Electric vehicles

Abstract

To enable a power unit, an electric power conversion unit and engine related components to be arranged compactly.SOLUTION: A driving motor 5, a speed reducer 6, a power generator 7 and an engine main body 8 are integrally arranged in this order in a vehicle width direction of a power unit room 2 so that heights of these are nearly equal. An electric power conversion unit 100, in which an inverter 101 for a motor, an inverter 102 for power generation and a DCDC converter 103 are integrated with one another, is arranged above the driving motor, the speed reducer and the power generator. Engine related components including a low-voltage battery B2, an air cleaner 106 and an oil filter 107a are arranged above the engine main body.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The technology disclosed herein belongs to the technical field of electric vehicles. [Background technology]

[0002] In an electric vehicle in which power is supplied to a drive motor to drive the vehicle, a structure is known in which, as shown in Patent Document 1, the drive motor, reduction gear, engine body, and generator are arranged integrally in this order across the width of the vehicle, and a power conversion unit including an inverter and converter is arranged above all of these. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-138718 Summary of the Invention [Problem to be solved by the invention]

[0004] When the power conversion unit is arranged in this manner, it becomes difficult to arrange engine-related components such as intake system components, combustion system components, cooling system components, and a battery above the engine body.

[0005] The technology disclosed herein has been made in view of these points, and its purpose is to arrange the power unit, power conversion unit, and engine-related parts in a compact manner. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, the technology disclosed herein targets an electric vehicle that includes a drive motor that uses electric power to drive the vehicle, a reducer that reduces the power from the drive motor and outputs it, a generator that generates power to be supplied to the drive motor, and an engine main body that drives the generator, and is configured to transmit the output of the reducer to the drive wheels, and is configured such that the drive motor, the reducer, the generator, and the engine main body are arranged integrally in this order and at approximately the same height in the vehicle width direction of a power unit room, a power conversion unit that integrates a motor inverter, a power generation inverter, and a DC-DC converter is arranged above the drive motor, the reducer, and the generator, and engine-related parts are arranged above the engine main body.

[0007] With this configuration, the power conversion unit and engine-related components can be arranged separately in the vehicle width direction above the power unit, which includes the drive motor, reducer, generator, and engine body, making it possible to arrange the power unit, power conversion unit, and engine-related components in a compact manner.

[0008] In one embodiment, the engine body is a rotary engine.

[0009] With this configuration, the rotary engine has a compact structure in the vertical direction, so it is possible to make the height of the drive motor, reducer, and generator approximately equal to that of the engine body, allowing them to be arranged more compactly.

[0010] In one embodiment, the rotation shaft of the engine body, the generator shaft of the generator, and the motor shaft of the drive motor extend in the vehicle width direction and are arranged on the same straight line.

[0011] According to this configuration, if a rotary engine is used as the engine body, the rotary engine is compact above its rotational axis, so it is easy to align the rotational axis in the same line as the motor shaft and generator shaft, making it easier to align the height of the engine body with that of the drive motor, reducer, and generator.

[0012] In one embodiment, the engine body is a front intake type and a front exhaust type, and the engine-related parts include intake-related parts arranged in front of the engine body, fuel and oil-related parts arranged directly above the engine body, and a battery arranged behind the engine body.

[0013] This configuration allows engine-related components to be appropriately positioned in the front-rear direction above the engine body.

[0014] In one embodiment, the engine-related parts are arranged so as to extend outward in the vehicle width direction beyond the engine body, and exhaust-related parts are routed to the sides of the engine body, below the engine-related parts, and to the rear of the engine body.

[0015] With this configuration, a space is formed below the portion of the engine-related parts that protrudes outward in the vehicle width direction, and this space can be used to arrange exhaust-related parts, making it possible to arrange engine-related parts, including exhaust-related parts, in a compact manner. [Effects of the Invention]

[0016] As described above, the technology disclosed herein allows the power unit, power conversion unit, and engine-related components to be arranged compactly. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a block diagram illustrating a drive train of an electric vehicle according to an exemplary embodiment. [Figure 2]FIG. 2 is a plan view showing the power unit room. [Figure 3] FIG. 2 is a perspective view of the power unit compartment as seen from the left front. [Figure 4] FIG. [Figure 5] FIG. 3 is an end view taken along a plane corresponding to line VV in FIG. 2. [Figure 6] FIG. 3 is an end view taken along a plane corresponding to line VI-VI in FIG. 2. DETAILED DESCRIPTION OF THE INVENTION

