CN112544028A - 一种包括具有冷却剂流动通道的转子的混合动力模块 - Google Patents

一种包括具有冷却剂流动通道的转子的混合动力模块 Download PDF

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CN112544028A
CN112544028A CN201980051738.1A CN201980051738A CN112544028A CN 112544028 A CN112544028 A CN 112544028A CN 201980051738 A CN201980051738 A CN 201980051738A CN 112544028 A CN112544028 A CN 112544028A
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rotor
plates
plate
radially
motor
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E·于贝尔哈特
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Schaeffler Technologies AG and Co KG
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/108Structural association with clutches, brakes, gears, pulleys or mechanical starters with friction clutches
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/32Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT 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
    • B60K6/00Arrangement 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
    • B60K6/20Arrangement 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
    • B60K6/22Arrangement 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
    • B60K6/26Arrangement 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 motors or the generators
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
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    • B60K6/00Arrangement 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
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    • B60K6/22Arrangement 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
    • B60K6/38Arrangement 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 driveline clutches
    • B60K6/387Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT 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
    • B60K6/00Arrangement 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
    • B60K6/20Arrangement 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
    • B60K6/22Arrangement 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
    • B60K6/40Arrangement 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT 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
    • B60K6/00Arrangement 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
    • B60K6/20Arrangement 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
    • B60K6/42Arrangement 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
    • B60K6/48Parallel type
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H41/00Rotary fluid gearing of the hydrokinetic type
    • F16H41/24Details
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H45/00Combinations of fluid gearings for conveying rotary motion with couplings or clutches
    • F16H45/02Combinations of fluid gearings for conveying rotary motion with couplings or clutches with mechanical clutches for bridging a fluid gearing of the hydrokinetic type
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/27Rotor cores with permanent magnets
    • H02K1/2706Inner rotors
    • H02K1/272Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K21/00Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/14Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT 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
    • B60K6/00Arrangement 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
    • B60K6/20Arrangement 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
    • B60K6/42Arrangement 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
    • B60K6/48Parallel type
    • B60K2006/4825Electric machine connected or connectable to gearbox input shaft

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Abstract

本发明提供了一种电动机,所述电动机包括可围绕中心轴线旋转的转子。所述转子包括多个磁体和多个径向延伸通道,所述多个径向延伸通道从所述转子的内圆周表面径向向外延伸以将流体提供至所述磁体。一种构造电动机的方法,其包括:将可围绕中心轴线旋转的转子制造成包括多个磁体和多个径向延伸通道,所述多个径向延伸通道从所述转子的内圆周表面径向向外延伸以将流体提供至所述磁体。

Description

一种包括具有冷却剂流动通道的转子的混合动力模块
技术领域
本公开整体涉及电动机转子,并且更具体地涉及混合动力模块中的电动机转子。
背景技术
永磁电机包括转子和定子。通常,仅冷却定子。转子中的磁体因其具有很少冷却而可变热浸。
发明内容
一种电动机,其包括可围绕中心轴线旋转的转子。转子包括多个磁体和多个径向延伸通道,该多个径向延伸通道从转子的内圆周表面径向向外延伸以将流体提供至磁体。
