Hybrid EV Power Unit Layout for Compact Motor-Generator-Engine Packaging
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Solution Overview
Problem
Existing electric vehicle configurations face challenges in compactly arranging engine-related components such as intake systems, combustion systems, cooling systems, and batteries above the engine body due to the integration of drive motors, reduction drives, and generators in a vehicle width direction.
Innovation Solution
The configuration integrates a drive motor, reduction drive, and generator in a power unit compartment with equalized heights, placing the electric power conversion unit above these components and arranging engine-related components in a manner that allows for compact positioning, including a rotary engine with shafts aligned for space efficiency and separate placement of exhaust components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the drive motor, reduction drive, generator, and engine body are arranged in the vehicle width direction with equal heights, then the space utilization is improved, but the arrangement complexity of engine-related components above the engine body deteriorates
Solution Approach 1:
The patent transitions from traditional vertical stacking of components to a horizontal arrangement in the vehicle width direction, utilizing the lateral space more effectively. By arranging the drive motor, reduction drive, generator, and engine body side-by-side with equal heights, the design maximizes the use of available width while maintaining compact vertical profile, thus improving overall space utilization without excessive complexity
Solution Approach 2:
The power unit components are segmented into distinct modular units (drive motor, reduction drive, generator, engine body) that can be independently positioned and optimized. This segmentation allows each component to be arranged at its optimal location in the vehicle width direction while maintaining equal heights, facilitating better space utilization and simplified installation与维护
2Volume of moving object
If the electric power conversion unit is arranged above the drive motor, reduction drive, and generator, then the compactness of the power unit is improved, but the arrangement flexibility of engine-related components deteriorates
Solution Approach 1:
The electric power conversion unit is positioned in the vertical dimension above the horizontally arranged power components, creating a two-level spatial organization. This vertical placement achieves compactness by utilizing unused vertical space while leaving the horizontal arrangement flexible for engine-related components, thus resolving the contradiction between compactness and flexibility
Solution Approach 2:
Different regions of the vehicle are assigned different functional qualities: the horizontal lower level accommodates power transmission components requiring lateral access, while the vertical upper level houses the electric power conversion unit requiring minimal lateral interference. This localized functional differentiation enables both compactness and arrangement flexibility
3Productivity
If engine-related components are arranged above the engine body in a forward-intake type configuration, then the functional efficiency is improved, but the space for exhaust components deteriorates
Solution Approach 1:
Engine-related components are segmented and distributed in the vehicle width direction rather than concentrated above the engine body. Intake components are positioned forward, fuel and oil components are placed centrally above the engine, and exhaust components are routed laterally below other components. This segmentation allows each subsystem to occupy its optimal space, improving functional efficiency while preserving exhaust space
Solution Approach 2:
The exhaust system transitions from a vertical arrangement to a lateral arrangement below other components, utilizing the vertical space occupied by projected engine-related components. This three-dimensional routing of exhaust pipes through the lateral side and below other components resolves the space conflict while maintaining forward-intake functional efficiency
Data Source
AI summary
To arrange a power unit, an electric power conversion unit, and engine-related components compactly, a drive motor, a reduction drive, a generator, and an engine body are integrally arranged in this order in a vehicle width direction of a power unit compartment such that respective heights thereof are substantially the same. An electric power conversion unit, in which a motor inverter, an electric power generation inverter, and a DC/DC converter are integrated, is arranged above the drive motor, the reduction drive, and the generator. Engine-related components such as a low-voltage battery, an air cleaner, and an oil filter are arranged above the engine body.