Vehicle drive device

Abstract

The present application relates to a driving device for a vehicle. A housing main body (1) is provided with a first opening portion (23) which is opened along a first direction (V) and into which an inverter device (INV) is insertable; a surrounding wall portion (30) which is disposed along the first direction (V) in a manner of surrounding the first opening portion (23); and a second opening portion (25) which is formed in the surrounding wall portion (30) and into which a power supply cable (7) is insertable. A cover member (13) is fixed to the surrounding wall portion (30) in a manner of covering the first opening portion (23) by a plurality of fastening members (33) which are disposed apart from each other along an opening edge (23e) of the first opening portion (23). A second opening width (Y2) in a direction (H) orthogonal to the first direction (V) is smaller than an opening width (Y1) of the second opening portion (25) in the first direction (V), and a pair of fastening members (33(33a, 33b)) are disposed on both sides across the second opening portion (25).

Description

Technical Field

[0001] This invention relates to an automotive drive system comprising a rotating electric motor, an inverter device for driving and controlling the rotating electric motor, and a housing. Background Technology

[0002] International Publication No. 2013 / 069774 discloses a vehicle drive unit (motor power unit (4)) comprising a motor (11) as a driving power source for a vehicle, an inverter (12) driving the motor (11), and a reducer (13) that reduces the rotation of the motor (11) and transmits it to the wheels (9) (in the background art, reference numerals in parentheses refer to the document.). The motor power unit (4) comprises a housing that integrates a motor housing (15) housing the motor (11), an inverter housing (16) housing the inverter (12), and a reducer housing (17) housing the reducer (13). The inverter (12) and the motor (11) are electrically connected inside the integrated housing.

[0003] The motor housing (15) and the inverter housing (16) have removable end covers (18) that are shared with each other. Additionally, the inverter housing (16), as a separate cover component distinct from the end covers (18), has a removable upper surface cover (19) that covers the upper surface of the inverter housing (16). The inverter housing (16) is formed into a rectangular storage space. The inverter housing (16) has three integrally formed sidewalls (16a) extending from the motor housing (15) side, located above the outer peripheral surface of the cylindrical motor housing (15). Furthermore, a frame-like pedestal (24) for mounting the inverter (12) is disposed below the inner peripheral side enclosed by the sidewalls (16a). When the end cover (18) is installed on the motor housing (15), it also has an extension (18a) integrally formed on the upper side of the motor housing (15) in a manner that extends from the motor housing (15) side. This extension (18a) forms the remaining side of the side wall of the inverter housing (16) which has a cuboid storage space.

[0004] If the inverter (12) is placed on the pedestal (24) and the end cover (18) is installed, the lower and sides of the inverter housing (16) are covered. Furthermore, by abutting the upper end of the side wall of the inverter housing (16) (the upper end of the three side wall portions (16a) and the upper end of the extension portion (18a) of the end cover (18)) and fastening it, the inverter (12) is enclosed and housed inside the inverter housing (16). As described above, the housing of the motor power unit (4) is a housing that integrates the motor housing (15), the inverter housing (16), and the gearbox housing (17), so as described above, the motor (11) and the inverter (12) are electrically connected inside this housing.

[0005] Patent Document 1: International Publication No. 2013 / 069774

[0006] The inverter (12) converts the DC power supplied from the DC power source (lithium battery (2)) via the power cable into AC power to drive the motor (11). Additionally, the inverter (1) converts the AC power generated by the kinetic energy produced by the rotation of the wheels (9) in the motor (11) into DC power and charges the DC power source via the power cable. Generally, the voltage of the DC power source used to drive the motor (11), which serves as the driving force source for the vehicle, is a large voltage of tens to hundreds of volts, and the supplied current is also a large current of several to tens of amperes. Therefore, the power cable is usually thick and heavy.

[0007] The motor power unit (4) illustrated in International Publication No. 2013 / 069774 has a housing that integrates the motor housing (15), the inverter housing (16), and the gearbox housing (17). Therefore, as described above, the motor (11) and the inverter (12) are electrically connected inside this housing. However, the DC power supply (lithium battery (2)) is located outside the motor power unit (4), and the inverter (12) and the DC power supply are connected via a power cable as described above. Moreover, for this connection, openings are often formed in the side wall portion (16a) corresponding to the side wall of the inverter housing (16) or in the extension portion (18a) of the end cover (18).

[0008] The vehicle drive unit vibrates due to its own drive and the movement of the vehicle. If vibration occurs, the inertial force will exert a relatively large force on heavy objects. The power cable and the housing are specifically mechanically connected to the inverter housing (16) and electrically connected to the inverter (12). When the rigidity of the housing and the connection point between the housing and the power cable is insufficient, there is a concern that the openings formed in the side walls (side wall portion (16a), extension portion (18a)) of the inverter housing (16) may deform. The deformation of the openings also affects the side walls of the inverter housing (16), for example, sometimes the side walls of the inverter housing (16) may lift up at the point where they abut against the upper cover (18). That is, sometimes the sealing of the inverter housing (16) may be compromised. Summary of the Invention

[0009] In view of the above background, it is desirable to provide an automotive drive unit that can ensure the rigidity of the housing and properly connect the power cable without compromising the sealing of the inverter housing.

[0010] The vehicle drive system according to the above-described situation includes: a rotary motor; an inverter device that drives and controls the rotary motor; and a housing. The inverter device has a power connection terminal connected to a DC power supply. The housing includes: a housing body and a cover member that engages with the housing body. The housing body is integrally formed to form a first housing chamber for housing the rotary motor and a second housing chamber for housing the inverter device. The housing body has a first opening that opens from the second housing chamber toward the outside of the housing along a predetermined first direction and allows the inverter device to be inserted. The housing body also includes: a surrounding wall portion arranged along the first direction to surround the first opening portion, and a portion formed in the surrounding wall portion for connecting the DC power supply and the power connection terminal. The second opening into which the power cable for electrical connection is inserted is covered by a cover component which is fixed to the surrounding wall by a plurality of fastening components that are separately arranged along the opening edge of the first opening to cover the first opening. The power connection terminal includes a positive connection terminal connected to the positive terminal of the DC power supply and a negative connection terminal connected to the negative terminal of the DC power supply. The positive connection terminal and the negative connection terminal are arranged along the first direction. The opening direction of the second opening is set as the second direction. In the second direction view along the second direction, the opening width of the second opening in the direction orthogonal to the first direction, i.e., the second opening width, is smaller than the opening width of the second opening in the first direction, i.e., the first opening width. A pair of fastening components are arranged on both sides of the second opening.

