Vehicle manufacturing method

Abstract

[Problem] When re-manufacturing an electric vehicle having a motor from a vehicle having an engine, to enable a layout of the vehicle before modification to be utilized effectively. [Solution] This vehicle manufacturing method includes: a preparation step for preparing an engine block capable of accommodating engine components, and a motor unit including a motor and a motor housing for accommodating the motor; and a supporting step for supporting the motor unit on the engine block.

Description

Vehicle manufacturing method

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

[0002] Patent Document 1 discloses a method for remanufacturing (modifying) an electric vehicle having a motor from a vehicle having an internal combustion engine.

[0003] JP 2010-252584 A

[0004] In the above method, when replacing the engine with a motor, it is necessary to newly develop many parts to fit the layout of the vehicle before modification, which means that the layout of the vehicle before modification cannot be effectively used.

[0005] The present invention has been made in consideration of these technical challenges, and aims to make it possible to effectively utilize the layout of the vehicle before modification when reproducing an electric vehicle having a motor from a vehicle having an engine.

[0006] According to one aspect of the present invention, there is provided a method for manufacturing a vehicle, comprising: a preparation step of preparing an engine block capable of accommodating engine parts; and a motor unit having a motor and a motor housing that accommodates the motor; and a support step of supporting the motor unit on the engine block.

[0007] In the above-described embodiment, the engine block is left in place and the motor unit is supported by the engine block, rather than replacing the entire engine with the motor unit. Because the engine block is designed to fit the components around the engine in the vehicle before modification, supporting the motor unit on the engine block allows for effective use of the layout of the vehicle before modification.

[0008] Fig. 1 is a schematic diagram of a vehicle manufactured by a vehicle manufacturing method according to an embodiment of the present invention. Fig. 2 is a skeleton diagram of a motor unit. Fig. 3 is a schematic diagram showing a state in which the motor unit is supported on an engine block. Fig. 4 is a schematic diagram of a damper structure as viewed from the accessory side. Fig. 5 is a schematic diagram showing a state in which an oil flow path of the motor unit is connected to a heat exchanger. Fig. 6 is a flowchart showing a procedure for manufacturing a vehicle. Fig. 7 is a diagram for explaining the procedure for manufacturing a vehicle. Fig. 8 is a schematic diagram showing an example of a mount portion provided on an engine block.

[0009] Hereinafter, a method for manufacturing a vehicle 200 according to an embodiment of the present invention will be described with reference to the accompanying drawings.

[0010] First, a vehicle 200 manufactured by a method for manufacturing a vehicle 200 according to an embodiment of the present invention will be described.

[0011] FIG. 1 is a schematic diagram of a vehicle 200.

[0012] Vehicle 200 is a so-called conversion EV (Electric Vehicle) that is a vehicle driven by an internal combustion engine that has been modified so that it is driven by motor unit 100 instead of the engine. Note that modification is the reproduction of an object, and the modification method is nothing other than a production method (manufacturing method) of an object.

[0013] As shown in FIG. 1 , a vehicle 200 includes an engine block 20 , a motor unit 100 , a transmission 30 , accessories 40 , a power transmission mechanism 50 , and drive wheels 60 .

[0014] The engine block 20 is connected to a vehicle body 201 via an engine mount (not shown). In the vehicle before modification, the engine block 20 accommodates engine components.

[0015] An engine part is a part that constitutes an internal combustion engine. For example, an engine piston, a crankshaft, or other parts are engine parts. The engine piston and crankshaft have a portion that is housed in the engine block 20.

[0016] The motor unit 100 is supported by the engine block 20 .

[0017] The transmission 30 changes the speed of the output rotation of the motor unit 100 and transmits the rotation to the drive wheels 60. In this embodiment, the transmission 30 is an automatic transmission. However, the transmission 30 may also be a manual transmission.

[0018] In this embodiment, the drive wheels 60 are rear wheels of the vehicle 200. However, the drive wheels 60 may be front wheels of the vehicle 200.

