Electric vehicles

Abstract

To provide an electric vehicle that can suppress vibrations of high-voltage components located at the front of the drive unit. [Solution] The drive unit 30 comprises a split case 40 consisting of a plurality of case members fastened to each other while being arranged adjacently from one side to the other in the vehicle width direction, and a high-voltage component 16 is positioned on the front of the drive unit 30. An upper support portion 44A extending forward and upward of the vehicle and a lower support portion 44B extending forward and downward of the vehicle from the end case member are formed at the front of the fourth case 44 which constitutes the other end of the case 40 in the vehicle width direction. The upper part of the high-voltage component 16 is fastened to the front end face of the upper support portion 44A, the lower part of the high-voltage component 16 is fastened to the front end face of the lower support portion 44B, the upper part of the front bracket 11 is fastened to the other end face in the vehicle width direction of the upper support portion 44A, and the lower part of the front bracket 11 is fastened to the other end face in the vehicle width direction of the lower support portion 44B.

Description

Technical Field

[0001] The present invention relates to an electric vehicle.

Background Art

[0002] Patent Document 1 describes a technique for fixing an inverter unit to a plurality of attachment portions provided on a housing of a motor unit.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when the rigidity of the attachment portion to which the high-voltage component (inverter unit) is fixed cannot be sufficiently ensured due to the shape of the motor unit, there is a problem that the vibration of the high-voltage component increases.

[0005] Therefore, an object of the present invention is to provide an electric vehicle capable of suppressing vibration of a high-voltage component disposed on the front surface of a drive device.

Means for Solving the Problems

[0006] To solve the above problems, the present invention provides an electric vehicle comprising: a drive unit arranged in an engine room formed in the front of the vehicle and generating motor torque for driving; and a bracket for supporting the end of the drive unit in the vehicle width direction with the vehicle body, wherein the drive unit comprises a split case consisting of a plurality of case members fastened to each other in a state where they are lined up adjacent to each other from one side to the other in the vehicle width direction, a high-voltage component is arranged on the front of the drive unit, and when the case member constituting the other end of the case in the vehicle width direction is designated as an end case member, an upper support portion extending forward and upward from the end case member and a lower support portion extending forward and downward from the end case member are formed on the front of the end case member, the upper part of the high-voltage component is fastened to the front end surface of the upper support portion, the lower part of the high-voltage component is fastened to the front end surface of the lower support portion, the upper part of the bracket is fastened to the other end surface in the vehicle width direction of the upper support portion, and the lower part of the bracket is fastened to the other end surface in the vehicle width direction of the lower support portion. [Effects of the Invention]

[0007] Thus, according to the present invention, it is possible to provide an electric vehicle that can suppress vibrations of high-voltage components located on the front of the drive unit. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a plan view of the drive system of an electric vehicle according to one embodiment of the present invention. [Figure 2] Figure 2 is a rear view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 3] Figure 3 is a right side view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 4] Figure 4 is a front view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 5] Figure 5 is a cross-sectional view of the electric vehicle shown in Figure 3, taken along the VV direction. [Figure 6] Figure 6 is a cross-sectional view of the electric vehicle shown in Figure 3, taken along the VI-VI line. [Modes for carrying out the invention]

[0009] An electric vehicle according to one embodiment of the present invention comprises a drive unit arranged in an engine room formed at the front of the vehicle and generating motor torque for driving, and a bracket for supporting the end of the drive unit in the vehicle width direction with the vehicle body, wherein the drive unit comprises a split case made up of a plurality of case members fastened to each other in an adjacent arrangement from one side to the other in the vehicle width direction, a high-voltage component is arranged on the front of the drive unit, and when the case member constituting the other end of the case in the vehicle width direction is designated as the end case member, an upper support portion extending forward and upward from the end case member and a lower support portion extending forward and downward from the end case member are formed at the front of the end case member, the upper part of the high-voltage component is fastened to the front end face of the upper support portion, the lower part of the high-voltage component is fastened to the front end face of the lower support portion, the upper part of the bracket is fastened to the other end face in the vehicle width direction of the upper support portion, and the lower part of the bracket is fastened to the other end face in the vehicle width direction of the lower support portion. As a result, the electric vehicle according to one embodiment of the present invention can suppress vibrations of high-voltage components located on the front of the drive unit. [Examples]

[0010] Hereinafter, an electric vehicle according to one embodiment of the present invention will be described with reference to the drawings. Figures 1 to 6 show an electric vehicle according to one embodiment of the present invention.