[0011] In cases where a second opening for power cable insertion is formed in the surrounding wall portion enclosing a first opening into which an inverter device can be inserted, this second opening may reduce the rigidity of the surrounding wall portion. If the rigidity of the surrounding wall portion is insufficient, for example, if the opening edge of the first opening portion deforms, the cover member configured to cover the first opening portion may float up from the first opening portion, creating a gap. According to this structure, even with such a second opening portion, since the width of the second opening portion is smaller than the width of the first opening portion, it is easier to minimize the deformation of the opening edge of the first opening portion. Furthermore, since a pair of the plurality of fastening members arranged along the opening edge of the first opening portion are arranged on both sides of the second opening portion with respect to the second opening portion, the cover member is fixed to the surrounding wall portion near the second opening portion. Therefore, it is easier to minimize the deformation of the opening edge of the first opening portion caused by the second opening portion, and it is also possible to appropriately suppress the situation where the cover member floats up from the opening edge of the first opening portion. Thus, according to this structure, it is possible to provide an automotive drive unit that ensures the rigidity of the housing and allows for proper connection of the power cable without compromising the sealing of the inverter housing.

[0012] Further features and advantages of the vehicle drive system will become clear from the following description of illustrative and non-limiting embodiments illustrated with reference to the accompanying drawings. Attached Figure Description

[0013] Figure 1 This is an axial side view of the exterior of a vehicle drive unit.

[0014] Figure 2 It is a 3D view of the exterior of a vehicle drive unit.

[0015] Figure 3 This is a schematic diagram of a vehicle drive system.

[0016] Figure 4 This is an axial sectional view of a vehicle drive unit.

[0017] Figure 5 This is a schematic circuit block diagram of the electrical system that drives the rotating electric motor.

[0018] Figure 6 This is a partially enlarged side view of the housing with the power cable installed.

[0019] Figure 7 This is a cross-sectional perspective view of the area near the opening for power connection.

[0020] Figure 8 This is an enlarged sectional view of the axial portion near the opening for power connection with the power cable installed. Detailed Implementation

[0021] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Figure 3 Schematic diagram Figure 4 As shown in the axial sectional view, the vehicle drive unit 100 includes a rotary motor MG, an inverter unit INV for driving and controlling the rotary motor MG, and a housing 1. Figure 1 Exterior side view, Figure 2 As shown in the perspective view, the housing 1 includes a housing body 2 and cover components (axial first cover 11, axial second cover 12, and upper surface cover 13 (cover component)) that are joined to the housing body 2. The housing body 2 is integrally formed in such a way that it forms at least a first housing chamber 5 for housing the rotary motor MG and a second housing chamber 3 for housing the inverter device INV. Here, "integrally formed" means, for example, that it is a single component formed from the same material as a die casting. The housing body 2 has a dividing wall 4 that divides the first housing chamber 5 and the second housing chamber 3. That is, the housing 1 is integrally formed internally with at least a first housing chamber 5 for housing the rotary motor MG and a second housing chamber 3 for housing the inverter device INV, which is divided from the first housing chamber 5 by the dividing wall 4.

[0022] The vehicle drive unit 100 includes: a rotary motor MG mounted on a first shaft A1, a pair of output components OUT mounted on a second shaft A2 and drivenly connected to a pair of wheels W, a transmission mechanism TM that transmits driving force between the rotary motor MG and the output components OUT, and an inverter device INV that controls the drive of the rotary motor MG. The rotary motor MG is the driving force source for the pair of wheels W. The transmission mechanism TM includes a reversing gear mechanism CG and a differential gear mechanism DF (output differential gear device). The differential gear mechanism DF distributes the driving force transmitted from the rotary motor MG to the pair of wheels W. Although details will be described later, the pair of side gears (first side gear S1 and second side gear S2) of the differential gear mechanism DF correspond to the pair of output components OUT. In this embodiment, the vehicle drive unit 100, in the power transmission path connecting the rotary motor MG (which is a power generating device) and the wheels W, has a reversing gear mechanism CG and a differential gear mechanism DF sequentially arranged from the rotary motor MG side as the transmission mechanism TM (power transmission device).

[0023] The axis of the rotary electric motor MG (first axis A1) and the axis of the differential gear mechanism DF (second axis A2) are arranged on different parallel axes. The axis of the reversing gear mechanism CG (third axis A3) is arranged parallel to the first axis A1 and the second axis A2. That is, the first axis A1, the second axis A2, and the third axis A3 are different imaginary axes and are arranged parallel to each other.

