Vehicle and vehicle manufacturing method

Abstract

[Problem] To reduce the dimension of a unit in a predetermined direction. [Solution] A unit has a rotating electrical machine, a first gear connected to the downstream side of the rotating electrical machine, a second gear that meshes with the first gear, and a shaft connected to the downstream side of the second gear. The shaft has a first output end and a second output end, the rotating electrical machine and the first gear are disposed on a first axis, the second gear, the shaft, the first output end, and the second output end are disposed on a second axis, and the second gear is disposed between the first output end and the second output end.

Description

Unit, vehicle, and vehicle manufacturing method

[0001] The present invention relates to a unit, a vehicle, and a method for manufacturing a vehicle.

[0002] Patent Document 1 discloses a unit including an electric motor, an automatic transmission, and a linking part that transmits the power of the electric motor to the automatic transmission.

[0003] JP 2013-005637 A

[0004] However, in the unit of Patent Document 1, the radial dimension of the electric motor and the power transmission device is the outer diameter of the unit, and is the same in all directions.

[0005] The present invention aims to reduce the size of the unit in a predetermined direction.

[0006] According to one aspect of the present invention, a unit includes a rotating electric machine, a first gear connected downstream of the rotating electric machine, a second gear meshing with the first gear, and a shaft connected downstream of the second gear, the shaft having a first output end and a second output end, the rotating electric machine and the first gear being arranged on a first axis, the second gear, the shaft, the first output end, and the second output end being arranged on a second axis, and the second gear being sandwiched between the first output end and the second output end.

[0007] According to one aspect of the present invention, the dimension in the first direction in which the first gear and the second gear are aligned increases, but the dimension in the second direction (predetermined direction) intersecting the first direction can be reduced. This makes it possible to create an advantageous layout when the constraints in the first direction are loose and the constraints in the second direction are strict. This allows the dimension of the unit in the predetermined direction to be reduced.

[0008] FIG. 1 is a configuration diagram of a vehicle equipped with a unit according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the unit. FIG. 3 is a side view of the unit. FIG. 4 is a skeleton diagram of the unit. FIG. 5 is a skeleton diagram of a unit according to a comparative example. FIG. 6 is a configuration diagram illustrating a first step of a vehicle manufacturing method. FIG. 7 is a configuration diagram illustrating a second step of a vehicle manufacturing method.

[0009] Hereinafter, a drive unit 100 as a unit according to an embodiment of the present invention and a vehicle 1 equipped with the drive unit 100 will be described with reference to the drawings.

[0010] First, a vehicle 1 will be described with reference to Fig. 1. Fig. 1 is a configuration diagram of a vehicle 1 equipped with a drive unit 100.

[0011] The vehicle 1 is a so-called conversion electric vehicle (EV) in which the internal combustion engine 9 (see FIG. 6 ) is removed from a vehicle driven by the internal combustion engine 9 and instead a drive unit 100 is installed so that the vehicle is driven by the drive unit 100. The vehicle 1 includes the drive unit 100, a transmission 2 as a first power transmission mechanism, an accessory 3, a belt 4 as a second power transmission mechanism, and drive wheels 5.

[0012] The drive unit 100 is an electric drive unit including a rotating electric machine 10 (see FIG. 2), which will be described later. The specific configuration of the drive unit 100 will be described in detail later with reference to FIG.

[0013] Although the unit is used to drive the drive wheels 5 of the vehicle 1, the invention is not limited to this and may be used to drive, for example, an electrical appliance. The unit is also called a motor unit (a unit having at least a motor), a power transmission device (a device having at least a power transmission mechanism (e.g., a gear mechanism and / or a differential gear mechanism)), etc. A device (unit) having a motor and a power transmission mechanism belongs to the concepts of both a motor unit and a power transmission device.

[0014] The transmission 2 changes the speed of the driving force from the drive unit 100 and transmits it to the driving wheels 5. The transmission 2 may be an automatic transmission or a manual transmission.

[0015] The accessory 3 is driven by the drive unit 100. The accessory 3 is, for example, an alternator that generates electricity when rotated by the rotating electric machine 10. The accessory 3 is connected downstream of a second output end 40b (see FIG. 2 ) of a second shaft 40 described later.

