Electric vehicle

Abstract

An electric vehicle is provided. Two thermal management modules composed of a water module that distributes cooling water and a refrigerant module that distributes refrigerant are provided in front of an electric drive unit provided inside a front cabin. Also, two high-voltage units composed of a power distribution unit that is electrically connected to the electric drive unit via a cable and a vehicle-mounted charging unit are provided above the electric drive unit in a state of being stacked in the vertical direction, with the power distribution unit connected to the electric drive unit by a thicker cable being positioned lower than the vehicle-mounted charging unit.

Description

Technical Field

[0001] This disclosure relates to electric vehicles. Background Technology

[0002] Electric vehicles include an electric drive unit that integrates a motor and gear-like components for driving. Japanese Patent Application Publication No. 2023-124124 discloses an electric vehicle with a structure in which a high-voltage unit is mounted above the electric drive unit.

[0003] With multiple high-voltage units positioned above the electric drive unit, the number of cables connecting these units increases. Furthermore, other equipment is located around the electric drive unit. Therefore, it is necessary to route multiple cables through the confined space surrounding the electric drive unit. Summary of the Invention

[0004] In one embodiment of this disclosure, an electric vehicle is provided as follows:

[0005] An electric vehicle, wherein:

[0006] High-voltage batteries;

[0007] The electric drive unit receives power from a high-voltage battery to generate the driving force for the electric vehicle.

[0008] Multiple high-voltage units are electrically connected to the aforementioned electric drive unit; and

[0009] The thermal management module is formed by integrating a component of the circulation loop of the heat transfer medium.

[0010] In an electric vehicle, the aforementioned electric drive unit, the aforementioned multiple high-voltage units, and the aforementioned thermal management module are disposed inside the front compartment located at the front of the electric vehicle.

[0011] The aforementioned high-voltage units are stacked on top of the aforementioned electric drive unit in a vertical direction, wherein the thicker the cable connecting the high-voltage unit and the aforementioned electric drive unit, the lower the high-voltage unit connected to the cable is located. Attached Figure Description

[0012] Figure 1 This is a schematic diagram showing the layout of an electric vehicle as viewed from above in one embodiment.

[0013] Figure 2 It is a schematic representation. Figure 1 A diagram showing the layout of the front compartment of an electric vehicle when viewed from the left.

[0014] Figure 3 It is a schematic representation. Figure 1 A diagram showing the layout of the front compartment of an electric vehicle when viewed from above. Detailed Implementation

[0015] The following is for reference Figures 1-3 One embodiment of the electric vehicle is described in detail. Furthermore, in the figures, the arrows indicating directions "FR", "RR", "RH", "LH", "UP", and "DW" represent front, rear, right, left, top, and bottom, respectively, based on the vehicle's direction of travel.

[0016] <Structure of Electric Vehicle 10>

[0017] Figure 1 The electric vehicle 10 shown in this embodiment has four wheels, consisting of left and right front wheels 11 and left and right rear wheels 12. The electric vehicle 10 is a front-wheel drive battery-electric vehicle that drives the left and right front wheels 11. The electric vehicle 10 has two electrical systems: a high-voltage system and a low-voltage system.

[0018] A front compartment 13 is provided at the front of the electric vehicle 10. Above the front compartment 13 is an openable and closable hood 13A (see reference). Figure 2 The front compartment 13 is configured such that the interior can be accessed from above the vehicle by opening the hood 13A. A high-voltage battery 14 is located rearward of the front compartment 13 in the electric vehicle 10. The high-voltage battery 14 is located under the floor and connected to the high-voltage system of the electric vehicle 10. On the other hand, an electric drive unit 15 is located inside the front compartment 13. The electric drive unit 15 receives power from the high-voltage battery 14 to generate driving force for the electric vehicle 10. In the case of the electric vehicle 10, the electric drive unit 15 is configured to drive the left and right front wheels 11. The electric drive unit 15 includes at least a motor 15A that generates driving force (see reference). Figure 2 The electric drive unit 15 is configured to include a motor 15A, gear-like components constituting a reduction mechanism and a differential mechanism, and a frequency converter 15B (see reference). Figure 2 A unit housed within a housing.

[0019] Furthermore, a low-voltage battery 16 and a radiator 17 are installed inside the front compartment 13. The low-voltage battery 16 is connected to the low-voltage system of the electric vehicle 10. The radiator 17 is a heat exchanger that cools the cooling water through heat exchange with the outside air. The radiator 17 is located at the front of the front compartment 13 so that it is easily accessible by the wind. The low-voltage battery 16 is located inside the front compartment 13, forward of the electric drive unit 15 and rearward of the radiator 17.