[0024] In the following description, the direction parallel to the aforementioned axes (A1 to A3) will be referred to as the "axial direction L" of the vehicle drive unit 100. Furthermore, the side of axial direction L (in this embodiment, the side where the rotary motor MG is disposed relative to the differential gear mechanism DF, referred to...) Figure 3 as well as Figure 4 The axis A1, A2, and A3 are designated as "Axial First Side L1" and their opposite side as "Axial Second Side L2". The direction orthogonal to each of the aforementioned first axis A1, second axis A2, and third axis A3 is designated as "Radial R" based on each axis. When it is not necessary to distinguish which axis is the reference, and when the reference axis is clearly defined, it is sometimes simply referred to as "Radial R". The vertical direction along which the vehicle drive unit 100 is mounted in the vehicle is designated as "Up-Down Direction V". In this embodiment, the Up-Down Direction First Side V1, which is one side of the Up-Down Direction V, is upward, and the Up-Down Direction Second Side V2, which is the other side, is downward. When the vehicle drive unit 100 is mounted in a vehicle in a state parallel to the horizontal plane, one direction of the Radial R coincides with the Up-Down Direction V. The direction orthogonal to both the axis L and the Up-Down Direction V is called "Width Direction H". One side of the Width Direction H is called the Width Direction First Side H1, and the other side is called the Width Direction Second Side H2. Similar to the Up-Down Direction V, one direction of the Radial R also coincides with the Width Direction H. Furthermore, in the following description, terms related to the orientation and position of each component also include the concept of variations due to manufacturing tolerances. Additionally, the orientation of each component refers to the orientation in which they are assembled into the vehicle drive unit 100. Furthermore, in this embodiment, the vertical direction V corresponds to the first direction, and the axial direction L corresponds to the second direction.

[0025] The first storage chamber 5 formed in the housing 1 has a peripheral wall portion 29 formed to surround the rotary motor MG, the reversing gear mechanism CG, and the differential gear mechanism DF. The first storage chamber 5 of the housing 1 is surrounded by the peripheral wall portion 29 in the vertical direction V and the width direction H, and has openings on both sides in the axial direction L. Here, the opening on the first axial side L1 of the first storage chamber 5 is referred to as the axial first opening 21, and the opening on the second axial side L2 of the first storage chamber 5 is referred to as the axial second opening 22. The axial first opening 21 is blocked by an axial first cover 11 that engages with the end of the axial first side L1 of the peripheral wall portion 29. The axial second opening 22 is blocked by an axial second cover 12 that engages with the end of the axial second side L2 of the peripheral wall portion 29. That is, the first storage chamber 5 is formed as a space surrounded by the peripheral wall portion 29, the axial first cover 11, and the axial second cover 12.

[0026] A portion of the peripheral wall 29 functions as a dividing wall 4 separating the first storage chamber 5 and the second storage chamber 3. A surrounding wall 30 extending along the vertical direction V is formed from the peripheral wall 29. The surrounding wall 30 surrounds the inverter device INV in a direction orthogonal to the vertical direction V, forming the second storage chamber 3. The end of the surrounding wall 30 on the first vertical side V1 (upper) is open, forming an opening (vertical opening (first opening 23)) from the second storage chamber 3 toward the outside of the housing 1. The inverter device INV is housed in the second storage chamber 3 through this first opening 23. That is, the housing body 2 has a first opening 23 that opens from the second storage chamber 3 toward the outside of the housing 1 along a predetermined first direction (vertical direction V) and allows the inverter device INV to be inserted. An upper surface cover 13 (cover member) is configured to cover the first opening 23, and the first opening 23 is blocked by the upper surface cover 13, which engages with the end of the surrounding wall 30. Figure 2 As shown, the upper surface cover 13 is fixed to the surrounding wall portion 30 by a plurality of fastening members 33 arranged separately from each other along the opening edge 23e of the first opening portion 23. That is, the second storage chamber 3 is formed as a space enclosed by the dividing wall portion 4 (peripheral wall portion 29), the surrounding wall portion 30 and the upper surface cover 13.

[0027] In this embodiment, the upper cover 13 has a flat plate portion. The first opening edge 23e is located on a plane, and the flat plate portion of the upper cover 13 is also located on a plane. By abutting the flat plate portion of the upper cover 13 against the first opening edge 23e, the first opening 23 can be blocked by the upper cover 13. Thus, if the upper cover 13 has a flat plate portion, the first opening edge 23e of the first opening 23 can be easily secured to the upper cover 13 by the fastening member 33. However, if the first opening 23 (first opening edge 23e) is easily deformable, the upper cover 13 may float relative to the first opening edge 23e. Although details will be described later, this embodiment has a structure that can easily secure the first opening edge 23e and the upper cover 13, and also has a structure that can appropriately suppress the floating of the upper cover 13.

[0028] A rotary electric motor (MG) is a rotating electric motor / generator that operates using multi-phase alternating current (e.g., three-phase alternating current), and can function as both a motor and a generator. (See reference...) Figure 5 As will be described later, the rotary motor MG receives power from the high-voltage battery BH (DC power supply (referred to as "high-voltage DC power supply" in the case of the low-voltage battery BL described later)) for power operation, or supplies (regenerates) the power generated by the inertial force of the vehicle to the high-voltage battery BH.

[0029] like Figure 4 , Figure 5 As shown, the rotary electric machine MG has a stator 81 fixed to a housing 1, etc., and a rotor 82 supported radially inward of the stator 81 for rotation. The stator 81 includes a stator core and stator coils 83 wound around the stator core, and the rotor 82 includes a rotor core and permanent magnets disposed on the rotor core. The rotor 82 of the rotary electric machine MG is connected to the input gear G1 (see reference 1) via a rotor shaft 82a and an input component IN. Figure 3 , Figure 4 )Driver connection.

[0030] The input gear G1 is driven to connect with the reversing gear mechanism CG. In this embodiment, the reversing gear mechanism CG has two gears (first reversing gear G2 and second reversing gear G3) connected by a shaft member. The first reversing gear G2 meshes with the input gear G1, and the second reversing gear G3 meshes with the differential input gear G4 of the differential gear mechanism DF. The differential gear mechanism DF is driven to connect with the wheels W via the output shaft OX. The differential gear mechanism DF is composed of a plurality of meshing bevel gears. In this embodiment, the first side gear S1 on the first axial side L1 is connected to one output shaft OX via a connecting shaft JT, and the second side gear S2 on the second axial side L2 is connected to another output shaft OX. The rotation and torque input to the differential input gear G4 are distributed and transmitted to the two output shafts OX (i.e., the two wheels W) via the first side gear S1 and the second side gear, respectively. Thus, the vehicle drive unit 100 can transmit the torque of the rotary motor MG to the wheels W to drive the vehicle.