根据电动机的实施例,通道可在转子内轴向地且周向地延伸。通道可具有阶梯式构型。转子可由在轴向方向上堆叠的多个板形成。通道可由形成在板中的多个部分径向重叠的孔形成。径向重叠的孔可借由板中的在轴向方向上的每一连续板中的孔离中心轴线逐渐更加径向向外而形成通道。板可具有相同构型并且经旋转取向使得板中的每一者具有与板中的直接轴向相邻的板不同的旋转取向。板中的每一者可从直接轴向相邻的板旋转地偏移相同的角度。板中的每一者可包括多个圆周扇区。扇区中的每一者可包括多个孔。每个圆周扇区的孔可具有不同构型。板可基于圆周扇区的数量具有旋转偏移的重复图案。扇区中的每一者可包括多个孔组。孔组中的每一者可包括相同数量的扇区的孔。扇区中的每一者的孔组中的每一者可具有特定于相应扇区的相同构型。转子可包括轴向延伸通道。径向延伸通道可从转子的内圆周表面径向向外延伸至轴向延伸通道。轴向延伸通道可在磁体的径向内侧。转子可包括连接狭槽和接收磁体的磁体接收狭槽。连接狭槽可从轴向延伸通道延伸至磁体接收狭槽。磁体接收狭槽可成对布置,并且每一对可包括第一磁体接收狭槽和第二磁体接收狭槽。连接狭槽可包括第一连接狭槽和第二连接狭槽,并且第一连接狭槽可从轴向延伸通道延伸至第一磁体接收狭槽,并且第二连接狭槽可从轴向延伸通道延伸至第二磁体接收狭槽,使得轴向延伸通道中的每一者包括从其延伸的第一连接狭槽中的至少一者和第二连接狭槽中的至少一者。多个径向延伸通道可延伸至轴向延伸通道中的同一个中。可延伸至轴向延伸通道中的同一个中的多个径向延伸通道彼此轴向偏移。电动机可包括转子承载件,该转子承载件包括从中穿过以将流体提供至转子的内圆周表面的径向延伸孔。
一种构造电动机的方法,其包括:将可围绕中心轴线旋转的转子制造成包括多个磁体和多个径向延伸通道,该多个径向延伸通道从转子的内圆周表面径向向外延伸以将流体提供至磁体。该方法可包括:提供各自具有从中轴向延伸穿过的多个孔的多个板。制造转子可包括:将多个板轴向堆叠在一起,使得孔部分径向重叠以形成径向延伸通道。
附图说明
下面通过参考以下附图来描述本公开,附图中:
图1示出了根据本公开的实施例的混合动力模块;
图2示出了板的平面视图,该板与相同构型的其他板堆叠在一起以形成图1所示的混合动力模块的转子区段;
图3示出了图2所示的转子区段之一的周向部分的透视图;并且
图4示出了转子区段之一的轴向部分的多个堆叠板的周向剖视图。
具体实施方式
本公开提供通道,这些通道冲压至转子冲片中以向磁转子区段提供另外的冷却。在一个实施例中,磁转子区段在包括湿式发动机连接/分离离合器的湿式混合动力模块中的电动机中使用。这种另外的冷却可借助于通过减少转子的热浸来延长更高电流运行时间来提供改进的电动机能力。降低转子操作温度可通过减少添加以改进磁热耐久性的元件而使得能够使用较便宜的磁体。较便宜的磁体包含与常规磁体(诸如例如常规的广泛使用的钕磁体)相比较少的镝,或者不包含镝。包含较少的镝或不包含镝的磁体包括马格马磁技术公司(Magma Magnetic Technologies)出售的“无镝”和“少镝”尼奥磁体。在一个实施例中,孔设计成使得每个冲片(即,板),在堆叠在相邻冲片的顶部之前旋转90度。通道使冷却流体穿过转子堆叠从内径(但部在气隙中)移动到尽可能靠近磁体拐角以去除过量的热量。
图1示出了根据本发明的实施例的混合动力模块10。模块10包括经配置用于附接至内燃机的混合动力驱动单元12和经配置用于附接至变速器输入轴的变矩器14。以已知的方式,混合动力驱动单元12可选择性地操作以将扭矩从内燃机传递至变矩器14,或者经由驱动单元12的电动机16直接驱动变矩器14。沿着这些线路,混合动力驱动单元12包括发动机连接/分离离合器18,该发动机连接/分离离合器用于选择性地将变矩器14连接至输入轴20,该输入轴经配置用于例如经由飞轮不可旋转地连接至内燃机的曲轴,或者将变矩器14与输入轴20分离,使得变矩器只能由电动机16驱动。
电动机16包括定子22和转子24,其中定子22在壳体26的轴向突出的变速器侧凸缘26b处固定至混合动力驱动单元12的壳体26。壳体26还包括与凸缘26b相反地突出的轴向突出的发动机侧凸缘26a。由于转子24包括多个环形转子区段25,该多个环形转子区段各自包括受线圈中的电流激励的多个周向间隔的磁体25a(在至少一些优选实施例中,这些磁体是永磁体),所以在向定子22的线圈提供电流时,转子24围绕混合动力模块10的中心轴线CA旋转。如本文所用,术语轴向地、径向地和周向地相对于中心轴线CA来使用。转子24在其内圆周表面24a处不可旋转地固定至转子承载件28(该转子承载件具有圆柱形状),使得转子24和转子承载件一起围绕中心轴线CA旋转。