[0020] Configuration of High Voltage Unit and Thermal Management Module

[0021] Next, refer to Figure 2 and Figure 3 The layout of the high-voltage unit and thermal management module inside the front compartment 13 of the electric vehicle 10 is described. Figure 2 The image shows the interior layout of the front compartment 13 as viewed from the left. Figure 3 The image shows the interior layout of the front compartment 13 as viewed from above. The high-voltage unit is connected to the high-voltage system of the electric vehicle 10. The thermal management module is a module for distributing the heat transfer medium. As a circulation loop for the heat transfer medium, the electric vehicle 10 has two loops: a water loop for cooling water circulation and a refrigerant loop for refrigerant circulation for air conditioning. The radiator 17 is connected to the water loop.

[0022] As a thermal management module located inside the front compartment 13, the electric vehicle 10 includes a water module 18 for distributing cooling water and a refrigerant module 19 for distributing refrigerant. The water module 18 is a general term for components related to the distribution of cooling water to the various components to which cooling water is supplied. Components distributing cooling water to the water module 18 include a radiator 17, a high-voltage battery 14, and an electric drive unit 15. The water module 18 is equipped with multiple electric pumps that deliver cooling water to each component and multiple switching valves that switch the flow of cooling water to each component. The refrigerant module 19 is a general term for components related to the distribution of refrigerant to the various components to which refrigerant is supplied. The refrigerant distributed by the refrigerant module 19 is used for air conditioning in the vehicle compartment, cooling the high-voltage battery 14, etc. The refrigerant module 19 includes multiple expansion valves that vaporize liquefied refrigerant and deliver it to the various components. In the case of the electric vehicle 10, the refrigerant module 19 includes a water-cooled condenser 19A that cools the refrigerant through heat exchange with cooling water supplied from the water module 18, and a regulator for gas-liquid separation of the cooled refrigerant. Furthermore, an electric pump 18A is provided in the water module 18 to deliver cooling water to the condenser 19A.

[0023] On the other hand, as a high-voltage unit located inside the front compartment 13, the electric vehicle 10 includes a power distribution unit 20 and an on-board charging unit 21. The power distribution unit 20 is a high-voltage unit that distributes power from the high-voltage battery 14 to various high-voltage devices of the electric vehicle 10, including the inverter 15B. The on-board charging unit 21 is a high-voltage unit that controls the charging of the high-voltage battery 14. Furthermore, in addition to a charging circuit for charging control, the on-board charging unit 21 also includes a step-down circuit that steps down the power from the high-voltage system to supply power to the low-voltage system. The power distribution unit 20 and the on-board charging unit 21 are electrically connected to the electric drive unit 15 via cables 23 and 24, respectively. The cable 23 connecting the power distribution unit 20 and the electric drive unit 15 is thicker than the cable 24 connecting the on-board charging unit 21 and the electric drive unit 15. Additionally, the water module 18 also distributes cooling water to the power distribution unit 20 and the on-board charging unit 21.

[0024] Furthermore, a high-voltage heater 22 is installed inside the front compartment 13. The high-voltage heater 22 uses electricity from the high-voltage battery 14 to heat the cooling water. The high-voltage heater 22 is configured to heat the cooling water passing through the condenser 19A of the refrigerant module 19. The heated cooling water is used, for example, for heating the vehicle compartment and heating the high-voltage battery 14.

[0025] In the case of the electric vehicle 10, the water module 18 and the refrigerant module 19 are positioned in front of the electric drive unit 15. Furthermore, the water module 18 and the refrigerant module 19 are arranged vertically with the refrigerant module 19 positioned above the water module 18. Additionally, the aforementioned low-voltage battery 16 is positioned to the left of the water module 18 and the refrigerant module 19.

[0026] On the other hand, the power distribution unit 20 and the on-board charging unit 21 are stacked vertically above the electric drive unit 15. The power distribution unit 20, which is connected to the electric drive unit 15 via a thick cable 23, is positioned below the on-board charging unit 21, which is connected to the electric drive unit 15 via a thin cable 24. Furthermore, in the case of the electric vehicle 10, a high-voltage heater 22 is provided above the electric drive unit 15, positioned above the power distribution unit 20 and the on-board charging unit 21.

[0027] <The Role of the Implementation Method>

[0028] In the electric vehicle 10, an electric drive unit 15 is installed inside the front compartment 13. Furthermore, multiple thermal management modules (water module 18, refrigerant module 19) and multiple high-voltage units (power distribution unit 20, on-board charging unit 21) are installed around the electric drive unit 15.