[0031] like Figure 5 As shown, the rotating motor MG is driven and controlled by the inverter device INV. The inverter device INV includes an inverter circuit 60 that converts power between DC and multiphase AC. In this embodiment, an inverter circuit 60 is shown that is connected to the AC rotating motor MG and the high-voltage battery BH, and converts power between multiphase (here, three-phase U-phase, V-phase, and W-phase) AC and DC. The inverter circuit 60 is configured with multiple switching elements, is connected to the high-voltage battery BH and the AC rotating motor MG, and converts power between DC and multiphase AC (here, three-phase AC). The high-voltage battery BH is, for example, a secondary battery (battery) such as a nickel-metal hydride battery or a lithium battery, and a double-layer capacitor. When the rotating motor MG is the driving force source of the vehicle, the high-voltage battery BH is a high-voltage, high-capacity DC power source, with a rated power supply voltage of, for example, 200 to 400 volts. Although details will be described later, the high-voltage battery BH and the inverter device INV are electrically connected via a power cable 7.

[0032] A DC link capacitor 64 (smoothing capacitor) is provided on the DC side of the inverter circuit 60 to smooth the voltage (DC link voltage) between the positive power line P and the negative power line N on the DC side of the inverter circuit 60. The inverter circuit 60 has multiple (here, three) AC single-phase arms composed of series circuits of upper-side and lower-side switching elements. Preferably, the switching elements are power semiconductor devices capable of high-frequency operation, such as IGBTs (Insulated Gate Bipolar Transistors), power MOSFETs (Metal Oxide Semiconductor Field Effect Transistors), SiC-MOSFETs (Silicon Carbide-Metal Oxide Semiconductor FETs), SiC-SITs (SiC-Static Induction Transistors), and GaN-MOSFETs (Gallium Nitride MOSFETs). Figure 5 As shown in this embodiment, an IGBT is illustrated as a switching element. This embodiment also includes a freewheeling diode, and the inverter circuit 60 is integrated into a single power module to form a switching element module.

[0033] like Figure 5 As shown, the inverter circuit 60 is controlled by the inverter control unit 65 (M-CTRL). The inverter control unit 65 is constructed with logic circuits such as microcomputers as its core components. Based on the target torque of the rotating motor MG, the inverter control unit 65 performs current feedback control using vector control and controls the rotating motor MG via the inverter circuit 60. The target torque of the rotating motor MG is provided, for example, as a request signal from other control devices such as the vehicle control unit 91 (VCL-CTRL), which is one of the higher-level control devices in the vehicle. The actual current flowing in the stator coils 83 of each phase of the rotating motor MG is detected by the current sensor 84. In addition, the magnetic pole position of the rotor of the rotating motor MG at each moment is detected, for example, by the rotation sensor 85 such as a resolver.

[0034] The inverter control unit 65 uses the detection results from the current sensor 84 and the rotation sensor 85 to perform current feedback control. To perform current feedback control, the inverter control unit 65 is configured with various functional units, each implemented through the cooperation of hardware and software (programs) such as a microcomputer. Since current feedback control is well-known, a detailed explanation is omitted here.

[0035] The vehicle control unit 91 and the inverter control unit 65 are low-voltage circuits whose core microcomputers operate at voltages of, for example, 5 volts or 3.3 volts, and are powered by a low-voltage battery BL (low-voltage DC power supply) with a voltage lower than that of the high-voltage battery BH (e.g., 12-24 volts). Therefore, the inverter control unit 65 has a drive circuit that relays the driving capability (e.g., the ability to operate downstream circuitry by adjusting voltage amplitude, output current, etc.) of the switching control signals (in the case of IGBTs) for each switching element. The control terminals of each switching element constituting the inverter circuit 60 are connected to the microcomputer, etc., which is the core of the inverter control unit 65, via the drive circuit, and are independently switched. The inverter control unit 65 is constructed by mounting circuit components on one or more substrates.

[0036] The inverter unit INV is configured as a unit including the inverter control device 65, DC link capacitor 64, and inverter circuit 60 (power module) as described above. The inverter unit INV, as a unit, is disposed in the second storage chamber 3 inside the housing 1 and is fixed to the housing 1 by fasteners such as bolts.

[0037] like Figure 5 As shown, the stator coils 83 of the inverter unit INV and the rotating electric machine MG are electrically connected via AC bus 50. AC bus 50 includes an inverter-side AC bus 51, an AC bus connector 52, and a rotating electric machine-side AC bus 53. The AC bus connector 52 is disposed between the first housing chamber 5 and the second housing chamber 3, with the partition wall 4 extending through it. One end of the AC bus connector 52 is electrically connected to the inverter-side AC bus 51 inside the second housing chamber 3. The other end of the AC bus connector 52 is electrically connected to the rotating electric machine-side AC bus 53 inside the first housing chamber 5.

[0038] As described above, the high-voltage battery BH and the inverter unit INV are electrically connected via power cable 7. A power connector 70 is located at the front end of power cable 7, and this power connector 70 is mounted on housing 1 (see reference 1). Figure 6 , Figure 8 (etc.). The power connector 70 is provided with power terminals (first power terminal 71, second power terminal 72) that are electrically connected to the power cable 7. Additionally, the inverter unit INV has a power connection terminal T that connects to the high-voltage battery BH. The power connection terminal T is connected to the DC bus 55 of the inverter unit INV (positive bus 54, negative bus 56: see reference). Figure 5It can be integrated into the circuit or configured as another component electrically connected to the DC bus 55. The high-voltage battery BH and the inverter device INV (inverter circuit 60) are electrically connected by electrically connecting the power terminals (first power terminal 71, second power terminal 72) of the power connector 70 to the power connection terminals T (first connection terminal T1, second connection terminal T2).

