Hybrid electric vehicle drive motor mounting module

• US 6,022,048 A
• Filed: 07/02/1998
• Issued: 02/08/2000
• Est. Priority Date: 07/02/1998
• Status: Expired due to Fees

• Current Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Original Assignee: Navistar International Transportation Corp. (Volkswagen AG)
• Inventors: Donley, Harl, Harshbarger, M. Chad, Lasecki, Michael P., Schuler, Nathan L.
• Primary Examiner(s): Dickson, Paul N.
• Assistant Examiner(s): WINNER, TONY H
• Application Number:
  US09/109,431
• Time in Patent Office: 586 Days
• Field of Search: 180/291, 180/299, 180/300, 180/65.2, 180/65.4, 180/312, 180/204, 280/781
• US Class Current: 280/781
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10S 903/951 Assembly or relative location of components

Abstract

A drive motor mounting module for a hybrid electric vehicle and the motor mounting module in combination with the hybrid electric vehicle. More specifically, the drive motor mounting module is comprised of a drive motor, a front motor mount support bracket, a chassis front support bracket, a chassis cross member, two rear motor mount brackets, two cross braces, two vertical channels and two motor module locating mounts. The entire module can be modularly assembled prior to installation to the vehicle chassis on a main assembly line. The mounting module engages the drive motor to the chassis by three point mountings.

Claims

1. A three point drive motor mounting module for a hybrid electric vehicle with a chassis with two frame rails which includes an engine, and an electric generator engaged to the chassis, an electric control system and batteries electrically engaged to the generator, and a drive line engaged to a drive axle assembly and wheels, comprising:

(a) an electric drive motor;

(b) said motor electrically engaged to the electric control system and batteries;

(c) said motor mechanically engaged to the drive line of the vehicle;

(d) a chassis cross member installed between the frame rails;

(e) said chassis cross member having a chassis front support bracket;

(f) a frame mount casting engaged rearward of said chassis cross member to each of the frame rails;

(g) each of said frame mount castings having a rear isolator;

(h) said chassis front support bracket having a rubber isolator;

(i) a front motor support bracket engaged to a front section of said motor;

(j) said front motor support bracket shaped to engage to said chassis front support bracket of said chassis cross member to sandwich said rubber isolator, and to allow said motor to be lowered and engaged to the chassis;

(k) a right rear motor mount bracket engaged to a right rear underside of said motor;

(l) a left rear motor mount bracket engaged to a left rear underside of said motor;

(m) a vertical channel engaged to each of said right and left rear motor mount brackets;

(n) a cross brace engaged between an upper portion of each of said vertical channels;

(o) a motor module locating casting mount engaged to each of said vertical channels; and

(p) said motor module locating casting mounts shaped to fit within said rear motor mount brackets to allow said motor to be lowered and engaged to the chassis.

2. The motor mount module of claim 1, wherein:

(a) said front motor support bracket is right angle shaped with a horizontal chassis cross member engagement face directed forward relative to the vehicle;

(b) said chassis front support bracket is right angle shaped with a front motor horizontal engagement face directed rearward relative to the vehicle; and

(c) said horizontal chassis cross member engagement face is engaged to said front motor horizontal engagement face with said rubber isolator sandwiched between to prevent metal to metal contact.

3. The motor mount module of claim 2, wherein:

(a) said vertical channels being comprised of a front section, a back section, and a side section;

(b) said rear motor mount brackets being comprised of a front face, a back face, and an inner side face;

(c) said front faces of said rear motor mount brackets being engaged to said front sections of said vertical channels;

(d) said rear faces of said rear motor mount brackets being engaged to said rear sections of said vertical channels;

(e) said inner side faces of said motor mount brackets being shaped to conform to said rear underside of said motors.

4. The motor mount module of claim 3 wherein:

(a) a second cross brace runs between said upper portion of said vertical channels.

5. The motor mount module of claim 3, wherein:

(a) said frame mount castings are "V" shaped where said frame mount castings engage said motor module locating casting mounts;

(b) said motor module locating casting mounts are "V" shaped to engage within said frame mount castings; and

(c) said motor module locating casting mounts are engaged to said frame mount castings with said rear isolators sandwiched between to prevent metal to metal contact.

6. A hybrid electric vehicle, comprising:

(a) a chassis with two frame rails;

(b) an engine and electric generator engaged to said chassis;

(c) an electric control system and batteries electrically engaged to said generator;

(d) said electric control system and batteries mechanically engaged to said chassis;

(e) a drive line engaged to a drive axle assembly and wheels;

(f) said drive axle assembly mechanically engaged to said chassis;

(g) an electric drive motor electrically engaged to said electric control system and batteries;

(h) said motor mechanically engaged to said drive line of said vehicle;

(i) a chassis cross member installed between the frame rails;

(j) said chassis cross member having a chassis front support bracket;

(k) a frame mount casting engaged rearward of said chassis cross member to each of said frame rails;

(l) each of said frame mount castings having a rear isolator;

(m) said chassis front support bracket having a rubber isolator;

(n) a front motor support bracket engaged to a front section of said motor;

(o) said front motor support bracket shaped to engage to said chassis front support bracket of said chassis cross member to sandwich said rubber isolator, and to allow said motor to be lowered and engaged to the chassis;

(p) a right rear motor mount bracket engaged to a right rear underside of said motor;

(q) a left rear motor mount bracket engaged to a left rear underside of said motor;

(r) a vertical channel engaged to each of said right and left rear motor mount brackets;

(s) a cross brace engaged between an upper portion of each of said vertical channels;

(t) a motor module locating casting mount engaged to each of said vertical channels; and

(u) said motor module locating casting mounts shaped to fit within said rear motor mount brackets to allow said motor to be lowered and engaged to said chassis.

