Method for manufacturing vehicle

Abstract

When an electric vehicle having an electric motor is reproduced from a vehicle having an engine, the layout of the vehicle before reformation can be effectively utilized. This method for manufacturing a vehicle comprises: a preparation step for preparing an engine block capable of accommodating an engine component, and a motor unit having a motor and a motor case for accommodating the motor; and a support step for supporting the motor unit on the engine block.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a vehicle. Background Art

[0002] Patent Document 1 discloses a method of reproducing (rebuilding) an electric vehicle having an electric motor from a vehicle having an internal combustion engine (engine).

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2010-252584

[0006] Problems to be solved by the invention

[0007] In the above method, when the engine is replaced with an electric motor, many new components need to be developed to adapt to the layout of the vehicle before the modification. In other words, there is a problem that the layout of the vehicle before the modification cannot be effectively utilized. Summary of the Invention

[0008] The present invention has been made in view of such technical problems, and an object of the present invention is to effectively utilize the layout of the vehicle before the reconstruction when reproducing an electric vehicle having an electric motor from a vehicle having an engine.

[0009] According to one embodiment of the present invention, a method for manufacturing a vehicle is provided, comprising: a preparation step of preparing an engine body capable of accommodating engine components, and a motor unit having an electric motor and a motor housing for accommodating the electric motor; and a support step of supporting the motor unit on the engine body.

[0010] Effects of the Invention

[0011] In this method, rather than replacing the engine and engine block with the motor unit, the engine block remains and the motor unit is supported by it. Because the engine block is designed to fit within the engine-related components of the pre-remodeled vehicle, supporting the motor unit on the engine block effectively utilizes the pre-remodeled vehicle's layout. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is a schematic structural diagram of a vehicle manufactured by the vehicle manufacturing method according to the embodiment of the present invention.

[0013] Figure 2 This is a schematic diagram of the motor unit.

[0014] Figure 3 This is a schematic structural diagram showing a state in which the motor unit is supported by the engine body.

[0015] Figure 4 This is a schematic diagram of the vibration damping structure viewed from the auxiliary equipment side.

[0016] Figure 5 This is a schematic configuration diagram showing a state where the oil flow path of the motor unit is connected to the heat exchanger.

[0017] Figure 6 This is a flowchart showing the procedure for manufacturing a vehicle.

[0018] Figure 7 A diagram for explaining the procedure for manufacturing a vehicle.

[0019] Figure 8 This is a schematic structural diagram showing an example of a mounting portion provided on an engine body. DETAILED DESCRIPTION

[0020] Hereinafter, a method for manufacturing vehicle 200 according to an embodiment of the present invention will be described with reference to the drawings.

[0021] First, the vehicle 200 manufactured by the method for manufacturing the vehicle 200 according to the embodiment of the present invention will be described.

[0022] Figure 1 It is a schematic structural diagram of the vehicle 200.

[0023] Vehicle 200 is a so-called conversion EV (Electric Vehicle), a vehicle powered by an internal combustion engine that has been modified to be driven by motor unit 100 instead of the engine. Modification is the reproduction of an item, and the modification method is the production method (manufacturing method) of the item.

[0024] like Figure 1 As shown, vehicle 200 includes an engine body 20 , a motor unit 100 , a transmission 30 , auxiliary equipment 40 , a power transmission mechanism 50 , and drive wheels 60 .

[0025] The engine block 20 is connected to the vehicle body 201 via an engine mount (not shown). In a vehicle before modification, the engine block 20 houses engine components.

[0026] The engine parts are parts that constitute the internal combustion engine. For example, the engine piston, crankshaft, and other parts are engine parts. The engine piston and crankshaft have parts that are housed in the engine body 20.

[0027] The motor unit 100 is supported by the engine body 20 .

[0028] The transmission 30 changes the speed of the output rotation of the motor unit 100 and transmits the speed to the drive wheels 60. In the present embodiment, the transmission 30 is an automatic transmission. However, the transmission 30 may also be a manual transmission.