[0019] The accessory 40 is driven by the output rotation of the motor unit 100 transmitted via the power transmission mechanism 50. The accessory 40 is, for example, an alternator that generates electricity when rotated. The power transmission mechanism 50 may be a belt power transmission mechanism, a chain power transmission mechanism, or a gear power transmission mechanism.

[0020] FIG. 2 is a skeleton diagram of the motor unit 100.

[0021] As shown in FIG. 2 , the motor unit 100 includes a motor 10 , a first gear train 11 , a second gear train 12 , a third gear train 13 , an output shaft 14 , an output shaft 15 , and a motor housing 16 .

[0022] The motor 10 is a rotating electric machine that functions as both an electric motor that receives power from a battery (not shown) to rotate and a generator that generates electricity by rotating with an external force. When regenerative control is being performed, the motor 10 functions as a generator.

[0023] The first gear train 11 is composed of a first gear 11a provided on an output shaft 10a of the motor 10 and a second gear 11b that meshes with the first gear 11a. The first gear train 11 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0024] The second gear train 12 is made up of a third gear 12 a that rotates integrally with the second gear 11 b and a fourth gear 12 b that meshes with the third gear 12 a. The second gear train 12 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0025] The third gear train 13 is made up of a fifth gear 13 a that rotates integrally with the second gear 11 b and a sixth gear 13 b that meshes with the fifth gear 13 a. The third gear train 13 is a speed reduction mechanism that reduces the output rotation of the motor 10.

[0026] The output shaft 14 rotates integrally with the fourth gear 12b and outputs the rotation of the motor 10, which has been reduced in speed via the first gear train 11 and the second gear train 12. In this embodiment, the rotation of the output shaft 14 is transmitted to a torque converter (not shown) of the transmission 30.

[0027] The output shaft 15 rotates integrally with the sixth gear 13b and outputs the rotation of the motor 10, which has been reduced in speed via the first gear train 11 and the third gear train 13. In this embodiment, the rotation of the output shaft 15 is transmitted to the accessory 40 via a power transmission mechanism 50.

[0028] FIG. 3 is a schematic diagram showing the motor unit 100 supported on the engine block 20. As shown in FIG.

[0029] 3, piston housing portions 21a, 21b, 21c, and 21d and crankshaft support wall portions 22a, 22b, and 22c are provided inside engine block 20. In the following, unless a piston housing portion is individually specified, it will be referred to as piston housing portion 21, and unless a crankshaft support wall portion is individually specified, it will be referred to as crankshaft support wall portion 22.

[0030] In the vehicle before modification, the piston accommodating portion 21 accommodates an engine piston. In the vehicle before modification, the crankshaft support wall portion 22 supports the crankshaft together with openings 23 a, 23 b that open to the outside of the engine block 20.

[0031] The motor unit 100 is disposed in a space formed by removing a portion of the plurality of crankshaft support wall portions 22 by cutting or the like.

[0032] Specifically, in the motor unit 100, the output shaft 14 is supported in the opening 23a via a bearing 95. Furthermore, the output shaft 15 is supported in the opening 23b via a bearing 96.

[0033] At least a portion of the crankshaft support wall portions 22 may be removed depending on the shape of the motor unit 100. Note that, for example, even when a portion of the crankshaft support wall portion 22a is removed but the crankshaft support wall portions 22b and 22c are not, or when a portion of the crankshaft support wall portion 22b is removed but the crankshaft support wall portions 22a and 22c are not, it can be said that at least a portion of the crankshaft support wall portions 22 is removed.

[0034] In addition, the motor unit 100 has the motor housing 16 fixed to a fixing member 24 housed in the piston housing portion 21b and a fixing member 25 housed in the piston housing portion 21c.

[0035] In this embodiment, the fixing members 24, 25 are cylindrical members with bottoms, and the bottom 24a of the fixing member 24 and the fixing portion 16a of the motor housing 16 are connected by a bolt 97, and the bottom 25a of the fixing member 25 and the fixing portion 16b of the motor housing 16 are connected by a bolt 98.