[0016] The belt 4 transmits the driving force of the drive unit 100 to the accessories 3 .

[0017] The drive wheels 5 are connected downstream of a first output end 40a (see FIG. 2 ) of a second shaft 40, which will be described later. Here, the drive wheels 5 are rear wheels of the vehicle 1, but may also be front wheels of the vehicle 1.

[0018] Next, the configuration of the drive unit 100 will be described with reference to Figures 2 and 3. Figure 2 is a cross-sectional view of the drive unit 100, and Figure 3 is a side view of the drive unit 100.

[0019] As shown in FIG. 2, the drive unit 100 includes a rotating electric machine 10, a reducer 20 as a reduction mechanism, a first shaft 30, a second shaft 40 as a shaft, a housing 50, a flywheel 60, and a pulley 70.

[0020] The rotating electric machine 10 has a motor function and / or a generator function. The rotating electric machine 10 is disposed on a first axis C1. The rotating electric machine 10 has a stator 11 and a rotor 12. The stator 11 is supported non-rotatably by a motor support portion 51c (described later) of the housing 50. The rotor 12 is provided on the inner periphery of the stator 11 and rotates relative to the stator 11. A small-diameter gear 21 is attached to the rotor 12 via a first shaft 30. The rotor 12 rotates together with the first shaft 30 and the small-diameter gear 21.

[0021] The reducer 20 has a small diameter gear 21 as a first gear and a large diameter gear 22 as a second gear.

[0022] The small diameter gear 21 is connected downstream of the rotating electric machine 10. The small diameter gear 21 is arranged on the first axis C1. Arranged on the first axis C1 means that the small diameter gear 21 is arranged coaxially with other components arranged on the first axis C1.

[0023] The large diameter gear 22 meshes with the small diameter gear 21. The large diameter gear 22 is arranged on a second axis C2 parallel to the first axis C1. "Arranged on the second axis C2" means that the large diameter gear 22 is arranged coaxially with other components arranged on the second axis C2. The large diameter gear 22 is formed with a larger diameter than the small diameter gear 21. Therefore, the small diameter gear 21 and the large diameter gear 22 form a reducer 20 that reduces the output of the rotating electric machine 10 and transmits it downstream.

[0024] 3, if the rotating electric machine MG alone were to produce the same output as the drive unit 100, the radial dimension (W1) of the rotating electric machine MG would be the outer diameter of the unit, and would be the same in all directions. Therefore, there is a risk that the width dimension of the unit would be large.

[0025] In contrast, in the drive unit 100, the dimension in the first direction (here, the height direction) in which the small-diameter gear 21 and the large-diameter gear 22 are aligned is larger than that of the rotating electric machine MG, but the dimension (W2) in the second direction (here, the width direction) as a predetermined direction intersecting (here, perpendicular to) the first direction can be made smaller than that of the rotating electric machine MG (W2<W1). Therefore, a layout that is advantageous when the constraints in the first direction are loose and the constraints in the second direction are strict can be achieved. Therefore, the dimension in the predetermined direction of the drive unit 100 can be reduced.

[0026] Furthermore, the larger the maximum output torque of the rotating electric machine 10, the larger the physical size of the rotating electric machine 10 becomes, but by providing the reducer 20 downstream of the rotating electric machine 10, the torque of the rotating electric machine 10 is increased by the reducer 20. Therefore, it becomes possible to set the maximum output torque of the rotating electric machine 10 to a small value, providing the option of reducing the physical size of the rotating electric machine 10.

[0027] As shown in FIG. 2, the large diameter gear 22 is disposed between the first output end 40a and the second output end 40b of the second shaft 40, and is located on the first output end 40a side.

[0028] The influence of the behavior of the drive wheels 5 is important because the driver perceives changes in the behavior of the vehicle 1 while driving as changes in the behavior of the vehicle 1. Changes in behavior transmitted to the input element of the first output end 40a (here, the transmission 2) are directly linked to changes in the behavior of the drive wheels 5. On the other hand, changes in behavior transmitted to the accessory 3 are not directly linked to changes in the behavior of the vehicle 1 that the driver perceives while driving. Therefore, by providing the large-diameter gear 22 closer to the first output end 40a than the second output end 40b, the distance between the large-diameter gear 22 and the first output end 40a can be shortened, thereby suppressing the effects of twisting and bending of the second shaft 40 and reducing changes in the behavior of the vehicle 1.