[0029] In the present embodiment, the drive wheels 60 are rear wheels of the vehicle 200. However, the drive wheels 60 may be front wheels of the vehicle 200.

[0030] The auxiliary device 40 is rotationally driven by the output of the motor unit 100 transmitted via the power transmission mechanism 50. The auxiliary device 40 is, for example, an AC generator that is rotationally driven to generate electricity. The power transmission mechanism 50 may be a belt-type power transmission mechanism, a chain-type power transmission mechanism, or a gear-type power transmission mechanism.

[0031] Figure 2 It is a schematic diagram of the motor unit 100 .

[0032] like Figure 2 As shown, the motor unit 100 includes a motor 10 , a first gear set 11 , a second gear set 12 , a third gear set 13 , an output shaft 14 , an output shaft 15 , and a motor case 16 .

[0033] The electric motor 10 is a rotating electrical machine that functions as a motor driven by power supplied from a battery (not shown) and as a generator that generates electricity by rotating using external force. During regenerative control, the electric motor 10 functions as a generator.

[0034] The first gear train 11 is composed of a first gear 11a provided on the output shaft 10a of the motor 10 and a second gear 11b meshing with the first gear 11a. The first gear train 11 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0035] The second gear train 12 is composed of a third gear 12a that rotates integrally with the second gear 11b and a fourth gear 12b that meshes with the third gear 12a. The second gear train 12 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0036] The third gear train 13 is composed of a fifth gear 13a that rotates integrally with the second gear 11b and a sixth gear 13b that meshes with the fifth gear 13a. The third gear train 13 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0037] The output shaft 14 rotates integrally with the fourth gear 12b and outputs the rotation of the motor 10 reduced in speed by the first gear group 11 and the second gear group 12. In this embodiment, the rotation of the output shaft 14 is transmitted to a torque converter (not shown) of the transmission 30.

[0038] The output shaft 15 rotates integrally with the sixth gear 13b and outputs the rotation of the motor 10 reduced in speed by the first gear train 11 and the third gear train 13. In this embodiment, the rotation of the output shaft 15 is transmitted to the auxiliary equipment 40 via the power transmission mechanism 50.

[0039] Figure 3 1 is a schematic structural diagram showing a state in which the motor unit 100 is supported by the engine body 20 .

[0040] like Figure 3 As shown, piston housings 21a, 21b, 21c, and 21d and crankshaft support walls 22a, 22b, and 22c are provided inside the engine body 20. Hereinafter, unless otherwise specified, the piston housing will be referred to as the piston housing 21, and unless otherwise specified, the crankshaft support wall will be referred to as the crankshaft support wall 22.

[0041] In the vehicle before the modification, the engine piston is housed in the piston housing 21. In the vehicle before the modification, the crankshaft support wall 22 supports the crankshaft together with the openings 23a and 23b that open to the outside of the engine body 20.

[0042] The motor unit 100 is arranged in a space formed by removing a portion of the plurality of crankshaft support wall portions 22 by cutting or the like.

[0043] Specifically, in the motor unit 100 , the output shaft 14 is supported by the opening 23 a via the bearing 95 , and the output shaft 15 is supported by the opening 23 b via the bearing 96 .

[0044] The plurality of crankshaft supporting wall portions 22 may be at least partially removed depending on the shape of the motor unit 100. Furthermore, for example, removing a portion of the crankshaft supporting wall portion 22a without removing the crankshaft supporting wall portions 22b and 22c, or removing a portion of the crankshaft supporting wall portion 22b without removing the crankshaft supporting wall portions 22a and 22c, is also referred to as removing at least a portion of the plurality of crankshaft supporting wall portions 22.

[0045] In the motor unit 100 , the motor case 16 is fixed to the fixing member 24 housed in the piston housing portion 21 b and the fixing member 25 housed in the piston housing portion 21 c .

[0046] In this embodiment, the fixing members 24 and 25 are cylindrical members with bottoms. The bottom 24a of the fixing member 24 is connected to the fixing portion 16a of the motor housing 16 by bolts 97, and the bottom 25a of the fixing member 25 is connected to the fixing portion 16b of the motor housing 16 by bolts 98.

