Patent ID: 12257909

DETAILED DESCRIPTION OF EMBODIMENTS

Examples

The electromechanical integration unit10of the embodiment will be described with reference toFIGS.1to5. The electromechanical integration unit10is mounted on a vehicle. Vehicles are, for example, hybrid electric vehicle driven by engines and motors. However, the vehicles are not limited to hybrid electric vehicle. For example, the vehicle may be a battery electric vehicle or an electrified vehicle driven by a motor, such as a fuel-powered vehicle.

Here, each direction of the electromechanical integration unit10in the drawings corresponds to a direction when mounted on a vehicle. That is, each direction of the electromechanical integration unit10in the drawings corresponds to the direction of the vehicle. Therefore, the direction FR indicates the front in the front-rear direction of the vehicle. The direction RR indicates the rear of the vehicle in the front-rear direction. The direction LH indicates a left direction in the left-right direction of the vehicle. The direction RH indicates a right direction in the left-right direction of the vehicle. The direction UP indicates an upward direction in the up-down direction of the vehicle. The direction DW indicates a vertical direction of the vehicle.

As shown inFIGS.1and2, the electromechanical integration unit10includes a plurality of motors50and52, a gear mechanism54, a plurality of electrical units20and30, a branch unit36, a power socket38, and a housing12. The housing12integrally houses a plurality of motors50and52, a gear mechanism54, a plurality of electrical units20and30, and a branch unit36.

The housing12is a housing member. The housing12has a first chamber R1and a second chamber R2. The second chamber R2is located above the first chamber R1. The housing12includes a housing body14and a cover plate16. The housing body14has a bottom wall14aand a peripheral wall14b. The peripheral wall14bextends upward from an outer peripheral edge of the bottom wall14a. The housing body14is made of a conductive material such as aluminum. The housing body14has an opening portion14cin the second chamber R2(i.e., the upper portion). The opening portion14cof the housing body14is defined by a peripheral wall14b. The housing body14is provided with a partition wall14d. In the housing12, a first chamber R1and a second chamber R2are defined by a partition wall14d. The cover plate16is detachably attached to the opening portion14cof the housing body14. The cover plate16closes the opening portion14cof the housing body14. The cover plate16is a plate-shaped member. The cover plate16is made of a conductive material such as aluminum. At a rear portion of the cover plate16, a power socket38is disposed so as to be exposed to the outside of the housing12. A connector6connected to the power socket38via a power cable4of the power source2of the vehicle is connected. As a result, electric power from the power source2is supplied to the electromechanical integration unit10.

A plurality of motors50and52and gear mechanisms54are disposed in the first chamber R1of the housing12. The plurality of motors50and52are driving motors that drive wheels of the vehicle. The plurality of motors50and52includes a first motor50and a second motor52. The gear mechanism54includes, for example, a planetary gear mechanism, a reduction gear mechanism, and a differential gear mechanism. The plurality of motors50,52and the gear mechanism54are connected to the wheels of the vehicle. Specifically, the plurality of motors50,52is connected to the wheels via a gear mechanism54. The electromechanical integration unit10outputs the power of the plurality of motors50and52to the wheels via the gear mechanism54. The plurality of motors50and52are driven by electric power from the power source2of the vehicle. However, the motor is not limited to a plurality of motors (two motors in the present embodiment), and may include at least one motor.

In the second chamber R2of the housing12, a plurality of electrical units20and30, a motor terminal block40, and a branch unit36are arranged. The plurality of electrical units20,30includes an upper electrical unit20and a lower electrical unit30. The lower electrical unit30is disposed below the upper electrical unit20. The branch unit36is electrically connected to the power socket38. The branch unit36is electrically connected to each of the plurality of electrical units20and30. The electric power supplied from the power source2via the power socket38is distributed to the respective electrical units20and30by the branch unit36. As shown inFIG.3, the electromechanical integration unit10includes a power control circuit28and a charging circuit32. The power control circuit28includes a plurality of electrical units20and30. In other words, the branch unit36distributes the power from the power source2to the power control circuit28and the charging circuit32.

