WO2008003986A1 - A wheel-mounted electrical machine - Google Patents

A wheel-mounted electrical machine Download PDF

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Publication number
WO2008003986A1
WO2008003986A1 PCT/GB2007/002554 GB2007002554W WO2008003986A1 WO 2008003986 A1 WO2008003986 A1 WO 2008003986A1 GB 2007002554 W GB2007002554 W GB 2007002554W WO 2008003986 A1 WO2008003986 A1 WO 2008003986A1
Authority
WO
WIPO (PCT)
Prior art keywords
wheel
electrical machine
rotor
brake
stator
Prior art date
Application number
PCT/GB2007/002554
Other languages
French (fr)
Inventor
Michael Ulrich Lamperth
Malte Jaensch
Original Assignee
Imperial Innovations Limited
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 Imperial Innovations Limited filed Critical Imperial Innovations Limited
Priority to JP2009517434A priority Critical patent/JP5254967B2/en
Priority to EP07733495.1A priority patent/EP2043886B1/en
Publication of WO2008003986A1 publication Critical patent/WO2008003986A1/en
Priority to US12/349,330 priority patent/US8008817B2/en

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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
    • B60K7/00—Disposition of motor in, or adjacent to, traction wheel
    • B60K7/0007—Disposition of motor in, or adjacent to, traction wheel the motor being electric
    • 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
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/34—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles
    • B60K17/356—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles having fluid or electric motor, for driving one or more wheels
    • 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
    • B60K6/22—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
    • B60K6/26—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 motors or the generators
    • 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
    • B60K6/22—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
    • B60K6/36—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 transmission gearings
    • B60K6/365—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 transmission gearings with the gears having orbital motion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L15/00—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles
    • B60L15/20—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
    • B60L15/2009—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed for braking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0061—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electrical machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0076—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to braking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/10—Electric propulsion with power supplied within the vehicle using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines
    • B60L50/16—Electric propulsion with power supplied within the vehicle using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines with provision for separate direct mechanical propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L7/00—Electrodynamic brake systems for vehicles in general
    • B60L7/10—Dynamic electric regenerative braking
    • B60L7/12—Dynamic electric regenerative braking for vehicles propelled by dc motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L7/00—Electrodynamic brake systems for vehicles in general
    • B60L7/24—Electrodynamic brake systems for vehicles in general with additional mechanical or electromagnetic braking
    • B60L7/26—Controlling the braking effect
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2793—Rotors axially facing stators
    • H02K1/2795—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2796—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the rotor face a stator
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/102—Structural association with clutches, brakes, gears, pulleys or mechanical starters with friction brakes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/14—Structural association with mechanical loads, e.g. with hand-held machine tools or fans
    • 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
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/04—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing
    • B60K17/043—Transmission unit disposed in on near the vehicle wheel, or between the differential gear unit and the wheel
    • B60K17/046—Transmission unit disposed in on near the vehicle wheel, or between the differential gear unit and the wheel with planetary gearing having orbital motion
    • 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
    • B60K7/00—Disposition of motor in, or adjacent to, traction wheel
    • B60K2007/0038—Disposition of motor in, or adjacent to, traction wheel the motor moving together with the wheel 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
    • B60K7/00—Disposition of motor in, or adjacent to, traction wheel
    • B60K2007/0092—Disposition of motor in, or adjacent to, traction wheel the motor axle being coaxial to the wheel axle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2220/00—Electrical machine types; Structures or applications thereof
    • B60L2220/40—Electrical machine applications
    • B60L2220/44—Wheel Hub motors, i.e. integrated in the wheel hub
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/10—Vehicle control parameters
    • B60L2240/36—Temperature of vehicle components or parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/40—Drive Train control parameters
    • B60L2240/42—Drive Train control parameters related to electric machines
    • B60L2240/423—Torque
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L2260/00—Operating Modes
    • B60L2260/20—Drive modes; Transition between modes
    • B60L2260/28—Four wheel or all wheel drive
    • H—ELECTRICITY
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    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
    • H—ELECTRICITY
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    • 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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    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/72—Electric energy management in electromobility

Definitions

  • This invention relates to a wheel-mounted electrical machine, a wheel mounting assembly for a vehicle, and a vehicle.
  • Automotive vehicles such as passenger cars (sometimes referred to as “automobiles”) are often criticised for producing emissions that are harmful to humans and the environment. There is therefore increasing interest in automotive vehicles with reduced emissions and with greater fuel efficiency, such as electric and hybrid-electric vehicles.
  • hybrid-electric vehicles One problem that affects hybrid-electric vehicles is the problem of accommodating in the vehicle the electrical components, such as the electrical motor used to power the vehicle.
  • the accommodation of components in vehicles is sometimes referred to as "packaging".
  • the electrical components in hybrid-electric vehicles must be positioned in a way that is operationally effective and that does not interfere with other components of the vehicle. Ideally, the electrical components should also be positioned so as not to intrude into the passenger space of the vehicle.
  • hybrid-electric vehicles are adaptations of solely fossil fuel-powered vehicles — for example, the chassis, body, suspension and certain driveline components may be retained - it is necessary to fit the additional electrical components around the existing components of the vehicle without interfering with the operation of those components. This can be difficult and can lead to great complexity in hybrid-electric vehicles, particularly in relation to driveline components.
  • An object of this invention is to address these problems.
  • a wheel-mounted electrical machine for powering a vehicle, the electrical machine including at least one rotor and at least one stator, the stator mounted on structure adjacent the wheel and the rotor drivingly connected to the wheel to drive the wheel relative to the stator.