[0047] Thus, in the motor unit 100, the output shafts 14 and 15 are supported by the openings 23a and 23b that can support the crankshaft. Furthermore, the motor housing 16 is supported by the piston housings 21b and 21c by fixing the motor housing 16 to the fixing members 24 and 25 housed in the piston housings 21b and 21c.

[0048] As a result, the piston housings 21b and 21c can bear the reaction force when the motor 10 rotates. That is, the rotation of the motor unit 100 with the output shafts 14 and 15 as the rotation axis can be limited. In addition, since the point receiving the reaction force can be moved away from the rotation axis, the force received by the piston housings 21b and 21c can be reduced. In other words, by leaving a distance from the rotation axis to the force-receiving point, a greater force can be borne. Furthermore, in this embodiment, since the structure of the engine of the vehicle before the modification is utilized, the number of newly developed components can be reduced.

[0049] The support structure for supporting the motor unit 100 by the piston housing portions 21 b and 21 c is not essential, and other support structures may be used to receive the reaction force when the motor 10 rotates.

[0050] In addition, in this embodiment, two fixing components (fixing components 24 and 25) are provided. This allows the piston housings 21b and 21c to evenly bear the reaction force during the rotation of the electric motor 10. However, the number of fixing components can be appropriately changed. Furthermore, the fixing component can be provided on any one of the piston housings 21a to 21d. Furthermore, even if the engine installed in the vehicle before modification is not a four-cylinder engine, the above-described support structure using the piston housing to support the electric motor unit 100 can be adopted.

[0051] In addition, a damping structure 70 (see FIG. 1 ) for damping the vibration of the fixing member housed in the piston housing 21 may be provided. Figure 4 ).

[0052] Examples of the shock-absorbing structure 70 include an air shock-absorbing structure that produces a shock-absorbing effect based on air pressure by sealing the piston housing 21, and a spring shock-absorbing structure that produces a shock-absorbing effect based on the force of a spring. The air shock-absorbing structure may utilize either positive pressure or negative pressure. The spring shock-absorbing structure may utilize either a compression spring or an extension spring. The shock-absorbing structure 70 is not limited to any one structure.

[0053] Figure 4 This is a schematic structural diagram of the vibration damping structure 70 as viewed from the auxiliary equipment 40 side. Figure 4 An air damping structure is shown as an example of the damping structure 70 .

[0054] Figure 4 The damping structure 70 shown includes the fixing member 26 accommodated in the piston housing 21 , a link mechanism 71 connecting the fixing member 26 and the fixing portion 16 c of the motor housing 16 , and a cover 72 sealing the upper opening of the piston housing 21 .

[0055] The link mechanism 71 is connected to the fixing member 26 via a swing shaft 71 a , and is connected to the fixing portion 16 c of the motor case 16 via a swing shaft 71 b .

[0056] Thus, when the motor unit 100 swings about the rotation axis due to the reaction force during rotation of the motor 10 (see the solid arrow), the fixing member 26 is pulled downward by the link mechanism 71 (see the white arrow).

[0057] Here, the space between the fixing member 26 and the cover 72 within the piston housing 21 is sealed by the fixing member 26 and the cover 72. Therefore, the damping effect generated by the air pressure (negative pressure) prevents the displacement of the fixing member 26. In other words, the swinging of the motor unit 100 is prevented.

[0058] Thus, by providing the damping structure 70, the reaction force during the rotation of the electric motor 10 can be attenuated. Therefore, since vibration and shock can be mitigated, the impact on the occupants of the vehicle 200 can be reduced. Furthermore, in this embodiment, the damping structure 70 is provided by utilizing the structure of the engine of the vehicle before the modification, thereby reducing the need for newly developed components.

[0059] Figure 5 1 is a schematic configuration diagram showing a state in which the oil flow path 17 of the motor unit 100 and the heat exchanger 80 are connected.