[0029] The portion of the interior of the front compartment 13 located further rearward than the electric drive unit 15 becomes difficult to access from above when the hood 13A is open. Furthermore, the suspension systems for the front wheels 11 are located on both sides of the electric drive unit 15 in the vehicle width direction within the front compartment 13. Therefore, the space for other components on either side of the electric drive unit 15 is limited. Thus, considering the workability of component assembly, repair, and inspection during the manufacturing of the electric vehicle 10, the front and upper portions of the electric drive unit 15 are considered suitable locations for the thermal management module and the high-voltage unit. Of these two portions, the front portion of the electric drive unit 15 is more easily exposed to drafts, making it less prone to heat accumulation.

[0030] If the temperature of the thermal management module increases, the temperature of the cooling water and refrigerant distributed to each component also increases. Therefore, in the electric vehicle 10, a thermal management module is provided in front of the electric drive unit 15, which is easily exposed to the wind during driving. Furthermore, a high-voltage unit is provided above the electric drive unit 15.

[0031] Above the electric drive unit 15, the power distribution unit 20 and the on-board charging unit 21, two high-voltage units, are arranged in a stacked configuration in the vertical direction. Both high-voltage units are electrically connected to the electric drive unit 15 via cables 23 and 24. The cable 23 connecting the power distribution unit 20 and the electric drive unit 15 is thicker than the cable 24 connecting the on-board charging unit 21 and the electric drive unit 15. On the other hand, the power distribution unit 20 is positioned closer to the electric drive unit 15 than the on-board charging unit 21. Therefore, the cable 23 connecting the power distribution unit 20 and the electric drive unit 15 can be shorter than the cable 24 connecting the on-board charging unit 21 and the electric drive unit 15. Conversely, when the power distribution unit 20 is positioned above the on-board charging unit 21, the thicker cable 23 is longer than the thinner cable 24. Therefore, when the power distribution unit 20 is arranged below the vehicle charging unit 21 as in this embodiment, the total weight of the cables 23 and 24 is reduced compared to the case where the vehicle charging unit 21 is arranged below the power distribution unit 20.

[0032] <Effects of the Implementation Method>

[0033] Electric vehicle 10 achieves the following effects.

[0034] (1) Two high-voltage units, a power distribution unit 20 and an on-board charging unit 21, are arranged on top of the electric drive unit 15 in a stacked manner in the vertical direction. These units are electrically connected to the electric drive unit 15 via cables 23 and 24. Furthermore, the power distribution unit 20, which is connected to the electric drive unit 15 via a thicker cable 23, is positioned below the on-board charging unit 21, which is connected to the electric drive unit 15 via a thinner cable 24. With this configuration, the length of the thicker cable 23 can be made shorter than that of the thinner cable 24. Therefore, the increase in the total weight of the cables 23 and 24 can be suppressed.

[0035] (2) Generally, the thicker the cable, the more difficult it is to operate. In contrast, in this embodiment, the power distribution unit 20, which is connected by a thick cable 23, is positioned directly above the electric drive unit 15. Therefore, wiring the cable 23, which is thicker and more difficult to operate than the cable 24, becomes easier.

[0036] (3) A thermal management module is provided in front of the electric drive unit 15. More specifically, the thermal management module consists of two modules: a water module 18 for distributing cooling water and a refrigerant module 19 for distributing refrigerant for air conditioning, which are provided in front of the electric drive unit 15. Since the front of the electric drive unit 15 is more susceptible to drafts than the upper part of the electric drive unit 15, according to this embodiment, by providing a thermal management module in front of the electric drive unit 15, the cooling efficiency of the draft air on the thermal management module is improved.

[0037] (4) The refrigerant module 19 has a water-cooled condenser 19A that cools the refrigerant through heat exchange with the cooling water distributed by the water module 18. Furthermore, the refrigerant module 19 is positioned above the water module 18. During the operation of the electric vehicle 10, airflow passes through the upper part of the front compartment 13 inside the front compartment 13. To address this, according to this embodiment, the refrigerant module 19 is positioned in front of the electric drive unit 15 in a location where airflow is more easily reached than through the water module 18. Therefore, the cooling efficiency of the refrigerant in the condenser 19A can be improved.

[0038] (5) Above the power distribution unit 20 and the on-board charging unit 21, which are located above the electric drive unit 15, a high-voltage heater 22 for electrically heating the cooling water is provided. For example, it is considered to integrate the high-voltage heater 22, which is located in the water circuit for cooling water circulation, with the water module 18. However, in this case, since the volume of the water module 18 increases, it may be impossible to ensure sufficient installation space in front of the electric drive unit 15. To address this issue, according to this embodiment, by separating the high-voltage heater 22 from the water module 18 and placing it in another location, their overall installation efficiency is improved.

