Vehicle Drive System Power Control Device Mounting
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Solution Overview
Problem
The existing vehicle drive system has a recessed space between the first and second rotary electric machines that is not effectively utilized, leading to a higher mounting height of the power control unit (PCU), which limits the arrangement efficiency.
Innovation Solution
The power control device is mounted on the outer peripheral surface of the case, with its lower part positioned between the outer peripheral surfaces of the first and second rotary electric machines, which are inclined relative to each other, allowing the power control device to be placed in the recessed space, thereby reducing its height. This configuration includes a terminal block, a direct current-direct current converter, and other components arranged to fit within this space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the power control device is mounted on the case in the related art configuration, then the PCU can be directly mounted to the case, but the height of the PCU becomes higher and the recessed space is not effectively utilized
Solution Approach 1:
The power control device is repositioned from a conventional horizontal mounting arrangement to a vertical arrangement that utilizes the recessed space between the rotary electric machines. The PCU is mounted on the outer peripheral surface of the case with its lower part extending into the recessed space, effectively using the third dimension (vertical depth) to reduce the horizontal footprint and overall height.
Solution Approach 2:
The power control device is nested into the recessed space formed between the first and second rotary electric machines. The lower part of the PCU is positioned within the space surrounded by the line connecting the cross points, allowing the PCU to occupy otherwise unused volume within the existing structure, similar to nesting one object within another.
2Device complexity
If the PCU is mounted in the conventional position, then the mounting structure is simple, but the arrangement efficiency is reduced due to unused recessed space
Solution Approach 1:
The mounting structure utilizes the vertical dimension by positioning the PCU on the outer peripheral surface of the case rather than on the top surface. This dimensional shift allows the PCU to extend downward into the recessed space, improving arrangement efficiency without significantly increasing structural complexity.
Solution Approach 2:
The mounting structure is optimized for the specific local condition of the recessed space. The PCU is positioned to fit within the space surrounded by the line connecting the cross points, utilizing the unique geometric characteristics of the recessed area between the rotary electric machines to achieve better arrangement efficiency.
Data Source
AI summary
A vehicle drive system includes: a case accommodating a first rotary electric machine and a second rotary electric machine that are arranged to have respective rotational axes parallel to each other and to be radially adjacent to each other; and a power control device configured to control the first rotary electric machine and the second rotary electric machine. The case includes a peripheral wall portion surrounding the first rotary electric machine and the second rotary electric machine, and the power control device is mounted in a mounting section provided on an outer peripheral surface of the peripheral wall portion. A lower part of the power control device is located in a space surrounded by a line connecting a first cross point, and a second cross point, the first rotary electric machine and the second rotary electric machine.