[0060] like Figure 5 As shown, the engine block 20 has a coolant flow path 28 through which coolant flows. Coolant flow path 28 is connected to a radiator 90 via radiator hoses 91 and 92. Coolant flow path 28, radiator 90, and radiator hoses 91 and 92 constitute a coolant circuit through which the coolant circulates. The coolant is, for example, cooling water, but is not limited thereto.

[0061] exist Figure 5 , a water pump 40 a and a fan 40 b are shown as auxiliary equipment 40 driven by the motor unit 100 via the power transmission mechanism 50 .

[0062] The motor unit 100 includes an oil flow path 17 through which oil flows. The oil flow path 17 is connected to a heat exchanger 80. The heat exchanger 80 exchanges heat with the coolant flowing in the coolant circuit, thereby cooling the oil flowing in the oil flow path 17.

[0063] exist Figure 5 In the embodiment, the oil flow path 17 is directly connected to the heat exchanger 80. However, in the vehicle before the modification, the oil flow path 17 may be connected to the heat exchanger 80 via an oil flow path provided in the engine.

[0064] The heat exchanger 80 may be a heat exchanger already included in the vehicle before the modification, or may be newly prepared.

[0065] By utilizing the existing coolant flow path 28 provided in the engine body 20 in this manner, it is possible to reduce the man-hours required to design a new structure for cooling the oil of the motor unit 100. Therefore, the design burden of the motor unit 100 can be reduced.

[0066] Next, a method for manufacturing vehicle 200 will be described. Figure 6 This is a flowchart showing the procedure for manufacturing the vehicle 200 . Figure 7 It is a diagram for explaining the procedure of manufacturing the vehicle 200.

[0067] In step S1 (preparation process), Figure 7 As shown, the engine body 20 and the motor unit 100 are prepared.

[0068] The engine body 20 is a component of the engine mounted on the vehicle before the modification. In addition, the engine body 20 can also be newly prepared.

[0069] In step S2 (removal process), at least a portion of the plurality of crankshaft support wall portions 22 provided inside the engine body 20 is removed. Specifically, in this embodiment, the crankshaft support wall portions 22 are removed by cutting or the like. Figure 7 In this embodiment, as shown in FIG. Figure 4 As shown, the shape of the crankshaft support wall portion 22 after a portion thereof is removed by cutting or the like is formed into an arch shape that follows the shape of the motor unit 100. Alternatively, all of the plurality of crankshaft support wall portions 22 may be removed.

[0070] In step S3 (supporting step), the motor unit 100 is supported on the engine body 20 so that the motor unit 100 is arranged Figure 7 Thus, the motor unit 100 is accommodated in a space formed by removing a portion of the plurality of crankshaft support wall portions 22 .

[0071] Fixing members 24, 25 (see Figure 3 ) After the output shafts 14 and 15 are supported by the openings 23a and 23b, they are housed in the piston housings 21b and 21c from the upper openings. The fixing members 24 and 25 are then fixed to the motor housing 16 using bolts 97 and 98.

[0072] The fixing members 24, 25 may be pre-connected to the motor housing 16 before the output shafts 14, 15 are supported in the openings 23a, 23b. However, in this case, high precision is required for positioning the fixing members 24, 25 relative to the motor housing 16. By attaching the fixing members 24, 25 after the output shafts 14, 15 are supported in the openings 23a, 23b, the fixing members 24, 25 can be easily attached.

[0073] As the shock absorbing structure 70, Figure 4 In the case of the air damper structure shown, before the output shafts 14 and 15 are supported by the openings 23a and 23b, the motor housing 16 is connected and fixed to the fixing member 26 using the link mechanism 71. Then, after the output shafts 14 and 15 are supported by the openings 23a and 23b, the cover 72 is attached to the engine body 20.

[0074] In step S4 (connection process), the oil flow path 17 is connected to the heat exchanger 80 (see Figure 5 ).

[0075] The connection step may be performed before or after the output shafts 14 and 15 of the motor unit 100 are supported by the openings 23 a and 23 b of the engine body 20 .