  • the rotor may be mounted around an axle of the wheel and coupled thereto so as to drive the axle and hence the wheel.
  • the rotor may be mounted to a hub of the wheel and coupled thereto so as to drive the hub and hence the wheel.
  • the rotor may be mounted in place of a rotating component of a brake.
  • the rotor may be mounted in ( place of a disc of a disc brake.
  • the rotor may be mounted in place of a drum of a drum brake.
  • the stator may be mounted to structure of the suspension system adjacent the wheel.
  • the stator may be mounted to an upright of the suspension system.
  • the stator may be mounted in place of a stationary component of a brake.
  • the stator may be mounted in place of a brake calliper of a disc brake.
  • the stator may be mounted in place of brake shoes and pistons of a drum brake.
  • embodiments of the invention can adapt an existing vehicle, or components thereof, to use as or in an electric or hybrid- electric vehicle with minimum adaptation thereof.
  • the rotor may be drivingly connected to the wheel via a gear train.
  • the gear train may comprise an epicyclic gear train.
  • a first component of the epicyclic gear train may be coupled to the rotor; a second component of the epicyclic gear train may be coupled to the wheel; and a third component of the epicyclic gear train may be coupled to the stator.
  • the coupling may be by direct connecting.
  • the coupling may be via intermediate structure or an intermediate component or components.
  • the third component may be mounted to structure to which the stator is mounted.
  • the rotor may be coupled to a sun gear of the epicyclic gear train; the wheel may be connected to an arrangement of planet gears of the epicyclic gear train; the stator may be coupled to an annulus of the epicyclic gear train.
  • the electrical machine may be an axial flux electrical machine. It may be a radial flux electrical machine.
  • the axial flux electrical machine may have a rotor sandwiched between each of two portions of the stator.
  • the rotor may have permanent magnets thereon or therein.
  • the stator may include one or more electrical windings thereon or therein, arranged to set up a magnetic field.
  • the axial flux electrical machine may include plural ones of the rotor.
  • Each rotor may be axially spaced from the or each other rotor.
  • Each rotor may be concentric with the or each other rotor. Where there are plural ones of the rotor, each rotor may be sandwiched between two stator portions. There may be only one stator portion between juxtaposed ones of the rotors.
  • the electrical machine may comprise a brake.
  • the brake may operate on the rotor to slow the rotor.
  • the brake may operate on the rotor to slow the rotor by friction.
  • the brake may press brake pads into contact with the rotor.
  • the brake may be a disc brake with the rotor, or at least part thereof, serving as the disc of the disc brake.
  • the electrical machine may include a brake calliper.
  • the calliper may be mounted on the stator.
  • the calliper may be mounted with the stator on the structure adjacent the wheel.
  • the brake may be axially spaced from the rotor.
  • the brake may include a brake disc coaxial with the electrical machine.
  • the brake disc may also be drivingly connected to the wheel.
  • Cooling means may be provided adjacent the stator in order to remove heat generated by the stator.
  • the cooling means may be provided in structure of the stator.
  • the cooling means may include one or more heat exchangers arranged to remove heat from the stator.
  • the cooling means may include fluid-carrying channels provided in structure of the stator.
  • the cooling means may include structure arranged to add to the exposed surface area of the stator.
  • the cooling means may include one or more cooing fins.
  • a wheel mounting assembly for a vehicle comprising:
  • wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle; and a hub arranged for rotatable mounting relative to the wheel-bearing housing structure; the assembly further comprising an electrical machine comprising at least one rotor and at least one stator, the stator mounted on the wheel-bearing housing structure and the rotor mounted on the hub.
  • a wheel mounting assembly for a vehicle comprising:
  • wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle
  • the assembly further comprising the electrical machine of the first aspect of the invention, the stator of the electrical machine mounted on the wheel-bearing housing structure and the rotor drivingly connected to the wheel to drive the wheel relative to the stator and hence the wheel-bearing housing structure.
  • a vehicle including the wheel-mounted electrical machine of the first aspect and/or the wheel mounting assembly of the other aspect and/or the wheel mounting assembly of the further aspect.
  • the vehicle may be arranged controllably to supply electrical power to the electrical machine in order to operate the electrical machine as a motor and thereby drive the vehicle.
  • the vehicle may be arranged to operate the electrical machine as a generator and to store electrical energy generated thereby for use later in operating the electrical machine as a motor to drive the vehicle.
  • the vehicle may include a respective one of the wheel-mounted electrical machine of the first aspect and/or the wheel mounting assembly of the other aspect and/or the wheel mounting assembly of the further aspect at each of two, more or all wheels of the vehicle.
  • Figure 1 is a diagrammatic sectional view of a first embodiment in which an electrical machine having a single rotor is mounted in a wheel of a vehicle, on a hub thereof, the section being through a vertical axial plane;
  • Figure 2 is a diagrammatic sectional view of a second embodiment, similar to the first embodiment, but in which the electrical machine has two rotors;
  • Figure 3 is a diagrammatic sectional view of a third embodiment, similar to the first embodiment, but in which an epicyclic gear train is provided between components of the electrical machine and the wheel;
  • Figure 4 is a diagrammatic sectional view of a fourth embodiment, similar to the first embodiment, but in which a brake is provided that acts axially on the rotor of the electrical machine;
  • Figure 5 is a diagrammatic sectional view of a fifth embodiment, similar to the first embodiment, but in which a brake is provided that acts on a disc coaxial with and axially spaced from the electrical machine;
  • Figure 6 is a diagrammatic sectional view of a sixth embodiment, similar to the first embodiment, but in which a brake is provided that acts radially on the rotor of the electrical machine;
  • Figure 7 is a diagrammatic elevation view of the rotor and part of the brake of the sixth embodiment.