离合器18包括多个离合器片,其中至少一些离合器片在其外径端部处由形成在转子承载件28的内圆周表面28a上的花键32以可轴向滑动的方式支撑。更具体地,离合器片包括外带花键离合器片30a,这些外带花键离合器片具有外花键,这些外花键接收在花键32之间,使得片30a在其直径处以可轴向滑动的方式支撑。离合器片还包括内带花键离合器片30b,这些内带花键离合器片包括内花键,使得片30b在其直径处由内支撑件34以可轴向滑动的方式支撑,该内支撑件固定至反压板36,该反压板不可旋转地固定至轴20。离合器18还包括活塞38,该活塞可沿着轴20的外圆周轴向滑动,以基于活塞38的前侧和后侧上的流体压力差来接合和脱开离合器18。当活塞38迫使片30a、30b抵靠反压板36时,离合器18接合,并且来自轴20的扭矩通过片30a、30b传递至转子承载件28中,然后转子承载件将所接收的扭矩传递至阻尼器组件14。活塞38通过由支撑板42支撑的弹簧40轴向地保持远离片30a、30b。活塞38还弹性地连接至抬离控制板43,该抬离控制板限制活塞38相对于片30a、30b的抬离。
壳体26包括轴向延伸突出部44,该轴向延伸突出部设置在轴20的径向外侧的离合器18的发动机侧上。突出部44支撑滚珠轴承46,该滚珠轴承将转子凸缘48旋转地支撑在突出部44上。滚珠轴承46的内座圈位于突出部44的外圆周表面上,并且转子凸缘48从滚珠轴承46的外座圈的外圆周表面延伸至转子承载件28。
变矩器14包括一起形成盖31的前盖31a和后盖31b,其中紧固件29轴向通过前盖31a的径向延伸段(该径向延伸段径向向内延伸以与中心轴线CA相交)和转子承载件28的径向延伸部分,以将盖31固定至转子承载件28。后盖31b形成叶轮52的叶轮壳50,该叶轮包括多个叶轮叶片54,所述叶轮叶片由叶轮壳50的圆形叶片支撑部分50a支撑,该叶片支撑部分成形为环形碗并且接触叶轮叶片54的后边缘。
变矩器14还包括涡轮56,该涡轮配置为限定活塞,该活塞可轴向地朝向和远离叶轮壳50运动,使得涡轮56的接合段接合叶轮壳50的接合段,从而形成锁止离合器。涡轮56包括涡轮壳58,该涡轮壳支撑多个涡轮叶片60。变矩器14还包括定子62,该定子轴向地位于涡轮56与叶轮52之间,以在从涡轮叶片60流出的流体到达叶轮叶片54之前重新引导该流体,以提高变矩器14的效率。变矩器14还包括阻尼器组件64,该阻尼器组件固定至涡轮壳58。阻尼器组件64经配置用于接收来自涡轮壳58的扭矩以及将扭矩传递至变速器输入轴。为了将扭矩传递至变速器输入轴,阻尼器组件64包括支撑毂66,该支撑毂包括花键内圆周表面,该花键内圆周表面用于不可旋转地连接至变速器输入轴的外圆周表面。
摩擦材料68粘合到涡轮壳58的外径向延伸部70的径向延伸的面向叶轮的表面上,该径向延伸的面向叶轮的表面在叶片60的径向外侧并且形成涡轮56的接合段,以用于接合叶轮壳50的径向延伸壁72,该径向延伸壁在叶片54的径向外侧并且形成叶轮壳50的接合段。在其他实施例中,作为粘合到外径向延伸部70的替代或补充,摩擦材料68可粘合到径向延伸壁72的径向延伸的面向涡轮的表面或粘合到径向延伸部70与壁72之间的一个或多个附加圆盘。无论摩擦材料68是粘合到外径向延伸部70、径向延伸壁72还是一个或多个附加圆盘,摩擦材料68都轴向地设置在延伸部70与壁72之间,以将涡轮56的接合段与叶轮壳50的接合段选择性地旋转接合。变矩器14通过前盖31a处的紧固件29接收从混合动力驱动单元12输入的扭矩,该扭矩传递至叶轮52。叶轮52在锁止离合器脱开时,经由从叶轮叶片54到涡轮叶片60的流体流动驱动涡轮56,或者在锁止离合器接合时,经由摩擦材料68驱动涡轮。然后涡轮56驱动阻尼器组件64,该阻尼器组件继而驱动变速器输入轴。
图2至图4示出了如何根据本公开的实施例形成转子区段25的细节。图2示出了板74的平面视图,该板与相同构型的其他板74堆叠在一起以形成转子区段25。图3示出了转子区段25之一的周向部分的透视图。图4示出了转子区段25之一的轴向部分的多个堆叠板74的周向剖视图。
图3示出了堆叠在一起以形成单个转子区段25的多个板74。在图4所示的实施例中,转子区段由轴向地堆叠在彼此顶部的四十八个板74形成。图4仅示出了图3所示的板74的轴向部分,并且提供十六个板74的放大视图。
如图2所示,每个板74包括内圆周表面75a和外圆周表面75b。在表面75a、75b之间,板74包括用于接收磁体25a的多个周向间隔的狭槽76a、76b。狭槽76a、76b布置在对77之间,其中每一对狭槽包括一个狭槽76a和一个狭槽76b,其中每个狭槽76a相对于同一对77的狭槽76b镜像对称。更具体地,每一对77由穿过表面75a、75b且位于对77的狭槽76a、76b之间的相应对平面PP分开,并且每一对77的狭槽76a、76b与彼此相对于对平面PP镜像对称。在图2所示的实施例中,存在十六对77狭槽76a、76b。板74包括延伸至内圆周表面75a中的多个细长孔78a、78b、78c、78d。在图2所示的实施例中,板74包括四个细长孔78a、78b、78c、78d,其中所有细长孔78a、78b、78c、78d都形成在板74的同一九十度扇区80a中。细长孔78a、78b、78c、78d在周向方向上是细长的,以在内圆周表面74a中提供扩大入口以用于接收流体。
