CN114786979A

CN114786979A - Electric drive unit

Info

Publication number: CN114786979A
Application number: CN202080085978.6A
Authority: CN
Inventors: M.凯利; S.伊什卡瓦; G.郑
Original assignee: Dyson Technology Ltd
Current assignee: Dyson Technology Ltd
Priority date: 2019-12-13
Filing date: 2020-10-14
Publication date: 2022-07-22
Also published as: GB2590382B; WO2021116648A1; GB201918371D0; GB2590382A

Abstract

A vehicle (100) has an electric drive unit (102), the electric drive unit (102) having an elongate axis (110), a gearbox (104), an electric motor (106) mounted to the gearbox (104) and configured to provide drive to the gearbox (104), and an inverter (108) mounted to the gearbox (104) and configured to provide drive current to the electric motor (106). The elongate axis (110) is orthogonal to the input and output rotational axes of the gearbox (104). The electric drive unit (102) has a first mount (134), a second mount (135) and a third mount (140) which connect the electric drive unit (102) to the body of the vehicle (100) at their respective first, second and third mounting points such that the elongate axis (110) of the electric drive unit assumes a pitch angle of greater than 45 °.

Description

Electric drive unit

Technical Field

The invention relates to an electric vehicle having an Electric Drive Unit (EDU).

Background

Electric and hybrid electric vehicles are increasingly common. One such vehicle may include at least one Electric Drive Unit (EDU), each driving a corresponding pair of wheels. The EDU may include a gear box and an electric motor. The motor may be supplied with a drive current by an inverter.

It is desirable to provide an electric vehicle having an improved mounting arrangement for at least one electric drive unit, preferably having improved packaging and/or safety characteristics, and/or reduced manufacturing costs and/or complexity.

Disclosure of Invention

The invention provides a vehicle comprising an electric drive unit having an elongate axis and comprising:

a gear case;

a motor mounted to the gearbox and configured to provide drive to the gearbox;

an inverter mounted to the gearbox and configured to provide a drive current to the motor;

wherein the elongate axis is orthogonal to the input and output rotational axes of the gearbox, and the electric drive unit comprises first, second and third mounts connecting the electric drive unit to the body of the vehicle at their respective first, second and third mounting points such that the elongate axis of the electric drive unit assumes a pitch angle of greater than 45 °.

The pitch angle is measured relative to a lower surface of the vehicle body, which is substantially parallel to a surface on which the vehicle rests in use.

The use of three mounts and a pitch angle of more than 45 ° may result in an improved mounting arrangement of the at least one electric drive unit. Depending on the particular implementation, these features may provide improved packaging and/or security features, and/or reduced cost and/or complexity.

The first and second mounting points may carry most or substantially all of the weight of the electric drive unit through the respective first and second mounting, which may result in reduced manufacturing costs and/or complexity, and/or improved distribution of various forces acting on the electric drive unit in use.

The third mounting point may be a torque reaction point, which may result in reduced manufacturing cost and/or complexity. This may also provide an improved distribution of forces acting on the electric drive unit in use.

The electric drive unit may be mounted such that its elongate axis is substantially vertical. The additional longitudinal space provided by this arrangement may provide improved packaging characteristics, as well as the option of providing improved safety characteristics by increasing the fold area of the vehicle, for example, as compared to a horizontal electric drive unit arrangement. Vertical is to be understood here not to mean strictly vertical, but to cover a range of angles, for example between 70-110 degrees.

The first and second mounts may be positioned higher than the third mount. This may provide a stable mounting for the electric drive unit, reduce cost and/or complexity and/or improve the distribution of various forces acting on the electric drive unit in use.

The inverter may be mounted to a first lateral side of the gearbox and the motor may be mounted to a second lateral side of the gearbox opposite the first lateral side. This may provide a relatively compact and balanced arrangement.

The first mount may form part of the inverter or be attached to the inverter. This may provide a convenient and compact mounting arrangement on the inverter side of the electric drive unit.

The second mount may form part of the motor or be attached to the motor. This may provide a convenient and compact mounting arrangement on the motor side of the electric drive unit.