[0011] In Figures 1 to 6, the up, down, front, rear, left, and right directions are based on the electric vehicle as it is positioned on the vehicle, with the front-rear direction of the vehicle being the front-rear direction, the left-right direction (vehicle width direction) being the left-right direction, and the up-down direction (vehicle height direction) being the up-down direction.

[0012] As shown in Figure 1, a drive unit 30 that generates motor torque for driving is provided in the engine compartment 3 at the front of the vehicle 1. The drive unit 30 is positioned transversely in the engine compartment 3 such that its internal motor output shaft 51 (see Figure 5) extends in the vehicle width direction. The vehicle 1 in this embodiment constitutes an electric vehicle.

[0013] Drive wheels (not shown) are located to the left and right of the drive unit 30, and the rotation output from the drive unit 30 is transmitted to the drive wheels. The vehicle 1 comprises a body 2, which has a subframe 2A and a body member 2B. The subframe 2A and body member 2B constitute the bottom of the body 2 and support the drive unit 30. The subframe 2A supports the rear of the drive unit 30 and lower arms (not shown), etc. The body member 2B supports the ends of the drive unit 30 in the vehicle width direction, etc.

[0014] As shown in Figure 5, the drive unit 30 comprises a motor 50, a reduction mechanism 53, a differential device 54, and a split case 40 that serves as a housing for these components.

[0015] Case 40 comprises a first case 41 that constitutes the left end of the drive unit 30, a second case 42 fastened to the right end of the first case 41, a third case 43 fastened to the right end of the second case 42, a fourth case 44 connected to the right end of the third case 43, and a cover member 45 fastened to the right end of the fourth case 44.

[0016] The first case 41 has a partition member 41A at its right end, and the partition member 41A extends in the front-to-back and up-to-down directions so as to separate the internal space of the first case 41 from the internal space of the second case 42. The partition member 41A rotatably supports the left end of the motor output shaft 51 of the motor 50 and the right end of the differential device 54, and the reduction shaft 53A of the reduction mechanism 53 passes through it.

[0017] In the third case 43, a motor 50 is disposed. At the center of the motor 50, a hollow motor output shaft 51 for outputting motor torque is provided. The motor output shaft 51 extends in the vehicle width direction from the inside of the second case 42 to the inside of the fourth case 44.

[0018] The second case 42 is provided with a bearing 57 that rotatably supports a portion of the motor output shaft 51 to the left of the motor 50. The fourth case 44 is provided with a bearing 58 that rotatably supports a portion of the motor output shaft 51 to the right of the motor 50.

[0019] In the first case 41 and the second case 42, a speed reduction mechanism 53 for reducing the rotation transmitted from the motor 50 and a differential device 54 for differentially and rotatably transmitting the rotation reduced by the speed reduction mechanism 53 to the left and right drive shafts 55, 56 are arranged.

[0020] The differential device 54 is disposed to the left of the left end portion of the motor output shaft 51. The differential device 54 includes a ring gear 54A to which rotation is transmitted from the speed reduction mechanism 53. The left drive shaft 55 is connected to the left end portion of the differential device 54. The right drive shaft 56 is connected to the right end portion of the differential device 54. This drive shaft 56 is coaxially disposed inside the hollow motor output shaft 51.

[0021] The speed reduction mechanism 53 has a reduction shaft 53A, a large-diameter first reduction gear 53B provided on the reduction shaft 53A, and a small-diameter second reduction gear 53C. The reduction shaft 53A is disposed in front of the differential device 54 and parallel to the motor output shaft 51. The first reduction gear 53B meshes with a gear 51A on the motor output shaft 51, and the second reduction gear 53C meshes with the ring gear 54A of the differential device 54.

[0022] The case 40 is formed with a roughly circular cross-sectional shape and has a cylindrical portion 40A extending in the vehicle width direction and a bulging portion 40B that bulges forward from the left end of the cylindrical portion 40A. The cylindrical portion 40A is the part that houses the motor 50, the motor output shaft 51 and the differential device 54. The bulging portion 40B is the part that houses the reduction mechanism 53. In a left side view, the case 40 has an oval shape formed by the combination of the cylindrical portion 40A and the bulging portion 40B, and in a plan view, it has an L-shape formed by the intersection of the cylindrical portion 40A and the bulging portion 40B.