[0036] In this way, the output shafts 14, 15 are supported in the openings 23a, 23b, which are capable of supporting the crankshaft, of the motor unit 100. Furthermore, the motor housing 16 is supported in the piston accommodating portions 21b, 21c by being fixed to the fixing members 24, 25 housed in the piston accommodating portions 21b, 21c.

[0037] This allows the piston housings 21b, 21c to receive the reaction force generated when the motor 10 rotates. In other words, rotation of the motor unit 100 around the output shafts 14, 15 as the rotation axis is restricted. Furthermore, since the point receiving the reaction force can be moved away from the rotation axis, the force received by the piston housings 21b, 21c can be reduced. In other words, by increasing the distance from the rotation axis to the point receiving the force, it becomes possible to receive a greater force. Furthermore, since this embodiment utilizes the structure of the engine of the vehicle before modification, it is possible to reduce the number of newly developed parts.

[0038] The support structure for supporting the motor unit 100 by the piston accommodating portions 21b and 21c is not essential, and the reaction force when the motor 10 rotates may be received by another support structure or the like.

[0039] Furthermore, in this embodiment, two fixing members (fixing members 24, 25) are provided. This allows the piston accommodating portions 21b, 21c to receive the reaction force generated when the motor 10 rotates in a balanced manner. However, the number of fixing members can be changed as appropriate. Also, it is possible to change which of the piston accommodating portions 21a to 21d each has a fixing member provided in as appropriate. Furthermore, even if the engine installed in the vehicle before modification is not a four-cylinder engine, the above support structure in which the motor unit 100 is supported by the piston accommodating portions can be employed.

[0040] Furthermore, a damper structure 70 (see FIG. 4) for damping the fixing member housed in the piston housing portion 21 may be provided.

[0041] The damper structure 70 may be, for example, an air damper structure that generates a damping action by air pressure by sealing the piston accommodating portion 21, or a spring damper structure that generates a damping action by utilizing the biasing force of a spring. The air damper structure may be one that uses positive pressure or one that uses negative pressure. The spring damper structure may be one that uses a compression spring or one that uses a tension spring. The damper structure 70 is not limited to either of these structures.

[0042] 4 is a schematic diagram of the damper structure 70 as viewed from the auxiliary device 40 side. FIG. 4 shows an air damper structure as an example of the damper structure 70.

[0043] The damper structure 70 shown in Figure 4 includes a fixing member 26 housed in the piston accommodating portion 21, a link mechanism 71 that connects and fixes the fixing member 26 to the fixing portion 16c of the motor housing 16, and a cover 72 that seals the upper opening of the piston accommodating portion 21.

[0044] The link mechanism 71 is connected to the fixing member 26 by a swing shaft 71a, and is connected to the fixing portion 16c of the motor housing 16 by a swing shaft 71b.

[0045] As a result, when the motor unit 100 swings around the rotation axis due to the reaction force generated when the motor 10 rotates (see the solid arrow), the fixing member 26 is pulled downward by the link mechanism 71 (see the hollow arrow).

[0046] Here, the space between the fixing member 26 and the cover 72 inside the piston accommodating portion 21 is sealed by the fixing member 26 and the cover 72. Therefore, the damping effect of the air pressure (negative pressure) prevents the fixing member 26 from being displaced. In other words, the motor unit 100 is prevented from swinging.

[0047] In this way, by providing the damper structure 70, it is possible to attenuate the reaction force generated when the motor 10 rotates. This reduces vibrations and impacts, thereby reducing shock to the occupants of the vehicle 200. Furthermore, in this embodiment, the damper structure 70 is provided using the structure of the engine of the vehicle before modification, which reduces the number of new parts that need to be developed.

[0048] FIG. 5 is a schematic diagram showing a state in which the oil flow path 17 of the motor unit 100 is connected to the heat exchanger 80. As shown in FIG.

