Power distribution system routed through subframe

Abstract

The present disclosure provides a power distribution system routed through a subframe. In some aspects, the technology described herein relates to a motor vehicle comprising: a subframe; the motor is mounted on the auxiliary frame; and a power distribution system electrically coupled to the electric machine. In particular, the power distribution system is routed at least partially through the subframe.

Description

Technical Field

[0001] The present disclosure generally relates to a power distribution system for an electrified vehicle, and more particularly to a power distribution system in which wiring passes through a subframe of the electrified vehicle. Background Art

[0002] A high-voltage traction battery pack typically supplies power to an electric motor and other electrical loads of an electrified vehicle. The traction battery pack includes a plurality of battery cells. Summary of the Invention

[0003] In some aspects, the technology described herein relates to a motor vehicle including: a subframe; an electric motor mounted to the subframe; and a power distribution system electrically coupled to the electric motor, wherein the power distribution system is at least partially routed through the subframe.

[0004] In some aspects, the technology described herein relates to a motor vehicle, wherein the subframe is made of a metallic material.

[0005] In some aspects, the technology described herein relates to a motor vehicle, wherein the power distribution system includes a wire.

[0006] In some aspects, the technology described herein relates to a motor vehicle, wherein the wire is embedded within the subframe.

[0007] In some aspects, the technology described herein relates to a motor vehicle, wherein the subframe includes an internal channel, and the wire is routed through the internal channel.

[0008] In some aspects, the technology described herein relates to a motor vehicle, wherein the internal channel is at least partially formed by stamping a first metal piece.

[0009] In some aspects, the technology described herein relates to a motor vehicle, wherein a second metal piece is connected to the first metal piece to enclose the internal channel.

[0010] In some aspects, the technology described herein relates to a motor vehicle, wherein the wire is not wound within an electromagnetic interference shield.

[0011] In some aspects, the technology described herein relates to a motor vehicle, wherein the wire is a cable.

[0012] In some aspects, the technology described herein relates to a motor vehicle, wherein the wire is a bus bar.

[0013] In some aspects, the technology described herein relates to a motor vehicle further including: a first component; and a second component, the second component being electrically coupled to the first component through the power distribution system.

[0014] In some aspects, the techniques described herein relate to a motor vehicle in which the first component is a battery pack and the second component is the electric motor.

[0015] In some aspects, the techniques described herein relate to a motor vehicle in which the motor vehicle is an electrified vehicle.

[0016] In some aspects, the techniques described herein relate to a motor vehicle in which a subframe is attached to a frame of the motor vehicle.

[0017] In some aspects, the techniques described herein relate to a method that includes powering or being powered from an electric motor of a motor vehicle via a power distribution system that is at least partially routed through a subframe that supports the electric motor.

[0018] In some aspects, the techniques described herein relate to a method in which the subframe is made of a metallic material.

[0019] In some aspects, the techniques described herein relate to a method in which the power distribution system includes wires.

[0020] In some aspects, the techniques described herein relate to a method in which the wires are not wound within an electromagnetic interference shield.

[0021] In some aspects, the techniques described herein relate to a method in which the wires are embedded within the subframe.

[0022] In some aspects, the techniques described herein relate to a method in which the subframe includes an internal channel and the wires are routed through the internal channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 An electrified vehicle is schematically illustrated.

[0024] Figure 2 Shows Figure 1 an assembly of a drive system of the electrified vehicle.

[0025] Figure 3 Is Figure 2 a cross-sectional view of a portion of a subframe. DETAILED DESCRIPTION

[0026] The present disclosure generally relates to a power distribution system for an electrified vehicle and more particularly to a power distribution system having wiring passing through a subframe of the electrified vehicle. Among other benefits, the subframe acts as a natural Faraday cage for the power distribution system while also reducing the number of components since the portion of the power distribution system's wiring passing through the subframe does not require a separate insulation shield. These and other features are discussed in more detail in the following paragraphs of the present detailed description.

[0027] Figure 1 A motor vehicle is schematically shown, which in this example is an electrified vehicle 10. The electrified vehicle 10 can include any type of electrified powertrain.