[0023] As shown in Figures 1, 2, 3, and 4, a left front bracket 10 is fixed to the left end of the drive unit 30 to support the drive unit 30 on the vehicle body 2, and a mount insulator 14 is connected to the front end 10E of the left front bracket 10. The mount insulator 14 is fixed to the vehicle body member 2B.

[0024] An elastic member 14A, such as a mounting rubber, is provided inside the mount insulator 14, and the left front bracket 10 and the mount insulator 14 are elastically connected via the elastic member 14A. Therefore, the left end of the drive unit 30 is elastically supported by the vehicle body member 2B via the left front bracket 10 and the mount insulator 14.

[0025] The left front bracket 10 has three fastening parts 10A, 10B, and 10C that are fastened to the left end of the first case 41. Fastening part 10A is located in front of the center position of the drive unit 30 (the axial center position of the motor output shaft 51) at the left end of the first case 41, and is positioned at the front end of the cylindrical part 40A. Fastening part 10B is located in front of and above fastening part 10A. Fastening part 10C is located in front of and below fastening part 10A.

[0026] A right front bracket 11, which supports the drive unit 30 on the vehicle body 2, is fixed to the right end of the drive unit 30, and a mount insulator 15 is connected to the front end 11E of the right front bracket 11. The mount insulator 15 is fixed to the vehicle body member 2B.

[0027] An elastic member 15A, such as a mounting rubber, is provided inside the mount insulator 15, and the right front bracket 11 and the mount insulator 15 are elastically connected via the elastic member 15A. Therefore, the right end of the drive unit 30 is elastically supported by the vehicle body member 2B via the right front bracket 11 and the mount insulator 15.

[0028] The right front bracket 11 has four fastening parts 11A, 11B, 11C, and 11D that are fastened to the right end of the fourth case 44. Fastening part 11A is fastened to the right end of the fourth case 44 at a position behind and above the center of the drive unit 30. Fastening part 11B is fastened to the right end of the fourth case 44 at a position in front and below the center of the drive unit 30.

[0029] An upper support portion 44A is formed on the upper front of the fourth case 44, to which the upper part of the right front bracket 11 and the upper part of the high-voltage component 16 are fixed. The upper support portion 44A extends from the front outer periphery of the fourth case 44 toward the front and above the vehicle. The front end surface of the upper support portion 44A forms a flat surface that extends in the vertical direction.

[0030] A lower support portion 44B is formed at the lower front of the fourth case 44, to which the lower part of the right front bracket 11 and the lower part of the high-voltage component 16 are fixed. The lower support portion 44B extends from the front outer periphery of the fourth case 44 toward the front and downward of the vehicle. The front end surface of the lower support portion 44B forms a flat surface that extends in the vertical direction.

[0031] The fastening portion 11C is fastened to the right end of the upper support portion 44A of the fourth case 44 at a position forward and above the center of the drive unit 30. The fastening portion 11D is fastened to the right end of the lower support portion 44B of the fourth case 44 at a position forward and below the center of the drive unit 30.

[0032] A rear bracket 12 is fixed to the center of the rear of the drive unit 30 in the vehicle width direction, supporting the drive unit 30 to the vehicle body 2. The rear bracket 12 has a main body portion 12E that is fastened to the drive unit 30, and two vehicle body side connecting portions 12F that extend rearward from the main body portion 12E. A dash panel 2C is provided behind the rear bracket 12, and the dash panel 2C separates the engine room 3 from the passenger compartment behind it (not shown).

[0033] The main body 12E is formed in a roughly box shape with the longer side in the vehicle width direction when viewed from above and from the rear. A mount insulator 20 is connected to the rear end of the vehicle body side connecting part 12F. The mount insulator 20 is fixed to the subframe 2A.

[0034] An elastic member 20A, such as a mounting rubber, is provided inside the mount insulator 20, and the rear bracket 12 and the mount insulator 20 are elastically connected via the elastic member 20A. Therefore, the rear surface of the drive unit 30 is elastically supported by the subframe 2A via the rear bracket 12 and the mount insulator 20.

[0035] The main body 12E has four fastening parts 12A, 12B, 12C, and 12D that are fastened to the case 40. Fastening part 12A is located in the upper left corner of the main body 12E and is fastened to the rear surface of the partition member 41A of the first case 41. Fastening part 12B is located in the upper right corner of the main body 12E and is fastened to the rear surface of the third case 43.