[0029] The first shaft 30 supports the small-diameter gear 21 and the rotor 12 of the rotating electrical machine 10. The first shaft 30 is the output shaft of the rotating electrical machine 10. A resolver 33 is provided on the first shaft 30 as a rotational speed detector that detects the rotational speed. The first shaft 30 rotates about a first axis C1. The first shaft 30 is rotatably supported on the housing 50 by bearings 31 and 32.

[0030] The second shaft 40 is connected downstream of the large diameter gear 22. The second shaft 40 is disposed on the second axis C2. The second shaft 40 rotates about the second axis C2. The second shaft 40 is rotatably supported in the housing 50 by bearings 41 and 42. The second shaft 40 is provided at the same position as the crankshaft (not shown) of the internal combustion engine 9 (see FIG. 6 ) removed from the vehicle 1.

[0031] The second shaft 40 has a first output end 40a and a second output end 40b. The first output end 40a and the second output end 40b are disposed on the second axis C2. The first output end 40a and the second output end 40b are disposed so as to be in the same position as the first output end and the second output end of the crankshaft, respectively.

[0032] The housing 50 is a housing member that houses the rotating electric machine 10, the reducer 20, the first shaft 30, the second shaft 40, and an inverter (not shown). The housing 50 is composed of one or more cases. Specifically, the housing 50 is composed of a first case 51, a second case 52, and a third case 53.

[0033] The housing 50 forms a 3-in-1 (3-in-1) drive unit 100. The 3-in-1 designation means that a portion of a motor case that houses the rotating electric machine 10, a portion of a reducer case that houses the reducer 20, and a portion of an inverter case that houses the inverter are integrally formed.

[0034] The first case 51 is formed in a cylindrical shape with both ends open, and has a support wall 51a, a shaft support portion 51b, and a motor support portion 51c.

[0035] The support wall 51a is disposed perpendicular to the axial direction of the first case 51. The axial direction refers to the axial direction of the rotation shafts of the components that make up the drive unit 100. The components are, for example, the rotating electric machine 10, the reducer 20, etc. The support wall 51a rotatably supports the first shaft 30 via a bearing 32. A resolver 33 and a cover 34 that houses the resolver 33 are attached to the support wall 51a.

[0036] The second case 52 is arranged to be aligned in the axial direction with the first case 51. The second case 52 closes one opening of the first case 51. The second case 52 rotatably supports the first shaft 30 via the bearing 31, and rotatably supports the second shaft 40 via the bearing 41.

[0037] The third case 53 is arranged to be aligned in the axial direction with the first case 51 and the second case 52. The third case 53 closes the other opening of the first case 51.

[0038] The flywheel 60 is disposed on the second shaft C2. The flywheel 60 transmits the output torque of the drive unit 100 to the transmission 2. The flywheel 60 is provided in the same position as the flywheel (not shown) of the internal combustion engine 9 (see FIG. 6 ) removed from the vehicle 1.

[0039] The pulley 70 is disposed on the second shaft C2. The belt 4 is wound around the pulley 70. The pulley 70 transmits the driving force of the drive unit 100 to the accessories 3 via the belt 4. The pulley 70 is provided in the same position as a pulley (not shown) of the internal combustion engine 9 (see FIG. 6 ) that has been removed from the vehicle 1.

[0040] In addition, when removing the internal combustion engine 9, if the pulley 70 is left in the vehicle 1 without being removed together with the internal combustion engine 9, and the pulley 70 is used when installing the drive unit 100, the pulley 70 will constitute the second power transmission mechanism.

[0041] Next, advantages of the drive unit 100 compared to a comparative example will be described with reference to Figures 4 and 5. Figure 4 is a skeleton diagram of the unit. Figure 5 is a skeleton diagram of a drive unit 200 as a comparative example.

[0042] As shown in FIG. 5 , the drive unit 200 according to the comparative example includes the rotating electric machine 10 , a speed reducer 120 as a speed reduction mechanism, a first shaft 30 , and a second shaft 40 .