Next, the power control circuit28will be described. The power control circuit28controls the power supplied to the plurality of motors50and52. The power control circuit28includes a boost converter22and a plurality of inverters24and26. The plurality of inverters24and26includes a first inverter24and a second inverter26. The boost converter22boosts the DC power from the power source2of the vehicle, and supplies the boosted DC power to the first inverter24and the second inverter26. The first inverter24converts the DC power from the boost converter22into AC power and supplies the AC power to the first motor50. The second inverter26converts the DC power from the boost converter22into AC power, and supplies the converted AC power to the second motor52.

The boost converter22is a DCDC converter. Specifically, the boost converter22includes two switching elements22a, a reactor22b, and two capacitive capacitors22c. One end of one of the switching elements22ais connected to the negative electrode2bof the power source2. The other end of one of the switching elements22ais connected to the positive electrode2aof the power source2via the reactor22b. The other end of one switching element22ais connected to one end of the other switching element22a. The other end of the other switching element22ais connected to the plurality of inverters24and26. In one embodiment, one capacitive capacitor22cis disposed between the power source2and the reactor22band the switching element22a. The other capacitive capacitor22cis disposed between the switching element22aand the plurality of inverters24and26.

Although not particularly limited, the switching element22aof the boost converter22is a Reverse conducting Insulated Gate Bipolar Transistor (RC-IGBT) element. That is, the switching element22ahas an IGBT structure and a diode structure connected in anti-parallel thereto. An emitter having an IGBT structure and an anode having a diode structure are connected to one end of the above-described switching element22a. A collector of an IGBT structure and a cathode of a diode structure are connected to the other end of the switching element22a. However, the switching element22ais not limited to RC-IGBT element, and may be a Metal-Oxide-Semi conductor Field-Effect Transistor (MOSFET) element or another type of switching element.

The first inverter24is a three-phase alternating current inverter circuit. The first inverter24has six switching elements24a. The first inverter24outputs, to the first motor50, AC power of three different phases, such as V-phase, U-phase, and W-phase, converted from DC power. The first inverter24is disposed between the boost converter22and the first motor50. The second inverter26is also a three-phase AC inverter circuit similar to the first inverter24. The second inverter26also has six switching elements (not shown). The second inverter26outputs, to the second motor52, the AC power of three different phases, such as the V-phase, the U-phase, and the W-phase, converted from the DC power. The second inverter26is disposed between the boost converter22and the second motor52. The switching elements24aof the first inverter24and the switching elements of the second inverter26are the same as the switching element22aof the boost converter22.

In the electromechanical integration unit10according to the present embodiment, a plurality of electrical components constituting the above-described power control circuit28is distributed to each of the plurality of electrical units20and30. The plurality of electrical units20,30is housed in a second chamber R2of the housing12. The upper electrical unit20includes two switching elements22aand two capacitive capacitors22cof the boost converter22, a switching element24aof the first inverter24, and a switching element of the second inverter26. The lower electrical unit30has a reactor22bof the boost converter22.

Here, the lower electrical unit30is an example of a “first electrical unit” in the technology disclosed in the present specification. The reactor22bis an exemplary “at least one first electrical component” in the technique disclosed in the present specification. The at least one first electrical component is not limited to a reactor22b. The at least one first electrical component may include other electrical components that constitute the power control circuit28in place of or in addition to the reactor22b. The upper electrical unit20is an example of a “second electrical unit” in the technology disclosed in the present specification. The two switching elements22aand the two capacitive capacitors22cof the boost converter22, the switching element24aof the first inverter24, and the switching element of the second inverter26are exemplary “at least one second electrical component” in the technique disclosed in the present specification.

