Hybrid Powertrain Converter Layout for Compact Motor Packaging
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Solution Overview
Problem
The existing powertrain structure of hybrid vehicles, which includes an engine, motor, and power converter, faces challenges in layout flexibility due to the power converter occupying significant space above the motor and case, making it difficult to install other devices and increasing the risk of collision damage.
Innovation Solution
A powertrain structure that includes a housing for the motor, a power converter with a smoothing capacitor and power module aligned in a horizontal direction, and a protrusion from the engine body, allowing the power converter to be partially located between the housing and protrusion, reducing vertical dimensions and improving layout freedom, while also positioning the connector for communication above the power converter to prevent collision damage and facilitate easier access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power converter is mounted above the motor case occupying the entire space, then the power converter can be stably installed, but the degree of freedom in layout is reduced
Solution Approach 1:
The patent transitions from a conventional vertical stacking arrangement (power converter directly above motor case) to a three-dimensional spatial configuration where the power converter is positioned between the motor case and the engine body, utilizing unused vertical space. This dimensional reorganization allows the power converter to be stably installed while freeing up horizontal space for other components, thereby resolving the contradiction between installation stability and layout freedom.
2Ease of manufacture
If the power converter occupies the entire space above the motor and case, then the power converter can be properly installed, but installing other devices becomes difficult
Solution Approach 1:
The patent segments the vertical space above the motor case into two distinct zones: the lower portion for the power converter and the upper portion for other devices (such as the EGR cooler). This spatial segmentation allows both the power converter to be properly installed with adequate workspace and other devices to be installed simultaneously, resolving the contradiction between installation ease and device installation flexibility.
3Ease of operation
If the connector for communication is positioned on the upper surface of the power converter, then access is facilitated, but collision damage risk increases
Solution Approach 1:
The patent applies local quality by positioning the connector for communication on the upper surface of the power converter specifically in a region that does not overlap with the protrusion in plan view. This localized placement ensures that the connector remains easily accessible for coupling operations while avoiding high-risk collision zones, thereby resolving the contradiction between ease of operation and collision damage risk.
Data Source
AI summary
A powertrain structure of a vehicle includes an engine, a motor, a battery, a power converter, a housing disposed on one side of an engine body in a horizontal first direction and configured to accommodate the motor therein, and a communication device. The power converter includes a smoothing capacitor and a power module which are lined up in a second direction, and a connector for communication provided to an upper surface of the power converter. A protrusion is disposed above the housing, which protrudes from a side surface of the engine body on the one side in the first direction to the one side. The power converter is partially located between the housing and the protrusion, and is disposed above the housing in a state where the connector for communication does not overlap with the protrusion in a plan view.