为了在转子区段25中形成通道,板74设置有多个孔81、82、83。孔81、82、83按组85布置,其中每一组85包括逐渐远离内圆周表面75a的三个孔81、82、83。更具体地,每一组85包括:第一孔81,其比孔82、83更靠近表面75a;第二孔82,其比孔83更靠近表面75a;以及第三孔83,其比孔81、82更远离表面75a。每个孔组85沿循在周向方向D1上周向延伸同时径向向外延伸的路径。更具体地,每个孔82在方向D1上从同一组85的对应孔81周向偏移,并且每个孔83在方向D1上从同一组85的对应孔82周向偏移。孔83中的每一者定位在两组77狭槽76a、76c之间,其中狭槽76a、76b的径向最内侧边缘86比孔83中的每一者的至少一部分更加径向向内。
板74形成为包括具有相同周向长度的多个扇区—第一扇区80a、第二扇区80b、第三扇区80c、第四扇区80d。在图2所示的实施例中,板74包括具有相同周向长度的四个部段80a、80b、80c、80d,其中每个扇区80a、80b、80c、80d为九十度跨度。换言之,扇区80a由穿过板74垂直于彼此从中心轴线CA延伸的两个平面P1、P2界定,扇区80b由穿过板74垂直于彼此从中心轴线CA延伸的两个平面P2、P3界定,扇区80c由穿过板74垂直于彼此从中心轴线CA延伸的两个平面P3、P4界定,并且扇区80d由穿过板74垂直于彼此从中心轴线CA延伸的两个平面P4、P1界定。
在图2所示的实施例中,每个扇区80a、80b、80c、80d包括多个孔组85,并且孔组85各自具有与相应扇区80a、80b、80c、80d中的其他孔组85相同的构型,使得相应扇区80a、80b、80c、80d的所有孔组85处于相同径向位置。更具体地,相应扇区80a、80b、80c、80d的所有孔81与内圆周表面75a相距相同距离,相应扇区80a、80b、80c、80d的所有孔82与内圆周表面75a相距相同距离,并且相应扇区80a、80b、80c、80d的所有孔83与内圆周表面75a相距相同距离。扇区80a的孔81、82、83标示为孔81a、82a、83a;扇区80b的孔81、82、83标示为孔81b、82b、83b;扇区80c的孔81、82、83标示为孔81c、82c、83c;并且扇区80d的孔81、82、83标示为孔81d、82d、83d。
在图2所示的实施例中,扇区80a、80b、80c、80d各自具有孔组85,其具有与其他扇区80a、80b、80c、80d的孔组85不同的构型。更具体地,孔81a、81b、81c、81d与内圆周表面75a相距不同的径向距离。从扇区80a开始、沿循方向D1并且以扇区80d结束,81a、81b、81c、81d随着每个相继的扇区80a、80b、80c、80d离内圆周表面75a径向更远地定位。换言之,扇区80b的孔81b比扇区80a的孔81a更加径向向外,扇区80c的孔81c比扇区80b的孔81b更加径向向外,并且扇区80d的孔81c比扇区80c的孔81c更加径向向外。扇区80a中的孔81a中的每一者与细长孔78a、78b、78c、78d中的一者相交。
类似地,在扇区80a、80b、80c、80d中的每一者中,孔82a、82b、82c、82d与内圆周表面75a径向相距不同的距离。从扇区80a开始、沿循方向D1并且以扇区80d结束,孔82a、82b、82c、82d随着每个相继的扇区80a、80b、80c、80d离内圆周表面75a径向更远地定位。换言之,扇区80b的孔82b比扇区80a的孔82a更加径向向外,扇区80c的孔82c比扇区80b的孔82b更加径向向外,并且扇区80d的孔82d比扇区80c的孔82c更加径向向外。
另外,在扇区80a、80b、80c、80d中的每一者中,所有孔83a、83b、83c、83d与内圆周表面75a相距相同的径向距离。因此,从扇区80a开始、沿循方向D1并且在扇区80d中结束,在每个相继的扇区80a、80b、80c、80d中,孔82a、82b、82c、82d在径向上更靠近同一组85的对应孔83a、83b、83c、83d,其中扇区80d的孔82d与孔83d相交。
板74还经配置使得扇区80a中的孔82a中的每一者与细长孔78a、78b、78c、78d中的一者相交。扇区80a中的孔83a中的每一者经由连接狭槽84a与狭槽76a中的一者汇合,并且扇区80c中的孔83c中的每一者经由连接狭槽84c与狭槽76b中的一者汇合。相比之下,扇区80b中的孔83b中的每一者和扇区80d中的孔83d中的每一者与狭槽76a、76b相异且不与其汇合。