[0076] In step S5 (mounting process), the engine body 20 and the motor unit 100 are mounted on the vehicle 200 (see Figure 1 ).

[0077] In the vehicle before the modification, the engine block 20 is designed to fit the components around the engine. Figure 8 As shown, the engine block 20 of this embodiment has a mounting portion 29 consisting of three bosses each having an internal thread. The mounting portion 29 is connected to the vehicle body 201 via an engine mount. Therefore, by utilizing the existing mounting portion 29 provided on the engine block 20, the engine block 20 and the motor unit 100 can be easily mounted on the vehicle 200.

[0078] Hereinafter, main functions and effects of the method for manufacturing vehicle 200 according to the embodiment of the present invention will be summarized.

[0079] (1) The method for manufacturing the vehicle 200 includes a preparation step of preparing the engine body 20 capable of accommodating engine components, the motor unit 100 including the motor 10 and the motor case 16 accommodating the motor 10 , and a support step of supporting the motor unit 100 on the engine body 20 .

[0080] Thus, rather than replacing the engine with the engine block 20 along with the motor unit 100, the engine block 20 remains and the motor unit 100 is supported by the engine block 20. Since the engine block 20 is designed to fit the engine-related components of the vehicle before the modification, supporting the motor unit 100 on the engine block 20 allows the layout of the vehicle before the modification to be effectively utilized.

[0081] (2) The engine body 20 has the openings 23 a and 23 b that can support the crankshaft. In the supporting step, the output shafts 14 and 15 of the motor unit 100 are supported by the openings 23 a and 23 b of the engine body 20 .

[0082] In the vehicle before the modification, the layout of the transmission 30 and other components was designed based on the crankshaft's axial position. Therefore, by supporting the output shafts 14 and 15 of the motor unit 100 in alignment with the positions of the openings 23a and 23b supporting the crankshaft, the scale of modification of the transmission 30 and other components can be minimized. In other words, the layout of the vehicle before the modification can be effectively utilized.

[0083] (3) The engine body 20 has the mounting portion 29 connected to the vehicle body 201 .

[0084] The mounting portion connected to the vehicle body is designed to fit the overall shape and structure of the vehicle, and its location varies significantly depending on the vehicle model. If a mounting portion were provided on the motor housing, it would need to be designed based on the vehicle model before modification. However, according to this embodiment, motor unit 100 is supported by openings 23a and 23b of engine body 20, which supports the crankshaft, and engine body 20 has mounting portion 29, eliminating the need for a separate mounting portion on motor unit 100. This reduces the design burden of designing the motor unit mounting portion based on the vehicle model.

[0085] (4) After removing at least a portion of the plurality of crankshaft support wall portions 22 ( 22 a , 22 b , 22 c ) provided inside the engine body 20 , a supporting step is performed.

[0086] By eliminating the plurality of crankshaft support walls 22, space for the motor unit 100 can be secured within the engine block 20. This reduces the amount of protrusion of the motor unit 100 from the engine block 20, contributing to miniaturization. Furthermore, by eliminating the crankshaft support walls to accommodate the shape of the motor unit, there is no need to design the motor housing for each engine block, which varies depending on the vehicle model. This reduces the design burden of the motor unit.

[0087] (5) Vehicle 200 includes heat exchanger 80 , engine body 20 includes coolant flow path 28 through which coolant supplied to heat exchanger 80 flows, and motor unit 100 includes oil flow path 17 through which oil flows. The method for manufacturing vehicle 200 includes a connecting step of connecting oil flow path 17 to heat exchanger 80 .

[0088] By utilizing the existing coolant flow path 28 provided in the engine block 20, the labor required to redesign the structure for cooling (heat exchanging) the oil in the motor unit 100 can be reduced. This reduces the design burden on the motor unit 100. Reusing the heat exchanger 80 from the pre-modified vehicle can reduce costs. The pump (water pump) that circulates the coolant and the radiator that cools the coolant can also be reused from the pre-modified vehicle, further reducing costs.