[0036] The fastening portion 12C is located at the lower left corner of the main body portion 12E and is fastened to the rear surface of the partition member 41A of the first case 41. The fastening portion 12D is located at the lower right corner of the main body portion 12E and is fastened to the rear surface of the third case 43.

[0037] A high-voltage component 16 is fixed to the front of the drive unit 30, near the right end in the vehicle width direction. The high-voltage component 16 consists of an inverter that converts power from a battery (not shown) to a predetermined voltage and frequency and supplies it to the motor 50. The high-voltage component 16 is formed in a roughly square, box-like shape when viewed from the front. The high-voltage component 16 has four fastening parts 16A, 16B, 16C, and 16D that are fastened to the case 40.

[0038] Fastening portion 16A is located in the upper left corner of the high-voltage component 16 and fastens to the upper front of the second case 42. Fastening portion 16C is located in the lower left corner of the high-voltage component 16 and fastens to the lower front of the second case 42.

[0039] The fastening portion 16B is located at the upper right corner of the high-voltage component 16 and is fastened to the front end of the upper support portion 44A on the front of the fourth case 44. The fastening portion 16D is located at the lower right corner of the high-voltage component 16 and is fastened to the front end of the lower support portion 44B on the front of the fourth case 44.

[0040] An electric water pump 17 is positioned in front of the left end of the drive unit 30, above the left front bracket 10. The water pump 17 pumps coolant cooled by a radiator (not shown) to the drive unit 30. The water pump 17 has a coolant inlet pipe 17A for taking in coolant, and a coolant outlet pipe 17B that extends perpendicular to the coolant inlet pipe 17A and discharges the coolant. A support portion 10F for supporting the water pump 17 from below is formed integrally with the left front bracket 10 on the upper part of the left front bracket 10.

[0041] Thus, the drive unit 30 includes a split case 40 consisting of a first case 41, a second case 42, a third case 43, and a fourth case 44, which are multiple case members fastened to each other while being arranged adjacently from one side to the other in the vehicle width direction. The fourth case 44 is a case member that constitutes the other end of the case 40 in the vehicle width direction, and constitutes the end case member in the present invention. The third case 43, which is adjacent to the fourth case 44 on one side in the vehicle width direction, constitutes the adjacent case member in the present invention.

[0042] As shown in Figure 6, the upper part of the right front bracket 11 is fastened to the upper support portion 44A by a bolt 61, thereby fastening the upper part of the right front bracket 11 together with the outer periphery of the fourth case 44 and the outer periphery of the third case 43. Additionally, the lower part of the right front bracket 11 is fastened to the lower support portion 44B by a bolt 62, thereby fastening the lower part of the right front bracket 11 together with the outer periphery of the fourth case 44 and the outer periphery of the third case 43. Here, the right front bracket 11 corresponds to the bracket described in the claims of the present invention.

[0043] As shown in Figures 1, 2, 3, and 4, the fastening position between the right front bracket 11 and the upper support portion 44A is located lower in the vehicle's vertical direction and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component 16 and the upper support portion 44A. The fastening position between the right front bracket 11 and the lower support portion 44B is located higher in the vehicle's vertical direction and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component 16 and the lower support portion 44B.

[0044] As described above, in this embodiment, the drive unit 30 includes a split case 40 consisting of a plurality of case members fastened to each other while being arranged adjacently from one side to the other in the vehicle width direction, and a high-voltage component 16 is positioned on the front of the drive unit 30. Furthermore, when the case member constituting the other end of the case 40 in the vehicle width direction is designated as the end case member, an upper support portion 44A extending forward and upward from the end case member and a lower support portion 44B extending forward and downward from the end case member are formed at the front of the end case member. The upper part of the high-voltage component 16 is fastened to the front end face of the upper support portion 44A, the lower part of the high-voltage component 16 is fastened to the front end face of the lower support portion 44B, the upper part of the right front bracket 11 is fastened to the other end face in the vehicle width direction of the upper support portion 44A, and the lower part of the right front bracket 11 is fastened to the other end face in the vehicle width direction of the lower support portion 44B.

[0045] As a result, the upper support portion 44A and the lower support portion 44B to which the high-voltage component 16 is fastened are connected via the right front bracket 11, allowing the right front bracket 11 to function as a stiffener that reinforces and improves the rigidity of the upper support portion 44A and the lower support portion 44B. Therefore, the support rigidity of the high-voltage component 16 by the upper support portion 44A and the lower support portion 44B can be improved. As a result, vibrations of the high-voltage component 16 located in front of the drive unit 30 can be suppressed.