[0028] Figure 1 The electrified vehicle 10 is schematically shown and includes an electrified drive system 12. In an embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). In another embodiment, the electrified vehicle 10 is a hybrid electric vehicle (HEV) or a plug-in hybrid electric vehicle (PHEV). Thus, although not shown in this embodiment, the electrified vehicle 10 can be equipped with an internal combustion engine that can be used alone or in combination with other energy sources to propel the electrified vehicle 10.

[0029] In the illustrated embodiment, the electrified vehicle 10 is an all-electric vehicle that is propelled only by electricity, such as by one or more electric motors 14, without any assistance from an internal combustion engine. The electric motor 14 can operate as an electric motor, a generator, or both. The electric motor 14 receives electrical power and provides a rotational output torque to one or more drive wheels 16.

[0030] The electrified vehicle 10 includes a power distribution system (sometimes abbreviated as “EDS”) 18. The power distribution system 18 is configured to electrically couple certain electrical components of the electrified vehicle 10 to each other. In Figure 1 this case, the power distribution system 18 electrically connects the electric motor 14 to the battery pack 20. In Figure 1 this case, the power distribution system 18 is schematically shown. It should be understood that the power distribution system 18 can include one or more wires, cables, bus bars (sometimes spelled “busbar”), electrical connectors, etc., as needed, to electrically couple the electrical components to each other.

[0031] The battery pack 20 is an exemplary electrified vehicle battery. The battery pack 20 can be a high-voltage traction battery pack that includes a plurality of battery arrays 25 (i.e., battery assemblies or rechargeable battery cell groups) capable of outputting electrical power to operate the electric motor 14 and / or other electrical loads of the electrified vehicle 10. Other types of energy storage devices and / or output devices can also be used to power the electrified vehicle 10.

[0032] In one embodiment, the electrified vehicle 10 is a pickup truck. However, the electrified vehicle 10 can also be a sedan, a van, a sport utility vehicle, or any other type of vehicle. Although specific component relationships are shown in the drawings of the present disclosure, the illustrations are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 10 are schematically shown and can vary within the scope of the present disclosure.

[0033] Figure 2 An exemplary axle assembly 22 of the drive system 12 of the electrified vehicle 10 is shown. Figure 1 In an embodiment, the axle assembly 22 is the rear axle assembly of the electrified vehicle 10. In another embodiment, the axle assembly 22 is the front axle assembly of the electrified vehicle 10. In yet another embodiment, the front and rear axles of the drive system 12 can each employ the axle assembly 22. In other words, the electrified vehicle 10 can be a rear-wheel drive vehicle, a front-wheel drive vehicle, or an all-wheel drive vehicle.

[0034] The axle assembly 22 can particularly include a subframe 24, an electric machine 14, a pair of axle housings 26, and a pair of axle shafts 28.

[0035] The subframe 24 can serve as a carrier for the axle assembly 22 and is configured to mount the electric machine 14. In this example, the subframe 24 is made of a metallic material. The size, shape, material composition, and overall configuration of the subframe 24 are not intended to limit the present disclosure. The present disclosure extends to subframes that are not carriers for axle assemblies. The subframe 24 can include one or more parts.

[0036] The subframe 24 is the frame to which the electric machine 14 is mounted. The subframe 24 is in turn connected to the frame of the electrified vehicle 10, such as by being connected to the frame rail 29, as Figure 3 shown.

[0037] The subframe 24 can include a top frame 32, a bottom frame 34, and opposing sidewalls 36. The top frame 32, bottom frame 34, and sidewalls 36 of the subframe 24 establish an open space 38 for receiving the electric machine 14.

[0038] In the present disclosure, the power distribution system 18 is at least partially routed through the subframe 24. In this example, the power distribution system 18 includes a wire 46 that is at least partially routed through the subframe 24, which is shown in part in dashed lines in Figure 2 As an example, the wire 46 can be a wire, a cable, a bundle of wires or cables, or a bus bar. The wire 46 is configured to distribute power between the battery pack 20 and the electric machine 14.