Next, the charging circuit32will be described. As illustrated inFIG.4, the charging circuit32converts the DC power supplied from the power source2of the vehicle into the charging power supplied to the auxiliary battery8of the vehicle. The charge circuit32is a DCDC converter circuit. Specifically, the charge circuit32includes two switching elements32a, a reactor32b, and two capacitive capacitors32c. One end of one of the switching elements32ais connected to the positive electrode2aof the power source2. The other end of the switching element32ais connected to the positive electrode8aof the auxiliary battery8via the reactor32b. The other end of one switching element32ais connected to one end of the other switching element32a. The other end of the other switching element32ais connected to the negative electrode8bof the auxiliary battery8. The other end of the other switching element32ais connected to the negative electrode2bof the power source2. In an exemplary embodiment, one capacitive capacitor32cis disposed between the power source2and the switching element32a. The other capacitive capacitor32cis disposed between the switching element32aand the reactor32band the auxiliary battery8. The rated voltage of auxiliary battery8is 12 volts. The auxiliary battery8is connected to various control systems and other auxiliary devices of the vehicle. The auxiliary battery8supplies power to these components. The switching element32aof the charge circuit32is the same as the switching element22aof the boost converter22.

The lower electrical unit30includes a plurality of electrical components and a base plate31in addition to the reactor22bof the power control circuit28. The plurality of electrical components constitutes the charging circuit32. The base plate31supports the plurality of electrical components. Here, the plurality of electrical components (that is, the two switching elements32a, the reactor32b, and the two capacitive capacitors32c) constituting the charge circuit32are exemplary of “at least one third electrical component” in the technique disclosed in the present specification.

In the lower electrical unit30, the charging circuit32is fixed to the upper surface (i.e., the upper electrical unit20side) of the base plate31. The reactor22bis fixed to the lower surface of the base plate31(i.e., the partition wall14dof the housing body14). The lower electrical unit30is attached to the partition wall14dof the housing12via the base plate31. Although described above, in the present embodiment, in the first chamber R1, the second motor52is positioned above the first motor50. The reactor22bof the power control circuit28of the lower electrical unit30is located above the first motor50in the second chamber R2. On the other hand, the reactor22bis not positioned above the second motor52in the second chamber R2(seeFIG.1). According to this configuration, the reactor22bcan be disposed in an excess space that can be caused by the arrangement of the first motor50and the second motor52. This makes it possible to reduce the size of the electromechanical integration unit10.

In the second chamber R2, the upper electrical unit20is fixed to the cover plate16of the housing12. Although not particularly limited, the first inverter24and the second inverter26and the electrical components other than the reactor22bof the boost converter22are disposed on the lower surface of the cover plate16. A control board27connected to the first inverter24, the second inverter26, and the boost converter22is disposed on the upper surface of the cover plate16. The control board27includes components such as a CPU and a processor incorporating memories. The control board27controls the operations of the first inverter24, the second inverter26, and the boost converter22. A protective cover18is provided on the cover plate16. The protective cover18is a plate-shaped member. The protective cover18is made of a conductive material such as aluminum. The protective cover18covers the control board27located on the upper surface of the cover plate16.