[0043] The reducer 120 is a planetary gear mechanism having a sun gear 121, planetary gears 122, a carrier 123, and a ring gear 124. In the reducer 120, the ring gear 124 is supported non-rotatably by the housing 150. The reducer 120 reduces the speed of the output torque of the rotating electric machine 10 input from the sun gear 121 via the first shaft 30, and outputs the reduced speed downstream from the carrier 123 via the second shaft 40. This allows the drive unit 200 to output driving force from both ends of the second shaft 40.

[0044] However, in the drive unit 200, the second shaft 40 is inserted through the inner periphery of the first shaft 30. Therefore, it is necessary to form the first shaft 30 in a cylindrical shape with a through-hole large enough to allow the second shaft 40 to be inserted therethrough, which may increase the outer diameter of the rotating electric machine 10 in all radial directions.

[0045] 4, in the drive unit 100, the dimension in the first direction (here, the height direction) in which the small-diameter gear 21 and the large-diameter gear 22 are aligned is larger than that of the drive unit 200, but the dimension in the second direction (here, the width direction), which is a predetermined direction intersecting (here, perpendicular to) the first direction, can be made smaller than that of the drive unit 200. Therefore, a layout that is advantageous when the constraints in the first direction are loose and the constraints in the second direction are strict can be achieved. Therefore, the dimension in the predetermined direction of the drive unit 100 can be reduced.

[0046] A method for manufacturing the vehicle 1 will be described below with reference to Figures 6 and 7. Figure 6 is a configuration diagram for explaining a first step of the method for manufacturing the vehicle 1. Figure 7 is a configuration diagram for explaining a second step of the method for manufacturing the vehicle 1.

[0047] The manufacturing method of the vehicle 1 is for manufacturing the vehicle 1 having a transmission 2, a belt 4, drive wheels 5 connected downstream of the transmission 2, and an accessory 3 connected downstream of the belt 4, with the input part (flywheel 60) of the transmission 2 and the input part (pulley 70) of the belt 4 being coaxially arranged. The manufacturing method of the vehicle 1 has a first step and a second step.

[0048] 6 , in the first step, a drive unit 100 is prepared. As described above, the drive unit 100 includes the rotating electric machine 10, the small-diameter gear 21 connected downstream of the rotating electric machine 10, the large-diameter gear 22 meshing with the small-diameter gear 21, and the second shaft 40 connected downstream of the large-diameter gear 22, the second shaft 40 having a first output end 40 a and a second output end 40 b, the rotating electric machine 10 and the small-diameter gear 21 being arranged on a first axis C1, the large-diameter gear 22, the second shaft 40, the first output end 40 a, and the second output end 40 b being arranged on a second axis C2, and the large-diameter gear 22 being sandwiched between the first output end 40 a and the second output end 40 b.

[0049] In this way, by providing the drive unit 100, it is possible to realize a coaxial state of the two power transmission mechanisms (the transmission 2 and the belt 4).

[0050] Furthermore, the manufacturing method of the vehicle 1 includes, at least prior to the second step, a step of removing the internal combustion engine 9 connected to the input portion of the transmission 2 and the input portion of the belt 4 .

[0051] That is, the drive unit 100 may be prepared after the internal combustion engine 9 is removed, or the drive unit 100 may be prepared in advance before the internal combustion engine 9 is removed.

[0052] 7 , in the second step, the drive unit 100 is mounted on the vehicle 1. At this time, the first output end 40a is connected to the input portion of the transmission 2, and the second output end 40b is connected to the input portion of the belt 4.

[0053] In the internal combustion engine 9, the input portion of the transmission 2 and the input portion of the belt 4 are often provided coaxially, and in a conversion EV in which a vehicle 1 with an internal combustion engine 9 is converted into an electric vehicle, applying a drive unit 100 configured in this manner can be said to be an advantageous conversion method. Note that conversion is nothing other than the act of reproduction, and a conversion method is a method of producing something (a manufacturing method).

[0054] Furthermore, since the internal combustion engine 9 exists in a vertically long space when viewed from the axial direction, when manufacturing a conversion EV, vertical constraints are loose but horizontal constraints are strict. Therefore, in such cases, it is very suitable to apply the drive unit 100 having this configuration.

[0055] The configuration and effects of the present embodiment will now be described.

