Dual-Motor Unit Layout With Integrated PCU and Drive Shaft
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Solution Overview
Problem
Conventional vehicle-mounted rotating electric machine units face inefficiencies due to offset placement of drive shafts and DC power connectors, leading to surplus space, increased wiring lengths, and reduced layout efficiency, as well as larger device configurations and longer assembly times.
Innovation Solution
A rotating electric machine unit design featuring multiple electric machines with parallel rotary shafts, a power control unit positioned orthogonally to the electric machines, a drive shaft parallel to the axial direction, and a power transmission part disposed alongside the electric machines and power control unit, optimizing the arrangement to reduce size and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the drive shaft is disposed offset from the rotating electric machine unit, then the rotating electric machine can be mounted in a vehicle, but surplus space is formed around the drive shaft and layout efficiency is reduced
Solution Approach 1:
The patent repositions the drive shaft from an offset arrangement to a coaxial arrangement with the rotary shaft, utilizing the axial dimension more efficiently. This dimensional optimization eliminates surplus space around the drive shaft while maintaining vehicle mounting capability, thereby improving layout efficiency without sacrificing adaptability.
2Ease of manufacture
If the DC power connector is disposed in the upper part with respect to the element module in the lower part, then power connection is achieved, but the wiring length increases
Solution Approach 1:
The patent integrates the DC power connector into the housing that also contains the element module, merging two previously separated components into a single integrated unit. This consolidation positions the power connector adjacent to the element module, dramatically reducing wiring length while maintaining power connection capability and simplifying the overall structure.
3Ease of operation
If two inverters are disposed in a split manner, then power control is achieved, but the device configuration increases in size
Solution Approach 1:
The patent integrates both inverters into a single inverter housing, merging two separate inverter units into one consolidated component. This integration maintains the power control capability for multiple rotating electric machines while significantly reducing the overall device configuration size and improving space utilization.
4Ease of operation
If the two rotating electric machines are connected to the two inverters on one side, then power control is achieved, but the wiring length increases and assembly man-hours increase
Solution Approach 1:
The patent positions both inverters on the same side as both rotating electric machines within a integrated housing structure, creating a compact arrangement where connections are minimized. This configuration reduces wiring length and simplifies assembly procedures, thereby decreasing assembly time while maintaining full power control capability.
5Ease of operation
If the inverters are positioned to face the motors in the vehicle up-down direction, then power control is achieved, but the overlap area with gears and drive shaft is small and layout efficiency is reduced
Solution Approach 1:
The patent repositions the inverters and rotating electric machines to arrange them alongside each other in the axial direction rather than facing each other in the up-down direction. This dimensional reconfiguration increases the overlap area with the gears and drive shaft, improving layout efficiency while maintaining power control capability.
Data Source
AI summary
A rotating electric machine unit includes a first and second rotating electric machine, a power control unit (PCU), a drive shaft, and a power transmission part. The first and second rotating electric machines have rotary shafts parallel to each other, and are disposed along a vehicle front-rear direction orthogonal to an axial direction of each rotary shaft. The PCU is disposed below the first and the second rotating electric machines in a vehicle up-down direction orthogonal to the axial direction of each rotary shaft. The drive shaft is disposed below the first rotating electric machine and behind the PCU. The power transmission part transmitting power between each rotary shaft and the drive shaft is disposed on the right side of each rotating electric machine and the PCU. A direction in which an outer shape of the PCU is longest is parallel to the vehicle front-rear direction.