  • Figure 8 is a diagrammatic sectional view of a seventh embodiment, similar to the first embodiment, but in which a brake is provided that acts axially on a segment rotor of the electrical machine, the brake replacing a segment of the stator of the electrical machine; and
  • Figure 9 is a diagrammatic elevation view of the stator and part of the brake of the seventh embodiment.
  • a hybrid-electric vehicle In a first embodiment of this invention, there is provided a hybrid-electric vehicle, only part 10 of which his shown in Figure 1.
  • the vehicle is a car with four wheels. Each of the wheels has a respective electrical machine 20 mounted therein.
  • the hybrid-electric vehicle is of the type in which an internal combustion engine is mechanically coupled to a generator to drive the generator and thereby generate electricity for operating the electrical machines 20 and thereby driving the car.
  • the arrangement of an exemplary one 20 of the electrical machines is described in more detail below, it being understood that the arrangement of each of the other electrical machines is substantially the same.
  • the part 10 of the vehicle shown in Figure 1 includes a wheel bearing housing 30 with a suspension strut 40 attached thereto.
  • the wheel bearing housing 30 houses a wheel bearing 35.
  • a drive shaft 50 is supported in the wheel bearing 35 and extends from an inner side of the bearing 35 that faces towards the centre of the car through the bearing 35 to emerge at the outer side thereof, facing away from the car.
  • a wheel hub 60 is mounted on the driveshaft 50 on the outer side thereof.
  • a wheel 70 is similarly mounted on the wheel hub 60.
  • the electrical machine 20 is an axial flux electrical machine. It has a rotor 22 and a stator 24.
  • the rotor 22 in the form of disc, with a circumferentially- distributed series of permanent magnets (not shown) arranged thereon.
  • the rotor 22 is positioned between two halves of the stator 24, such that the rotor 22 is axially sandwiched therebetween.
  • the stator 24 includes a stator winding (not shown) arranged to set up a magnetic field when an electrical current exists therein.
  • the electrical machine 20 can be operated as both a motor and a generator.
  • An appropriate electrical machine for use as the electrical machine 20 in this embodiment would be that described in UK Patent Application No. 0613570.1, the contents of which are hereby incorporated herein in their entirety.
  • the electrical machine 20 is fitted to the vehicle in place of a disc brake.
  • the rotor 22 is fitted to the wheel hub 60 in the way that a disc of a disc brake would be fitted thereto.
  • the stator 24 is mounted on the wheel bearing housing 30 in the way that a brake calliper of a disc brake would be fitted thereto.
  • the electrical machine can be fitted in substitution of a disc brake to a vehicle that is arranged to have disc brakes fitted thereto.
  • the electrical machines 20 can be operated as motors to provide rotary power to the wheels 70 to thereby drive the wheels 70 and accelerate the car.
  • the electrical machines 20 can also be operated as generators to resist motion of the wheels and thereby slow the car. Electricity generated in this way can be stored for later use in operating the electrical machines 20 as motors.
  • the electrical machines 20 can be used in regenerative braking.
  • the drive shaft is coupled to a mechanical driveline system (not shown) that is arranged to receive rotary power from an internal combustion engine.
  • the electrical machines 20 can be used to supplement the power supplied from the internal combustion engine via the mechanical driveline system.
  • Figure 2 shows a second embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This embodiment differs from the first embodiment in providing a modified electrical machine 100 in each wheel 70.
  • the modified electrical machine 100 is similar to the electrical machine 20 described above with reference to Figure 1, but differs in having two rotors 22 mounted to the hub 60 and axially spaced from one another.
  • the stator 130 differs in having three stator portions, such that each of the rotors 22 is sandwiched between two of the stator portions. In other respects, this second embodiment is the same as the first.
  • the modified electrical machine 120 By providing the modified electrical machine 120 with two rotors 22 each sandwiched between portions of the stator 130, the modified electrical machine 120 is able to generate more torque, both when being operated as a motor and a generator. Accordingly, the second embodiment is suited to applications where the hybrid-electric vehicle is a vehicle with large mass, such as a bus.
  • Figure 3 shows a third embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This third embodiment differs from the first embodiment in providing an epicyclic gear train 200 between the wheel 70 and the electrical machine 20. This and other modifications are described below.
  • the wheel-bearing housing 30 includes the wheel bearing 35 therein. There is, however, no drive shaft 50. Instead a short axle 250 is provided and is journalled in the bearing 35. The axle 250 extends from the bearing 35 only to the outer side thereof.
  • the rotor 22 of the electrical machine 20 is mounted on the axle 250.
  • the end of the axle 250 that is remote from the bearing 35 has a sun gear 202 of the epicyclic gear train 200 mounted thereon.
  • a planetary gear arrangement 204 of the epicyclic gear train 200 is fixed to the wheel 70.
  • An annulus 206 of the epicyclic gear train 200 is fixed to the stator 24 of the electrical machine.
  • this third embodiment is similar to the first.
  • Figure 4 shows a fourth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This fourth embodiment differs from the first embodiment in that the electrical machine 300 of this embodiment is modified to include a disc brake 310.
  • the disc brake 310 has a calliper 320 that is mounted to the stator 330 of the electrical machine 300 so as to sandwich the rotor 340 between portions of the calliper 320.
  • a housing of the calliper 320 may be integrally formed with structure of the stator 330.
  • the disc brake 310 is arranged to press brake pads (not shown) against the surfaces of the rotor 340, radially inside the magnets mounted thereon.
  • the rotor 340 acts as a disc of the disc brake 300.