[0049] As shown in Figure 5, the engine block 20 has a coolant flow path 28 through which coolant flows. The coolant flow path 28 is connected to a radiator 90 via radiator hoses 91 and 92. The coolant flow path 28, the radiator 90, and the radiator hoses 91 and 92 form a coolant circuit through which the coolant circulates. The coolant may be, for example, cooling water, but is not limited to this.

[0050] In FIG. 5, a water pump 40 a and a fan 40 b are shown as the accessories 40 driven by the motor unit 100 via the power transmission mechanism 50 .

[0051] The motor unit 100 has an oil flow path 17 through which oil flows. The oil flow path 17 is connected to a heat exchanger 80. The heat exchanger 80 exchanges heat with the coolant flowing through the coolant circuit. This cools the oil flowing through the oil flow path 17.

[0052] 5, the oil flow path 17 is directly connected to the heat exchanger 80. However, the oil flow path 17 may be connected to the heat exchanger 80 via an oil flow path that the engine has in the vehicle before modification.

[0053] The heat exchanger 80 may be the same as that provided in the vehicle before the modification, or may be a new heat exchanger.

[0054] In this way, by utilizing the existing coolant flow path 28 provided in the engine block 20, it is possible to reduce the amount of work required to design a new configuration for cooling the oil in the motor unit 100. This reduces the design burden on the motor unit 100.

[0055] Next, a description will be given of a method for manufacturing vehicle 200. Fig. 6 is a flowchart showing the procedure for manufacturing vehicle 200. Fig. 7 is a diagram for explaining the procedure for manufacturing vehicle 200.

[0056] In step S1 (preparation step), as shown in FIG. 7, the engine block 20 and the motor unit 100 are prepared.

[0057] The engine block 20 is a component of the engine that is installed in the vehicle before modification. Alternatively, the engine block 20 may be newly prepared.

[0058] In step S2 (removal step), at least some of the crankshaft support walls 22 provided inside the engine block 20 are removed. Specifically, in this embodiment, the portions surrounded by dashed lines in FIG. 7 are removed by cutting or the like. In this embodiment, the shape of the crankshaft support walls 22 after the portions are removed by cutting or the like is an arch shape that follows the shape of the motor unit 100, as shown in FIG. 4. It is also possible to remove all of the crankshaft support walls 22.

[0059] In step S3 (supporting step), the motor unit 100 is supported by the engine block 20 so that the motor unit 100 is positioned at the position shown by the two-dot chain line in Figure 7. As a result, the motor unit 100 is accommodated in the space formed by removing a portion of the multiple crankshaft support wall portions 22.

[0060] The fixing members 24, 25 (see FIG. 3) are inserted into the piston accommodating portions 21b, 21c from their upper openings after the output shafts 14, 15 are supported in the openings 23a, 23b. Thereafter, the fixing members 24, 25 and the motor housing 16 are fixed together with bolts 97, 98.

[0061] The fixing members 24, 25 may be connected to the motor housing 16 in advance before the output shafts 14, 15 are supported in the openings 23a, 23b. In this case, however, high precision is required in positioning the fixing members 24, 25 relative to the motor housing 16. By attaching the fixing members 24, 25 after the output shafts 14, 15 are supported in the openings 23a, 23b, the fixing members 24, 25 can be attached easily.

[0062] 4 is provided as the damper structure 70, before the output shafts 14, 15 are supported in the openings 23a, 23b, the motor housing 16 is connected and fixed to the fixing member 26 by the link mechanism 71. Then, after the output shafts 14, 15 are supported in the openings 23a, 23b, the cover 72 is attached to the engine block 20.

[0063] In step S4 (connecting step), the oil flow path 17 is connected to the heat exchanger 80 (see FIG. 5).

[0064] The connection process may be performed before the output shafts 14, 15 of the motor unit 100 are supported in the openings 23a, 23b of the engine block 20, or after the output shafts 14, 15 of the motor unit 100 are supported in the openings 23a, 23b of the engine block 20.

[0065] In step S5 (mounting step), the engine block 20 and the motor unit 100 are mounted on the vehicle 200 (see FIG. 1).