[0039] like Figure 1 as well as Figure 2 As shown, the housing body 2 includes a surrounding wall portion 30 arranged along the vertical direction V (first direction) to surround the first opening 23; and a power connection opening (second opening 25) formed in the surrounding wall portion 30 for inserting a power cable 7 that electrically connects the high-voltage battery BH to the power connection terminal T. Figure 1 , Figure 7 As shown, the power connection terminal T includes a positive connection terminal connected to the positive terminal of the high-voltage battery BH, and a negative connection terminal connected to the negative terminal of the high-voltage battery BH. For example, when the first connection terminal T1 is the negative connection terminal, the second connection terminal T2 is the positive connection terminal; when the first connection terminal T1 is the positive connection terminal, the second connection terminal T2 is the negative connection terminal. Furthermore, the positive and negative connection terminals are arranged along the vertical direction V. That is, the first connection terminal T1 and the second connection terminal T2 are arranged along the vertical direction V.

[0040] The power connection terminal T and the power terminal of the power connector 70 are connected, for example, via the terminal connection member 73, as described later. With the inverter device INV inserted into the second housing 3 through the first opening 23 and at least disposed within the second housing 3, preferably further secured within the second housing 3, the power connector 70 is inserted into the second housing 3 through the second opening 25, and the power connection terminal T is connected to the power terminal of the power connector 70 (the upper surface cover 13 may not be engaged, or preferably not engaged). Therefore, as... Figure 1 As shown, the first connecting terminal T1 and the second connecting terminal T2, arranged along the vertical direction V, are positioned in a location visually confirmable from the outside of the housing 1 when viewed axially along the axis L. In this example, a second opening 25 is provided in the surrounding wall portion 30. Moreover, in the axial view, the second opening 25 is formed into an elongated shape in the vertical direction V (first direction). In other words, in the axial view, the opening width of the second opening 25 in the direction orthogonal to the vertical direction V (width direction H: the direction orthogonal to the vertical direction V (first direction) and the axis L (second direction), i.e., the second opening width Y2, is smaller than the opening width of the second opening 25 in the vertical direction V, i.e., the first opening width Y1.

[0041] When the surrounding wall 30, which surrounds the first opening 23 into which the inverter device INV can be inserted, has a second opening 25 for inserting the power cable 7, this second opening 25 may reduce the rigidity of the surrounding wall 30. If the rigidity of the surrounding wall 30 is insufficient, for example, if the opening edge 23e of the first opening 23 deforms, the upper surface cover 13 (cover member) configured to cover the first opening 23 may float up from the first opening 23, creating a gap. According to this configuration, even with such a second opening 25, since the second opening width Y2 of the second opening 25 is smaller than the first opening width Y1, it is easier to suppress the deformation of the first opening edge 23e. In addition, since the first connection terminal T1 and the second connection terminal T2 are arranged along the vertical direction V, the width direction H of the power cable 7 connected to them is also likely to be smaller than the width in the vertical direction V. Therefore, even with such a setting for the opening width of the second opening 25, the power cable 7 can be properly inserted.

[0042] Additionally, refer to Figure 2 As described above, the upper surface cover 13 is secured to the surrounding wall portion 30 by a plurality of fastening members 33 arranged separately from each other along the opening edge 23e of the first opening 23. Furthermore, a pair of fastening members 33 (33a, 33b) are arranged on both sides, separated by the second opening 25. Specifically, as... Figure 2 As shown, the first fastening member 33a and the second fastening member 33b are disposed on both sides of the second opening 25, separated by the second opening 25. Near the second opening 25, the upper surface cover 13 is fastened to the surrounding wall portion 30, so the deformation of the first opening edge 23e caused by the second opening 25 is easily suppressed to a small extent, and the situation of the upper surface cover 13 floating off the first opening edge 23e can also be appropriately suppressed.

[0043] In other words, the width Y1 of the first opening is less than the distance X between the pair of fastening members 33 disposed on both sides of the second opening 25 (the distance X between the first fastening member 33a and the second fastening member 33b). By means of the pair of fastening members 33 across the second opening 25, the upper surface cover 13 is properly fastened to the surrounding wall portion 30, so the deformation of the first opening edge 23e caused by the second opening 25 can be suppressed to a small extent, and the situation where the upper surface cover 13 floats up from the first opening edge 23e can also be appropriately suppressed.

[0044] Of course, as long as it is ensured that the deformation of the first opening edge 23e can be sufficiently suppressed and the rigidity of the upper surface cover 13 rising from the first opening edge 23e can be ensured, the fastening member 33 can be configured only on either side of the second opening 25.

[0045] Furthermore, the second opening 25 is preferably formed as follows in the axial view: Figure 1 The shape is an ellipse, as shown. While satisfying the relationship between the first opening width Y1 and the second opening width Y2, the shape of the second opening 25 in the axial view can also be a rectangle, hexagon, octagon, or other polygonal shape. However, as in this embodiment, if the shape of the second opening 25 is elliptical, the corners disappear compared to a polygonal shape, thus easily ensuring the rigidity of the surrounding wall 30 around the second opening 25. Of course, ensuring sufficient rigidity of the surrounding wall 30 does not preclude the second opening 25 from being formed into a polygonal shape. Furthermore, the term "elliptical shape" in this embodiment also includes oblong shapes like those of a track and field track, egg shapes, and other roughly elliptical shapes.

[0046] In addition, in this embodiment, such as Figure 2 as well as Figure 7 As shown, in both the vertical view along the vertical direction V and the axial view, the opening edge of the first opening 23, i.e., the first opening edge 23e, overlaps with the opening edge of the second opening 25, i.e., the second opening edge 25e. That is, in this embodiment, the first opening 23 and the second opening 25 are formed close together, and the first opening edge 23e and the second opening edge 25e are disposed close together. In this case, the first opening edge 23e is prone to deformation. However, according to this embodiment, by considering the relationship between the first opening width Y1 and the second opening width Y2, the shape of the second opening 25, and the arrangement of the fastening member 33, as described above, the reduction in the rigidity of the first opening 23 can be suppressed, and deformation of the first opening 23 and lifting of the upper surface cover 13 can also be suppressed. Furthermore, as described later, in this embodiment, by fitting the power connector 70 into the second opening 25, the reduction in the rigidity of the first opening 23 can also be suppressed, and deformation of the first opening 23 and lifting of the upper surface cover 13 can also be suppressed.