[0056] (1) The drive unit 100 has a rotating electric machine 10, a small-diameter gear 21 connected downstream of the rotating electric machine 10, a large-diameter gear 22 meshing with the small-diameter gear 21, and a second shaft 40 connected downstream of the large-diameter gear 22, the second shaft 40 having a first output end 40a and a second output end 40b, the rotating electric machine 10 and the small-diameter gear 21 being arranged on a first axis C1, the large-diameter gear 22, the second shaft 40, the first output end 40a and the second output end 40b being arranged on a second axis C2, and the large-diameter gear 22 being sandwiched between the first output end 40a and the second output end 40b.

[0057] With this configuration, the dimension in the first direction in which the small-diameter gear 21 and the large-diameter gear 22 are aligned increases, but the dimension in the second direction (predetermined direction) intersecting the first direction can be reduced. This makes it possible to achieve an advantageous layout when restrictions in the first direction are loose and restrictions in the second direction are strict. This allows the dimension of the drive unit 100 in the predetermined direction to be reduced.

[0058] (2) The small diameter gear 21 and the large diameter gear 22 form the reducer 20 .

[0059] According to this configuration, the larger the maximum output torque of the rotating electric machine 10, the larger the physical size of the rotating electric machine 10 becomes, but by providing the reducer 20 downstream of the rotating electric machine 10, the torque of the rotating electric machine 10 is increased by the reducer 20. Therefore, it becomes possible to set the maximum output torque of the rotating electric machine 10 to a small value, and the option of reducing the physical size of the rotating electric machine 10 becomes available.

[0060] (3) The vehicle 1 has a drive wheel 5 connected downstream of the first output end 40a and an accessory 3 connected downstream of the second output end 40b, and the large diameter gear 22 is located on the first output end 40a side.

[0061] The influence of the behavior of the drive wheels 5 is important because the driver perceives changes in the behavior of the vehicle 1 while driving as changes in the behavior of the vehicle 1. Changes in behavior transmitted to the input element of the first output end 40a (here, the transmission 2) are directly linked to changes in the behavior of the drive wheels 5. On the other hand, changes in behavior transmitted to the accessory 3 are not directly linked to changes in the behavior of the vehicle 1 that the driver perceives while driving. Therefore, by providing the large-diameter gear 22 closer to the first output end 40a than the second output end 40b, the distance between the large-diameter gear 22 and the first output end 40a can be shortened, thereby suppressing the effects of twisting and bending of the second shaft 40 and reducing changes in the behavior of the vehicle 1.

[0062] (4) A manufacturing method for a vehicle 1 having a transmission 2, a belt 4, drive wheels 5 connected downstream of the transmission 2, and an accessory 3 connected downstream of the belt 4, in which an input portion (flywheel 60) of the transmission 2 and an input portion (pulley 70) of the belt 4 are coaxially arranged, includes a rotating electric machine 10, a small-diameter gear 21 connected downstream of the rotating electric machine 10, a large-diameter gear 22 meshing with the small-diameter gear 21, and a second shaft 40 connected downstream of the large-diameter gear 22, the second shaft 40 having a first output end 40a and a second output end 40b. b, wherein the rotating electric machine 10 and the small-diameter gear 21 are arranged on a first axis C1, and the large-diameter gear 22, the second shaft 40, the first output end 40a, and the second output end 40b are arranged on a second axis C2, and the large-diameter gear 22 is arranged sandwiched between the first output end 40a and the second output end 40b, and the method includes a first step of preparing a drive unit 100, and a second step of mounting the drive unit 100 so that the first output end 40a is connected to the input part of the transmission 2 and the second output end 40b is connected to the input part of the belt 4.

[0063] With this configuration, the dimension in the first direction in which the small-diameter gear 21 and the large-diameter gear 22 are aligned increases, but the dimension in the second direction (predetermined direction) intersecting the first direction can be reduced. This makes it possible to achieve an advantageous layout when restrictions in the first direction are loose and restrictions in the second direction are strict. This allows the dimension of the drive unit 100 in the predetermined direction to be reduced.

[0064] Furthermore, by providing the drive unit 100 having this configuration, it is possible to realize a coaxial state of the two power transmission mechanisms (the transmission 2 and the belt 4).