[0018] Exemplary embodiments will be described in detail below with reference to the drawings. In the following description, the longitudinal direction of the vehicle will be simply referred to as the "longitudinal direction," the front side of the vehicle will be simply referred to as the "front side," and the rear side of the vehicle will be simply referred to as the "rear side." The vehicle width direction is the left-right direction of the vehicle, and the left side of the vehicle will be simply referred to as the "left side," and the right side of the vehicle will be simply referred to as the "right side." Note that, in the lateral direction, the left side when viewed from the rear side to the front side will be referred to as the left, and the right side will be referred to as the right.

[0019] Fig. 1 is a block diagram showing a drive system of an electric vehicle according to an exemplary embodiment. Fig. 2 is a plan view schematically showing a power unit. Figs. 1 and 2 only show a schematic view of the drive system of the vehicle 1, and the arrangement of each component does not limit the actual arrangement of the components.

[0020] Vehicle 1 is a series hybrid vehicle. Vehicle 1 is equipped with a power unit P consisting of an electric drive unit 10 for driving vehicle 1 using electric power and an engine body 8 for generating electricity. Electric drive unit 10 has a drive motor 5 that drives the vehicle using electric power, a reduction gear 6 that reduces the power from drive motor 5 and outputs it, and a generator 7 that generates electric power to be supplied to drive motor 5.

[0021] The engine has an engine body 8 and engine-related parts. The engine body 8 is mainly used to drive a generator 7 to generate electricity, and the power to run the vehicle 1 is generated by a drive motor 5. The power generated by the drive motor 5 is changed in speed by a reducer 6 and then transmitted to drive wheels 92 (here, the front wheels) via a differential device 91.

[0022] The vehicle 1 includes a high-voltage battery B1 and a low-voltage battery B2. The high-voltage battery B1 is charged with electricity generated by a generator 7. A power generation inverter 102 is provided between the generator 7 and the high-voltage battery B1. The power generation inverter 102 is electrically connected to the generator 7 and the high-voltage battery B1. Electricity generated by the generator 7 is supplied to the high-voltage battery B1 via the power generation inverter 102. A motor inverter 101 is provided between the drive motor 5 and the high-voltage battery B1. The motor inverter 101 is electrically connected to the drive motor 5 and the high-voltage battery B1. The motor inverter 101 converts electricity from the high-voltage battery B1 into power for driving the drive motor 5 and outputs the power to the drive motor 5. A DC-DC converter 103 is provided between the high-voltage battery B1 and the low-voltage battery B2. The DC-DC converter 103 is electrically connected to the high-voltage battery B1 and the low-voltage battery B2. Electricity from the high-voltage battery B1 is supplied to the low-voltage battery B2 via the DC-DC converter 103. The electricity generated by the generator 7 is supplied to the low-voltage battery B2 via a power generation inverter 102 and a DC-DC converter 103. The motor inverter 101, the power generation inverter 102, and the DC-DC converter 103 together constitute a power conversion unit 100.

[0023] Fig. 3 is a perspective view of the power unit room 2 as seen from the left front. As shown in Fig. 2 and Fig. 3, the vehicle 1 has, at the front, a pair of left and right body side frames 31 that extend at least in the front-rear direction and are arranged on both sides in the vehicle width direction, and sub-frames 34 each having side members 34a that extend in the front-rear direction are fastened to the lower parts of the body side frames 31.

[0024] The power unit P is disposed in a power unit room 2 formed by the body side frames 31 and the subframe 34. The power unit P is supported between the left and right body side frames 31, 31 via support members 38 provided on the body side frames 31.

[0025] A power conversion unit 100, which integrates a motor inverter 101, a power generation inverter 102, and a DC-DC converter 103, is disposed above the drive unit housing 9, which houses the drive motor 5, the reducer 6, and the generator 7. Engine-related parts such as an air cleaner 106, an oil filter 107a, an oil cooler 107b, and a low-voltage battery B2 are disposed above the engine body 8.

