermore, the first support region 33 and the second support region 39 are provided in the same plane perpendicular to the left-right direction.

[0058] Therefore, compared to a case where the first support area 33 and the second support area 39 are not arranged in the same plane, the wire harness 31 can be prevented from being unnecessarily lengthened. Furthermore, if the wire harness 31 has the same length, when there is no left-right misalignment between the first and second support areas 33 and 39, the excess length of the wire harness 31 can be increased, making it easier for the wire harness 31 to slack. As a result, the wire harness 31 can be prevented from being stretched between the first and second support areas 33 and 39 when the drive unit 10 and the power generation unit 20 swing. Furthermore, when the wire harness 31 is fixed, there is no need to adjust its left-right position, thereby improving workability.

[0059] While the embodiments of the present invention have been described above, the above embodiments merely illustrate a part of application examples of the present invention, and the technical scope of the present invention is not intended to be limited to the specific configurations of the above embodiments.

Claims

1. A hybrid power system, which is equipped in a vehicle, wherein: The hybrid system comprises: a drive unit having a motor for driving the wheels; as well as a power generation unit having an engine and a generator configured to be driven by the engine, The power generation unit is provided adjacent to the drive unit in a state separated from the drive unit. The lower portion of one of the drive unit and the power generation unit is fixed to the vehicle body via a first mounting member so that the upper portion of the one unit can swing independently of the other of the drive unit and the power generation unit. The other of the drive unit and the power generation unit has its upper portion fixed to the vehicle body via a second mounting member so that its lower portion can swing independently of the one unit.

2. The hybrid system according to claim 1, wherein: The hybrid system further includes an inverter for controlling the motor and the generator. The inverter is arranged above the one unit fixed by the first mounting member.

3. The hybrid system according to claim 2, wherein: The drive unit is mounted on the vehicle body via the first mounting member. The power generation unit is mounted on the vehicle body via the second mounting member. The drive unit is arranged behind the power generation unit in the front-rear direction of the vehicle.

4. The hybrid system according to claim 3, wherein: The hybrid system further includes a wiring harness connected between the generator and the inverter and arranged between the drive unit and the power generation unit. The generator has a connection portion connected to the wire harness on the opposite side of the drive unit.

5. The hybrid power system according to claim 4, wherein: The driving unit includes a first supporting member that supports a midway portion of the wire harness at a position closest to the power generation unit.

6. The hybrid power system according to claim 5, wherein: The first supporting member comprises: a main body portion, which is fixed to the driving unit; as well as A holding portion, mounted on the main body, for holding the wiring harness. The holding position of the wire harness by the holding portion is lower than the fixing position of the main body portion to the driving unit.

7. The hybrid power system according to claim 5 or 6, wherein: The power generation unit includes a second support member that supports a midway portion of the wire harness below the first support member.

8. The hybrid power system according to claim 7, wherein: When the middle portion of the wire harness supported by the first supporting member is defined as the first supporting region and the middle portion of the wire harness supported by the second supporting member is defined as the second supporting region, The first support region and the second support region are set so as not to be misaligned in a vehicle width direction of the vehicle when viewed from the front-rear direction of the vehicle.

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