7. The hybrid electric vehicle of claim 6, wherein:

(a) said front motor support bracket is right angle shaped with a horizontal chassis cross member engagement face directed forward relative to the vehicle;

(b) said chassis front support bracket is right angle shaped with a front motor horizontal engagement face directed rearward relative to the vehicle; and

(c) said horizontal chassis cross member engagement face is engaged to said front motor horizontal engagement face with said rubber isolator sandwiched between to prevent metal to metal contact.

8. The hybrid electric vehicle of claim 7, wherein:

(a) said vertical channels being comprised of a front section, a back section, and a side section;

(b) said rear motor mount brackets being comprised of a front face, a back face, and an inner side face;

(c) said front faces of said rear motor mount brackets being engaged to said front sections of said vertical channels;

(d) said rear faces of said rear motor mount brackets being engaged to said rear sections of said vertical channels;

(e) said inner side faces of said motor mount brackets being shaped to conform to said rear underside of said motors.

9. The hybrid electric vehicle of claim 8, wherein:

(a) a second cross brace runs between said upper portion of said vertical channels.

10. The hybrid electric vehicle of claim 8, wherein:

(a) said frame mount castings are "V" shaped where said frame mount castings engage said motor module locating casting mounts;

(b) said motor module locating casting mounts are "V" shaped to engage within said frame mount castings; and

(c) said motor module locating casting mounts are engaged to said frame mount castings with said rear isolators sandwiched between to prevent metal to metal contact.

11. A process for installing an electric drive motor to a vehicle with a chassis with two frame rails which includes an engine, and an electric generator engaged to the chassis, an electric control system and batteries electrically engaged to the generator, and a drive line engaged to a drive axle assembly and wheels, comprising the steps of:

(a) assembling an off-line portion of a motor mount module off of a main assembly line, comprising the steps of;

(i) engaging a motor mount support bracket to a front of an electric drive motor;

(ii) installing a right rear motor mount bracket to a right rear underside of said motor;

(iii) installing a left rear motor mount bracket to a left rear underside of said motor;

(iv) engaging a separate vertical channel to said right rear motor mount bracket and to said left rear motor mount bracket;

(v) engaging a cross brace between upper portions of said vertical channels; and

(vi) engaging a motor module locating casting mount to each said vertical channel;

(b) assembling an on-line portion of a motor mount module on a main assembly line, comprising the steps of;

(i) engaging a frame mount casting to an inner face of each of the frame rails, each said frame mount casting having a rear isolator,

(ii) engaging a chassis cross member to and between the frame rails, said chassis cross member having a chassis front support bracket and said chassis front support bracket having a rubber isolator;

(iii) lowering said off-line portion of said motor mount module to said chassis with said front motor support bracket contacting said chassis front support bracket and said motor module locating casting mounts contacting said frame mount castings; and

(iv) engaging said motor mount support bracket to chassis front support bracket and said motor module locating casting mounts to said frame mount castings;

(c) electrically engaging said motor to the electric control system and batteries; and

(d) mechanically engaging said motor to the drive line of the vehicle.

12. The process of claim 11, wherein:

(a) said front motor support bracket is right angle shaped with a horizontal chassis cross member engagement face directed forward relative to the vehicle;

(b) said chassis front support bracket is right angle shaped with a front motor horizontal engagement face directed rearward relative to the vehicle; and

(c) said horizontal chassis cross member engagement face is engaged to said front motor horizontal engagement face with said rubber isolator sandwiched between to prevent metal to metal contact.

13. The process of claim 12, wherein:

(a) said vertical channels being comprised of a front section, a back section, and a side section;

(b) said rear motor mount brackets being comprised of a front face, a back face, and an inner side face;

(c) said front faces of said rear motor mount brackets being engaged to said front sections of said vertical channels;

(d) said rear faces of said rear motor mount brackets being engaged to said rear sections of said vertical channels;

(e) said inner side faces of said motor mount brackets being shaped to conform to said rear underside of said motors.

14. The process of claim 13, wherein:

(a) said frame mount castings are "V" shaped where said frame mount castings engage said motor module locating casting mounts;

(b) said motor module locating casting mounts are "V" shaped to engage within said frame mount castings; and

(c) said motor module locating casting mounts are engaged to said frame mount castings with said rear isolators sandwiched between to prevent metal to metal contact.