[0047] Furthermore, even if the first opening edge 23e and the second opening edge 25e overlap only in either the vertical or axial view, or if they do not overlap in either the vertical or axial view, it is preferable to ensure the rigidity of the first opening 23 by considering the relationship between the first opening width Y1 and the second opening width Y2, the shape of the second opening 25, the arrangement of the fastening member 33, and the engagement of the power connector 70 with the second opening 25, as described above. In this embodiment, "opening edge" refers to the frame-like portion surrounding the opening. More specifically, the first opening edge 23e is a portion that surrounds the first opening 23 and forms a mating surface for engagement with the upper surface cover 13 (cover member). In the illustrated example, the first opening edge 23e includes a flange-like portion that protrudes outward from the surrounding wall portion 30 toward the outside of the first opening 23. Similarly, the second opening edge 25e is a frame-like portion that surrounds the second opening 25 and protrudes outward from the surrounding wall portion 30 toward the axial direction L.

[0048] As described above, by connecting the power connection terminal T to the power terminal of the power connector 70, the high-voltage battery BH and the inverter device INV (inverter circuit 60) are electrically connected. The power terminals (first power terminal 71, second power terminal 72) of the power connector 70 are integrally provided with or electrically connected to the DC bus 55 (positive bus 54, negative bus 56) of the inverter device INV, or to the power connection terminal T (first connection terminal T1, second connection terminal T2) electrically connected to the DC bus 55. For example, as Figure 8 As shown, the first power terminal 71 and the first connection terminal T1 are fastened together by the terminal connecting member 73, and the second power terminal 72 and the second connection terminal T2 are also fastened together by the terminal connecting member 73. Although a fastening member (screw) is shown as the terminal connecting member 73 here, it could also be a rivet or the like.

[0049] A power connector 70 is located at the front end of the power cable 7 (the front end of the side opposite to the side connected to the high-voltage battery BH). The power connector 70 is made of rigid resin and has wires and power terminals inside. Figure 6 As shown, the power connector 70 is mounted on the housing 1 such that it covers the second opening 25. At this time, as... Figure 8 As shown, the outer peripheral surface 70a of the power connector 70 is fitted with the inner peripheral surface 25a of the second opening 25. By fitting the power connector 70 with the second opening 25, the second opening 25 is strengthened, and deformation of the second opening 25 is easily suppressed. Moreover, this also makes it easier to minimize deformation of the first opening edge 23e.

[0050] Furthermore, although detailed illustrations are omitted, the power connector 70 may also have a main body and a cover. Alternatively, without the cover being attached to the main body, the first power terminal 71 may be fastened to the first connection terminal T1 via the terminal connection member 73, and the second power terminal 72 may be fastened to the second connection terminal T2, before the cover is attached to the main body.

[0051] In this embodiment, the high-voltage battery BH has a high voltage of 200 to 400 volts. Furthermore, it consumes a large current, ranging from several amperes to tens of amperes. Therefore, the power cable 7 becomes a relatively thick and heavy component. If the power cable 7 is installed in the housing 1 via the power connector 70, the load of the power cable 7 is also applied to the second opening 25. Moreover, if vibrations caused by vehicle movement or vibrations accompanying the drive of the vehicle drive unit 100 occur, inertial forces may sometimes act on the power cable 7, further increasing the load on the second opening 25. Therefore, regarding the rigidity of the second opening 25 and the first opening 23, it is preferable to consider not only the rigidity in the static state but also the rigidity in the dynamic state. According to this embodiment, since the width of the second opening Y2 is smaller than the width of the first opening Y1, even when vibrations that easily generate relatively large acceleration in the vehicle act on the second opening 25 along the vertical direction V, it is easier to minimize the deformation of the second opening 25, and consequently, it is easier to minimize the deformation of the first opening 23.

[0052] Furthermore, although this embodiment illustrates a form where the power connector 70 is made of rigid resin, the power connector 70 may also be made of soft resin, or it may be formed by blocking the second opening 25 with a sheet-like resin cover. In this case, although the fitting of the power connector 70 into the second opening 25 does not improve the rigidity of the second opening 25, such a form is not a problem if the rigidity of the second opening 25 is sufficient.

[0053] [Other Implementation Methods]

[0054] Other embodiments will be described below. Furthermore, the structures of the embodiments described below are not limited to individual applications; they can be combined with the structures of other embodiments as long as no contradictions arise.

[0055] (1) In the above description, the form in which the second opening 25 opens along the axial direction L is illustrated. That is, the case where the second direction is the axial direction L is illustrated and explained. However, the second direction may also be along the width direction H. Or the second direction may also be a direction inclined relative to both the axial direction L and the width direction H. In addition, in the above description, the form in which the first opening 23 opens toward the first side V1 in the vertical direction is illustrated and explained. That is, the form in which the first direction is along the vertical direction V is illustrated and explained. However, the first opening 23 may also open toward a direction intersecting the vertical direction V, for example, it may open toward the second side H2 in the width direction. In addition, although in this embodiment, the form in which the height of the first storage chamber 5 in the vertical direction V is different depending on the position of the width direction H in the axial view is illustrated, when the height of the first storage chamber 5 in the vertical direction V is approximately constant, and the second storage chamber 3 is arranged on the first side V1 in the vertical direction of the first storage chamber 5, the first opening 23 may also open toward the first side H1 in the width direction. In this case, the first direction is the width direction H, and the second direction becomes either the axial direction L or the vertical direction V. Alternatively, the first opening 23 can also open along the axial direction L. In this case, the first direction is the axial direction L, and the second direction is either the width direction H or the vertical direction V.