[0026] FIG. 4 is a front view of the power unit P. The drive motor 5, the reduction gear 6, and the generator 7 are housed in a drive unit housing 9. The drive unit housing 9 is integrally formed by connecting a first housing 11, a second housing 12, a third housing 13, and a fourth housing 14 in the vehicle width direction. In detail, the drive unit housing 9 is configured such that the second housing 12 and the third housing 13, which are substantially cylindrical and extend in the vehicle width direction, are connected, and the first housing 11 and the fourth housing 14 close the openings on both the left and right sides. An actuator 105 is disposed near the front of the upper part of the third housing 13. An engine case 15, which houses the engine main body 8, is also integrally formed with the drive unit housing 9.

[0027] The first housing 11, the second housing 12, the third housing 13, the fourth housing 14, and the engine case 15 are integrally configured by being connected so that their cylindrical peripheral walls, each having approximately the same diameter, are continuous. The first housing 11, the second housing 12, the third housing 13, the fourth housing 14, and the engine case 15 are continuous so that their peripheral walls are approximately flush, particularly at the upper end. As a result, the drive motor 5, the reduction gear 6, the generator 7, and the engine body 8 are integrally arranged in this order in the vehicle width direction of the power unit room 2, at approximately the same height.

[0028] Fig. 5 is a diagram schematically showing an end surface cut along a plane corresponding to line VV in Fig. 2, and Fig. 6 is a diagram schematically showing an end surface cut along a plane corresponding to line VI-VI in Fig. 2. Note that in Figs. 5 and 6, the structures of the drive motor 5, the reducer 6, the generator 7, and the engine body 8 are omitted or simplified.

[0029] The first housing 11 is located at the outermost position in the vehicle width direction of the drive unit housing 9, and faces the body side frame 31 and the sub-frame 34. The power unit P has a right end supported by a support member 38 at the top of the first housing 11. A first bearing 21a is provided in the first housing 11. The first bearing 21a rotatably supports one end 20a of the motor shaft 20.

[0030] The second housing 12 is connected to the left side of the first housing 11. The cylindrical interior of the second housing 12 is partitioned in the vehicle width direction by a partition wall 12a. A through-hole 12b is provided in the approximate center of the partition wall 12a, allowing the motor shaft 20 to pass through in the vehicle width direction. On the right side of the partition wall 12a, a drive motor 5 is disposed in a drive motor accommodating section 5a formed by the first housing 11 and the second housing 12. On the left side of the partition wall 12a, a reducer 6 is disposed in a reducer accommodating section 6a formed by the second housing 12 and the third housing 13. In addition, a fifth bearing portion 62a is provided in the partition wall 12a, behind the motor shaft 20. The fifth bearing portion 62a rotatably supports one end of an intermediate shaft 62 of the reducer 6.

[0031] The third housing 13 is connected to the left side of the second housing 12. The third housing 13 has a partition wall 13a at its right end that divides the vehicle into a reduction gear housing section 6a and a generator housing section 7a in the vehicle width direction. A through hole 13b is provided in the approximate center of the partition wall 13a, allowing the motor shaft 20 to pass through in the vehicle width direction. A boss is formed on the periphery of the through hole 13b, and the boss protrudes to both the left and right sides from the partition wall 13a. A second bearing portion 21b is provided at the end of the through hole 13b facing the reduction gear housing section 6a. The second bearing portion 21b rotatably supports the motor shaft 20. A third bearing portion 51a is provided at the end of the through hole 13b facing the generator housing section 7a. The third bearing portion 51a rotatably supports one end of the generator shaft 50. In addition, a sixth bearing portion 62b is provided in the partition wall 13a, behind the motor shaft 20. The sixth bearing portion 62b rotatably supports the other end portion of the intermediate shaft 62 of the reducer 6.

[0032] The fourth housing 14 is connected to the third housing 13 on the left side of the partition wall 13a. The generator 7 is accommodated in a generator accommodating section 7a formed by the third housing 13 and the fourth housing 14 on the left side of the partition wall 13a. The fourth housing 14 is provided with a fourth bearing 51b. The fourth bearing 51b rotatably supports the other end of the generator shaft 50. The fourth housing 14 is integrally formed with the engine case 15 adjacent to it on the left side.