[0066] In a vehicle before modification, the engine block 20 is designed to fit with the components around the engine. For example, as shown in FIG. 8 , the engine block 20 of this embodiment has a mount portion 29 consisting of three bosses, each of which has a female thread. The mount portion 29 is connected to the vehicle body 201 via an engine mount. Therefore, by utilizing the existing mount portion 29, etc., provided on the engine block 20, the engine block 20 and the motor unit 100 can be easily mounted on the vehicle 200.

[0067] The main effects of the manufacturing method for the vehicle 200 according to the embodiment of the present invention will be summarized below.

[0068] (1) The manufacturing method of the vehicle 200 includes a preparation process for preparing an engine block 20 capable of accommodating engine parts, and a motor unit 100 having a motor 10 and a motor housing 16 that accommodates the motor 10, and a support process for supporting the motor unit 100 on the engine block 20.

[0069] According to this, rather than replacing the engine together with the engine block 20 with the motor unit 100, the engine block 20 is left in place and the motor unit 100 is supported by the engine block 20. The engine block 20 is designed to fit the components around the engine in the vehicle before modification, so by having the engine block 20 support the motor unit 100, the layout of the vehicle before modification can be effectively utilized.

[0070] (2) The engine block 20 has openings 23a, 23b capable of supporting the crankshaft, and in the supporting step, the output shafts 14, 15 of the motor unit 100 are supported by the openings 23a, 23b of the engine block 20.

[0071] In a vehicle before modification, the layout of the transmission 30 and other components is designed to match the axial position of the crankshaft. Therefore, by supporting the output shafts 14, 15 of the motor unit 100 in accordance with the positions of the openings 23a, 23b that support the crankshaft, it is possible to minimize the scale of modification of the transmission 30 and other components, for example. In other words, the layout of the vehicle before modification can be effectively utilized.

[0072] (3) The engine block 20 has a mount portion 29 that is connected to the vehicle body 201 .

[0073] The mounts connected to the vehicle body are designed to fit the overall shape and structure of the vehicle, and are located in completely different positions depending on the vehicle model. If mounts were provided on the motor housing, the mounts on the motor housing would need to be designed depending on the vehicle model before modification. On the other hand, according to this embodiment, the motor unit 100 is supported by the openings 23a, 23b of the engine block 20 that supports the crankshaft, and the engine block 20 has the mounts 29, so there is no need to design a separate mount on the motor unit 100. This reduces the design burden of designing the mounts of the motor unit depending on the vehicle model.

[0074] (4) At least a portion of the crankshaft support wall portions 22 (22a, 22b, 22c) provided inside the engine block 20 is removed, and then a support process is performed.

[0075] By removing the multiple crankshaft support walls 22, space can be secured inside the engine block 20 to place the motor unit 100. This reduces the amount of protrusion of the motor unit 100 from the engine block 20, contributing to miniaturization. Furthermore, by removing the crankshaft support walls to fit the shape of the motor unit, it is no longer necessary to design the exterior shape of the motor housing of the motor unit for each engine block, which differs depending on the vehicle model. This reduces the design burden of the motor unit.

[0076] (5) The vehicle 200 includes a heat exchanger 80, the engine block 20 includes a coolant flow path 28 through which coolant supplied to the heat exchanger 80 flows, and the motor unit 100 includes an oil flow path 17 through which oil flows. The manufacturing method of the vehicle 200 includes a connection step of connecting the oil flow path 17 to the heat exchanger 80.

[0077] By utilizing the existing coolant flow path 28 provided in the engine block 20, the man-hours required to newly design a configuration for cooling (heat exchanging) the oil in the motor unit 100 can be reduced. This reduces the design burden on the motor unit 100. Costs can be reduced by reusing the heat exchanger 80 that is installed in the vehicle before the modification. Costs can also be reduced by reusing the pump (water pump) that circulates the coolant and the radiator that cools the coolant from the vehicle before the modification.

