Hybrid Vehicle Power Converter Layout for Compact Motor Packaging
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Solution Overview
Problem
The existing powertrain structures of hybrid vehicles face challenges in layout flexibility due to the space occupation by the power converter, which limits the installation of other devices above the motor and reduces the degree of freedom in layout.
Innovation Solution
A powertrain structure that includes a power converter with a DC busbar, smoothing capacitor, and power module aligned in a horizontal direction, with an AC busbar extending downwardly, and a case design with offset accommodating parts to reduce vertical and horizontal dimensions, allowing for compact placement and increased layout flexibility, while also positioning the power converter to absorb collision loads by being located rearward of the engine or housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power converter is disposed above the motor housing, then the power converter can be installed in the available space, but the rate of power converter occupying the space above the motor increases, making it difficult to install other devices above the motor
Solution Approach 1:
The patent changes the arrangement dimension of power converter components from vertical stacking to horizontal linear arrangement. The DC busbar, smoothing capacitor, and power module are arranged in a line along the vehicle width direction (second direction), transforming the spatial occupation from three-dimensional vertical stacking to two-dimensional horizontal extension, thereby reducing vertical space occupation while maintaining component functionality.
Solution Approach 2:
The case is divided into two distinct accommodating parts: a first accommodating part for the power module, smoothing capacitor, and DC busbar, and a second accommodating part protruding downward for the AC busbar. This segmentation allows independent optimization of each component's spatial requirements and enables the AC busbar to extend downward separately, reducing interference with other components.
2Ease of manufacture
If the AC busbar is disposed to extend toward one side of the power module in the second direction, then connection to motor is achieved, but dimensions of spaces occupied by components in the second direction increase
Solution Approach 1:
The AC busbar is configured to extend downwardly from the power module in the vehicle up-down direction rather than horizontally along the vehicle width direction. This dimensional change allows the AC busbar to connect to the motor while minimizing horizontal space occupation, as the downward extension utilizes the vertical space already allocated for the second accommodating part.
3Volume of moving object
If the first accommodating part has large vertical dimension to accommodate all components, then all components can be housed, but the height of the power converter increases
Solution Approach 1:
The case is segmented into two accommodating parts with different vertical extents. The first accommodating part houses the power module, smoothing capacitor, and DC busbar at a certain height, while the second accommodating part protrudes downward to house the AC busbar. This segmentation allows the main body (first accommodating part) to maintain a compact height while the secondary part (second accommodating part) extends downward to accommodate the AC busbar, thus reducing the overall vertical height of the power converter.
Solution Approach 2:
The second accommodating part is nested within or attached to the first accommodating part, with the AC busbar housed in the downward-protruding second part. This nested structure allows the AC busbar to be accommodated without increasing the main body height, as the second part utilizes the vertical space below the first part's bottom surface.
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 configuration reduces the vertical and horizontal space occupied by power converter components, enhances layout flexibility, and positions the power converter to minimize collision loads, enabling more compact and efficient installation of the powertrain components.
Implementation Method 1
a smoothing capacitor configured to smooth the direct current inputted from the battery via the DC busbar
Implementation Method 2
a power module configured to convert the direct current smoothed by the smoothing capacitor into alternating current
Data Source
Figure 1
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AI summary
A powertrain structure of a vehicle including an engine, a motor, a battery, a power converter, and a housing. The power converter including a direct current (DC) busbar, a smoothing capacitor, a power module, and an alternating current (AC) busbar lined up in this order in a horizontal first direction, and a case accommodating these components. The case has a first accommodating part extending in a horizontal second direction perpendicular to the first direction and accommodating the power module, the smoothing capacitor, and the DC busbar, and a second accommodating part protruding downwardly from an end of the first accommodating part on one side in the second direction, and accommodating a lower part of the AC busbar. The case is disposed above an upwardly-bulging curved part of the housing so that the second accommodating part is offset from a top part of the curved part to the one side in the second direction.