[0033] The engine case 15 is connected to the left side of the drive unit housing 9. The left end of the engine case 15 is spaced apart from the body side frame 31 and the sub-frame 34. The left end of the power unit P is supported by a support member 38 at the top of the engine case 15. The upper end of the engine case 15 is at approximately the same height as the upper end of the drive unit housing 9.

[0034] Within the drive unit housing 9 and engine case 15, the rotating shaft 80 of the engine body 8, the generator shaft 50 of the generator 7, and the motor shaft 20 of the drive motor 5 extend in the vehicle width direction and are arranged on the same straight line.

[0035] The drive motor 5 includes a rotor and a stator (not shown), and a motor shaft 20. A rotating magnetic field is generated when a three-phase alternating current is supplied to the stator, and the rotor and motor shaft 20 are rotated by the rotating magnetic field.

[0036] The motor shaft 20 has one end 20a rotatably supported by the first bearing portion 21a, and extends from the first housing 11, through the drive motor accommodating portion 5a, and penetrating the partition wall 12a of the second housing 12 into the reducer accommodating portion 6a.

[0037] The other end 20b of the motor shaft 20 passes through the partition wall 13a from the reducer housing 6a through the through-hole 13b. The other end 20b of the motor shaft 20 is formed to extend from the reducer housing 6a to the generator housing 7a.

[0038] The motor shaft 20 is integrally formed with an input shaft 61 of the reducer 6 in the reducer housing portion 6a. The rotational force of the drive motor 5 is input to the input shaft 61. The reducer 6 has an intermediate shaft 62 disposed behind the motor shaft 20 and substantially parallel to the motor shaft 20. A gear (not shown) is disposed between the input shaft 61 and the intermediate shaft 62. The intermediate shaft 62 transmits the power reduced by the gear to an output shaft (not shown).

[0039] The generator 7 includes a rotor and a stator (not shown), and a generator shaft 50. When the generator shaft 50 and the rotor are rotated by the power of the engine body 8, electricity is generated in the stator by electromagnetic induction.

[0040] The generator shaft 50 is disposed closer to the generator 7 than the other end 20b of the motor shaft 20. One end of the generator shaft 50 is supported by a third bearing 51a provided in the third housing 13, and the other end is supported by a fourth bearing 51b provided in the fourth housing 14. The motor shaft 20 and the generator shaft 50 are disposed side by side in a straight line with a gap in the vehicle width direction.

[0041] A rotating shaft 80 of the engine body 8 is disposed on the left side of the generator shaft 50. The generator shaft 50 and the rotating shaft 80 of the engine body 8 are disposed side by side on a straight line with a gap in the vehicle width direction.

[0042] The engine body 8 is disposed adjacent to the left side of the generator 7. The engine body 8 is preferably a rotary engine. A rotary engine has a more compact structure in the vertical direction than a reciprocating engine, so it is easy to make the heights of the drive motor 5, reduction gear 6, and generator 7 approximately equal to that of the engine body 8, allowing them to be disposed in a compact manner.

[0043] Engine-related parts are arranged above the engine body 8. The engine-related parts include intake-related parts arranged in front of the engine body 8, fuel- and oil-related parts arranged directly above the engine body 8, and a low-voltage battery B2 arranged behind the engine body 8. The intake-related parts include, for example, an air cleaner 106 and an intake duct 106a. The fuel- and oil-related parts include, for example, an oil filter 107a and an oil cooler 107b.

[0044] Furthermore, intake-related parts and exhaust-related parts are provided on the front side of the engine body 8. The intake-related parts include, for example, an air cleaner 106 and an intake duct 106a. The exhaust-related parts include, for example, an exhaust manifold and an exhaust pipe 108 connected to the exhaust manifold (not shown). In other words, the engine body 8 is a front intake type and a front exhaust type.

[0045] 2 and 6, the low-voltage battery B2 and the air cleaner 106, which are engine-related components, are arranged so as to protrude outward in the vehicle width direction beyond the engine main body 8. Specifically, the low-voltage battery B2 is arranged so as to overlap above the left support member 38. The air cleaner 106 is arranged in front of the low-voltage battery B2 so as to protrude to the left from above the left body side frame 31. Therefore, a space is formed on the side of the engine main body 8 and below the low-voltage battery B2 and the air cleaner 106. Using this space, exhaust-related components such as the exhaust pipe 108 are routed from the front of the engine main body 8, to the side of the engine main body 8, below the low-voltage battery B2 and the air cleaner 106, and to the rear of the engine main body 8.