参考图3,转子区段25包括堆叠在彼此顶部的相同构型的六十四个板74。每个板74相较于直接轴向相邻的板74旋转九十度。图3的视图中的底部板74a包括在图3所示的部分中的细长孔78d。与板74a直接轴向相邻的板74b在方向D1上相较于板74a旋转九十度,使得板74的细长孔78a和细长孔78b包括在图3所示的部分中。与板74b直接轴向相邻的板74c在方向D1上相较于板74b旋转九十度,并且与板74c直接轴向相邻的板74d在方向D1上相较于板74c旋转九十度,使得细长孔78a、78b、78c、78d在图3所示的板74c、74d的部分中都不可见。接着,与板74d直接轴向相邻并且在方向D1上相较于板74d旋转九十度的板74e与板74a处于完全相同的旋转取向,使得板74a的细长孔78d与板74d的细长孔78d直接轴向对准。因此,板74经旋转取向使得板形成重复图案,其中每个板74具有与在沿着第一轴向方向的顺序中的四个板74的板74相同的旋转取向和/或与在沿着第二轴向方向的顺序中在板74之后四个板74的板74相同的旋转取向。应指出,每个板74可包括除了四个之外的不同数量的扇区,其中旋转取向的重复图案是基于扇区的数量。
板74经旋转取向使得每个板74的扇区80a与在第一轴向方向上直接相邻的板74的扇区80d对准并且与在第二轴向方向上直接相邻的板74的扇区80b对准;每个板74的扇区80b与在第一轴向方向上直接相邻的板74的扇区80a对准并且与在第二轴向方向上直接相邻的板74的扇区80c对准;每个板74的扇区80c与在第一轴向方向上直接相邻的板74的扇区80b对准并且与在第二轴向方向上直接相邻的板74的扇区80d对准;并且每个板74的扇区80d与在第一轴向方向上直接相邻的板74的扇区80c对准并且与在第二轴向方向上直接相邻的板74的扇区80a对准。
图4示出了如何使板74的孔81、82、83与彼此对准以形成从转子24的内圆周表面24a延伸至狭槽76a、76b的通道88,这些通道用于接收磁体25a以提供冷却剂来冷却磁体25a。图4示出了从内圆周表面24a一直延伸至狭槽76a的一个通道88以及其他通道88的部分,在转子24的最终构造中,其他通道中的至少大多数将从内圆周表面24a中一直延伸至狭槽76a、76b中的一个。通道88从内圆周表面24a径向地、轴向地且周向地延伸至磁体25a并且具有阶梯式构型。径向重叠的孔通过板74中的每一连续板中的孔在轴向方向上离中心轴线逐渐更加径向向外而形成通道88。
图4所示的剖面示出了顶部板74f的扇区80d,其中孔81d与内圆周表面24a径向间隔。从顶部板74f开始在第一轴向方向A1上的下一个板74g包括在所示剖面中的扇区80a,其中孔81a由细长孔78a至78d中的一个流体连结至内圆周表面75a。从板74g开始在第一轴向方向A1上的下一个板74h包括在所示剖面中的扇区80b,其中孔81b直接流体连结至孔81a。如图所示,由于孔81b比孔81a更加径向向外地与内圆周表面24a间隔,并且孔81b最内侧直径90a比孔81a的最外侧直径90b更加径向向内,使得板74g的孔81a和板74h的孔81b部分地径向重叠以形成阶梯式流体连接。板74g的孔81a和板74h的孔81b也部分周向重叠。下两个板74i、74j包括相应孔81c、81d,其继续部分重叠的图案以延长孔81a、81b的阶梯式流体连接,其中孔81c与孔81b部分径向重叠,并且孔81d与孔81c部分径向重叠。
与板74g处于完全相同的旋转取向的下一个板74k包括在扇区80a中的孔82a,其与板74j的孔81d部分径向重叠。下三个板74l、74m、74n包括相应孔82b、82c、82d,其继续部分重叠的图案以延长孔81a、81b、81c、81d、82a的阶梯式流体连接,其中孔82b与孔82a部分径向重叠,孔82c与孔82b部分径向重叠,并且孔82d与孔82c部分重叠。板74n的孔82d与板74n的孔83d汇合以使阶梯式通道88与轴向延伸直通通道90汇合。通道90通过转子24的板74的孔83—即,孔83a、83b、83c、83d(图2)—与彼此直接轴向对准而形成。形成在每第四板74中的多个轴向间隔的连接狭槽84a然后将通道90连接至狭槽76a。
