EV Front-End Layout for Mechatronic Unit Collision Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrified vehicles face challenges in protecting the motor, inverter, and auxiliaries such as the electric compressor from impacts during frontal collisions, as they are not adequately shielded from the electric compressor and load-bearing parts.

Innovation Solution

The mechatronic unit and auxiliaries are positioned between the front wheels, within the wheel diameter, to absorb impact forces, and the integrated thermal unit is installed above the mechatronic unit, reducing exposure to frontal collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the motor, inverter, and auxiliaries are installed in the front of the vehicle cabin, then the space utilization is improved, but the components are exposed to impact forces from frontal collisions

Engineering Contradiction:

Improvespace utilizationVSAvoidimpact force from frontal collision

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent positions the mechatronic unit and auxiliaries within the wheel diameter area, utilizing the lateral space between the front wheels rather than only the longitudinal space in front of the cabin. This dimensional repositioning allows the components to be protected by the wheel structure during frontal collisions while maintaining efficient space utilization in the vehicle's front section.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The front wheels serve as an intermediary protective structure between the impact force from frontal collisions and the mechatronic unit with auxiliaries. By positioning the components within the wheel diameter area, the wheel structure acts as a first line of defense, absorbing and distributing impact forces before they reach the sensitive electronic components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the electric compressor is installed behind the motor, then the layout flexibility is improved, but the conductor connection part remains vulnerable to impact

Engineering Contradiction:

Improvelayout flexibilityVSAvoidimpact force on conductor connection part

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent integrates the motor, inverter, and electric compressor into a unified mechatronic unit that is positioned within the wheel diameter area. This merging of previously separate components into a single protected assembly ensures that all critical electrical components benefit from the same impact protection provided by the wheel structure, while maintaining layout flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20260014880A1Electrified vehicle

Publication Date: 2026.01.15 TOYOTA JIDOSHA KK

AI summary

An electrified vehicle includes a mechatronic unit incorporating a motor that is a motive power source for driving front wheels and an electric power control device that supplies electricity of a battery to the motor. The electrified vehicle includes an integrated thermal unit that is an auxiliary. The mechatronic unit and the integrated thermal unit are installed between the front wheel on a vehicle right side and the front wheel on a vehicle left side, inside a wheel diameter of the front wheel as seen in a vehicle side view.