The electromechanical integration unit10includes a plurality of motor terminals m1to m6, a plurality of reactor terminals x1, x2, and a plurality of connecting terminals y1to y8. An m6from the plurality of motor terminals m1is provided in the second chamber R2of the housing12. From the plurality of motor terminals m1to m6includes six motor terminals from the first motor terminal m1to the sixth motor terminal m6. The plurality of motor terminals m1to m6is arranged in the order from the first motor terminal m1to the sixth motor terminal m6from the front to the rear in the second chamber R2. m6from the motor terminals m1has a plate-like shape having a pair of wide surfaces. m6from the plurality of motor terminals m1are arranged such that their wide surfaces are substantially aligned. m6from the plurality of motor terminals m1is made of a conductive material such as a metallic material. The partition wall14dof the housing12is provided with a through-hole14epenetrating from the first chamber R1to the second chamber R2. A motor terminal block40is provided on the opening of the through-hole14eformed in the second chamber R2. The motor terminal block40has a generally box shape. The motor terminal block40is formed of an insulating material such as resin. The motor terminal block40is disposed on the partition wall14dso as to close the opening. m6from the plurality of motor terminals m1is supported and fixed above the partition wall14dby the motor terminal block40. m6from the plurality of motor terminals m1protrudes upward from the upper surface of the motor terminal block40. The motor terminal block40is provided with a plurality of motor busbars56protruding toward the first chamber R1through the through-hole14e. An upper end of each of the plurality of motor busbars56is m6from a corresponding motor terminal m1. A lower end of each of the plurality of motor busbars56is electrically connected to the first motor50or the second motor52, respectively. Accordingly, m6from the plurality of motor terminals m1is electrically connected to the first motor50or the second motor52via the plurality of motor busbars56. Specifically, the third motor terminal m3from the first motor terminal m1is electrically connected to the first motor50(seeFIG.3). The fourth motor terminal m4to the sixth motor terminal m6are connected to the second motor52(seeFIG.3).

A y8is provided from a plurality of connecting terminals y1on the left side surface of the upper electrical unit20. The plurality of connection terminals y1to y8includes eight connection terminals from the first connection terminal y1to the eighth connection terminal y8. As an example, the plurality of connection terminals y1to y8are arranged in the order from the first connection terminal y1to the eighth connection terminal y8from the front to the rear. The connecting terminals y1to y8have a plate shape or a foil shape having a pair of wide surfaces. y8from the plurality of connection terminals y1is fixed to the upper electrical unit20via the connection terminal block42. Thus, y8from the plurality of connecting terminals y1is integrally formed with the upper electrical unit20. That is, y8from the plurality of connecting terminals y1is fixed to the cover plate16together with the upper electrical unit20. The connection terminal block42has a generally box shape. The connection terminal block42is formed using an insulating material such as a resin. y8from the plurality of connection terminals y1is exposed from the lower end portion of the connection terminal block42on the left side surface of the connection terminal block42. A wiring (not shown) constituting a part of the power control circuit28is arranged inside the connection terminal block42. y8from the plurality of terminals y1are connected to corresponding wires, and are connected to the power control circuit28. Specifically, the first connecting terminal y1is electrically connected to one end of the other switching element (the reactor22boutput-side) of the boost converter22via the wire. Each of the seventh connection terminals y7from the second connection terminal y2is electrically connected to two corresponding switching elements of the plurality of switching elements24aof the first inverter24or the plurality of switching elements of the second inverter26via the wiring. The eighth connecting terminal y8is electrically connected to the power source2via the wire.

The lower electrical unit30is provided with a plurality of reactor terminals x1, x2. The plurality of reactor terminals x1, x2includes a first reactor terminal x1and a second reactor terminal x2. In one embodiment, the plurality of reactor terminals x1, x2have a plate-like configuration having a pair of wide surfaces. The plurality of reactor terminals x1, x2are arranged such that their wide surfaces are substantially aligned. Each of the plurality of reactor terminals x1, x2is arranged adjacently to m6from the plurality of motor terminals m1. The first reactor terminal x1is located in front of the plurality of motor terminals m1. The second reactor terminal x2is located behind the plurality of motor terminals m1. The plurality of reactor terminals x1, x2are arranged substantially in a straight line together with the plurality of motor terminals (seeFIGS.1and2). The plurality of reactor terminals x1, x2extend upward from the plurality of connecting terminals y1of the upper electrical unit20toward y8from the reactor22blocated at the lower portion of the lower electrical unit30. The plurality of reactor terminals x1, x2are electrically connected to the reactor22b. The first reactor terminal x1is electrically connected to the switching element22aof the reactor22b. The second reactor terminal x2is electrically connected to the power source2of the reactor22b.

