CN110312879B - 具有利用端环的压铆而固定到毂的转子的混合驱动模块 - Google Patents

具有利用端环的压铆而固定到毂的转子的混合驱动模块 Download PDF

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CN110312879B
CN110312879B CN201880013048.2A CN201880013048A CN110312879B CN 110312879 B CN110312879 B CN 110312879B CN 201880013048 A CN201880013048 A CN 201880013048A CN 110312879 B CN110312879 B CN 110312879B
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A·萨蒂亚西兰
J·佩尔辛格
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Schaeffler Technologies AG and Co KG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/22—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
    • B60K6/40—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the assembly or relative disposition of components
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    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/42—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
    • B60K6/48—Parallel type
    • 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
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/42—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
    • B60K6/48—Parallel type
    • B60K2006/4825—Electric machine connected or connectable to gearbox input shaft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
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    • B60Y2200/92—Hybrid vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
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    • B60Y2400/426—Hydrodynamic couplings, e.g. torque converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S903/00—Hybrid electric vehicles, HEVS
    • Y10S903/902—Prime movers comprising electrical and internal combustion motors
    • Y10S903/903—Prime movers comprising electrical and internal combustion motors having energy storing means, e.g. battery, capacitor
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Abstract

一种混合驱动模块，包括变矩器的盖。所述混合驱动模块还包括连接到电动机的转子和盖的承载毂，该毂包括第一表面和从第一表面向外延伸的突起。所述混合驱动模块还包括设置在突起和转子之间并与第一表面接触的端环，其中，端环与突起和转子接合，并且突起利用承载毂和端环之间的干涉配合来限制端环和转子。