[0039] Furthermore, since the water module 18 contains both a section for high-temperature cooling water flow heated by the high-voltage heater 22 and a section for low-temperature cooling water flow, insulation is required for both sections. To address this, according to this embodiment, by assembling a structure that separates the high-voltage heater 22 from the water module 18, the complexity of the water module 18's structure can be prevented.

[0040] (Other implementation methods)

[0041] The above-described embodiments can be implemented by modification as follows. The above-described embodiments and the following modifications can be combined with each other within a technically compatible scope.

[0042] <Regarding high-voltage heaters 22>

[0043] • The high-voltage heater 22 can also be installed in a location different from the above embodiment. For example, the high-voltage heater 22 can be installed in front of, behind, or to the side of the electric drive unit 15. Alternatively, the high-voltage heater 22 can be installed on the exterior of the front compartment 13.

[0044] • The high-voltage heater 22 can also be integrated with the water module 18.

[0045] • It is also possible to make the electric vehicle 10 a structure without a high-voltage heater 22.

[0046] <Structure of the thermal management module>

[0047] Alternatively, the water module 18 and the refrigerant module 19 can be located inside the front compartment 13, in the part of the vehicle other than the front of the electric drive unit 15.

[0048] • As long as the functions of distributing cooling water and refrigerant are available, the specific structures of the water module 18 and the refrigerant module 19 can be appropriately modified.

[0049] It can also be configured to integrate the water module 18 and the refrigerant module 19 into a single thermal management module.

[0050] <Structure for high-voltage units>

[0051] The number and type of the multiple high-voltage units disposed above the electric drive unit 15 can also be appropriately changed. For example, the inverter 15B can be disposed separately from the electric drive unit 15, and the inverter 15B can be disposed above the electric drive unit 15 as one of the high-voltage units. Among the multiple high-voltage units disposed above the electric drive unit 15, high-voltage units that are not connected to the electric drive unit 15 by cables can also be included. In this case, if the electric vehicle 10 is configured in a manner that satisfies the following requirements (A) and (B), the effects of (1) and (2) described above can also be obtained. Requirement (A): Two or more high-voltage units that are electrically connected to the electric drive unit 15 by cables of different thicknesses are disposed above the electric drive unit 15. Requirement (B): The two or more high-voltage units are disposed in a stacked state in the vertical direction, and the thicker the cable connected to the electric drive unit 15, the lower the unit is located.

[0052] <other>

[0053] The electric drive unit 15 may include a motor 15A that receives power from the high-voltage battery 14 to generate the driving force for the electric vehicle 10, but other structures may be modified accordingly. For example, the electric drive unit 15 may be configured as a separate unit from the inverter 15B, or as a separate unit from the gears that constitute the reduction mechanism and differential mechanism.

[0054] Alternatively, the high-voltage battery 14, the low-voltage battery 16, and the heat sink 17 can be placed in locations different from those described in the above embodiments.

[0055] The electric vehicle 10 may also be configured as an electric drive unit different from the electric drive unit 15 located inside the front compartment 13, or as a four-wheel drive vehicle that drives the rear wheels 12 by an engine.

Claims

1. An electric vehicle, wherein, have: High-voltage batteries; An electric drive unit receives power from the high-voltage battery to generate the driving force of the electric vehicle. Multiple high-voltage units are electrically connected to the electric drive unit; as well as The thermal management module distributes the heat transfer medium. The electric drive unit, the plurality of high-voltage units, and the thermal management module are disposed inside the front compartment located at the front of the electric vehicle. The plurality of high-voltage units are arranged in a stacked manner above the electric drive unit in the vertical direction, wherein the thicker the cable connecting the high-voltage unit and the electric drive unit, the lower the high-voltage unit connected to the cable is located.

2. The electric vehicle according to claim 1, wherein, The thermal management module is configured with two modules: a refrigerant module for distributing refrigerant for air conditioning and a water module for distributing cooling water. Furthermore, the refrigerant module and the water module are located in front of the electric drive unit.

3. The electric vehicle according to claim 2, wherein, The refrigerant module has a water-cooled condenser that cools the refrigerant through heat exchange with cooling water distributed by the water module, and is disposed above the water module.

4. The electric vehicle according to any one of claims 1 to 3, wherein, A high-voltage heater for electrically heating cooling water is provided above the plurality of high-voltage units.

5. The electric vehicle according to claim 1, wherein, Among the plurality of high-voltage units, there are a power distribution unit for distributing power to the high-voltage battery and an on-board charging unit for charging the high-voltage battery.

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