Hybrid Vehicle Electric Machine Integration and Cooling
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Solution Overview
Problem
Converting existing vehicles with thermal drive into hybrid vehicles is challenging due to space constraints and complex cooling system installation, and activating auxiliary devices during electric-only modes is difficult, leading to high design and development costs.
Innovation Solution
A hybrid vehicle design featuring a main reversible electric machine and a secondary electric machine connected via an auxiliary shaft with a mechanical belt transmission, including a freewheel to enable auxiliary device activation and efficient cooling system integration, allowing for easier installation and cost-effective conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electric machine is added to an existing thermal vehicle to create a hybrid vehicle, then hybrid propulsion capability is achieved, but the vehicle complexity and installation difficulty increase significantly
Solution Approach 1:
The patent combines the electric machine, cooling system, and auxiliary device drive system into an integrated assembly that mounts to the existing thermal engine. The electric machine shares the engine bay space and uses the engine's cooling system infrastructure, merging multiple functions into a unified hybrid propulsion package that reduces overall system complexity.
Solution Approach 2:
The electric machine is designed to serve multiple functions: providing electric propulsion, driving auxiliary devices via belt transmission, and integrating with the existing cooling system. This multi-functionality reduces the need for separate dedicated systems, thereby reducing overall vehicle complexity while maintaining hybrid capability.
2Adaptability or versatility
If space is allocated for the electric machine in an existing vehicle, then hybrid drive functionality is enabled, but the available space for other components is reduced
Solution Approach 1:
The electric machine is positioned within the existing engine bay, nesting it among other engine components. The cooling system for the electric machine is integrated with the thermal engine's cooling system, with the electric machine's cooling channels positioned to utilize the same coolant flow paths, effectively nesting the cooling systems together to minimize space requirements.
Solution Approach 2:
The patent utilizes vertical space and three-dimensional arrangement within the engine bay rather than only horizontal expansion. The electric machine is mounted in a configuration that exploits available volume in the engine compartment, using the height and depth dimensions to accommodate the electric machine without significantly increasing the vehicle's overall footprint or encroaching on passenger cabin space.
3Temperature
If a cooling system is designed to cool both the thermal engine and electric machine, then thermal management is achieved, but the cooling system becomes more complex and cumbersome
Solution Approach 1:
The cooling system for the electric machine is merged with the thermal engine's cooling system. The electric machine's cooling channels are positioned to receive coolant from the engine's cooling circuit, and both systems share common coolant reservoirs, pumps, and radiators. This integration reduces the number of separate cooling systems from two to one, significantly reducing complexity while maintaining effective thermal management for both components.
4Ease of operation
If auxiliary devices are driven from the thermal engine's drive shaft, then auxiliary functions are provided, but auxiliary devices cannot operate during electric-only or Start&Stop modes
Solution Approach 1:
The electric machine is designed with a dual function: it provides electric propulsion and simultaneously serves as a drive source for auxiliary devices through a belt transmission system. This allows auxiliary devices to operate during electric-only modes and Start&Stop modes when the thermal engine is off, while still being able to receive power from the engine during thermal operation. The electric machine thus becomes a universal drive source that replaces the engine's direct drive function for auxiliaries, providing operational flexibility across all driving modes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and cost-effective implementation of hybrid technology in existing vehicles by simplifying the integration of electric machines and cooling systems, and ensures auxiliary device activation in electric-only modes, reducing overall design and development costs.
Implementation Method 1
a mechanical belt transmission which connects the electric machine, the auxiliary device and the drive shaft of the thermal engine to one another
Implementation Method 2
A hybrid vehicle comprises a cooling system, which the present inventors have recognized should be capable of cooling both the thermal engine, and the electric machine
Data Source
AI summary
A vehicle with hybrid drive having: a thermal engine provided with a drive shaft and having a block which houses the drive shaft and two heads which house the cylinders and are arranged in a “V” configuration; a cooling system provided with a hydraulic circuit in which a cooling fluid flows; a reversible electric machine placed above the block of the thermal engine and between the two heads; an auxiliary device; a mechanical transmission which connects the first electric machine, the auxiliary device and the drive shaft of the thermal engine to one another; and a freewheel interposed between the first mechanical transmission and the drive shaft of the thermal engine; the hydraulic circuit of the cooling system has a main branch which cools the thermal engine, and a secondary branch which is connected as an offtake to the main branch and cools the first electric machine; the secondary branch is connected as an offtake to the main branch by an inlet pipe and by an outlet pipe, which extend downwards from a lower wall of the electric machine to corresponding openings obtained through the block of the thermal engine.