The electric drive unit is substantially T-shaped in a front view, wherein the first mount and the second mount are positioned at opposite ends of a lateral part of the T-shape and the gear box forms a vertical part of the T-shape. This may provide a convenient and compact mounting arrangement. The elongate axis extends longitudinally through the vertical portion of the T.

The third mount may be disposed forward of a lower portion of the vertical portion. This may provide a convenient and compact mounting arrangement, and/or an improved distribution of various forces acting on the electric drive unit in use.

The gearbox may comprise an output shaft for driving the wheels of the vehicle, wherein the centre of gravity of the first electric drive unit is above the output shaft. This may provide a convenient and compact mounting arrangement.

The electric drive unit may be configured to drive a pair of front wheels of the vehicle.

Each of the first, second and third mounting elements may comprise a respective resilient mounting element and/or a respective mounting bracket.

The vehicle may comprise a further electric drive unit having a further elongate axis, and the further electric drive unit comprises:

another gearbox;

another electric motor mounted to the other gearbox and configured to provide drive to the other gearbox; and

another inverter mounted to another gearbox and configured to provide a drive current to another motor;

wherein the further elongate axis is orthogonal to the input and output rotational axes of the further gearbox and the further electric drive unit is mounted with the further elongate axis at a further pitch angle, the further pitch angle being less than the pitch angle.

The other electric drive unit may be mounted such that its elongate axis is substantially horizontal. Horizontal mounting may allow for more space above the electric drive unit, which may be particularly useful, for example, when another electric drive unit is positioned below a load space of the vehicle. Horizontal herein is to be understood as not referring to strictly horizontal but covering a range of angles, for example between 0-30 degrees.

Another electric drive unit may be configured to drive a pair of rear wheels of the vehicle.

The further electric drive unit may comprise a plurality of combined load bearing and torque reaction mounts connecting the further electric drive unit to the body of the vehicle at their respective mounting points. This may provide a convenient and compact alternative mounting arrangement, which may be particularly useful, for example, when another electric drive unit is positioned below the load space of the vehicle.

The further electric drive unit may comprise fourth, fifth, sixth and seventh mountings which mount the further electric drive unit to the body of the vehicle at its respective fourth, fifth, sixth and seventh mounting points. This may provide a convenient and compact alternative mounting arrangement, which may be particularly useful, for example, when another electric drive unit is positioned below the load space of the vehicle.

All mounts of the further electric drive unit may carry a part of the weight of the further electric drive unit. This may provide a convenient and compact alternative mounting arrangement, which may be particularly useful, for example, when another electric drive unit is positioned below the load space of the vehicle.

Each of the fourth, fifth, sixth and seventh mounts may comprise a respective resilient mount and/or mounting bracket. At least two of the fourth, fifth, sixth and seventh mounting elements may comprise a common bracket.

The fourth, fifth, sixth and seventh mounts may be disposed in substantially the same plane.

The electric drive unit may be a front electric drive unit having a mount on each of the inverter, the motor and the gearbox. Alternatively or additionally, the further electric drive unit may be a rear electric drive unit having one mount on each of the motor and the inverter and two mounts on the gearbox. These may provide a convenient and compact mounting arrangement.

Any of the mounts may comprise or take the form of a bracket attached to the electric drive unit. Alternatively, either mounting may form part of the electric drive unit, for example forming part of a motor, inverter or gearbox.

Drawings

In order that the invention may be more readily understood, embodiments thereof will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a partial perspective side view of a vehicle including a front Electric Drive Unit (EDU) and another rear EDU;

FIG. 2 is a partial perspective front view of the vehicle of FIG. 1 showing the front EDU of FIG. 1;

FIG. 3 is a partial perspective rear view of the vehicle of FIG. 1 showing another EDU of FIG. 1;

FIG. 4 is a left side view of the front EDU;

FIG. 5 is a right side view of the front EDU;

FIG. 6 is a perspective view of the front EDU with the mounts omitted for clarity;

FIG. 7 is another perspective view of the front EDU;

FIG. 8 is a perspective view of the front EDU showing its attachment to the vehicle front sub-frame;

FIG. 9 is a left side view of another EDU;

FIG. 10 is a right side view of another EDU of FIG. 9;

FIG. 11 is a perspective view of another EDU with mounts omitted for clarity;

FIG. 12 is another perspective view of another EDU;

FIG. 13 is a plan view of another EDU;

FIG. 14 is a plan view of another EDU mounted to the rear subframe of the vehicle of FIG. 1.