[0065] (5) The method for manufacturing the vehicle 1 includes, at least prior to the second step, a step of removing the internal combustion engine 9 connected to the input portion of the transmission 2 and the input portion of the belt 4 .

[0066] According to this configuration, in the internal combustion engine 9, the input portion of the transmission 2 and the input portion of the belt 4 are often provided coaxially, and it can be said that applying the drive unit 100 configured in this way to a conversion EV, which converts a vehicle 1 equipped with an internal combustion engine 9 into an electric vehicle, is an advantageous conversion method. Note that conversion is nothing other than the act of reproduction, and a conversion method is a method of producing something (a manufacturing method).

[0067] Furthermore, since the internal combustion engine 9 exists in a vertically long space when viewed from the axial direction, when manufacturing a conversion EV, vertical constraints are loose but horizontal constraints are strict. Therefore, in such cases, it is very suitable to apply the drive unit 100 having this configuration.

[0068] The drive unit 100 may be prepared after the internal combustion engine 9 is removed, or the drive unit 100 may be prepared in advance before the internal combustion engine 9 is removed.

[0069] Although an embodiment of the present invention has been described above, the above embodiment merely shows one application example of the present invention, and is not intended to limit the technical scope of the present invention to the specific configuration of the above embodiment.

[0070] For example, if it is desired to increase the output of the drive unit 100, the axial length of the rotating electrical machine 10 can be increased, and the axial length of the first case 51 in the housing 50 can be increased, thereby lengthening the second shaft 40. In this case as well, the dimension in the first direction in which the small diameter gear 21 and the large diameter gear 22 are aligned increases, but the dimension in the second direction (predetermined direction) intersecting the first direction can be reduced.

[0071] REFERENCE SIGNS LIST 100 Drive unit (unit) 1 Vehicle 2 Transmission (first power transmission mechanism) 3 Accessory 4 Belt (second power transmission mechanism) 5 Drive wheel 9 Internal combustion engine 10 Rotating electric machine 20 Speed ​​reducer (speed reduction mechanism) 21 Small diameter gear 22 Large diameter gear 40 Second shaft (shaft) 40a First output end 40b Second output end C1 First shaft C2 Second shaft

Claims

1. A unit, A rotating electric machine; A first gear connected downstream of the rotating electric machine; A second gear that meshes with the first gear; a shaft connected downstream of the second gear; having The shaft has a first output end and a second output end. the rotating electric machine and the first gear are disposed on a first shaft, the second gear, the shaft, the first output end, and the second output end are disposed on a second axis; The second gear is disposed between the first output end and the second output end, the rotating electric machine and the shaft have a portion that overlaps in a radial direction of the second axis, unit.

2. 2. The unit of claim 1, The first gear and the second gear constitute a reduction mechanism. unit.

3. A vehicle equipped with the unit according to claim 1 or 2, A drive wheel connected downstream of the first output end; an accessory connected downstream of the second output; having The second gear is located on the first output end side. vehicle.

4. A method for manufacturing a vehicle comprising: a first power transmission mechanism; a second power transmission mechanism; drive wheels connected downstream of the first power transmission mechanism; and an accessory connected downstream of the second power transmission mechanism, wherein an input portion of the first power transmission mechanism and an input portion of the second power transmission mechanism are coaxially arranged, a first step of preparing a unit including a rotating electric machine, a first gear connected downstream of the rotating electric machine, a second gear meshing with the first gear, and a shaft connected downstream of the second gear, the shaft having a first output end and a second output end, the rotating electric machine and the first gear being arranged on a first axis, the second gear, the shaft, the first output end, and the second output end being arranged on a second axis, the rotating electric machine and the shaft having portions that overlap in a radial direction of the second axis, and the second gear being sandwiched and arranged between the first output end and the second output end; a second step of mounting the unit such that the first output end is connected to an input portion of the first power transmission mechanism and the second output end is connected to an input portion of the second power transmission mechanism; having A method for manufacturing a vehicle.

5. A method for manufacturing a vehicle according to claim 4, and a step of removing an internal combustion engine connected to an input portion of the first power transmission mechanism and an input portion of the second power transmission mechanism at least prior to the second step. A method for manufacturing a vehicle.