WO2013071128A2 - Ensemble chaîne cinématique électrique et procédé d'installation - Google Patents

Ensemble chaîne cinématique électrique et procédé d'installation Download PDF

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Publication number
WO2013071128A2
WO2013071128A2 PCT/US2012/064477 US2012064477W WO2013071128A2 WO 2013071128 A2 WO2013071128 A2 WO 2013071128A2 US 2012064477 W US2012064477 W US 2012064477W WO 2013071128 A2 WO2013071128 A2 WO 2013071128A2
Authority
WO
WIPO (PCT)
Prior art keywords
vehicle
electric motor
cradle
electric
assembly
Prior art date
Application number
PCT/US2012/064477
Other languages
English (en)
Other versions
WO2013071128A3 (fr
Inventor
Thomas Andrew MUSSELMAN
David NILES
Robert Gordon Storc
Original Assignee
Magna E-Car Systems Of America, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Magna E-Car Systems Of America, Inc. filed Critical Magna E-Car Systems Of America, Inc.
Publication of WO2013071128A2 publication Critical patent/WO2013071128A2/fr
Publication of WO2013071128A3 publication Critical patent/WO2013071128A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K2001/001—Arrangement or mounting of electrical propulsion units one motor mounted on a propulsion axle for rotating right and left wheels of this axle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
    • B60K2001/0438—Arrangement under the floor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2304/00—Optimising design; Manufacturing; Testing
    • B60Y2304/07—Facilitating assembling or mounting
    • B60Y2304/072—Facilitating assembling or mounting by preassembled subunits
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2304/00—Optimising design; Manufacturing; Testing
    • B60Y2304/07—Facilitating assembling or mounting
    • B60Y2304/078—Facilitating assembling or mounting by interchangeable parts, e.g. new part adapting to old design
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2400/00—Special features of vehicle units
    • B60Y2400/61—Arrangements of controllers for electric machines, e.g. inverters

Definitions

  • This disclosure relates to vehicles having an electric powertrain assembly, and more particularly, to vehicles in which some models are powered solely by an internal combustion engine and in which some models are powered by an electric traction motor.
  • an electric powertrain assembly for a vehicle.
  • the electric powertrain assembly includes a cradle that is open ended and that has a first end and a second end which together define an opening.
  • the cradle is configured to mount to mounting members in a vehicle such that the cradle is in a horizontal orientation in the vehicle.
  • the electric powertrain assembly further includes an electric motor assembly having at least an electric motor, and having a first end and a second end. The first end of the electric motor assembly is connected to the first end of the cradle and the second end of the electric motor assembly is connected to the second end of the cradle so as to form an enclosed structure with the cradle.
  • the opening of the cradle faces aftwardly in the vehicle.
  • an electric powertrain assembly for a vehicle.
  • a first version of the vehicle is driven by an internal combustion engine having a selected bounding volume and which is supported in the first version of the vehicle at a plurality of first support points.
  • a second version of the vehicle is driven by the electric powertrain assembly.
  • the electric powertrain assembly includes a cradle, an electric motor assembly that includes an electric motor and that is connected to the cradle, a plurality of brackets configured to mount to a plurality of second support points in the second version of the vehicle, which are substantially identical in position to the first support points in the first version of the vehicle.
  • the cradle, the electric motor assembly and the plurality of brackets fit within the selected bounding volume.
  • a method of installing an electric powertrain assembly into a vehicle is provided.
  • a first version of the vehicle is driven by an internal combustion engine having a selected bounding volume and which is supported in the first version of the vehicle at a plurality of first support points.
  • a second version of the vehicle is driven by the electric powertrain assembly.
  • the method includes: a) providing an electric powertrain assembly including a cradle, an electric motor assembly including an electric motor, wherein the electric motor assembly is connected to the cradle, wherein the electric powertrain assembly fits within the selected bounding volume, and b) mounting the electric powertrain assembly to a plurality of second support points in the second version of the vehicle, which are substantially identical in position to the first support points in the first version of the vehicle.
  • Fig. 1 a is a side elevation view of a vehicle with an electric powertrain assembly.
  • FIG. 1 b is a perspective view of the electric powertrain assembly from the vehicle shown in Fig. 1 a.
  • Fig. 2 is a simplified structural diagram of the electric powertrain assembly.
  • Fig. 3 is a diagram of a bounding volume of the electric powertrain assembly.
  • Figs. 4a-c are diagrams showing installation of the electric powertrain assembly in an electric vehicle and removal of an electric motor assembly.
  • Fig. 5 is a diagram showing an alternative step of installation.
  • FIG. 6 is a diagram showing another alternative step of installation.
  • Fig. 7 is a perspective view of another electric powertrain assembly, viewed from above, behind, and the right.
  • Fig. 8 is a perspective view of the electric powertrain assembly with the cradle separated from the electric motor assembly.
  • Fig. 9 is a bottom view of the electric powertrain assembly.
  • Fig. 10 is a perspective view of the cradle.
  • Fig. 1 1 is a perspective view of the electric powertrain assembly with other components installed, viewed from above, behind, and the right.
  • Fig. 12 is a perspective view of the electric powertrain assembly with other components installed, viewed from above, behind, and the left. DETAILED DESCRIPTION
  • this disclosure describes an electric powertrain assembly (EPA) 10 for a vehicle 1 1 .
  • the EPA 10 may be modular and can allow the vehicle 1 1 to be more easily manufactured on an assembly line that also manufactures vehicles having internal combustion engines, which are currently manufactured in higher volumes than electric vehicles.