Detailed Description

Referring to the drawings, a vehicle 100 includes an Electric Drive Unit (EDU) in the form of an EDU 102. The EDU102 includes a gearbox 104. The motor 106 is mounted to the gearbox 104 and is configured to provide drive to an input shaft (not shown) of the gearbox 104. An inverter in the form of an inverter 108 is mounted to the gearbox 104 and is configured to provide drive current to the motor 106.

In the illustrated embodiment, the motor 106 is mounted to a first lateral side of the gearbox 104, and the inverter 108 is mounted to a second lateral side of the gearbox 104 opposite the first lateral side.

The EDU102 has an elongate axis 110 that extends generally through the gear box 104. As best shown in fig. 2 and 4-7, the elongate axis 110 is defined in the present embodiment as an axis that is orthogonal to the input and output rotational axes of the gearbox 104. The elongate axis 110 extends generally through a centerline through the gearbox 104. As best shown in fig. 2, the EDU is substantially T-shaped in a front view, and the elongate axis 110 extends generally according to the vertical portion of the T-shape.

In the illustrated embodiment, the EDU102 includes a first mounting bracket 134, the first mounting bracket 134 being bolted directly to the first inverter 108 by bolts 142 threaded into corresponding threaded bosses 144 (see fig. 6) on the inverter 108. The EDU102 includes a second mounting bracket 135 that is bolted directly to the electric motor 106 by bolts 152 that are threaded into corresponding threaded bosses 153 (see fig. 7) on the electric motor 106. The first and second mounting

brackets

134, 135 are positioned at opposite ends of the transverse portion of the T-shape, and the gearbox 104 forms the vertical portion of the T-shape.

As best shown in fig. 4, 5 and 8, the third mounting bracket 140 is bolted to the lower end of the gear case 104 by means of bolts 145 threaded into corresponding threaded bosses 147. In the illustrated embodiment, the third mounting bracket 140 is disposed forward of the lower portion of the vertical portion of the T-shape.

In the illustrated embodiment, the first mounting bracket 134 is attached to the inverter 108. In other embodiments, the first mounting bracket 134 may comprise the inverter 108 itself, or may be attached to the gearbox 104 or form a part of the gearbox 104. The first mounting bracket 134 has a resilient mounting portion 131.

Similarly, in the illustrated embodiment, a second mounting bracket 135 is attached to the motor 106. In other embodiments, the second mounting bracket 135 may comprise the motor itself, or may be attached to the gearbox 104 or form a part of the gearbox 104. The second mounting bracket 135 has a resilient mounting portion 136.

In the illustrated embodiment, a third mounting bracket 140 is attached to the gearbox 104. In other embodiments, the third mounting bracket 140 may comprise the gearbox 104 itself, or may be attached to or form part of another portion of the EDU 102. The third mounting bracket 140 has a resilient mounting portion 146.

Vehicle 100 includes a cross member 141, cross member 141 extending between front shock towers 138 of vehicle 100. The first mounting bracket 134 is connected to the vehicle 100 by its resilient mounting portion 131 at mounting point 137 of the cross member 141, and the second mounting 135 is connected to the vehicle 100 by its resilient mounting portion 136 at mounting point 139 of the cross member 141. In the illustrated embodiment, mounting

points

137 and 139 bear substantially all of the weight of the EDU through first and second mounting

brackets

134 and 135.

The vehicle 100 includes a front subframe 133. The third mounting bracket 140 is connected to a third mounting point 143 on the sub-frame 133 by its elastic mounting portion 146 at a position lower than the first and second mounting members 134 and 135 (see fig. 8). In the illustrated embodiment, the third mounting point 143 is a torque reaction mounting point that does not substantially bear the weight of the EDU. As seen in fig. 8, the resilient mounting portion 146 of the third mounting bracket 140 is bolted to the subframe 133 at both ends of the resilient mounting portion 146.