[0056] (2) In the above example, the form in which the first storage chamber 5 and the second storage chamber 3 are divided by the dividing wall 4 is shown. However, as long as the shell body 2 is integrally formed in such a way as to form the first storage chamber 5 and the second storage chamber 3, the dividing wall 4 does not need to be provided on the shell body 2.

[0057] (3) In the above, although a vehicle drive unit 100 with a rotary motor MG as the driving force source for the wheel W has been illustrated and explained, the vehicle drive unit 100 may also be a hybrid drive unit with both an internal combustion engine and a rotary motor MG as the driving force source for the wheel W of the vehicle (for example, various forms of hybrid drive units such as the so-called single motor parallel type and dual motor separate type).

[0058] (4) Although the above description illustrates a vehicle drive unit 100 with three shafts (first shaft A1, second shaft A2, and third shaft A3) arranged in parallel, the vehicle drive unit 100 may also consist of two shafts (first shaft A1 and second shaft A2) arranged in parallel. Furthermore, the vehicle drive unit 100 may also have one or more shafts different from the first shaft A1, second shaft A2, and third shaft A3, resulting in a structure with four or more shafts. Moreover, in the above-described case, some of the shafts may be arranged in a direction that is not parallel to the other shafts.

[0059] [Summary of Implementation Methods]

[0060] The following is a brief overview of the vehicle drive unit (100) described above.

[0061] In one embodiment, the vehicle drive unit (100) includes a rotary motor (MG), an inverter device (INV) for driving and controlling the rotary motor (MG), and a housing (1). The inverter device (INV) has a power connection terminal (T) connected to a DC power supply (BH). The housing (1) includes a housing body (2) and a cover member (13) that engages with the housing body (2). The housing body (1) forms a first storage chamber (5) for housing the rotary motor (MG) and a second storage chamber (5) for housing the inverter device (INV). 3) The housing body (1) is integrally formed in such a manner that it has a first opening (23) that opens from the second storage chamber (3) toward the outside of the housing (1) along a predetermined first direction (V) and allows the inverter device (INV) to be inserted. The housing body (2) also has a surrounding wall (30) arranged along the first direction (V) to surround the first opening (23), and a second opening formed in the surrounding wall (30) for inserting a power cable (7) that electrically connects the DC power supply (BH) to the power connection terminal (T). The opening (25), the cover member (13) is fixed to the surrounding wall (30) by a plurality of fastening members (33) arranged separately from each other to cover the first opening (23). The power connection terminal (T) includes a positive connection terminal (T1 or T2) connected to the positive terminal of the DC power supply (BH), and a negative connection terminal (T2 or T1) connected to the negative terminal of the DC power supply (BH). The positive connection terminal (T1 or T2) and the negative connection terminal (T2 or T1) T1) is arranged along the first direction (V), and the opening direction of the second opening (25) is set as the second direction (L). When viewed along the second direction (L), the opening width (Y2) of the second opening (25) in the direction (H) orthogonal to the first direction (V) is smaller than the opening width (Y1) of the second opening (25) in the first direction (V). A pair of fastening members (33 (33a, 33b)) are arranged on both sides across the second opening (25).

[0062] When the surrounding wall (30) surrounding the first opening (23) into which the inverter device (INV) can be inserted has a second opening (25) for inserting the power cable (7), the second opening (25) may reduce the rigidity of the surrounding wall (30). If the rigidity of the surrounding wall (30) is insufficient, for example, if the opening edge (23e) of the first opening (23) deforms, the cover member (13) configured to cover the first opening (23) may float up from the first opening (23) and create a gap. According to this structure, even when such a second opening (25) is formed, since the second opening width (Y2) of the second opening (25) is smaller than the first opening width (Y1), it is easier to suppress the deformation of the opening edge (23e) of the first opening (23). Furthermore, since the positive connection terminal (T1 or T2) and negative connection terminal (T2 or T1) of the power connection terminal (T) are arranged along the first direction (V), the width of the power cable (7) connected to them in the direction (H) orthogonal to the first direction (V) is also likely to be smaller than the width of the first direction (V). Therefore, even with such an opening width of the second opening (25), the power cable (7) can be properly inserted. In addition, since a pair (33a, 33b) of the plurality of fastening members (33) arranged along the opening edge (23e) of the first opening (23) are arranged on both sides of the second opening (25) across the second opening (25), the cover member (13) is fastened to the surrounding wall (30) near the second opening (25). Therefore, the deformation of the opening edge (23e) of the first opening (23) caused by the second opening (25) can be minimized, and the situation where the cover member (13) floats up from the opening edge (23e) of the first opening (23) can also be appropriately suppressed. Thus, according to this structure, an automotive drive unit (100) can be provided that ensures the rigidity of the housing (1) for housing the inverter (INV) without compromising its sealing, and can properly connect the power cable (7).

[0063] In addition, the width (Y1) of the first opening of the preferred vehicle drive unit (100) is smaller than the distance (X) between the pair of fastening members (33 (33a, 33b)).

[0064] According to this structure, the cover member (13) is properly fastened to the surrounding wall portion (30) through the pair of fastening members (33 (33a, 33b)) via the second opening (25). Therefore, the deformation of the opening edge (23e) of the first opening portion (23) caused by the second opening portion (25) can be minimized, and the situation where the cover member (13) floats up from the opening edge (23e) of the first opening portion (23) can also be appropriately suppressed.

[0065] In addition, the cover component (13) of the preferred vehicle drive unit (100) has a flat plate portion.