  • a particular vehicle may have several versions including a first version that is powered by an internal combustion engine (i.e. a gasoline- or diesel-powered version of the vehicle) and a second version that is powered by an electric motor assembly (i.e. an electrically-powered version of the vehicle), an example of which forms part of the EPA 10.
  • the EPA 10 may be configured so as to facilitate assembly of both electrically-powered and gasoline-or diesel-powered versions of the vehicle 1 1 on the same assembly line.
  • the vehicle 1 1 includes a body 17 which includes a powertrain compartment 19.
  • the body 17 may be substantially the same for both the first and second versions of the vehicle 1 1 .
  • the term 'body' is intended to be interpreted broadly and to include elements such as the vehicle's chassis (not shown) and the vehicle's body panels.
  • Fig. 1 b shows an example of the EPA 10 for the vehicle 1 1 , which mounts in the powertrain compartment 19 to the body 17.
  • the EPA 10 includes a cradle 12 and an electric motor assembly 14.
  • the EPA 10 receives power from a battery pack 13 and uses the power from the battery pack 15 to drive one or more wheels 15.
  • FIG. 1 b A set of directions defining forward, aft, left, and right directions are also shown in Fig. 1 b.
  • the forward and aft directions are longitudinal directions, and the left and right directions are lateral directions.
  • the cradle 12 may be generally C-shaped and may have a first leg 16 (which may also be referred to as a forward leg 16), a second leg 18 (which may also be referred to as a left leg 18), and a third leg 20 (which may also be referred to as a right leg 20).
  • the left leg 18 extends in the aft direction from a left side of the forward leg 16.
  • the right leg 20 extends in the aft direction from a right side of the forward leg 16.
  • the component could extend at some angle that includes a vector component that is directly aftwardly and a vector component that is lateral, or vertical. The same is true for components described as extending forwardly, leftwardly or rightwardly, or in any particular direction; the component need not extend directly in the described direction unless it is specifically described to extend directly in the described direction.
  • the three legs 16, 18 and 20 have generally rectangular hollow cross- sections.
  • the legs 16, 18 and 20 are made of separate pieces that are attached together, for example, by welding.
  • the left and right legs 18 and 20 may be connected to the forward leg 16 using other attachment techniques, such as bolting or brazing.
  • the three legs 16, 18 and 20 are part of a unitary structure formed by, for example, bending a single piece of tubing.
  • alternative cross-sectional shapes such as a circular cross-sectional shape, may be used for the legs 16, 18 and 20.
  • the legs 16, 18 and 20 are made of steel, however, other materials may be used instead.
  • the free ends of the legs 18 and 20 i.e.
  • the electric motor assembly 14 may be removably fastened to the cradle 12 by disengageable or removable fasteners, such as bolts.
  • a mounting bracket 22 may be attached to the left leg 18.
  • the mounting bracket 22 has one or more apertures 24 for receiving fasteners, such as bolts that thread into corresponding threaded apertures in the electric motor assembly 14. Other kinds of fasteners may be used instead.
  • the mounting bracket 22 is a steel plate that is welded to the left leg 18, but in other examples, other materials and attachment techniques may be used instead.
  • the mounting bracket 22 can alternatively be a built-up member or other structural member.
  • one or more fastener apertures 25 may be provided in the right leg 20.
  • the fastener apertures 25 may be reinforced by a thickened wall section of the right leg 20 or by using sections of tube or couplings. As with the mounting bracket 22, other kinds of fasteners may be used instead.
  • the left leg 18 can have one or more fastener apertures and the right leg 20 can have an attached mounting bracket.
  • the electric motor assembly 14 is positioned aft of the forward leg 16 of the cradle 12.
  • the electric motor assembly 14 includes an electric motor 26 and a gearbox 28 connected to the electric motor 26.
  • the gearbox 28 may be bolted to the electric motor 26.
  • the gearbox 28 is coaxial with the electric motor 26.
  • a common shaft 30 can run through the electric motor 26 and gearbox 28.
  • the common shaft 30 has ends configured to be attached to half-shafts used to turn the front wheels of the vehicle 1 1 .
  • Providing a co-axial gearbox 28 may facilitate fitting the EPA 10 in powertrain compartments of some smaller vehicles 1 1 .
  • the EPA 10 may further include left and right brackets 32 and 34 for mounting the EPA 10 to corresponding support structures in the vehicle 1 1 in a generally horizontal orientation.
  • the brackets 32 and 34 may be tailored to each individual model of vehicle. In other words, a first set of brackets 32 and 34 may be provided for mounting the EPA 10 to a first model of vehicle; a second set of brackets 32 and 34 may be provided for mounting the EPA 10 in a second model of vehicle; and a third set of brackets 32 and 34 may be provided for mounting the EPA 10 in a third model of vehicle, and so on.
  • the brackets 32 and 34 function as adaptors so that the basic structure of the EPA 10 can remain consistent so as to reduce the cost of manufacture of the EPA 10, while the brackets 32 and 34 permit the EPA 10 to be installed in different models of vehicle without having to change the basic structure of the EPA 10.
  • the left bracket 32 may be connected to the left leg 18.
  • the left bracket 32 may be a plate, a built-up member, or other structural member and may be made of steel or other material.
  • the left bracket 32 may be welded to the left leg 18 or connected by another attachment technique.
  • the left bracket 32 has a vehicle mounting end configured to be attached to a left mounting member of the vehicle 1 1 .