[0046] Furthermore, in this embodiment, when the case member adjacent to one side of the end case member in the vehicle width direction is considered an adjacent case member, the upper part of the right front bracket 11, the outer periphery of the end case member, and the outer periphery of the adjacent case member are fastened together by a bolt that fastens the upper part of the right front bracket 11 to the upper support part 44A, and the lower part of the right front bracket 11, the outer periphery of the end case member, and the outer periphery of the adjacent case member are fastened together by a bolt that fastens the lower part of the right front bracket 11 to the lower support part 44B.

[0047] As a result, the end case member and the adjacent case member are fastened together with a common bolt, allowing the upper support portion 44A and the lower support portion 44B to be indirectly connected via the bolt and the adjacent case member, thereby improving the support rigidity of the high-voltage component 16 by the upper support portion 44A and the lower support portion 44B.

[0048] Furthermore, because the bolts are fastened to the outer periphery of the end case member and the adjacent case member, the vertical distance between the two bolts can be increased, improving the fastening rigidity of the right front bracket 11 to the end case member, and thus suppressing vibration of the right front bracket 11.

[0049] Furthermore, in this embodiment, the fastening position between the right front bracket 11 and the upper support portion 44A is located lower in the vehicle's vertical direction and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component 16 and the upper support portion 44A, and the fastening position between the right front bracket 11 and the lower support portion 44B is located higher in the vehicle's vertical direction and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component 16 and the lower support portion 44B.

[0050] As a result, the bolts fastening the right front bracket 11 and the bolts fastening the high-voltage component 16 can be positioned sufficiently far apart in the upper support portion 44A and the lower support portion 44B, preventing stress from the bolts from concentrating on a part of the upper support portion 44A and the lower support portion 44B. Therefore, the rigidity of the right front bracket 11 can be improved, and vibration of the right front bracket 11 can be suppressed.

[0051] While embodiments of the present invention have been disclosed, it will be apparent to those skilled in the art that modifications can be made without departing from the scope of the invention. All such modifications and equivalents are intended to be included in the following claims. [Explanation of symbols]

[0052] 1 vehicle 2 car bodies 3. Engine Room 11 Right front bracket (bracket) 16 High-voltage components 30 Drive unit 40 cases 41. Case 1 (Case Components) 42. Case 2 (Case Components) 43. Case 3 (Case member, adjacent case member) 44. Case 4 (Case members, end case members) 44A Upper support part 44B Lower support part

Claims

1. A drive unit is located in the engine compartment formed at the front of the vehicle and generates motor torque for driving, An electric vehicle comprising a bracket that supports the vehicle body at the end of the drive unit in the vehicle width direction, The drive unit comprises a split case consisting of a plurality of case members fastened to each other in an adjacent arrangement from one side to the other in the vehicle width direction. High-voltage components are arranged on the front of the aforementioned drive unit. When the case member that constitutes the other end of the case in the vehicle width direction is designated as the end case member, An upper support portion extending forward and upward from the end case member and a lower support portion extending forward and downward from the end case member are formed on the front portion of the end case member. The upper part of the high-voltage component is fastened to the front end surface of the upper support portion. The lower part of the high-voltage component is fastened to the front end surface of the lower support portion. The upper part of the bracket is fastened to the other end face of the upper support portion in the vehicle width direction. An electric vehicle characterized in that the lower part of the bracket is fastened to the other end face in the vehicle width direction of the lower support portion.

2. When the case members adjacent to one side of the end case member in the vehicle width direction are designated as adjacent case members, The upper part of the bracket is fastened to the upper support portion by a bolt, thereby fastening the upper part of the bracket, the outer periphery of the end case member, and the outer periphery of the adjacent case member together. The electric vehicle according to claim 1, characterized in that the lower part of the bracket, the outer periphery of the end case member, and the outer periphery of the adjacent case member are fastened together by a bolt that fastens the lower part of the bracket to the lower support portion.

3. The fastening position between the bracket and the upper support portion is positioned lower in the vehicle's vertical direction and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component and the upper support portion. The electric vehicle according to claim 2, characterized in that the fastening position between the bracket and the lower support portion is located higher in the vertical direction of the vehicle and closer to the outer circumference of the end case member in the front-rear direction than the fastening position between the high-voltage component and the lower support portion.

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