[0046] As described above, according to this embodiment, the drive motor 5, the reduction gear 6, the generator 7, and the engine body 8 are integrally arranged in this order in the vehicle width direction of the power unit room 2, with their heights approximately equal. Above the drive unit housing 9 that houses the drive motor 5, the reduction gear 6, and the generator 7, the power conversion unit 100, which integrates the motor inverter 101, the power generation inverter 102, and the DC-DC converter 103, is arranged. Above the engine body 8, engine-related components such as the air cleaner 106, the intake duct 106a, the oil filter 107a, the oil cooler 107b, and the low-voltage battery B2 are arranged. Since the power conversion unit 100 and the engine-related components can be arranged separately above the drive unit housing 9 and above the engine body 8, the power conversion unit 100 and the engine-related components can be arranged compactly.

[0047] Furthermore, by making the engine body 8 a rotary engine and arranging its rotating shaft 80 and the motor shaft 20 of the generator shaft 50 in the same straight line extending in the vehicle width direction, the heights of the drive motor 5, reducer 6, generator 7 and engine body 8 can be aligned, resulting in a more compact configuration.

[0048] Furthermore, if the engine body 8 is a front intake type and a front exhaust type, and intake-related parts such as the air cleaner 106 and intake duct 106a are placed in front of the engine body 8, fuel- and oil-related parts such as the oil filter 107a and oil cooler 107b are placed directly above the engine body 8, and the low-voltage battery B2 is placed behind the engine body 8, it becomes possible to properly position the engine-related parts in the fore-and-aft direction above the engine body 8.

[0049] Furthermore, the low-voltage battery B2, the air cleaner 106, and the intake duct 106a are arranged to protrude outward in the vehicle width direction beyond the engine body 8. This allows exhaust-related parts such as the exhaust pipe 108 to be routed to the side of the engine body 8 and below the low-voltage battery B2, the air cleaner 106, and the intake duct 106a, and to the rear of the engine body 8, making it possible to arrange engine-related parts, including the exhaust-related parts, in a compact manner.

[0050] The above-described embodiments are merely examples and should not be construed as limiting the scope of the present disclosure. The scope of the present disclosure is defined by the claims, and all modifications and variations that fall within the scope of the claims equivalents are within the scope of the present disclosure. [Industrial Applicability]

[0051] The technology disclosed herein is useful for an electric vehicle in which a power unit, a power conversion unit, and engine-related parts are arranged compactly. [Explanation of symbols]

[0052] 1 vehicle 2 Power unit room 5 Drive motor 6 Reducer 7. Generator 8 Engine body 9 Drive unit housing 20 motor shaft 50 Generator shaft 80 Rotation axis 100 Power Conversion Unit 101 Motor inverter 102 Power generation inverter 103 DC-DC converter 106 Air cleaner 106a Intake duct 107a Oil filter 107b Oil cooler 108 Exhaust pipe B1 High voltage battery B2 Low voltage battery P Power Unit

Claims

1. An electric vehicle is provided with a drive motor that drives the vehicle using electric power, a reduction gear that reduces the power from the drive motor and outputs it, a generator that generates electric power to be supplied to the drive motor, and an engine body that drives the generator, and is configured to transmit the output of the reduction gear to drive wheels, the drive motor, the reducer, the generator, and the engine body are integrally arranged in this order in the vehicle width direction of a power unit room and at approximately the same height; a power conversion unit in which a motor inverter, a power generation inverter, and a DC-DC converter are integrated is disposed above the drive motor, the reducer, and the generator; engine-related components are disposed above the engine body; a rotation shaft of the engine body, a generator shaft of the generator, and a motor shaft of the drive motor are arranged on the same straight line extending in the vehicle width direction, the engine body is a front intake and front exhaust rotary engine, The engine-related components include intake-related components arranged in front of the engine body, fuel and oil-related components arranged directly above the engine body, and a battery arranged behind the engine body.

2. The electric vehicle according to claim 1, the engine-related parts are arranged so as to protrude outward in the vehicle width direction beyond the engine body, An electric vehicle, characterized in that exhaust-related parts are routed to the side of the engine body, pass below the engine-related parts, and are routed to the rear of the engine body.

Images