  • the vehicle mounting end of the left bracket 32 includes one or more fastener apertures for receiving fasteners, such as bolts, that mate with corresponding apertures of the mounting member of the vehicle 1 1 .
  • the right bracket 34 may be connected to the right leg 20.
  • the right bracket 34 may be similar to the left bracket 32, and may have a different geometry or material or use a different attachment technique.
  • An aft attachment member 36 may be positioned on the electric motor assembly 14 for attachment to an aft mounting member of the vehicle 1 1 .
  • the aft attachment member 36 projects from the aft side of the housing of the electric motor 26 and has one or more fastener apertures therethrough.
  • An intermediate member may be used to connect the aft attachment member 36 to the vehicle 1 1 .
  • the intermediate member may be fastened to the aft attachment member 36 and to the vehicle's aft mounting member, such as a suspension or frame cross-member using fasteners such as bolts.
  • the attachment member 36 can serve to prevent the electric motor assembly 14 from rotating about the common shaft 30 during operation of the vehicle 10.
  • Fig. 2 shows a simplified structural diagram of the EPA 10, when installed in the body of an electric vehicle.
  • the vehicle body 17 is illustrated as three fixed support points 38, although resilient vibration dampeners may be provided to the vehicle at these points. Forces and moments may be transmitted between the EPA 10 and the vehicle body 17. For instance, the weight of the EPA 10 as well as forces from the vehicle wheels 15 may be applied by the EPA 10 to the vehicle body.
  • the electric motor assembly 14 can act as a load-bearing fourth leg of the cradle 12 to form a closed four-member structural frame.
  • the EPA 10 may have a smaller longitudinal dimension than an electric powertrain assembly that includes both forward and aft legs and which must accommodate an electric motor assembly between the forward and aft legs.
  • the EPA 10 has a reduced overall bounding volume compared to some EPA's of the prior art, which may permit the EPA 10 to be installed in a vehicle that was designed to fit a small internal combustion engine, such as for example, some economy cars.
  • eliminating the fourth leg can reduce the weight and/or cost of the EPA 10 as compared to some EPA's of the prior art.
  • the dedicated structural members of a cradle can in some instances have a relatively low profile and could injure a vehicle occupant during a collision event if such members were to intrude into the passenger compartment.
  • Providing the EPA 10 in place of a dedicated aft cradle member reduces the likelihood of intrusion into the passenger compartment, since the profile of the EPA 10 is relatively large and there is correspondingly more structure that could hinder the EPA 10 from intruding into the passenger compartment during a collision event.
  • the EPA 10 may be configured to fit within a selected bounding volume 40.
  • the bounding volume 40 may be rectangular and defined by a width W, height H, and depth D. Alternatively other bounding volume geometries are also possible.
  • the selected bounding volume 40 may be selected based on the bounding volume of an internal combustion engine that may be mounted in the powertrain compartment of gasoline- or diesel-powered versions of the vehicle 1 1 .
  • the selected bounding volume 40 may be the same as the bounding volume of the aforementioned internal combustion engine to ensure that the EPA 10 can fit in any powertrain compartment in which the internal combustion engine can fit.
  • the bounding volume 40 can further be selected so that the EPA 10 fits on a lift configured to install internal combustion engines on an assembly line for gasoline- or diesel-powered versions of the vehicle.
  • the dimensions and geometry of the bounding volume 40 may be selected to be compatible with the dimensional and geometric limitations of the assembly line and the lift.
  • the EPA 10 may further be configured so that the left and right brackets 32 and 34 can connect to support points in the vehicle 1 1 that are the same as the corresponding support points in a gasoline- or diesel-powered version of the vehicle 1 1 .
  • the bounding volume may be selected so that the EPA 10 can fit within a plurality of different models of electric vehicle.
  • a manufacturer may configure the EPA 10 to fit in the powertrain compartments of a plurality of different models of vehicle. This permits the manufacturer to broaden the potential market for vehicles containing the EPA 10.
  • the EPA 10 may additionally include other components that would not be included in a gasoline- or diesel-powered version of the vehicle 1 1 .
  • the EPA 10 may additionally include a control system, a DC-DC converter for conversion of high-voltage current from the battery pack 13 to low voltage current, a cooling system that may include one or more water pumps and one or more control valves and a transmission control module that controls the transmission of current to the electric motor 26.
  • a control system for conversion of high-voltage current from the battery pack 13 to low voltage current
  • a cooling system that may include one or more water pumps and one or more control valves and a transmission control module that controls the transmission of current to the electric motor 26.
  • the bounding volume 40 may include one or more of the left and right brackets 32 and 34 that may be used to and the aft attachment member 36 as well as any mounting members connected thereto.
  • Figs. 4a-b illustrate the installation of the EPA 10 into the body 17 of the vehicle 1 1 .
  • the EPA 10 is provided by selecting the cradle 12 from a stock 42 of cradles based on the model of the vehicle 1 1 being manufactured.
  • Each cradle 12 held in stock is configured to fit the electric motor assembly 14 and further has left and right brackets configured to fit mounting members of bodies of different models of electric vehicle.
  • the selected cradle 12 has left and right brackets 32 and 34 configured to fit respective mounting members of the model of the vehicle 1 1 currently being manufactured.
  • the stock 42 of cradles may be located at a plant that manufactures the vehicle 1 1 or at a plant that manufactures the EPA 10.
  • the selected cradle 12 is connected to the electric motor assembly 14, as discussed above with reference to Fig. 1 b.
