Vehicle Driving Device Multilayer Power Control Unit Height Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing vehicle driving device has a suboptimal arrangement of the power control unit (PCU), leading to a large mounting height due to inefficient use of the recessed space between the first and second rotary electric machines.
Innovation Solution
The PCU is designed with a multilayer structure where the control board, power stack, reactor, capacitor, and water jacket are stacked in order from top to bottom, with the DC-DC converter positioned below, allowing the PCU assembly to be mounted in the recessed space between the rotary electric machines, thereby reducing the overall height and improving the arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power control unit is directly mounted on the case covering the opening, then the PCU is easily accessible and installable, but the mounting height becomes large due to inefficient use of recessed space
Solution Approach 1:
The patent transitions from a horizontal arrangement to a vertical stacked arrangement of PCU components. The control board, power card, reactor, capacitor, and water jacket are arranged in layers along the vertical height direction,充分利用 the recessed space between rotary electric machines and reducing the horizontal footprint while maintaining accessibility.
Solution Approach 2:
The power control unit components are nested within the recessed space formed between the first and second rotary electric machines. The stacked configuration allows components to be positioned within the available vertical clearance, effectively utilizing the three-dimensional space rather than occupying horizontal area.
2Volume of stationary object
If components are arranged in a stacked multilayer configuration, then the mounting height is reduced and space is utilized efficiently, but the arrangement complexity increases
Solution Approach 1:
The power control unit is segmented into distinct functional modules stacked in layers: control board layer, power card layer, reactor layer, capacitor layer, and water jacket layer. Each layer houses specific components with related functions, making the complex system manageable through modular segmentation.
Solution Approach 2:
Different regions of the PCU assembly are assigned different functions based on their spatial position. The control board is positioned at the top for control functions, power cards in the middle for power conversion, reactive components (reactor and capacitor) for power factor correction, and water jacket at the bottom for cooling. This local specialization optimizes both space utilization and functional efficiency.
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 effectively utilizes the recessed space, reducing the mounting height of the PCU, enhancing its arrangement, and improving workability, maintainability, and heat management by cooling the DC-DC converter and shielding against heat impacts.
Implementation Method 1
a water jacket that cools the DC-DC converter
Data Source
AI summary
A vehicle driving device includes a case that accommodates therein a first rotary electric machine and a second rotary electric machine arranged with rotation axes thereof parallel to each other and radially adjacent to each other, and a power control device that controls electric power supplied to the first rotary electric machine and the second rotary electric machine. In the power control device, a control board, a power card and a cooler, a reactor and a capacitor, and a water jacket are disposed in order from top in a height direction.