Here, the plurality of reactor terminals x1, x2is an exemplary “plurality of first terminals” in the technique disclosed in the present specification. y8from the plurality of connecting terminals y1is an exemplary “plurality of second terminals” in the technique disclosed in the present specification.

As shown inFIGS.1and5, the second chamber R2of the housing12is provided with a service hole14f. In the area exposed to the outside through the opening of the service hole14f, m8and the reactor terminals x1, x2from the plurality of motor terminals m1are connected to y8from the plurality of connecting terminals y1. In an exemplary embodiment, m8and the reactor terminals x1, x2are fastened from the plurality of motor terminals m1onto y8from the plurality of connecting terminals y1by fasteners such as bolts and nuts. Specifically, the first reactor terminal x1is connected to the first connecting terminal y1. The second reactor terminal x2is connected to the eighth connecting terminal y8. Therefore, the DC power from the power source2is supplied to the upper electrical unit20via the reactor22bof the lower electrical unit30. The first motor terminal m1is connected to the second connecting terminal y2. V-phase AC power is supplied from the upper electrical unit20to the first motor50. The second motor terminal m2is connected to the third connecting terminal y3. AC power of the U-phase is supplied from the upper electrical unit20to the first motor50. The third motor terminal m3is connected to the fourth connecting terminal y4. The W-phase AC power is supplied from the upper electrical unit20to the first motor50. The fourth motor terminal m4is connected to the fifth connecting terminal y5. V-phase AC power is supplied from the upper electrical unit20to the second motor52. The fifth motor terminal m5is connected to the sixth connecting terminal y6, and the U-phase AC power is supplied from the upper electrical unit20to the second motor52. The sixth motor terminal m6is connected to the seventh connecting terminal y7. The W-phase AC power is supplied from the upper electrical unit20to the second motor52.

In the electromechanical integration unit as in the present embodiment, for example, for the purpose of miniaturization of the electromechanical integration unit, it is conceivable that a plurality of components such as a motor and a power control circuit are accommodated in a common housing. In this case, when one or a plurality of service holes are formed in the housing, after the plurality of components are arranged in the housing, the terminal groups provided in the components can be connected to each other from the outside through the service hole. The number of service holes provided in the housing can be freely designed according to the number of terminals to be connected to each other (that is, the number of components). However, if a plurality of service holes is formed in the housing, for example, the size of the housing may be increased and the rigidity of the housing may be reduced.

In the electromechanical integration unit10of the present embodiment, the electric power control circuit28is configured to control the electric power supplied to the plurality of motors50and52by using the reactor22band a plurality of electrical components (for example, a plurality of switching elements22a,24aand the like) provided in the upper electrical unit20. The reactor22bis provided in the lower electrical unit30. The plurality of electrical components is provided in the upper electrical unit20. In other words, a plurality of electrical components constituting the power control circuit28is distributed to two electrical units, the upper electrical unit20and the lower electrical unit30. According to such a configuration, it is possible to increase the degree of freedom in design of the upper electrical unit20and the lower electrical unit30. Furthermore, the upper electrical unit20and the lower electrical unit30can be arranged by effectively utilizing a limited space in the housing12.

When a plurality of electrical components constituting the power control circuit28are distributed to two electrical units20,30, three components including two electrical units20,30need to be electrically connected to each other in the motors50,52. In this regard, in the above-described electromechanical integration unit10, three parties of a plurality of motor terminals m1electrically connected to the motors50and52to m6, a plurality of reactor terminals x1, x2provided in the lower electrical unit30, and a plurality of connecting terminals y1to y8provided in the upper electrical unit20are arranged so as to be exposed to the outside through a common-service-hole14f. According to such a configuration, the number of service holes required can be reduced with respect to the number of terminal groups to be connected to each other. Thus, for example, it is possible to avoid or suppress an increase in the size of the housing12and a decrease in the rigidity of the housing12.