  • other components such as a water pump, a diverter valve, a cabin heater, an electric vacuum pump, an electric air conditioner compressor, a DC-DC converter, cooling conduits, and a control unit may be connected to the cradle 12 and electric motor assembly 14 to form part of the EPA 10.
  • the assembled EPA 10 is lifted into the body 17 of the vehicle 1 1 by, for example, a lift 44.
  • the electric motor assembly 14 of the EPA 10 can include at least one support member (discussed below) positioned to fit the lift 44.
  • the lift 44 may be one that is configured to also install internal combustion engines along with related components, such as a radiator into gasoline- or diesel-powered versions of the vehicle 1 1 .
  • the left and right brackets 32 and 34 are attached to left and right mounting members 46 and 48 of the body 17.
  • the left and right brackets 32 and 34 may be bolted to the mounting members 46 and 48. Attaching the left and right brackets 32 and 34 to the left and right mounting members 46 and 48 may be performed using equipment that also attaches internal combustion engines to gasoline- or diesel-powered versions of the vehicle 1 1 .
  • the aft attachment member 36 of the EPA 10 can also be connected, using bolts for example, to an aft mounting member 50 of the vehicle 1 1 .
  • the aft mounting member 50 may be a suspension or frame cross-member.
  • An intermediate member (not shown) may be used to connect the aft attachment member 36 of the EPA 10 to the aft mounting member 50 of the vehicle 1 1 .
  • attaching the aft attachment member 36 to the aft mounting member 50 may be performed using equipment that also manufactures vehicles having internal combustion engines.
  • components of the cooling and electrical systems provided as part of the EPA 10 are connected to other components provided in the body of the vehicle 1 1 .
  • the electric motor assembly 14 is electrically connected to the drive battery, which may be located elsewhere in the vehicle.
  • the half-shafts may be connected to ends of the common shaft 30.
  • Fig. 4c shows how the motor assembly 14 may be removed from the vehicle 1 1 for maintenance or repair.
  • the electric motor assembly 14 is connected to the cradle 12 using fasteners at the left and right legs 18 and 20. Further, the aft attachment member 36 may be disconnected (e.g., unbolted in embodiments where bolts are used) from the aft mounting member 50 of the vehicle. As such, when the electric motor assembly 14 is in need of maintenance or repair, the fasteners may be unfastened and the electric motor assembly 14 may be removed from the body of the vehicle 1 1 as a unit, while the cradle 12 and components attached to the cradle 12 remain in the body.
  • components of the cooling and electrical systems connected to the electric motor assembly 14 are disconnected from the other components provided in the body of the vehicle 1 1 .
  • the electric motor assembly 14 is electrically disconnected from the drive battery and the electric air conditioning compressor is unbolted from the outside of the electric motor assembly 14.
  • the half-shafts may be disconnected from the ends of the common shaft 30.
  • Fig. 5 shows another way of providing the EPA 10 that may be used as an alternative to the way described with respect to Fig. 4a.
  • the EPA 10 may as a whole be selected from a stock 52 of EPAs having like electric motor assemblies connected to cradles having different sets of left and right brackets configured to fit respective mounting members of bodies of different models of electric vehicle.
  • the EPA 10 is selected based on the model of the vehicle 1 1 currently being manufactured.
  • the EPA 10 is thus provided having the cradle 12 preinstalled. For example, a manufacturer operating an electric vehicle assembly plant can select the EPA 10 from stock 52 and then provide the EPA 10 to a particular assembly line at a particular time, as needed.
  • Fig. 6 shows another way of providing the EPA 10 that may be used as an alternative to the way described with respect to Fig. 4a.
  • the EPA 10 has the electric motor assembly 14 connected to the cradle 12, the cradle 12 being without left and right brackets attached.
  • a manufacturer operating an electric vehicle assembly plant can provide the EPA 10 to a particular assembly line at a particular time, as needed.
  • Left and right brackets 32 and 34 are selected based on the particular model of vehicle being manufactured.
  • the left and right brackets 32 and 34 may be selected from a stock 54 of different left and right brackets that are used to mount the EPA 10 to different models of vehicle.
  • the stock left and right brackets 32 and 34 are configured to fit the EPA 10 and further configured to fit mounting members of bodies of different models of electric vehicle. For example, several different sets of left and right brackets may be held in stock 54, with each set configured differently to fit different vehicle bodies, while still fitting the EPA 10. In another example, only left and right brackets for a single model of electric vehicle are stocked.
  • the selected left and right brackets 32 and 34 are attached to the left and right legs 18 and 20 of the cradle 12 of the EPA 10. Such attachment may be carried out by welding or other attachment technique and may be performed by the manufacturer of the vehicle 1 1 or by the supplier of the EPA 10.
  • Fig. 7 shows another EPA 60 for an electric vehicle.
  • a set of axes defining forward, aft, left, and right directions is also shown.
  • the forward direction indicates the forward direction of travel of an electric vehicle that uses the EPA 60.
  • the EPA 60 includes a cradle 62 and an electric motor assembly 64.
  • the cradle 62 has a first or forward leg 66, a second or left leg 68, and a third or right leg 70.
  • the left leg 68 extends in the aft direction from a left side of the forward leg 66.
  • the right leg 70 extends in the aft direction from a right side of the forward leg 66.
  • the three legs 66, 68 and 70 have generally rectangular hollow cross-sections.
  • the legs 66, 68 and 70 are made of separate pieces that are welded together.
  • One or more reinforcement members 71 may be used to stiffen the joints of the left and right legs 68 and 70 to the forward leg 66.