  • the disc brake 300 When operated in this way, the disc brake 300 is used in combination with regenerative braking to slow the vehicle. Alternatively, the disc brake 300 is used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
  • this fourth embodiment is similar to the first.
  • Figure 5 shows a fifth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This fifth embodiment differs from the first embodiment in including a disc brake 400.
  • the electrical machine 20 is unmodified and the disc brake 400 is axially displaced from the rotor 22 and the stator 24 thereof.
  • the disc brake 400 includes a calliper 410 and a disc 420.
  • the calliper 410 is fixed to structure of the stator 24 so as to be axially adjacent thereto, on the outside thereof.
  • the disc 420 is coaxially mounted with the rotor 22 on the hub 60 so as to be sandwiched between structure of the calliper 410.
  • the calliper 410 is arranged to press brake pads (not shown) against the surfaces of the disc 420 in the conventional manner of disc brakes.
  • the disc brake 400 When operated in this way, the disc brake 400 can be used in combination with regenerative braking to slow the vehicle. Alternatively, the disc brake 400 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
  • this fifth embodiment is similar to the first.
  • Figure 6 shows a sixth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This sixth embodiment differs from the first embodiment in including a brake shoe arrangement 500.
  • the brake shoe arrangement 500 is mounted between the two parts of the stator 24 so as to extend around a circumferential section of the rim of the rotor 22.
  • the brake shoe arrangement 500 is arranged to press a brake shoe radially against the rim of the rotor 22.
  • Figure 7 shoes the brake shoe engaging the rim of the rotor 22 in this way. It will be understood that the brake shoe operates rather like a brake shoe of a dram brake, but differs in engaging a rim of a disc located radially inside the shoe, rather than the inner wall of a drum located radially outside the shoe.
  • the brake shoe arrangement 500 can be used in combination with regenerative braking to slow the vehicle.
  • the brake shoe arrangement 500 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
  • this sixth embodiment is the similar to the first.
  • Figure S shows a seventh embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure ⁇ , The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
  • This seventh embodiment differs from the first embodiment in including a disc brake arrangement that includes a brake calliper 600- This embodiment is therefore somewhat similar to others of the embodiments described above. However, this embodiment differs in that the brake calliper 600 replaces part of the stator of the electrical machine.
  • this embodiment includes a revised stator 620 that is similar to that 24 described above with reference to Figure L
  • the revised stator 620 is similar in being formed of two parts with the rotor 22 therebetween ⁇ but differs in that an axially-opposite segment of each part of the Figure 1 stator 24 is removed and replaced by the brake calliper 600 to form the revised stator 620.
  • the brake calliper 600 is sized to fit in the segment removed from the Figure 1 stator 24 and is airanged to be mounted to adjacent structure of the revised stator 620.
  • the brake calliper 600 is further arranged to apply brake pads (not shown) to each surface of the rotor 22.
  • Figure 9 shows the brake calliper 600 mounted in position on the revised stator 620.
  • the brake 600 can be used in combination with regenerative braking to slow the vehicle.
  • the brake 600 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
  • this seventh embodiment is the similar to the first.
  • One of more of the components of the electrical machines described above maybe as, or may include features of, corresponding components of the electrical machine described in UK Patent Application No. 0613570.1 , the contents of which are incorporated herein by reference.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Sustainable Energy (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
  • Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Motor Or Generator Cooling System (AREA)
  • Braking Arrangements (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

A hybrid-electric vehicle is provided having a respective electrical machine (20) in each wheel thereof. Each electrical machine (20) is of the axial-flux type, having a rotor (22) sandwiched axially between two parts of a stator (24). Each electrical machine (20) is fitted to the respective wheel such that the rotor (22) takes the place of a disc of a disc brake system, and the stator (24) is mounted in place of a calliper of the disc brake system.

Description

A WHEEL-MOUNTED ELECTRICAL MACHINE
TECHNICAL FIELD
This invention relates to a wheel-mounted electrical machine, a wheel mounting assembly for a vehicle, and a vehicle.
BACKGROUND
Automotive vehicles, such as passenger cars (sometimes referred to as "automobiles") are often criticised for producing emissions that are harmful to humans and the environment. There is therefore increasing interest in automotive vehicles with reduced emissions and with greater fuel efficiency, such as electric and hybrid-electric vehicles.
One problem that affects hybrid-electric vehicles is the problem of accommodating in the vehicle the electrical components, such as the electrical motor used to power the vehicle. The accommodation of components in vehicles is sometimes referred to as "packaging". The electrical components in hybrid-electric vehicles must be positioned in a way that is operationally effective and that does not interfere with other components of the vehicle. Ideally, the electrical components should also be positioned so as not to intrude into the passenger space of the vehicle. As many hybrid-electric vehicles are adaptations of solely fossil fuel-powered vehicles — for example, the chassis, body, suspension and certain driveline components may be retained - it is necessary to fit the additional electrical components around the existing components of the vehicle without interfering with the operation of those components. This can be difficult and can lead to great complexity in hybrid-electric vehicles, particularly in relation to driveline components.
Similar problems affect electric vehicles.
An object of this invention is to address these problems.
SUMMARY OF THE INVENTION According to a first aspect of this invention, there is provided a wheel-mounted electrical machine for powering a vehicle, the electrical machine including at least one rotor and at least one stator, the stator mounted on structure adjacent the wheel and the rotor drivingly connected to the wheel to drive the wheel relative to the stator.
The rotor may be mounted around an axle of the wheel and coupled thereto so as to drive the axle and hence the wheel. The rotor may be mounted to a hub of the wheel and coupled thereto so as to drive the hub and hence the wheel. The rotor may be mounted in place of a rotating component of a brake. The rotor may be mounted in ( place of a disc of a disc brake. The rotor may be mounted in place of a drum of a drum brake.