[0039] Figure 3A portion of the subframe 24, namely the top frame 32, is shown in cross-section. As shown, the subframe 24 includes an internal channel 50. The internal channel 50 is formed between a first metal piece 52 and a second metal piece 54. In this example, the first metal piece 52 is formed into a substantially U-shaped cross-section using a process such as stamping. The second metal piece 54 is substantially flat and is attached to the first metal piece 52 to enclose the internal channel 50. The second metal piece 54 can be attached to the first metal piece 52 using a process such as welding. Since the subframe 24 (i.e., the top frame 32) is made of a metal material, it acts as a natural Faraday cage for the wire 46. Thus, in a particular example, the wire 46 is not wound in an electromagnetic interference shield. As an example, the internal channel 50 can be formed using processes other than stamping and welding, such as by using additive manufacturing or investment casting to form the subframe 24. Although not shown, the subframe 24 can include openings that allow the power distribution system 18 (i.e., the wire 46) to be routed through the internal channel 50.

[0040] Although in Figure 3 the wire 46 is routed through the internal channel 50 of the subframe 24, according to other techniques, the wire 46 can be routed at least partially through the subframe 24. One such technique includes embedding at least a portion of the wire 46 into the subframe 24 during the formation of the subframe 24, including during a casting or molding process used to form the subframe 24. This can involve placing the wire 46 in a mold and then pouring or injecting molten metal around it, allowing the metal to solidify and enclose the wire 46.

[0041] It should be understood that terms such as "about", "substantially", and "generally" are not intended to be unbounded terms and should be interpreted in a manner consistent with how those terms would be interpreted by a person of ordinary skill in the art. It should also be understood that directional terms such as "upper", "top", "vertical", "forward", "backward", "side", "above", "below", etc. are used herein for illustrative purposes only with respect to the normal operating attitude of the vehicle and should not be considered restrictive.

[0042] Although the different examples have the specific components shown in the figures, the embodiments of the present disclosure are not limited to those particular combinations. Some of the components or features from one of the examples can be used in combination with the features or components from another of the examples. Additionally, the various figures of the present disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to show certain details of a particular component or arrangement.

[0043] A person of ordinary skill in the art will understand that the above embodiments are exemplary and not restrictive. That is, modifications of the present disclosure will fall within the scope of the claims. Therefore, the appended claims should be studied to determine their true scope and content.

[0044] According to the present invention, a method includes: supplying power to or from an electric motor of a motor vehicle via a power distribution system, the power distribution system being at least partially routed through a subframe that supports the electric motor.

[0045] In one aspect of the present invention, the subframe is made of a metallic material.

[0046] In one aspect of the present invention, the power distribution system includes wires.

[0047] In one aspect of the present invention, the wires are not wound within an electromagnetic interference shield.

[0048] In one aspect of the present invention, the wires are embedded within the subframe.

[0049] In one aspect of the present invention, the subframe includes an internal passage, and the wires are routed through the internal passage.

Claims

1. A motor vehicle, comprising: A subframe; An electric motor mounted to the subframe; And A power distribution system electrically coupled to the electric motor, wherein the power distribution system is at least partially routed through the subframe.

2. The motor vehicle according to claim 1, wherein the subframe is made of a metallic material.

3. The motor vehicle according to claim 1, wherein the power distribution system includes wires.

4. The motor vehicle according to claim 3, wherein the wires are embedded within the subframe.

5. The motor vehicle according to claim 3, wherein the subframe includes an internal passage, and the wires are routed through the internal passage.

6. The motor vehicle according to claim 5, wherein the internal passage is at least partially formed by stamping a first metallic piece.

7. The motor vehicle according to claim 6, wherein a second metallic piece is connected to the first metallic piece to enclose the internal passage.

8. The motor vehicle according to claim 3, wherein the wires are not wound within an electromagnetic interference shield.

9. The motor vehicle according to claim 3, wherein the wires are cables.

10. The motor vehicle according to claim 3, wherein the wires are busbars.

11. The motor vehicle according to claim 1, further comprising: A first component; And A second component electrically coupled to the first component through the power distribution system.

12. The motor vehicle according to claim 11, wherein the first component is a battery pack and the second component is the electric motor.

13. The motor vehicle according to claim 1, wherein the motor vehicle is an electrified vehicle.

14. The motor vehicle according to claim 1, wherein the subframe is attached to a frame of the motor vehicle.

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