  • the reinforcement members 71 may be plates or built-up members. In other examples other attachment techniques, such as bolting or brazing, may be used.
  • the legs 66, 68, 70 are made of steel, however, other materials may be used instead.
  • the electric motor assembly 64 may be connected to the cradle 62 by removable bolts.
  • a mounting bracket 72 may be attached to the left leg 68 for this purpose. The mounting bracket 72 is discussed in more detail below with reference to Fig. 8.
  • one or more bolt apertures may be provided at the right leg 70.
  • the bolt apertures can include sections of tube, situated inside the right leg 70, through which bolts 74 may be inserted. Such bolts 74 may be threaded into threaded apertures in the electric motor assembly 64.
  • two bolt apertures are used for two bolts 74 (one shown), though more or fewer may be used in other examples.
  • the electric motor assembly 64 is positioned aft of the forward leg 66 of the cradle 62.
  • the electric motor assembly 64 includes an electric motor 76 and a gearbox 78.
  • the housing of the gearbox 78 is bolted to the housing of the electric motor 76 to hold these components together and form a unitary component.
  • the gearbox 78 is coaxial with the electric motor 76, and a common shaft extends through the electric motor 76 and gearbox 78.
  • the common shaft has ends shown at 80 which are configured to be attached to half-shafts to turn the front wheels 15 of the vehicle 1 1 .
  • the electric motor assembly 64 may further include one or more cover pieces 81 to inhibit the intrusion of moisture and debris into the electric motor assembly 64.
  • the EPA 60 includes left and right brackets 82 and 84 configured to mount the EPA 60 to a predetermined model of electric vehicle.
  • the left bracket 82 is connected to the left leg 68.
  • the left bracket 82 is a built-up member composed of steel plates and is welded to the left leg 68.
  • the left bracket 82 has a free end configured to be attached to a left mounting member 87 of the vehicle 1 1 .
  • the free end may also be referred to as a vehicle mounting end.
  • the left mounting member 87 has one bolt aperture 89 for pendulum-mounting the EPA 60 to the vehicle body 17.
  • the vehicle mounting end of the left bracket 82 may be attached by one or more bolts 83 to the left mounting member 87.
  • the left bracket 82 can include sections of tube or couplings for reinforcing the bolt apertures that receive the bolts 83. Different left brackets may be manufactured to fit different left mounting members of different models of electric vehicle.
  • the right bracket 84 is connected to the right leg 70 of the cradle 62.
  • the right bracket 84 may be similar to the left bracket 82, or it may have a different geometry or material or use a different attachment technique than was used for the left bracket 82.
  • the vehicle mounting end of the right bracket 84 may include one or more bolt aperture 85 for receiving bolts that mate with corresponding apertures of the right mounting member of the vehicle 1 1 .
  • the right mounting member may be similar to the left mounting member 87 described above, and specifically may be attached to the vehicle body by a single bolt to pendulum- mount the EPA 60 to the body.
  • the bolt apertures 85 can include sections of tube or couplings.
  • FIG. 7 Also shown in Fig. 7 are one or more support members 88 and 92 configured to connect other components of the EPA 60 to the cradle 62.
  • the support members 88 and 92 can include pieces of formed plate or tubing that are welded to the cradle 62 and can have bolt apertures, or other attachment features, for connection of the other components.
  • the EPA 60 includes a DC-DC converter 1 12.
  • the DC- DC converter 1 12 in fastened to the support member 92 that extends from the right leg 70 of the cradle 62.
  • the DC-DC converter 1 12 takes high-voltage DC power from the battery pack 13 and outputs lower voltage power (e.g. 12-volt power) which may be sent to a low voltage battery (not shown), but which is ultimately used to provide power for low voltage accessories, such as a stereo system, cabin lights, headlamps and brake lamps, and other accessories.
  • the EPA 60 can also include a transmission control unit 96 connected to the electric motor assembly 64 by bolts, for example, and protected by a cover piece 97.
  • the transmission control unit 96 is used for controlling current to the electric motor assembly 64 so as to control the torque delivered by the electric motor assembly 64 to the wheels 15 of the vehicle 1 1 .
  • the transmission control unit 96 may be connected to the electric motor assembly 64 so that it is removed from the vehicle when the electric motor assembly 64 is removed from the vehicle for maintenance or repair.
  • the transmission control unit 96 may be additionally or alternatively connected to the cradle 62.
  • a cabin heater 123 which is used to heat coolant that is sent to a heater core (not shown) for heating air being drawn into the vehicle cabin can also be connected to the cradle 62, in this example, to the right leg 70.
  • the cabin heater 123 may be any suitable type of heater, such as, for example, a PTC heater.
  • the cabin heater 123 may be mounted to the cradle 62 so as to remain with the cradle 62 during maintenance or repair of the electric motor assembly 64 (e.g., as shown in Fig 4c).
  • aft attachment member 86 that may be positioned on the electric motor assembly 64 for attachment to an aft mounting member of the vehicle 1 1 .
  • the aft attachment member 86 includes at least one protrusion extending from the aft side of the housing of the electric motor 76 and having a bolt aperture. The aft attachment member 86 can serve to prevent the pendulum-mounted electric motor assembly 64 from rotating in reaction to the vehicle 1 1 being operated.
  • FIG. 2 The simplified structural diagram of Fig. 2 also applies to the EPA 60. That is, by virtue of its connection to the left and right legs 68, 70, the electric motor assembly 64 can act as a load-bearing fourth leg of the cradle 62 to form a closed four-legged structural frame. Use of the electric motor assembly 64 as the fourth leg of the cradle 62 means that the cradle 62 itself does not need a fourth leg, which can reduce the weight and/or cost of the EPA 60 as well as reduce risk during a crash as discussed above.