[0066] If the cover member (13) has a flat plate portion, the opening edge (23e) of the first opening (23) abuts against the cover member (13) and can be easily fastened by the fastening member (33). In this case, if the rigidity of the second opening (25) is low, the first opening (23) is also prone to deformation, and the cover member (13) may float relative to the opening edge (23e) of the first opening (23). However, by suppressing the deformation of the second opening (25), a structure can be provided that allows the opening edge (23e) of the first opening (23) and the cover member (13) to be easily fastened, and the floating of the cover member (13) can also be appropriately suppressed.

[0067] Furthermore, the second opening (25) of the preferred vehicle drive unit (100) is formed in an elliptical shape in the second direction (L) view.

[0068] While satisfying the relationship between the first opening width (Y1) and the second opening width (Y2), the shape of the second opening (25) in the second direction (L) view can also be a rectangle, a hexagon, an octagon, or a polygon. However, as in this structure, if the shape of the second opening (25) is set to an ellipse, the corners disappear compared to the polygonal case, making it easier to ensure the rigidity of the surrounding wall (30) of the second opening (25). In addition, "ellipse" also includes oblong shapes like those of a track and field track, egg shapes, and other roughly elliptical shapes.

[0069] In addition, a vehicle drive unit (100) is preferred, such that the outer peripheral surface (70a) of the connector (70) of the power cable (7) is fitted with the inner peripheral surface (25a) of the second opening (25).

[0070] Generally, the connector (70) of the power cable (7) is made of rigid resin and has wires and terminals inside. By fitting such a connector (70) into the second opening (25), the second opening (25) can be strengthened, and deformation of the second opening (25) can be easily suppressed. Moreover, this also makes it easier to minimize deformation of the opening edge (23e) of the first opening 23.

[0071] In addition, the preferred vehicle drive unit (100) has the opening edge of the first opening (23), i.e. the first opening edge (23e), overlapping with the opening edge of the second opening (25), i.e. the second opening edge (25e), in both the first direction (V) view along the first direction (V) and the second direction (L) view.

[0072] According to this structure, the first opening (23) and the second opening (25) are formed close to each other, and the first opening edge (23e) and the second opening edge (25e) are arranged close to each other. In this case, the first opening edge (23e) is prone to deformation. In such a structure, various embodiments of the vehicle drive device (100) described above are useful. That is, by the relationship between the first opening width (Y1) and the second opening width (Y2) described above, the shape of the second opening (25), the arrangement of the fastening member (33), etc., it is possible to suppress the reduction of the rigidity of the first opening (23), and also to suppress the deformation of the first opening (23) and the lifting of the cover member (13). In addition, when the power connector (70) is fitted with the second opening (25), it is also possible to suppress the reduction of the rigidity of the first opening (23), and to suppress the deformation of the first opening (23) and the lifting of the upper surface cover (13).

[0073] Explanation of reference numerals in the attached figures

[0074] 1: Housing, 2: Housing body, 3: Second storage chamber, 5: First storage chamber, 7: Power cable, 13: Upper surface cover (cover component), 23: First opening, 23e: First opening edge, 25: Second opening, 25a: Inner peripheral surface, 25e: Second opening edge, 30: Enclosing wall, 33: Fastening component, 33a, 33b: A pair of fastening components, 70: Power connector (connector for power cable), 70a: Outer peripheral surface, 100: Vehicle drive unit, BH: High voltage Battery (DC power supply), H: width direction (direction of the second opening orthogonal to the first direction), INV: inverter device, L: axial direction (second direction), MG: rotary motor, T: power connection terminal, T1: first connection terminal (negative connection terminal or positive connection terminal), T2: second connection terminal (positive connection terminal or negative connection terminal), V: vertical direction (first direction), X: spacing between a pair of fastening parts, Y1: width of the first opening, Y2: width of the second opening.

Claims

1. A vehicle drive unit comprising: a rotary motor; an inverter for driving and controlling the rotary motor; and a housing. The aforementioned inverter device has a power connection terminal for connecting to a DC power supply. The aforementioned housing includes a housing body and a cover component that engages with the housing body. The aforementioned housing body is integrally formed to form a first storage chamber for housing the aforementioned rotary motor and a second storage chamber for housing the aforementioned inverter device. The aforementioned housing body has a first opening that extends from the second storage chamber toward the outside of the housing along a predetermined first direction, allowing the inverter device to be inserted. The aforementioned housing body further includes: a surrounding wall portion arranged along the first direction to surround the first opening, and a second opening portion formed in the surrounding wall portion for inserting a power cable that electrically connects the DC power supply and the power connection terminal. The aforementioned cover component is secured to the aforementioned surrounding wall portion by a plurality of fastening components arranged separately from each other along the opening edge of the aforementioned first opening, thereby covering the aforementioned first opening. The aforementioned power connection terminals include: a positive connection terminal connected to the positive terminal of the aforementioned DC power supply, and a negative connection terminal connected to the negative terminal of the aforementioned DC power supply. The aforementioned positive terminal and negative terminal are arranged along the aforementioned first direction. The direction of the opening of the second opening is defined as the second direction. In the second-direction view along the second direction, the opening width of the second opening in the direction orthogonal to the first direction, i.e., the second opening width, is smaller than the opening width of the second opening in the first direction, i.e., the first opening width. A pair of the aforementioned fastening components are arranged on both sides, separated by the aforementioned second opening.

2. The vehicle drive device according to claim 1, wherein, The width of the first opening is less than the distance between the pair of fastening components.

3. The vehicle drive unit according to claim 1 or 2, wherein, The aforementioned cover component has a flat plate-shaped portion.

4. The vehicle drive unit according to any one of claims 1 to 3, wherein, The second opening is formed in an elliptical shape in the second view.

5. The vehicle drive unit according to any one of claims 1 to 4, wherein, The outer peripheral surface of the connector of the power cable is fitted into the inner peripheral surface of the second opening.

6. The vehicle drive unit according to any one of claims 1 to 5, wherein, In both the first direction view and the second direction view along the first direction, the opening edge of the first opening, i.e., the first opening edge portion, overlaps with the opening edge of the second opening, i.e., the second opening edge portion.

Images