Hybrid EV Power Unit Layout for In-Compartment Charger Packaging
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Solution Overview
Problem
Existing electric vehicles face challenges in accommodating a charger within the engine compartment due to the space occupied by the engine, driving apparatus, and electric-power control device, leading to potential space constraints.
Innovation Solution
The integration of a mechanical-electrical unit comprising the electric motor and power transmission device within a single casing adjacent to the engine, with the charger and intake pipe positioned above this unit in the vertical direction, creating space for their accommodation within the engine compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the engine, driving apparatus and electric-power control device are disposed within the engine compartment, then the power transmission function is achieved, but the space for accommodating the charger becomes insufficient
Solution Approach 1:
The patent utilizes the vertical dimension within the engine compartment to accommodate the charger. By positioning the charger above the mechanical-electrical integrated unit in the vertical direction, the design transforms a two-dimensional space constraint into a three-dimensional solution, allowing the charger to coexist with other components without horizontal space conflict.
Solution Approach 2:
The patent merges the driving apparatus and electric-power control device into a single mechanical-electrical integrated unit housed in one casing. This consolidation reduces the overall space occupation and creates a compact configuration that enables the charger to be positioned above the integrated unit within the same engine compartment.
2Area of stationary object
If the charger is disposed outside the engine compartment, then sufficient space is provided for the charger, but the charger becomes vulnerable to external damage and loses protection
Solution Approach 1:
The patent combines the charger with other engine components within the same engine compartment, specifically positioning it above the mechanical-electrical integrated unit. This integration provides the charger with the same protective enclosure and structural support as other engine components, shielding it from external collisions and environmental damage.
3Area of stationary object
If the mechanical-electrical integrated unit is positioned to accommodate the charger above it, then space utilization is optimized, but the vertical dimension of the unit increases
Solution Approach 1:
The patent accepts an increase in vertical dimension as a necessary trade-off to utilize the three-dimensional space within the engine compartment effectively. By arranging components in the vertical direction rather than horizontally, the design optimizes overall space utilization while maintaining a compact footprint.
Data Source
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AI summary
An electric vehicle (10;200) includes: an intake device (32) provided upstream of an intake pipe (20) of an engine (12); a power transmission device (16;206) configured to transmit a power of an electric motor (MG2;MGd) to drive wheel; an electric-power control device (74) configured to control an electric power transferred between a driving battery (64) and the electric motor (MG2;MGd); and a charger (66) configured to charge the driving battery (64) with the electric power supplied from an external power supply (100). The electric motor (MG2;MGd) and the power transmission device (16;206) constitute at least a part of a driving apparatus (92;208). The driving apparatus (92;208) and the electric-power control device (74) constitute a mechanical-electrical integrated unit (90) which is housed in a single casing (40;210) and which is located in a position adjacent to the engine (12). The charger (66) and the intake device (32) are located on an upper side of the mechanical-electrical integrated unit (90) in a vertical direction of the electric vehicle (10;200).