  • Fig. 8 illustrates the cradle 62 removed from the electric motor assembly 64.
  • the mounting bracket 72 has one or more bolt apertures 75 for receiving bolts that thread into corresponding threaded apertures (not shown) in the electric motor assembly 64.
  • the threaded apertures are located on the housing of the gearbox 78.
  • the mounting bracket 72 is a formed steel plate that is welded to the left leg 68, but in other examples, other materials and attachment techniques may be used.
  • the mounting bracket 72 can alternatively be a built-up member or other structural member.
  • the bolt apertures 75 may be reinforced by sections of tube, plate, or couplings. In this example, three bolt apertures 75 are used, though more or fewer may be used in other examples.
  • Fig. 8 also shows threaded bolts apertures 106 on the housing of the electric motor 76 for receiving bolts that extend through the bolt apertures 99 of the right leg 70 of the cradle 62 to attach the cradle 62 to the electric motor assembly 64.
  • the bolt apertures 74 can include sections of tube or coupling.
  • the EPA 60 can further include an electric air conditioner compressor 124 connected to the forward side of the housing of the electric motor 76 by at least a fastener, such as one or more bolts that thread into apertures in the housing. In this example, three bolts are used. Locating the electric air conditioner 124 compressor on the forward side of the electric motor 76 allows the electric motor 76 to act as a noise dampener, which can reduce noise inside the passenger cabin due to operation of the compressor 124. When the electric motor assembly 64 is removed for maintenance or repair, as shown in Fig. 4c, the electric air conditioner compressor 124 may be unbolted from the electric motor 76 and left to hang, by its plumbing for example, without breaking apart the air conditioning system. In other examples, the electric air conditioner compressor 124 may be additionally or alternatively connected to the housing of the gearbox 78.
  • a fastener such as one or more bolts that thread into apertures in the housing. In this example, three bolts are used. Locating the electric air conditioner 124 compressor on the forward side of the electric motor 76
  • Fig. 9 shows the EPA 60 from below.
  • the electric motor assembly 64 can further include at least one support member positioned to fit a lift, such as the lift used to install the EPA 60 into an electric vehicle as described above with reference to Fig 4b.
  • Two flat support members 108 and two support members 1 10 having apertures are provided to fit the lift.
  • the support members 108, 1 10 are protrusions or legs extending from the bottom of the housing of the electric motor 76.
  • additional or alternative support members may be provided to the housing of the gearbox 78.
  • Fig. 10 shows the cradle 62 in a configuration that may be stocked as described above with reference to Fig. 4a. Also shown in this view is a flat support member 90, such as a plate, connected to the forward side of the forward leg 66.
  • Fig. 1 1 shows the EPA 60 with other components installed.
  • the EPA 60 can further include at least one water pump 1 16 and at least one control valve 122 that form part of a cooling system for the EPA 10 and that are connected to the cradle 62 and that therefore stay with the cradle 62 in the vehicle 1 1 when the electric motor assembly 64 is removed for maintenance or repair, as discussed above with reference to Fig. 4c.
  • three water pumps 1 16 are used, though more or fewer may be used in other examples.
  • the three water pumps 1 16 are shown in Fig. 1 1 as mounted to supports extending from the cradle 62.
  • the water pumps 1 16 circulate cooling water (i.e., coolant) via cooling conduits 120 to various heat- generating components of the vehicle 1 1 .
  • the control valves 122 can also be connected to the cradle 62 by, for example, the support member 88 (see Fig. 7) to form part of this cooling system.
  • three control valves are used, though in other examples more or fewer may be used.
  • wiring 128 that electrically connects various components of the EPA 60 to other components of the EPA 60 or other components situated elsewhere in the vehicle 1 1 , such as the drive battery and cabin electronics.
  • Fig. 12 shows another view of the EPA 60 with other components installed.
  • the EPA 60 can further include an electric vacuum pump 1 14 fastened to the support member 90 (shown in Fig. 10) that extends from the forward leg 66.
  • the electric vacuum pump 1 14 may, for example, be used by vacuum-assisted brakes (if provided) on the vehicle 1 1 .
  • the EPA 60 includes the DC-DC converter 1 14, the transmission control module 1 16, and a control system.
  • an intermediate member 100 that may be used to connect the aft attachment member 86 of the EPA 60 to a structural member of the vehicle 1 1 (e.g. a frame member).
  • the intermediate member 100 may be bolted to the aft attachment member 86 through at least one bolt aperture 102, and can further include at least a bolt aperture 104 for connection to the aft mounting member of the vehicle 1 1 , such as a component of the suspension (e.g. the aforementioned suspension or frame cross-member).
  • the intermediate member 100 may be a steel plate, rod, bar, or other structural member of other material.
  • Components of the EPA 60 may be arranged within the bounding volume 40 shown in Fig. 3, and the description related to this figure may be referenced.
  • the cradles 12 and 62 have been described as each having three legs, it will be understood that the cradle 12 or 62 could have a different number of legs.
  • the cradle 12 or 62 could be formed from a single arcuate C- shaped member having first and second ends which define a gap that is ultimately occupied by the electric motor assembly 14 or 64.
  • the cradle 12 or 62 could alternatively be formed from 5 members including a central member, two angled members welded to ends of the central member, and finally side members welded to free ends of the angle members, thereby forming an open-ended shape that may be generally C-shaped.