The stator may be mounted to structure of the suspension system adjacent the wheel. The stator may be mounted to an upright of the suspension system. The stator may be mounted in place of a stationary component of a brake. The stator may be mounted in place of a brake calliper of a disc brake. The stator may be mounted in place of brake shoes and pistons of a drum brake.
By mounting the rotor of the electrical machine in place of the disc of a disc brake, and the stator in place of the calliper of a disc brake, embodiments of the invention can adapt an existing vehicle, or components thereof, to use as or in an electric or hybrid- electric vehicle with minimum adaptation thereof.
The rotor may be drivingly connected to the wheel via a gear train. The gear train may comprise an epicyclic gear train. A first component of the epicyclic gear train may be coupled to the rotor; a second component of the epicyclic gear train may be coupled to the wheel; and a third component of the epicyclic gear train may be coupled to the stator. The coupling may be by direct connecting. The coupling may be via intermediate structure or an intermediate component or components. For example, the third component may be mounted to structure to which the stator is mounted. The rotor may be coupled to a sun gear of the epicyclic gear train; the wheel may be connected to an arrangement of planet gears of the epicyclic gear train; the stator may be coupled to an annulus of the epicyclic gear train. The electrical machine may be an axial flux electrical machine. It may be a radial flux electrical machine. The axial flux electrical machine may have a rotor sandwiched between each of two portions of the stator. The rotor may have permanent magnets thereon or therein. The stator may include one or more electrical windings thereon or therein, arranged to set up a magnetic field. The axial flux electrical machine may include plural ones of the rotor. Each rotor may be axially spaced from the or each other rotor. Each rotor may be concentric with the or each other rotor. Where there are plural ones of the rotor, each rotor may be sandwiched between two stator portions. There may be only one stator portion between juxtaposed ones of the rotors.
The electrical machine may comprise a brake. The brake may operate on the rotor to slow the rotor. The brake may operate on the rotor to slow the rotor by friction. The brake may press brake pads into contact with the rotor. The brake may be a disc brake with the rotor, or at least part thereof, serving as the disc of the disc brake. The electrical machine may include a brake calliper. The calliper may be mounted on the stator. The calliper may be mounted with the stator on the structure adjacent the wheel.
The brake may be axially spaced from the rotor. The brake may include a brake disc coaxial with the electrical machine. The brake disc may also be drivingly connected to the wheel.
Cooling means may be provided adjacent the stator in order to remove heat generated by the stator. The cooling means may be provided in structure of the stator. The cooling means may include one or more heat exchangers arranged to remove heat from the stator. The cooling means may include fluid-carrying channels provided in structure of the stator. The cooling means may include structure arranged to add to the exposed surface area of the stator. The cooling means may include one or more cooing fins.
According to another aspect of this invention, there is provided a wheel mounting assembly for a vehicle, the assembly comprising:
wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle; and a hub arranged for rotatable mounting relative to the wheel-bearing housing structure; the assembly further comprising an electrical machine comprising at least one rotor and at least one stator, the stator mounted on the wheel-bearing housing structure and the rotor mounted on the hub.
According to a further aspect of this invention, there is provided a wheel mounting assembly for a vehicle, the assembly comprising:
wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle; and
a wheel rotatably mounted relative to the wheel-bearing housing structure;
the assembly further comprising the electrical machine of the first aspect of the invention, the stator of the electrical machine mounted on the wheel-bearing housing structure and the rotor drivingly connected to the wheel to drive the wheel relative to the stator and hence the wheel-bearing housing structure.
Optional features of the first aspect of the invention may be optional features of the other and further aspects of the invention.
According to a still further aspect of this invention, there is provided a vehicle including the wheel-mounted electrical machine of the first aspect and/or the wheel mounting assembly of the other aspect and/or the wheel mounting assembly of the further aspect.
The vehicle may be arranged controllably to supply electrical power to the electrical machine in order to operate the electrical machine as a motor and thereby drive the vehicle. The vehicle may be arranged to operate the electrical machine as a generator and to store electrical energy generated thereby for use later in operating the electrical machine as a motor to drive the vehicle.
The vehicle may include a respective one of the wheel-mounted electrical machine of the first aspect and/or the wheel mounting assembly of the other aspect and/or the wheel mounting assembly of the further aspect at each of two, more or all wheels of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a diagrammatic sectional view of a first embodiment in which an electrical machine having a single rotor is mounted in a wheel of a vehicle, on a hub thereof, the section being through a vertical axial plane;
Figure 2 is a diagrammatic sectional view of a second embodiment, similar to the first embodiment, but in which the electrical machine has two rotors;
Figure 3 is a diagrammatic sectional view of a third embodiment, similar to the first embodiment, but in which an epicyclic gear train is provided between components of the electrical machine and the wheel;
Figure 4 is a diagrammatic sectional view of a fourth embodiment, similar to the first embodiment, but in which a brake is provided that acts axially on the rotor of the electrical machine;
Figure 5 is a diagrammatic sectional view of a fifth embodiment, similar to the first embodiment, but in which a brake is provided that acts on a disc coaxial with and axially spaced from the electrical machine;
Figure 6 is a diagrammatic sectional view of a sixth embodiment, similar to the first embodiment, but in which a brake is provided that acts radially on the rotor of the electrical machine;
Figure 7 is a diagrammatic elevation view of the rotor and part of the brake of the sixth embodiment;
Figure 8 is a diagrammatic sectional view of a seventh embodiment, similar to the first embodiment, but in which a brake is provided that acts axially on a segment rotor of the electrical machine, the brake replacing a segment of the stator of the electrical machine; and
Figure 9 is a diagrammatic elevation view of the stator and part of the brake of the seventh embodiment.