The EDU102 is mounted with its axis 110 at a pitch angle greater than 45 °. In the illustrated embodiment, the pitch angle is substantially vertical. In this context, the term "vertical" is used in its ordinary sense and is not necessarily limited to strictly 90 °.

In the illustrated embodiment, the EDU102 drives a set of front wheels 130 of the vehicle 100 via respective output shafts 151 of the gearbox 104. The center of gravity of the EDU102 is above the output shaft.

In the illustrated embodiment, the vehicle 100 includes another EDU 112. The other EDU112 includes another gearbox 114. Another motor 116 is mounted to the other gearbox 114 and is configured to provide drive to an input shaft (not shown) of the other gearbox 114. Another inverter in the form of another inverter 118 is mounted to the other gearbox 114 and is configured to provide drive current to the other motor 116.

In the illustrated embodiment, another electric motor 116 is mounted to a first lateral side of another gearbox 114, and another inverter 118 is mounted to a second lateral side of the other gearbox 114 opposite the first lateral side. As best shown in fig. 13, the other EDU is substantially T-shaped in plan.

The other EDU112 has another elongate axis 120 that extends generally through the other gearbox 114. As best shown in fig. 9 and 10, the elongate axis 120 is defined as an axis that is orthogonal to the input and output rotational axes of the other gearbox 114. The elongate axis 110 extends generally through a centerline through the gearbox 114.

Another EDU112 is mounted with its other elongate axis 120 at another pitch angle, which may be less than 45 °. In the embodiment shown, the further pitch angle is approximately horizontal. In this context, the word "horizontal" is used in its ordinary sense and is not necessarily limited to strictly 0 °.

In the illustrated embodiment, the other EDU includes a fourth mounting bracket 156, a fifth mounting bracket 158, and a sixth mounting bracket 160.

The fourth mounting bracket 156 is bolted directly to the other inverter 118 by means of bolts 164 (see fig. 9, 13 and 14) that are screwed into corresponding threaded bosses 166 (see fig. 11) on the other inverter 118. The fourth mounting bracket 156 is attached by its resilient mounting portion 173 to a fourth mounting point 157 that is located on the rear sub-frame 150 (see fig. 14) of the vehicle 100.

The fifth mounting bracket 158 is bolted directly to the other motor 116 by means of bolts 168 (see fig. 10) which are threaded into corresponding threaded bosses 170 (see fig. 12) on the other motor 116. Fifth mounting bracket 158 is attached by its resilient mounting portion 174 to a fifth mounting point 159 that is located on rear sub-frame 150 of vehicle 100.

A fourth mounting bracket 156 and a fifth mounting bracket 158 are positioned at opposite ends of a transverse portion of a T-shape (see fig. 13) formed by the other EDU112 in a plane. The gear case 114 forms a vertical portion of a T-shape.

The sixth mounting bracket 160 is a common bracket for both resilient mounting

portions

175, 176. The sixth mounting bracket 160 is bolted directly to the further gearbox 114 by means of threaded bolts 165 (see fig. 9, 10, 13 and 14) being screwed into corresponding threaded bosses 161 (see fig. 11 and 12). Sixth mounting bracket 160 is attached by its resilient mounting

portions

175, 176 to sixth mounting point 171 and seventh mounting point 172 located on rear sub-frame 150 of vehicle 100.

Each of the fourth 156, fifth 158, and sixth 160 mounting brackets is a combined load bearing and torque reaction mount that connects the other EDU112 to the vehicle 100 at its corresponding mounting point.

In the illustrated embodiment, another EDU112 is configured to drive a pair of rear wheels 132 of the vehicle.

The mounts for the front EDU102 may consist of only the first, second and third resilient mounts in the particular geometric relationship shown. The concrete advantages are that: providing a first load bearing mount on a first upper lateral side of the EDU; providing a second load bearing mount on a second upper lateral side of the EDU opposite the first upper lateral side of the EDU; and providing a third torque reaction mount at a lower end of the EDU. These advantages include efficient mounting of the EDU to the vehicle, particularly the front end of the vehicle, in a compact manner, thereby improving production and installation efficiencies.