Description

具有利用端环的压铆而固定到毂的转子的混合驱动模块
相关申请的交叉引用
本申请要求2017年3月13日提交的美国申请No.15/456,884的优先权，其公开内容通过引用整体并入本文。
技术领域
本公开总体上涉及一种混合驱动模块，其包括具有转子的电动机。转子可能需要固定到毂上。
背景技术
车辆可以利用内燃机和电动机的混合组合来为车辆提供动力。电动机的转子可以固定到毂上，以防止端环移动而与转子和承载毂接触。
发明内容
根据第一实施例，一种混合驱动模块包括变矩器的盖。所述混合驱动模块还包括连接到电动机的转子和盖的承载毂，该毂包括第一表面和从第一表面向外延伸的突起。所述混合驱动模块还包括设置在突起和转子之间并与第一表面接触的端环，其中，端环与突起和转子接合，并且突起利用承载毂和端环之间的干涉配合来限制端环和转子。
根据第二实施例，一种将部件固定到包括变矩器和包含转子的电动机的混合驱动模块的承载毂的方法，该方法包括将端环连接到转子和从承载毂的第一表面向外延伸的突起。该方法还包括在承载毂和端环之间提供干涉配合。
根据第三实施例，一种混合驱动模块包括连接到电动机的转子的承载毂，该毂包括从表面向外延伸的突起。混合驱动模块还包括设置在突起和转子之间的端环，其中，端环利用承载毂和端环之间的干涉配合与表面处的突起接合。
附图说明
图1是混合驱动模块的剖视图。
图2是描绘在安装、组装和循环条件期间承载件上的端环的示例。
图3是用于固定到转子段和承载毂的端环的压铆几何形状的示例。
具体实施方式
本文描述了本公开的实施例。然而，应该理解，所公开的实施例仅仅是示例，并且其它实施例可以采用各种和替代形式。这些图不一定按比例；某些结构特征可能会被夸大或最小化，以显示特定部件的详细信息。因此，在此公开的具体结构和功能细节不应被解释为限制，而仅仅作为用于教导本领域技术人员以各种方式使用实施例的代表性基础。如本领域普通技术人员将理解的，参考任何一个附图示出和描述的各种特征可以与一个或多个其它附图中示出的特征组合以产生未明确示出或描述的实施例。所示特征的组合提供了典型应用的代表性实施例。然而，对于特定应用或实现，可能需要与本公开的教导一致的特征的各种组合和修改。
模块化混合变速器模块可包括安装在铆接到变矩器盖上的承载件上的转子段。转子段可能需要最小化或消除在混合变速器模块的运行期间移动或移位的能力。某些设计可以使用收缩配合到承载件上的环，以便于减少运动。环可以包括在其上的弹簧元件，弹簧元件可以在转子段上施加压缩力，或者环本身可以用作弹簧元件。压缩力可以防止转子段在运行期间移动。该力应该旨在高于特定的最小极限，最小极限可以基于来自电动机转子的扭矩驱动来计算。在温度循环期间，由于承载件和收缩配合环的热膨胀的不同系数，在升高的温度下可能存在收缩配合干涉的损失。收缩配合的损失使环上的弹簧元件松动，从而将转子上的夹紧载荷减小到低于最小所需极限的值，这可允许转子段在运行期间移动，这也称为“行走现象”。对端环或承载件使用相同的材料可以防止“行走现象”。此外，可以选择将转子段收缩配合到承载件上，消除对弹簧元件的需要并防止转子在运行期间移位。
图1是混合驱动模块100的剖视图。混合驱动模块100(下文中称为模块100)可包括但不限于以下部件：旋转轴线AR；变矩器110；毂105；端板125；包括转子122的电动机120。变矩器110可以包括盖112、叶轮113、涡轮114和导轮116。承载毂105可以包括通过一个或多个铆钉109以不可相对旋转的方式连接到盖112。承载毂105可以包括圆周表面107和突起106。承载毂105还可以包括两个或更多个部件，这些部件与组件中的附加金属件固定在一起。转子122可以与表面107接合并且例如通过花键143不可相对旋转地连接到毂105。板125可以与转子122接合。一个或多个突起106可以从圆周表面107沿方向RD径向向外延伸，由形成毂105的材料形成，与板125接触，并且在方向AD1上限制板125和转子122。
在一个示例性实施例中，突起106可以相对于与方向AD1相反的轴向方向AD2上的移动限制板125和转子122。也就是说，突起106固定了转子122在毂105上的轴向位置。例如，突起106与板125接触，这迫使转子122与毂105的肩部137接触。因此，转子122不能沿方向AD1或AD2移位。
在一个示例性实施例中，毂105可包括圆周表面138和突起139。虽然该实施例的表面138可以是圆周的，但它也可以是平面的或基本上平面的，并且不限于圆周表面。模块100还可以包括与表面138接合的旋转变压器(resolver)转子128。突起139可以从圆周表面138沿方向RD径向向外延伸，由形成毂105的材料形成，并且将转子128固定到毂105。旋转变压器127可以固定到壳体115。旋转变压器127可以检测旋转变压器转子128在毂105上的旋转位置，以便控制电动机120的旋转和功率输出。
在一个示例中，模块100包括输入部件130或布置成接合输入部件130并且包括分离离合器132。部件130布置成例如从内燃机(未示出)接收扭矩。离合器132包括至少一个不可相对旋转地连接到毂105的离合器板133、不可相对旋转地连接到输入部件130的内部承载件134、不可相对旋转地连接到内部承载件134的离合器板135以及可轴向移动以打开和闭合离合器132的活塞板136。离合器132使输入部件130和盖112能够选择性地连接。因此，模块100可以以至少三种模式起作用。对于第一种模式，离合器132打开，并且电动机120经由转子122是变矩器110的唯一扭矩源。对于第二种模式，离合器132闭合，电动机120不驱动变矩器110，并且变矩器110的唯一扭矩源是经由分离离合器的输入部件130。对于第三种模式，离合器132闭合并且电动机120用于向输入部件130提供扭矩以启动附接到输入部件130的内燃机(未示出)。
在一个示例性实施例中，变矩器110可包括扭转振动减振器111，其具有连接到涡轮114的输入部件118、布置成连接到变速器输入轴(未示出)的输出部件119以及至少一个与输入部件118和输出部件119接合的弹簧121。
在一个示例性实施例中，毂105可以由铸铝制成，但是也可以使用其它材料，例如铸造球墨铸铁。在具有两个或更多个主要部件的承载毂105中，可以在部件中使用不同的材料。突起106和139可以是与毂的铸铝(例如非铸造)不同的材料，并且不是通过任何类型的弯曲操作形成的。替代地，可以通过对铸造毂压铆来制造突起106和139。例如，可以使用一个或多个冲头相应于铸造毂的部分形成变形部分。变形部分可以形成突起106和139并且在没有紧固件或其它添加材料的情况下将转子和旋转变压器转子固定到毂。具体地，通过压铆而变形和移位的材料形成突起106和139，并在突起106和板125之间以及突起139和转子127之间产生相应的干涉配合。
铸造工艺中形成的突起与压铆突起之间的差异可以通过材料的物理特性来举例说明。例如，形成铸造毂(并且不压铆或通过压铆变形)的铝和形成变形突起的材料之间的差异。例如，形成铸造毂且不压铆或通过压铆变形的材料(例如，不包括邻接突起106或139的材料)具有每单位体积‘x’个晶格缺陷，包括点缺陷或瑕疵、线缺陷或表面缺陷-晶界。形成突起106的材料可以具有每单位体积大于‘x’个的‘y’个晶格缺陷，包括点缺陷或瑕疵、线缺陷或表面缺陷-晶界。形成突起139的材料可以具有每单位体积大于‘x’个的‘z’个晶格缺陷，包括点缺陷或瑕疵、线缺陷或表面缺陷-晶界。晶格缺陷的增加是由于形成原始铸造毂的材料通过压铆工艺变形所致。
在一个示例性实施例中，毂105由铝制成，其可用于减小毂的重量和转动惯量，并且盖112由钢制成，降低了制造盖112的成本并增加了盖112的耐用性。在另一个实施例中，由于4140钢的高延展性，承载毂可以由4140钢制成。在其它实施例中，其它材料可用于承载毂，包括但不限于不锈钢或其它金属和合金、铸造球墨铸铁或其它类似材料。
图2是描绘在包括安装、组装和循环条件的各种条件期间承载件上的端环的示例。端板125可以与转子122和承载毂105接触。如图2所示，端板125可以具有各种区域或位置，端板125相对于转子122和承载件105安置在所述区域或位置上。由于端板125、转子122和承载件105的热膨胀系数的变化，在各种条件下，每种条件都可以使这些部件基于压力或温度膨胀或收缩。例如，端板125被描绘为在组装过程中基于端板125和转子122的膨胀/收缩而与转子122基本平齐。不同的材料可以基于端环125和承载件105的温度和压力具有不同膨胀系数。
当端环125安装到承载件105上时，端环125和承载件105可以具有不同的热膨胀系数。当端环125被加热时，压迫可以推动端环125以在端环125和承载件105的接触点处引起变形。压迫可以向端环125的不同点施加压力，但是可以理想地，在端板保持承载件125或转子122的载荷相对较大的区域或点处施加压力。在端环125被冷却时，在端环125和承载件105之间可形成收缩配合或干涉配合。
如图2所示，端环125在循环阶段期间可以位于安装阶段或组装期间之间的中间点。当然，该位置可以基于用于端环125和承载件105的材料的热膨胀系数而变化。
图3是用于将转子段固定到承载毂105的端环125的压铆几何形状的示例。压铆工艺可用于机械保持以防止在混合模块的升高的温度下的“行走现象”。例如，承载毂105可以由4140钢或其它材料制成。端环125可以是不锈钢材料。在一些实施例中，端环125和承载件105可以是相同的材料。在利用相同材料的端环125和承载件105的实施例中，利用奥氏体或非磁性材料可能是有益的。这种材料可以防止来自转子的磁通不逸出。
压铆可以利用各种几何形状在端环125和承载件105之间产生干涉配合。压铆工艺可以包括具有与承载毂相对应的几何形状的端环，以便产生干涉配合。例如，端环可以包括45度角，该角与承载毂的45度角对准，形成干涉配合，以防止转子移动。在另一个实施例中，端环可以包括大于45度的角并且与承载毂的角度小于45度的突起对准，或反之亦然。
虽然可以利用压铆工艺在承载毂105和转子122之间产生干涉配合，但是还可以使用位于端环125后的卡环或弹性挡圈。卡环或弹性挡圈可以附接到端环125和毂105上，以便将端环125固定到转子122。弹簧元件也可以与收缩配合设置一起使用，或者用在不使用收缩配合设置的场景中。弹簧元件可以放置在端环125上并且定位在端环125和承载件105之间。
虽然以上描述了示例性实施例，但并不意味着这些实施例描述了权利要求所涵盖的所有可能形式。说明书中使用的词语是描述性词语而不是限制性词语，并且应当理解，在不脱离本公开的精神和范围的情况下，可以进行各种改变。如前所述，各种实施例的特征可以组合以形成可能未明确描述或说明的本发明的其它实施例。虽然各种实施例可以被描述为相对于一个或多个期望特性提供优于或优先于其它实施例或现有技术实现，但是本领域普通技术人员认识到可以妥协一个或多个特征或特性以实现期望的整体***属性，这取决于具体的应用和实现。这些属性可以包括但不限于成本、强度、耐久性、生命周期成本、可销售性、外观、包装、尺寸、可维护性、重量、可制造性、易于组装等。因此，就任何被描述为关于一个或多个特性不如其它实施例或现有技术实现所希望的程度的实施例而言，这些实施例不在本公开的范围之外并且对于特定应用可能是期望的。