SPECIFIC DESCRIPTION OF CERTAIN EXEMPLARY EMBODIMENTS
In a first embodiment of this invention, there is provided a hybrid-electric vehicle, only part 10 of which his shown in Figure 1. The vehicle is a car with four wheels. Each of the wheels has a respective electrical machine 20 mounted therein. The hybrid-electric vehicle is of the type in which an internal combustion engine is mechanically coupled to a generator to drive the generator and thereby generate electricity for operating the electrical machines 20 and thereby driving the car. The arrangement of an exemplary one 20 of the electrical machines is described in more detail below, it being understood that the arrangement of each of the other electrical machines is substantially the same.
The part 10 of the vehicle shown in Figure 1 includes a wheel bearing housing 30 with a suspension strut 40 attached thereto. The wheel bearing housing 30 houses a wheel bearing 35. A drive shaft 50 is supported in the wheel bearing 35 and extends from an inner side of the bearing 35 that faces towards the centre of the car through the bearing 35 to emerge at the outer side thereof, facing away from the car. A wheel hub 60 is mounted on the driveshaft 50 on the outer side thereof. A wheel 70 is similarly mounted on the wheel hub 60. Thus, save for the presence of the electrical machine 20, the assembly of the wheel bearing housing 30, the wheel bearing 35, the drive shaft 50, the hub 60 and the wheel 70 is conventional.
As is shown in Figure 1, the electrical machine 20 is an axial flux electrical machine. It has a rotor 22 and a stator 24. The rotor 22 in the form of disc, with a circumferentially- distributed series of permanent magnets (not shown) arranged thereon. The rotor 22 is positioned between two halves of the stator 24, such that the rotor 22 is axially sandwiched therebetween. The stator 24 includes a stator winding (not shown) arranged to set up a magnetic field when an electrical current exists therein. The electrical machine 20 can be operated as both a motor and a generator. An appropriate electrical machine for use as the electrical machine 20 in this embodiment would be that described in UK Patent Application No. 0613570.1, the contents of which are hereby incorporated herein in their entirety.
With continued reference to Figure 1, the electrical machine 20 is fitted to the vehicle in place of a disc brake. The rotor 22 is fitted to the wheel hub 60 in the way that a disc of a disc brake would be fitted thereto. Similarly, the stator 24 is mounted on the wheel bearing housing 30 in the way that a brake calliper of a disc brake would be fitted thereto. Thus, the electrical machine can be fitted in substitution of a disc brake to a vehicle that is arranged to have disc brakes fitted thereto.
In operation, the electrical machines 20 can be operated as motors to provide rotary power to the wheels 70 to thereby drive the wheels 70 and accelerate the car. The electrical machines 20 can also be operated as generators to resist motion of the wheels and thereby slow the car. Electricity generated in this way can be stored for later use in operating the electrical machines 20 as motors. Thus, the electrical machines 20 can be used in regenerative braking.
In a modification of the embodiment described above with reference to Figure 1, the drive shaft is coupled to a mechanical driveline system (not shown) that is arranged to receive rotary power from an internal combustion engine. In such a modification, the electrical machines 20 can be used to supplement the power supplied from the internal combustion engine via the mechanical driveline system.
Figure 2 shows a second embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This embodiment differs from the first embodiment in providing a modified electrical machine 100 in each wheel 70. The modified electrical machine 100 is similar to the electrical machine 20 described above with reference to Figure 1, but differs in having two rotors 22 mounted to the hub 60 and axially spaced from one another. The stator 130 differs in having three stator portions, such that each of the rotors 22 is sandwiched between two of the stator portions. In other respects, this second embodiment is the same as the first.
By providing the modified electrical machine 120 with two rotors 22 each sandwiched between portions of the stator 130, the modified electrical machine 120 is able to generate more torque, both when being operated as a motor and a generator. Accordingly, the second embodiment is suited to applications where the hybrid-electric vehicle is a vehicle with large mass, such as a bus.
Figure 3 shows a third embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This third embodiment differs from the first embodiment in providing an epicyclic gear train 200 between the wheel 70 and the electrical machine 20. This and other modifications are described below.
As in the first embodiment, the wheel-bearing housing 30 includes the wheel bearing 35 therein. There is, however, no drive shaft 50. Instead a short axle 250 is provided and is journalled in the bearing 35. The axle 250 extends from the bearing 35 only to the outer side thereof. The rotor 22 of the electrical machine 20 is mounted on the axle 250. The end of the axle 250 that is remote from the bearing 35 has a sun gear 202 of the epicyclic gear train 200 mounted thereon. A planetary gear arrangement 204 of the epicyclic gear train 200 is fixed to the wheel 70. An annulus 206 of the epicyclic gear train 200 is fixed to the stator 24 of the electrical machine.
In other respects, this third embodiment is similar to the first.
By providing an epicyclic gear train between electrical machine 20 and the wheel 70, the torque generated by the electrical machine 20 is increased as it is transmitted to the wheel 70. Figure 4 shows a fourth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This fourth embodiment differs from the first embodiment in that the electrical machine 300 of this embodiment is modified to include a disc brake 310. The disc brake 310 has a calliper 320 that is mounted to the stator 330 of the electrical machine 300 so as to sandwich the rotor 340 between portions of the calliper 320. In certain embodiments a housing of the calliper 320 may be integrally formed with structure of the stator 330. The disc brake 310 is arranged to press brake pads (not shown) against the surfaces of the rotor 340, radially inside the magnets mounted thereon. Thus, the rotor 340 acts as a disc of the disc brake 300.