Similarly, the mounts for the rear EDU112 may consist of only the first, second, third and fourth mounts in the particular geometric relationship shown (corresponding to the fourth, fifth, sixth and seventh resilient mounts in the illustrated embodiment). The concrete advantages are that: providing a first load bearing and torque reaction mount on a first lateral side of the EDU; providing a second load bearing and torque reaction mount on a second lateral side of the EDU opposite the first lateral side; and providing third and fourth load bearing and torque reaction mounts at an end of the EDU opposite the location of the first mount and the second mount. These advantages include efficient mounting of the EDU to the vehicle, particularly the rear end of the vehicle, in a compact manner, thereby improving production and installation efficiencies.

One skilled in the art will appreciate that each mount may be attached to its respective mounting point by its respective resilient portion using a plurality of bolts. In the illustrated embodiment, the EDU102 is attached to the vehicle at three attachment points by its three resilient mounting portions, and the EDU112 is attached to the vehicle at four attachment points by its four resilient mounting portions.

In other embodiments, mounting

points

137 and 139 carry a majority of the weight of the EDU, with third mounting point 143 carrying the remainder of the weight while still acting as a torque reaction point. It will be appreciated that other combinations of load bearing and/or torque reaction mounts and mounting points may be employed, for example, depending on packaging and engineering requirements.

Although the vehicle 100 shown is a sedan, the present invention is applicable to other types of vehicles, such as trucks and vans.

Although the invention has been described with reference to specific embodiments, it should be understood that the invention may be embodied in many other forms that fall within the scope of the appended claims.

Claims

1. A vehicle comprising an electric drive unit that is substantially T-shaped in a forward view and that includes:

a gearbox forming a vertical portion of the T-shape, wherein an elongate axis of the drive unit is orthogonal to input and output rotational axes of the gearbox and extends longitudinally through the vertical portion of the T-shape;

a motor mounted to the gearbox and configured to provide drive to the gearbox;

wherein the electric drive unit comprises first, second and third mounts which connect the electric drive unit to the body of the vehicle at their respective first, second and third mounting points such that the elongate axis is oriented at a pitch angle to a surface of the body which is substantially parallel to a flat surface on which the vehicle rests during use, the pitch angle being greater than 45 °;

and wherein the first mount and the second mount are positioned at opposite ends of a transverse portion of the T-shape.

2. A vehicle as claimed in any preceding claim wherein the electric drive unit is mounted such that its elongate axis is substantially vertical.

3. The vehicle of any of the preceding claims, wherein the first mount and the second mount are positioned higher than the third mount.

4. A vehicle as claimed in any preceding claim wherein the inverter is mounted to a first lateral side of the gearbox and the electric motor is mounted to a second lateral side of the gearbox opposite the first lateral side.

5. A vehicle as claimed in any preceding claim wherein the first mount forms part of or is attached to the inverter.

6. A vehicle as claimed in any preceding claim wherein the second mount forms part of or is attached to the motor.

7. A vehicle as claimed in any preceding claim comprising one or more output shafts for driving wheels of the vehicle, wherein the centre of gravity of the first electric drive unit is above the one or more output shafts.

8. The vehicle of any preceding claim, wherein the electric drive unit is configured to drive a pair of front wheels of the vehicle.

9. The vehicle of any preceding claim, comprising a further electric drive unit having an elongate axis, and the further electric drive unit comprising:

another gearbox;

another motor mounted to the other gearbox and configured to provide drive to the other gearbox; and

another inverter mounted to the other gearbox and configured to provide a drive current to the other motor;

wherein the further electric drive unit is mounted with its elongate axis at a further pitch angle which is less than the pitch angle of the electric drive unit.

10. A vehicle as claimed in claim 9, wherein the further electric drive unit is mounted such that its elongate axis is substantially horizontal.

11. A vehicle as claimed in claim 9 or 10, wherein the further electric drive unit is configured to drive a pair of rear wheels of the vehicle.

12. A vehicle as claimed in any one of claims 9 to 11 wherein the further electric drive unit comprises a plurality of combined load bearing and torque reaction mounts connecting the further electric drive unit to the body of the vehicle at their respective mounting points.

13. The vehicle of claim 12, wherein the other electric drive unit includes fourth, fifth, sixth and seventh mounts that mount the other electric drive unit to a body of the vehicle at their respective mounting points.