  • an example of an electric powertrain assembly for a vehicle includes a cradle having a forward leg, a left leg extending aft from a left side of the forward leg, and a right leg extending aft from a right side of the forward leg.
  • the electric powertrain assembly further includes an electric motor assembly having an electric motor and a gearbox connected to the electric motor.
  • the electric motor assembly is positioned aft of the forward leg of the cradle.
  • the electric motor assembly is connected to the left leg and the right leg of the cradle.
  • the electric motor assembly acts as a load-bearing fourth leg of the cradle.
  • the electric powertrain assembly can further include a left bracket connected to the left leg, the left bracket being configured to be attached to a left mounting member of the vehicle.
  • the electric powertrain assembly can further include a right bracket connected to the right leg, the right bracket being configured to be attached to a right mounting member of the vehicle 1 1 .
  • the electric motor assembly can further include an aft attachment member positioned to be attached to an aft mounting member of the vehicle 1 1 .
  • the electric motor assembly and the cradle 16 may be arranged within a bounding volume, the bounding volume being predetermined to fit within a plurality of different models of electric vehicle and/or within a vehicle having both a gasoline- or diesel-powered version and an electrically-powered version.
  • the gearbox 78 may be coaxial with the electric motor, and the electric motor assembly can further include a common shaft having ends configured to be attached to half-shafts. [0097]
  • the electric motor assembly and the cradle may be arranged within a bounding volume, the bounding volume being predetermined to fit a lift configured to install internal combustion engines.
  • the electric motor assembly can further include at least one support member positioned to fit the lift.
  • the electric motor assembly may be removably fastened to the cradle.
  • the electric powertrain assembly can further include an electric air conditioner compressor removably fastened to the electric motor assembly.
  • the electric powertrain assembly can further include a DC-DC converter, an electric vacuum pump, a water pump, and a cabin heater connected to the cradle. [00101]
  • the electric powertrain assembly can further include a transmission control unit connected to the electric motor assembly. [00102]
  • the forward leg, the left leg, and the right leg of the cradle may be made of separate pieces that are attached together.
  • an electric powertrain assembly for an electric vehicle includes a cradle having a forward leg, a left leg extending aft from a left side of the forward leg, and a right leg extending aft from a right side of the forward leg.
  • the electric powertrain assembly further includes an electric motor assembly having an electric motor and a gearbox connected to the electric motor.
  • the gearbox is positioned coaxially with the electric motor.
  • the electric motor assembly further has a common shaft having ends configured to be attached to half-shafts.
  • the electric motor assembly is positioned aft of the forward leg of the cradle.
  • the electric motor assembly is removably fastened to the left leg and the right leg of the cradle.
  • the electric motor assembly further has an aft attachment member positioned to be attached to an aft mounting member of the vehicle 1 1 .
  • the electric powertrain assembly further includes a left bracket connected to the left leg of the cradle, the left bracket being configured to be attached to a left mounting member of a model of a plurality of different models of electric vehicle.
  • the electric powertrain assembly further includes a right bracket connected to the right leg of the cradle, the right bracket being configured to be attached to a right mounting member of the model of the plurality of different models of electric vehicle.
  • the electric powertrain assembly further includes at least one of a DC-DC converter, an electric vacuum pump, a water pump, and a cabin heater connected to the cradle.
  • the electric powertrain assembly further includes a transmission control unit connected to the electric motor assembly.
  • the cradle, the electric motor assembly, the transmission control unit, and the at least one of the DC-DC converter, the electric vacuum pump, the water pump, and the cabin heater are arranged within a bounding volume.
  • the bounding volume is predetermined to fit within the plurality of different models of electric vehicle.
  • the electric powertrain assembly can further include an electric air conditioner compressor removably fastened to the electric motor assembly.
  • a method of installing an electric powertrain assembly into an electric vehicle is disclosed.
  • the vehicle 1 1 is of a model and has a body.
  • the method includes providing an electric powertrain assembly having an electric motor assembly connected to left and right legs of a cradle.
  • the left and right legs extend aft from respective left and right sides of a forward leg of the cradle.
  • the cradle has left and right brackets configured to fit respective mounting members of the model of the vehicle.
  • the method further includes lifting the electric powertrain assembly into the body of the vehicle, and attaching the left and right brackets to the left and right mounting members of the body of the vehicle 1 1 .
  • Providing the electric powertrain assembly can include selecting the cradle from a stock of cradles based on the model of the vehicle, the stock of cradles being configured to fit the electric motor assembly and having different left and right brackets configured to fit mounting members of bodies of different models of electric vehicle, and connecting the selected cradle to the electric motor assembly.
  • Providing the electric powertrain assembly can include selecting the electric powertrain assembly from a stock of electric powertrain assemblies having cradles having left and right brackets based on the model of the vehicle 1 1 , the stock of electric powertrain assemblies configured to fit mounting members of bodies of different models of electric vehicle.
  • Providing the electric powertrain assembly can include selecting left and right brackets from a stock of left and right brackets based on the model of the vehicle 1 1 , the stock of left and right brackets configured to fit mounting members of bodies of different models of electric vehicle, and attaching the selected left and right brackets to the left and right legs of the cradle.
  • the method can further include attaching an aft attachment member of the electric motor assembly to an aft mounting member of the vehicle.
  • the electric motor assembly can include an electric motor and a gearbox that is coaxial with the electric motor, and the method can further include connecting half-shafts to ends of a common shaft of the electric motor assembly.