Claims (10)

1.一种混合驱动模块，包括：
变矩器的盖；
承载毂，其连接到电动机的转子和盖，该承载毂包括第一外表面和从第一外表面从轴向以及径向向外延伸的突起，所述承载毂的第一外表面与所述转子的内表面接触；和
端环，其设置在突起和转子之间，所述端环的内表面与第一外表面接触，其中，所述端环与所述突起的从轴向以及径向向外延伸的突起表面接合，所述端环与所述转子的径向表面接合，并且所述突起利用承载毂和端环之间的干涉配合来限制端环和转子。
2.根据权利要求1所述的混合驱动模块，其中，所述干涉配合包括在所述承载毂和端环上的倒角。
3.根据权利要求1所述的混合驱动模块，其中，所述干涉配合位于突起和端环之间。
4.根据权利要求1所述的混合驱动模块，其中，所述承载毂和端环的几何形状彼此对应以形成干涉配合。
5.根据权利要求1所述的混合驱动模块，其中，所述干涉配合被配置成能够为所述端环的轴向平移提供止动结构。
6.根据权利要求1所述的混合驱动模块，其中，所述端环和承载毂由冷轧钢制成。
7.根据权利要求6所述的混合驱动模块，其中，所述冷轧钢包括4140钢。
8.根据权利要求1所述的混合驱动模块，其中，所述突起塑性地变形而成。
9.根据权利要求1所述的混合驱动模块，其中，所述端环和承载毂由不同的材料制成。
10.根据权利要求1所述的混合驱动模块，其中，所述干涉配合位于承载毂和端环的拐角之间。
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