When operated in this way, the disc brake 300 is used in combination with regenerative braking to slow the vehicle. Alternatively, the disc brake 300 is used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
In other respects, this fourth embodiment is similar to the first.
Figure 5 shows a fifth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This fifth embodiment differs from the first embodiment in including a disc brake 400. Thus, there are similarities with the fourth embodiment described above with reference to Figure 4. However, in this fifth embodiment, the electrical machine 20 is unmodified and the disc brake 400 is axially displaced from the rotor 22 and the stator 24 thereof. More specifically, the disc brake 400 includes a calliper 410 and a disc 420. The calliper 410 is fixed to structure of the stator 24 so as to be axially adjacent thereto, on the outside thereof. The disc 420 is coaxially mounted with the rotor 22 on the hub 60 so as to be sandwiched between structure of the calliper 410. The calliper 410 is arranged to press brake pads (not shown) against the surfaces of the disc 420 in the conventional manner of disc brakes.
When operated in this way, the disc brake 400 can be used in combination with regenerative braking to slow the vehicle. Alternatively, the disc brake 400 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
In other respects, this fifth embodiment is similar to the first.
Figure 6 shows a sixth embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure 1. The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This sixth embodiment differs from the first embodiment in including a brake shoe arrangement 500. The brake shoe arrangement 500 is mounted between the two parts of the stator 24 so as to extend around a circumferential section of the rim of the rotor 22. The brake shoe arrangement 500 is arranged to press a brake shoe radially against the rim of the rotor 22. Figure 7 shoes the brake shoe engaging the rim of the rotor 22 in this way. It will be understood that the brake shoe operates rather like a brake shoe of a dram brake, but differs in engaging a rim of a disc located radially inside the shoe, rather than the inner wall of a drum located radially outside the shoe.
When used in this way, the brake shoe arrangement 500 can be used in combination with regenerative braking to slow the vehicle. Alternatively, the brake shoe arrangement 500 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
In other respects, this sixth embodiment is the similar to the first. Figure S shows a seventh embodiment that is similar to the first embodiment shown in, and described above with reference to, Figure ϊ , The same reference numerals are therefore used in the description of this embodiment to identify components that this embodiment shares with the first embodiment described above with reference to Figure 1.
This seventh embodiment differs from the first embodiment in including a disc brake arrangement that includes a brake calliper 600- This embodiment is therefore somewhat similar to others of the embodiments described above. However, this embodiment differs in that the brake calliper 600 replaces part of the stator of the electrical machine. Thus, this embodiment includes a revised stator 620 that is similar to that 24 described above with reference to Figure L The revised stator 620 is similar in being formed of two parts with the rotor 22 therebetween^ but differs in that an axially-opposite segment of each part of the Figure 1 stator 24 is removed and replaced by the brake calliper 600 to form the revised stator 620. The brake calliper 600 is sized to fit in the segment removed from the Figure 1 stator 24 and is airanged to be mounted to adjacent structure of the revised stator 620. The brake calliper 600 is further arranged to apply brake pads (not shown) to each surface of the rotor 22.
Figure 9 shows the brake calliper 600 mounted in position on the revised stator 620.
In use, the brake 600 can be used in combination with regenerative braking to slow the vehicle. Alternatively, the brake 600 can be used as a back-up system in the event that regenerative braking fails or fails to slow the vehicle sufficiently quickly.
IQ other respects, this seventh embodiment is the similar to the first.
One of more of the components of the electrical machines described above maybe as, or may include features of, corresponding components of the electrical machine described in UK Patent Application No. 0613570.1 , the contents of which are incorporated herein by reference.

Claims

1. A wheel-mounted electrical machine for powering a vehicle, the electrical machine including at least one rotor and at least one stator, the stator mounted on structure adjacent the wheel and the rotor drivingly connected to the wheel to drive the wheel relative to the stator.
2. A wheel-mounted electrical machine according to claim 1, wherein the rotor is mounted around an axle of the wheel and coupled thereto so as to drive the axle and hence the wheel.
3. A wheel-mounted electrical machine according to claim 1, wherein the rotor is mounted to a hub of the wheel and coupled thereto so as to drive the hub and hence the wheel.
4. A wheel-mounted electrical machine according to any preceding claim, wherein the rotor is mounted in place of a rotating component of a brake.
5. A wheel-mounted electrical machine according to claim 4, wherein the rotor is mounted in place of a disc of a disc brake.
6. A wheel-mounted electrical machine according to claim 4, wherein the rotor is mounted in place of a drum of a drum brake.
7. A wheel-mounted electrical machine according to any preceding claim, wherein the stator is mounted in place of a stationary component of a brake.
8. A wheel-mounted electrical machine according to claim 7, wherein the stator is mounted in place of a brake calliper of a disc brake.
9. A wheel-mounted electrical machine according to claim 8, wherein the stator is mounted in place of brake shoes and pistons of a dram brake.
10. A wheel-mounted electrical machine according to any preceding claim, wherein the rotor is drivingly connected to the wheel via a gear train.
11 A wheel-mounted electrical machine according to claim 10, wherein the gear train comprises an epicyclic gear train.
12. A wheel-mounted electrical machine according to claim 11, wherein a first component of the epicyclic gear train is coupled to the rotor; a second component of the epicyclic gear train is coupled to the wheel; and a third component of the epicyclic gear train is coupled to the stator.
13. A wheel-mounted electrical machine according to claim 11 or claim 12, wherein the rotor is coupled to a sun gear of the epicyclic gear train, the wheel is connected to an arrangement of planet gears of the epicyclic gear train, and the stator is coupled to an annulus of the epicyclic gear train.