  • Lifting the electric powertrain assembly into the body of the vehicle and attaching the left and right brackets to the left and right mounting members may be performed on an assembly line using equipment that also manufactures vehicles having internal combustion engines.
  • Lifting the electric powertrain assembly into the body of the vehicle may be performed by a lift configured to install internal combustion engines.
  • the electric motor assembly may be removably fastened to the cradle.
  • the electric powertrain assembly can further include an electric air conditioner compressor removably fastened to the electric motor assembly.
  • an electric powertrain assembly for a vehicle includes a cradle having a forward leg, a left leg extending aft from a left side of the forward leg, and a right leg extending aft from a right side of the forward leg.
  • the electric powertrain assembly further includes an electric motor assembly having an electric motor and a gearbox connected to the electric motor.
  • the electric motor assembly is positioned aft of the forward leg of the cradle.
  • the electric motor assembly is fixed to the left leg and the right leg of the cradle. Load transfer that occurs between left leg and the right leg of the cradle at the aft portion of the electric powertrain assembly is substantially entirely transmitted through the electric motor assembly.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)

Abstract

L'invention porte sur un ensemble chaîne cinématique électrique qui, dans un aspect, réalise un ensemble chaîne cinématique électrique pour un véhicule. Une première version du véhicule est entraînée par un moteur à combustion interne ayant un volume limite choisi et qui est supporté dans la première version du véhicule en une pluralité de premiers points d'appui. Une seconde version du véhicule est entraînée par l'ensemble chaîne cinématique électrique. L'ensemble chaîne cinématique électrique comprend un berceau, un ensemble moteur électrique qui comprend un moteur électrique et qui est relié au berceau, une pluralité de consoles configurées pour se monter sur une pluralité de seconds points d'appui dans la seconde version du véhicule, qui sont sensiblement identiques en position aux premiers points d'appui de la première version du véhicule. Le berceau, l'ensemble moteur électrique et la pluralité de consoles se logent dans le volume limite choisi.
PCT/US2012/064477 2011-11-09 2012-11-09 Ensemble chaîne cinématique électrique et procédé d'installation WO2013071128A2 (fr)

Applications Claiming Priority (2)

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US201161557606P 2011-11-09 2011-11-09
US61/557,606 2011-11-09

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WO2013071128A3 WO2013071128A3 (fr) 2013-07-04

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104709057A (zh) * 2014-12-31 2015-06-17 浙江吉利汽车研究院有限公司 锻造结构的纯电动汽车动力总成托架
US9676411B2 (en) 2014-10-01 2017-06-13 Caterpillar Inc. Electric drive retrofit kit
CN109436094A (zh) * 2018-11-23 2019-03-08 东风电动车辆股份有限公司 一种用于电动汽车附件集成安装的副车架及其连接系统
US10294634B2 (en) 2014-10-01 2019-05-21 Caterpillar Inc. Rear entry electric drive motor module
EP3539808A1 (fr) * 2018-03-12 2019-09-18 MAN Truck & Bus SE Agencement pour palier d'entraînement

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US4484648A (en) * 1979-06-29 1984-11-27 Jephcott Edmund F Ultra narrow enclosed motor vehicles
US6397965B1 (en) * 2000-08-31 2002-06-04 New Flyer Industries Limited Engine configuration for mass transit vehicle
US20100025131A1 (en) * 2006-04-03 2010-02-04 Bluwav Systems, Llc Electric propulsion system
US7886861B2 (en) * 2007-09-06 2011-02-15 Mitsubishi Jidosha Kogyo Kabushiki Kaisha Electric vehicle
US20110155489A1 (en) * 2009-09-16 2011-06-30 Swissauto Powersports Llc Electric vehicle and on-board battery charging apparatus therefor

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Publication number Priority date Publication date Assignee Title
US4484648A (en) * 1979-06-29 1984-11-27 Jephcott Edmund F Ultra narrow enclosed motor vehicles
US6397965B1 (en) * 2000-08-31 2002-06-04 New Flyer Industries Limited Engine configuration for mass transit vehicle
US20100025131A1 (en) * 2006-04-03 2010-02-04 Bluwav Systems, Llc Electric propulsion system
US7886861B2 (en) * 2007-09-06 2011-02-15 Mitsubishi Jidosha Kogyo Kabushiki Kaisha Electric vehicle
US20110155489A1 (en) * 2009-09-16 2011-06-30 Swissauto Powersports Llc Electric vehicle and on-board battery charging apparatus therefor

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9676411B2 (en) 2014-10-01 2017-06-13 Caterpillar Inc. Electric drive retrofit kit
US10294634B2 (en) 2014-10-01 2019-05-21 Caterpillar Inc. Rear entry electric drive motor module
CN104709057A (zh) * 2014-12-31 2015-06-17 浙江吉利汽车研究院有限公司 锻造结构的纯电动汽车动力总成托架
EP3539808A1 (fr) * 2018-03-12 2019-09-18 MAN Truck & Bus SE Agencement pour palier d'entraînement
US10953738B2 (en) 2018-03-12 2021-03-23 Man Truck & Bus Ag Arrangement for a drive mounting
CN109436094A (zh) * 2018-11-23 2019-03-08 东风电动车辆股份有限公司 一种用于电动汽车附件集成安装的副车架及其连接系统
CN109436094B (zh) * 2018-11-23 2023-12-19 东风电动车辆股份有限公司 一种用于电动汽车附件集成安装的副车架及其连接系统

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