Hybrid Combustion Engine Layout for Modular Electric Motor Integration

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Solution Overview

Problem

Existing combustion engines with hybrid systems face challenges in managing the integration of electrical components, which limits their ability to accommodate various customer applications and future hybridization technologies.

Innovation Solution

The solution involves a redesigned combustion engine architecture that integrates electric motors, generators, and other components in a way that optimizes space, assembly, and functionality, including the use of a common rail in the cylinder head lid, a wiring harness, and a control unit strategically placed for easier installation and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electric motors are integrated into the combustion engine, then the engine can accommodate diverse customer applications and future hybridization technologies, but the device complexity and integration challenges increase

Engineering Contradiction:

Improveability to accommodate diverse customer applicationsVSAvoidintegration complexity of electrical components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal engine architecture that can accommodate multiple hybrid system configurations (mild hybrid, full hybrid, plug-in hybrid) through standardized mounting locations and interfaces. The engine block is designed with predefined positions for electric motors, generators, and battery systems that can be configured differently based on customer requirements, allowing one base design to serve multiple applications without requiring complete redesigns.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the engine system into modular components with standardized interfaces. Electrical components such as electric motors, generators, and control units are designed as separate modules that can be independently installed, removed, or replaced. This modular approach reduces integration complexity by allowing each component to be optimized independently while maintaining compatibility through standardized mounting and connection points.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If components are arranged in traditional transmission-side installation positions, then the engine architecture remains simple and familiar, but the ability to accommodate future hybrid technologies is limited

Engineering Contradiction:

Improvesimplicity of engine architectureVSAvoidreadiness for future hybridization technologies

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent incorporates predefined mounting locations, reinforcement structures, and interface preparations during the base engine design phase, before hybrid components are actually installed. This preliminary action includes designing strengthened engine blocks with pre-positioned mounting points for electric motors and generators, and preparing communication interfaces and power distribution systems in advance, so that future hybridization can be achieved by simply adding components rather than redesigning the entire architecture.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple electrical components are integrated into the engine, then customer application diversity increases, but the installation space and assembly difficulty increase

Engineering Contradiction:

Improverange of customer applicationsVSAvoidassembly ease of electrical components

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple electrical components and their supporting infrastructure into integrated assemblies. For example, electric motors and generators are positioned to share common mounting structures and cooling systems. The control units are strategically located near the components they control, reducing wiring length and complexity. This merging approach reduces the number of separate assembly operations required while maintaining the ability to support diverse hybrid configurations.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach allows for a more versatile and efficient integration of hybrid systems, enhancing the engine's ability to meet diverse customer requirements while reducing complexity and improving assembly and service efficiency.

Implementation Method 1

internal combustion engine with at least one electric motor (8, 12, 20) arranged at one end of the internal combustion engine

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentEP3298267B1Combustion engine with a electric motor

Publication Date: 2025.04.23 DEUTZ AG

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AI summary

An internal combustion engine comprising at least one electric motor (8, 13, 16, 20) arranged on the crankcase of the internal combustion engine, at least one controller (1) for controlling the internal combustion engine and/or the electric motor, and at least one high-voltage inverter (15).