[0078] (6) The engine block 20 has a piston accommodating section 21 (21a, 21b, 21c) capable of accommodating an engine piston, and the engine block 20 supports the motor unit 100 by accommodating fixing members (24, 25, 26) in the piston accommodating section 21 and fixing the motor housing 16 of the motor unit 100 to the fixing members (24, 25, 26).

[0079] This allows the piston housing 21 to receive the reaction force generated when the motor 10 rotates. In other words, rotation of the motor unit 100 around the output shafts 14, 15 as the rotation axis is restricted. In addition, the point receiving the reaction force can be moved away from the rotation axis, so the force received by the piston housing 21 can be reduced. In other words, by increasing the distance from the rotation axis to the point receiving the force, it becomes possible to receive a greater force. Furthermore, in this embodiment, the structure of the engine of the vehicle before modification is used, so the number of newly developed parts can be reduced.

[0080] (7) A damper structure 70 is provided to damp the fixing member 26 inside the piston accommodating portion 21 .

[0081] By providing the damper structure 70, it is possible to attenuate the reaction force generated when the motor 10 rotates. This reduces vibrations and impacts, thereby reducing shock to the occupants of the vehicle 200. Furthermore, in this embodiment, the damper structure 70 is provided using the structure of the engine of the vehicle before modification, which reduces the number of new parts that need to be developed.

[0082] 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.

[0083] REFERENCE SIGNS LIST 10 Motor 14 Output shaft 15 Output shaft 16 Motor housing 17 Oil flow path 20 Engine block 21a Piston accommodating portion 21b Piston accommodating portion 21c Piston accommodating portion 21d Piston accommodating portion 22a Crankshaft support wall portion 22b Crankshaft support wall portion 22c Crankshaft support wall portion 23a Opening 23b Opening 24 Fixing member 25 Fixing member 26 Fixing member 28 Coolant flow path 29 Mount portion 70 Damper structure 80 Heat exchanger 200 Vehicle 201 Vehicle body 100 Motor unit

Claims

1. a preparation step of preparing an engine block capable of accommodating engine components, and a motor unit having a motor and a motor housing accommodating the motor; a supporting step of supporting the motor unit on the engine block so that the motor unit is positioned inside the engine block; A method for manufacturing a vehicle having the above structure.

2. a preparation step of preparing an engine block capable of accommodating engine components, and a motor unit having a motor and a motor housing accommodating the motor; a supporting step of supporting the motor unit on the engine block; and the engine block has an opening capable of supporting a crankshaft, In the supporting step, an output shaft of the motor unit is supported in the opening of the engine block. Vehicle manufacturing method.

3. a preparation step of preparing an engine block capable of accommodating engine components, and a motor unit having a motor and a motor housing accommodating the motor; a supporting step of supporting the motor unit on the engine block; and removing at least some of a plurality of crankshaft support walls provided inside the engine block, and then performing the supporting step; Vehicle manufacturing method.

4. a preparation step of preparing an engine block capable of accommodating engine components, and a motor unit having a motor and a motor housing accommodating the motor; a supporting step of supporting the motor unit on the engine block; A method for manufacturing a vehicle having the vehicle includes a heat exchanger; the engine block includes a coolant flow path through which coolant supplied to the heat exchanger flows, the motor unit includes an oil flow path through which oil flows; The method for manufacturing a vehicle includes a connecting step of connecting the oil flow path to the heat exchanger. Vehicle manufacturing method.

5. a preparation step of preparing an engine block capable of accommodating engine components, and a motor unit having a motor and a motor housing accommodating the motor; a supporting step of supporting the motor unit on the engine block; and the engine block includes a piston accommodating portion capable of accommodating an engine piston, a fixing member is accommodated in the piston accommodating portion, and the motor housing of the motor unit is fixed to the fixing member, thereby supporting the motor unit on the engine block; Vehicle manufacturing method.

6. 6. A method for manufacturing a vehicle according to claim 5, a damper structure for damping the fixing member in the piston accommodating portion; Vehicle manufacturing method.