[0089] (6) The engine body 20 includes a piston housing portion 21 (21a, 21b, 21c) capable of housing the engine piston. Fixing members 24, 25, 26 are housed in the piston housing portion 21. By fixing the motor housing 16 of the motor unit 100 to the fixing members (24, 25, 25), the motor unit 100 is supported by the engine body 20.

[0090] As a result, the piston housing 21 can withstand the reaction force when the electric motor 10 rotates. That is, the rotation of the motor unit 100 with the output shafts 14 and 15 as the rotation axis can be limited. In addition, since the point receiving the reaction force can be moved away from the rotation axis, the force received by the piston housing 21 can be reduced. In other words, by leaving a distance from the rotation axis to the force-receiving point, a greater force can be withstand. Furthermore, in this embodiment, since the structure of the engine of the vehicle before the modification is utilized, the number of newly developed components can be reduced.

[0091] (7) A vibration-damping structure 70 is provided to dampen vibration of the fixing member 26 in the piston housing 21 .

[0092] The provision of the damping structure 70 damps the reaction force during the rotation of the motor 10. This mitigates vibration and shock, thereby reducing the impact on the occupants of the vehicle 200. Furthermore, in this embodiment, the damping structure 70 is provided by utilizing the structure of the engine of the vehicle before the modification, thereby reducing the need for newly developed components.

[0093] While the embodiment of the present invention has been described above, the above embodiment merely shows an application example of the present invention and does not limit the technical scope of the present invention to the specific configuration of the above embodiment.

[0094] Explanation of symbols

[0095] 10: Electric motor

[0096] 14: Output shaft

[0097] 15: Output shaft

[0098] 16: Motor housing

[0099] 17: Oil flow path

[0100] 20: Engine body

[0101] 21a: Piston storage

[0102] 21b: Piston storage

[0103] 21c: Piston storage

[0104] 21d: Piston storage

[0105] 22a: Crankshaft supporting wall

[0106] 22b: Crankshaft supporting wall

[0107] 22c: Crankshaft supporting wall

[0108] 23a: Opening

[0109] 23b: Opening

[0110] 24: Fixing parts

[0111] 25: Fixing parts

[0112] 26: Fixing parts

[0113] 28: Coolant flow path

[0114] 29: Installation

[0115] 70: shock-absorbing structure

[0116] 80: Heat exchanger

[0117] 200: Vehicle

[0118] 201: Body

[0119] 100: Motor unit.

Claims

1. A method for manufacturing a vehicle, comprising: A preparation step of preparing an engine body capable of accommodating engine components, and a motor unit having an electric motor and a motor housing for accommodating the electric motor; The supporting step includes supporting the motor unit on the engine body.

2. The method for manufacturing a vehicle according to claim 1, wherein: The engine body has an opening portion capable of supporting a crankshaft. In the supporting step, the output shaft of the motor unit is supported by the opening portion of the engine body.

3. The method for manufacturing a vehicle according to claim 1, wherein: The engine body has a mounting portion connected to a vehicle body.

4. The method for manufacturing a vehicle according to claim 1, wherein: The supporting step is performed after removing at least a portion of a plurality of crankshaft supporting wall portions provided inside the engine body.

5. The method for manufacturing a vehicle according to claim 1, wherein: The vehicle includes a heat exchanger, The engine body includes a coolant flow path through which coolant supplied to the heat exchanger flows. The motor unit includes an oil flow path through which oil flows. The vehicle manufacturing method includes a connecting step of connecting the oil flow path to the heat exchanger.

6. The method for manufacturing a vehicle according to claim 1, wherein: The engine body includes a piston housing portion capable of housing an engine piston. The motor unit is supported by the engine body by accommodating a fixing member in the piston accommodating portion and fixing the motor case of the motor unit to the fixing member.

7. The method for manufacturing a vehicle according to claim 6, wherein: A vibration damping structure is provided for damping vibration of the fixing member in the piston housing.

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