如图2至图4所示,多个板74在图2至图4所示的实施例中为八个板或者具有四个板的相同地对准的图案的两组,该多个板的扇区80a、80b、80c、80d中的每一者的孔81、82部分径向重叠以在细长孔78a、78b、78c、78d的帮助下形成通道88,这些通道使转子24的内圆周表面24a与轴向延伸通道90流体连接,然后该轴向延伸通道由多个连接狭槽84a流体连接至狭槽76a。连接狭槽84c也在与连接狭槽84c相反的周向方向上从通道90延伸,使得连接狭槽84c将通道90流体连接至狭槽76b。因此,一起参考图2至图4,板74i和74m各自包括在图4中不可见的将通道90流体连接至狭槽76b的连接狭槽84c。因此,每个轴向延伸通道90从多个阶梯式通道88接收流体,并且将流体经由多个轴向间隔连接狭槽84a提供至一个磁体接收狭槽76a并经由多个轴向间隔连接狭槽84b提供至接收狭槽76b。
阶梯式通道88形成为从内圆周表面24a轴向地、周向地且径向地延伸至轴向延伸通道90,使得在混合动力模块10的部件旋转期间产生的离心力致使流体(在优选实施例中,为自动变速器流体(ATF))穿过转子24的内圆周表面24a流动至磁体接收狭槽76a、76b中以冷却磁体25a。回顾图1,ATF从离合器18径向向外流动通过转子承载件28中的径向延伸直通孔28b以到达转子24的内圆周表面24a,在内圆周表面处,ATF进入通道88。每个转子区段25在堆叠中仅偏移5度,使得狭槽76a和76b的端部区域在转子区段之间稍微重叠。冷却剂将流动通过由冲片开槽的孔路径以到达磁体狭槽76a、76b,然后沿着转子区段25径向流出至整个转子堆叠的任一端部并且得以喷射至定子22的线圈上。
在前面的说明书中,已参考特定示例性实施例及其示例描述了本发明。然而,将显而易见的是,在不脱离所附权利要求书中所阐述的本发明的更广泛的精神和范围的情况下,可对其做出各种修改和改变。因此,说明书和附图应被认为是说明性的而非限制性的。
附图标记说明
CA中心轴线 PP狭槽对平面 P1、P2、P3、P4扇形平面 D1周向方向 A1轴向方向 10混合动力模块 12混合动力驱动单元 14变矩器 16电动机 18发动机连接/分离离合器 20输入轴 22定子 24转子 24a内圆周表面 25转子区段 25a磁体 26壳体 26a轴向突出的发动机侧凸缘 26b轴向突出的变速器侧凸缘 26c径向延伸壳体段 28转子承载件 28a内圆周表面 28b径向延伸通孔 29紧固件 30a外带花键离合器片 30b外带花键作用片 31盖 31a前盖 31b后盖 32花键 34内支撑件 36对压板 38活塞 40弹簧 42支撑板 43抬离控制板44壳体突出部 46滚珠轴承 48转子凸缘 50叶轮壳50a圆形叶片支撑部分 52叶轮 54叶轮叶片 56涡轮 58涡轮壳 60涡轮叶片 62定子 64阻尼器组件 66支撑毂 68摩擦材料 70外径向延伸部 72径向延伸壁 74、74a至74n转子板 75a内圆周表面75b外圆周表面 76a、76b磁体接收狭槽 77狭槽对 78a、78b、78c、78d细长孔 80a、80b、80c、80d板部段 81、81a、81b、81c、81d内孔 82、82a、82b、82c、82d中间孔 83、83a、83b、83c、83d外孔 84a、84c连接狭槽85孔组 86径向最内侧狭槽边缘 88阶梯式通道 90轴向延伸通道 90a最内侧直径 90b最外侧直径。

Claims (10)

1.一种电动机,其包括:
转子,所述转子可围绕中心轴线旋转,所述转子包括多个磁体和多个径向延伸通道,所述多个径向延伸通道从所述转子的内圆周表面径向向外延伸以将流体提供至所述磁体。
2.根据权利要求1所述的电动机,其中所述通道在所述转子内轴向地且周向地延伸。
3.根据权利要求1所述的电动机,其中所述通道具有阶梯式构型。
4.根据权利要求3所述的电动机,其中所述转子由在轴向方向上堆叠的多个板形成,所述通道由形成在所述板中的多个部分地径向重叠的孔形成。
5.根据权利要求4所述的电动机,其中所述径向重叠的孔借由所述板中的在所述轴向方向上的每一连续板中的所述孔离所述中心轴线逐渐更加径向向外而形成所述通道。
6.根据权利要求4所述的电动机,其中所述板具有相同构型并且经旋转取向使得所述板中的每一者具有与所述板中的直接轴向相邻的板不同的旋转取向。
7.根据权利要求6所述的电动机,其中所述板中的每一者从所述直接轴向相邻的板旋转地偏移相同的角度。
8.根据权利要求1所述的电动机,其还包括转子承载件,所述转子承载件包括从中穿过以将流体提供至所述转子的所述内圆周表面的径向延伸孔。
9.一种混合动力模块,其经配置用于布置在变速器上游和内燃机下游的扭矩路径中,所述混合动力模块包括:
根据权利要求8所述的电动机;以及
包括前盖的变矩器,所述转子承载件固定至所述前盖。
10.一种构造电动机的方法,其包括:
将可围绕中心轴线旋转的转子制造成包括多个磁体和多个径向延伸通道,所述多个径向延伸通道从所述转子的内圆周表面径向向外延伸以将流体提供至所述磁体。
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