Now, referring toFIGS.6and7, an exemplary assembly process in the second chamber R2of the electromechanical integration unit10will be described in detail. Here, the power socket38and the branch unit36are not shown. Further, the description of the attachment of the power socket38and the branch unit36is omitted. First, as shown inFIGS.6and7, the motor terminal block40for supporting m6from the plurality of motor terminals m1is mounted on the through-hole14eof the partition wall14d. At this time, the plurality of motor busbars56extending to the first chamber R1are electrically connected to one of the first motor and the second motor (not shown). Next, the base plate31of the lower electrical unit30is fixed to an area located on the second motor of the partition wall14d. At this time, the lower electrical unit30is arranged such that the plurality of reactor terminals x1, x2are located on both sides of m6from the plurality of motor terminals m1. The upper electrical unit20is then attached to the cover plate16. At this time, the connection terminal block42is fixed to the upper electrical unit20. The connection terminal block42is fixed to the lower surface of the cover plate16together with the upper electrical unit20. A control board27is fixed to an upper surface of the cover plate16. Then, the protective cover18is mounted on the control board27disposed on the cover plate16. Then, the cover plate16to which the upper electrical unit20is attached is attached to the opening portion14cof the housing body14. At this time, on y8from the plurality of connection terminals y1arranged in the connection terminal block42, m6from the plurality of corresponding motor terminals m1, and a plurality of reactor terminals x1, x2of the lower electrical unit30are arranged. Finally, through the service hole14fof the housing12, m6are bolted from the plurality of connecting terminals y1to y8, the plurality of reactor terminals x1, x2, and the plurality of motor terminals m1. As described above, the electromechanical integration unit10is assembled.

The housing12in the present embodiment includes a housing body14having an opening portion14cin the second chamber R2, and a cover plate16. The cover plate16is detachably attached to the opening portion14c. Here, the upper electrical unit20is fixed to the cover plate16together with y8from the plurality of connecting terminals y1. According to this configuration, after the cover plate16is attached to the housing body14, y8from the plurality of connecting terminals y1and m6and the plurality of reactor terminals x1, x2can be connected to each other from the plurality of motor terminals m1through the service hole14f.

The plurality of reactor terminals x1, x2in the present embodiment are arranged in a straight line from the plurality of motor terminals m1together with m6. According to this configuration, m6and the plurality of reactor terminals x1, x2can be arranged from the plurality of motor terminals m1along the peripheral wall14bof the housing12provided with the service hole14fAccordingly, the plurality of motor terminals m1to m6and the plurality of reactor terminals x1, x2and the plurality of connecting terminals y1to y8are easily connected through the service hole14f.

The plurality of reactor terminals x1, x2in the present embodiment have a pair of terminals arranged on both sides of m6from the plurality of motor terminals m1. According to this configuration, it is possible to avoid or suppress the wiring connected to the plurality of reactor terminals x1, x2from being crossed with the plurality of wiring connected to m6from the plurality of motor terminals m1. This makes it possible to avoid an excessive increase in temperature caused by the proximity of the plurality of wires. However, the configuration is not limited to the configuration of the present embodiment, and the plurality of reactor terminals x1, x2may not be located on both sides of m6from the plurality of motor terminals m1. Further, the order of the arrangement of the plurality of motor terminals m1to m6is not limited to the embodiment. m6may be arranged in another order from the plurality of motor terminals m1. In this case, the arrangement of y8from the plurality of connecting terminals y1may also be changed according to the arrangement of m6and the plurality of reactor terminals x1, x2from the plurality of motor terminals m1.

Although the specific examples disclosed by the present disclosure have been described in detail above, these are merely examples and do not limit the scope of claims. The techniques described in the claims include various modifications and alternations of the specific examples illustrated above. The technical elements described in this specification or in the drawings may be used alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. The technology illustrated in the present specification or the drawings can achieve a plurality of objects at the same time, and has technical usefulness in achieving one of the objects.