Mechatronic Unit Layout for Lower EV Center of Gravity

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Solution Overview

Problem

The high center of gravity of the mechatronic unit in electric vehicles, due to the arrangement of power controllers above the transaxle, hinders efforts to lower the vehicle's center of gravity, and poses challenges in managing load distribution during frontal collisions.

Innovation Solution

The power controller is arranged at the outer side of the transaxle, with a recessed surface on the external side surface of the mechatronic unit, allowing the front side member to bend during a frontal collision, thus lowering the center of gravity and managing load distribution effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the power controller is arranged above the transaxle, then the mechatronic unit structure is simplified, but the center of gravity of the vehicle is raised

Engineering Contradiction:

Improvemechanatronic unit structureVSAvoidcenter of gravity position

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The patent transitions from a vertical stacking arrangement (power controller above transaxle) to a lateral arrangement (power controller beside transaxle). This dimensional change in spatial configuration allows the power controller to be positioned at the outer side of the transaxle in the lateral direction, thereby lowering the center of gravity while maintaining integration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If the power controller is arranged above the transaxle, then the mechatronic unit is compact, but the load distribution during frontal collision is unfavorable

Engineering Contradiction:

Improvemechanatronic unit sizeVSAvoidcollision load distribution

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent creates a localized recessed surface on the external side surface of the mechatronic unit at a specific height position. This local structural modification provides a dedicated contact point for the front side member during collision, enabling controlled load transfer while preserving the overall compact integration of the mechatronic unit.

Inventive Principle:

Principle #3Local quality

3Temperature

If the power controller is arranged at the outer side of the transaxle, then the center of gravity is lowered, but the external side surface requires additional structural features

Engineering Contradiction:

Improvecenter of gravity positionVSAvoidexternal side surface structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The recessed surface on the external side surface serves multiple functions: it acts as a structural feature enabling the lateral arrangement of the power controller for center of gravity reduction, and simultaneously functions as a collision interface for load management during frontal impact. This multi-functionality eliminates the need for separate collision protection structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250381850A1Mechatronic unit and electric vehicle

Publication Date: 2025.12.18 TOYOTA JIDOSHA KK

AI summary

A mechatronic unit is integrally formed from a transaxle and at least one power controller. The at least one power controller is arranged at an outer side of the transaxle in a lateral direction. The mechatronic unit includes a recessed surface located on an external side surface, above a horizontal line lying along an uppermost portion of a drive shaft in a vertical direction, and laterally inward from the lower area located below the horizontal line.