14. A wheel-mounted electrical machine according to any preceding claim, wherein the electrical machine is an axial flux electrical machine.
15. A wheel-mounted electrical machine according to claim 14, wherein the axial flux electrical machine includes a plurality of rotors, each rotor axially spaced from the or each other rotor.
16. A wheel-mounted electrical machine according to claim 15, wherein each rotor may be sandwiched between two stator portions.
17. A wheel-mounted electrical machine according to any preceding claim, wherein the electrical machine comprises a brake.
18. A wheel-mounted electrical machine according to claim 17, wherein the brake operates on the rotor to slow the rotor.
19. A wheel-mounted electrical machine according to claim 18, wherein the brake presses material into frictional contact with the rotor to slow the rotor.
20. A wheel-mounted electrical machine according to claim 18 or claim 19, wherein the brake acts as a disc brake with the rotor, or at least part thereof, serving as the disc of the disc brake.
21. A wheel-mounted electrical machine according to any one of claim 17 to claim 20, wherein the electrical machine include a brake calliper mounted on the stator or mounted with the stator on the structure adjacent the wheel.
22. A wheel-mounted electrical machine according to any one of claim 17 to claim 21, wherein the brake presses material into frictional contact with a circumferentially-outer part of the rotor to slow the rotor.
23. A wheel-mounted electrical machine according to claim 22, wherein the circumferentially-outer part is the rim of the rotor.
24. A wheel-mounted electrical machine according to any one of claim 17 to claim 21, wherein the stator includes a gap therethrough in an axial direction through which the brake is operable to act on the rotor.
25. A wheel-mounted electrical machine according to claim 24, wherein at least part of the stator is substantially annular and includes a substantially segment-shaped gap therein through which the brake is operable to act on the rotor.
26. A wheel-mounted electrical machine according to claim 24 or claim 25, when dependent on claim 21, wherein the brake calliper is mounted in the gap.
27. A wheel-mounted electrical machine according to claim 17, wherein the brake is axially spaced from the rotor and comprises a brake disc coaxial with the electrical machine that is drivingly connected to the wheel.
28. A wheel mounting assembly for a vehicle, the assembly comprising: wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle; and a hub arranged for rotatable mounting relative to the wheel-bearing housing structure;
the assembly further comprising an electrical machine comprising at least one rotor and at least one stator, the stator mounted on the wheel-bearing housing structure and the rotor mounted on the hub.
29. A wheel mounting assembly for a vehicle, the assembly comprising:
wheel-bearing housing structure arranged to accommodate a wheel bearing and arranged for fixing to suspension components of the vehicle; and
a wheel rotatably mounted relative to the wheel-bearing housing structure;
the assembly further comprising the electrical machine of the first aspect of the invention, the stator of the electrical machine mounted on the wheel-bearing housing structure and the rotor drivingly connected to the wheel to drive the wheel relative to the stator and hence the wheel-bearing housing structure.
30. A vehicle including a wheel-mounted electrical machine according to any one of claim 1 to claim 27, and/or a wheel mounting assembly according to claim 28 and/or a wheel mounting assembly according to claim 29.
31. A vehicle according to claim 30 and further being a hybrid-electric vehicle.
32. A vehicle according to claim 30 or claim 31, wherein the vehicle is arranged controllably to supply electrical power to the electrical machine in order to operate the electrical machine as a motor and thereby drive the vehicle and is further arranged to operate the electrical machine as a generator and to store electrical energy generated thereby for use later in operating the electrical machine as a motor to drive the vehicle.
33. A vehicle according to any one of claim 30 to claim 32, wherein the vehicle may include a respective one or a wheel-mounted electrical machine according to any one of claim 1 to claim 27, and/or a wheel mounting assembly according to claim 28 and/or a wheel mounting assembly according to claim 29, at each of two, more or all wheels of the vehicle.
PCT/GB2007/002554 2006-07-07 2007-07-09 A wheel-mounted electrical machine WO2008003986A1 (en)

Priority Applications (3)

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JP2009517434A JP5254967B2 (en) 2006-07-07 2007-07-09 Wheel-mounted electronic equipment
EP07733495.1A EP2043886B1 (en) 2006-07-07 2007-07-09 A wheel-mounted electrical machine
US12/349,330 US8008817B2 (en) 2006-07-07 2009-01-06 Wheel-mounted electrical machine

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GBGB0613570.1A GB0613570D0 (en) 2006-07-07 2006-07-07 An electrical machine
GB0613570.1 2006-07-07
GB0709516.9 2007-05-17
GBGB0709516.9A GB0709516D0 (en) 2006-07-07 2007-05-17 An electrical machine
GBGB0709628.2A GB0709628D0 (en) 2006-07-07 2007-05-18 A wheel-mounted electrical machine
GB0709628.2 2007-05-18

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US8008817B2 (en) 2006-07-07 2011-08-30 Evo Electric Ltd. Wheel-mounted electrical machine
WO2010110027A1 (en) * 2009-03-27 2010-09-30 アイシン精機株式会社 Brake device for in-wheel motor
WO2010130774A1 (en) * 2009-05-14 2010-11-18 Siempelkamp Maschinen- Und Anlagenbau Gmbh & Co. Kg Continuous press having a planetary gear
CN102421590A (en) * 2009-05-14 2012-04-18 西姆佩尔坎普机械设备制造有限责任公司和两合公司 Continuous press having a planetary gear
EP2466729A1 (en) * 2009-08-11 2012-06-20 Toyota Jidosha Kabushiki Kaisha Power generating device and braking device
EP2466729A4 (en) * 2009-08-11 2015-11-18 Toyota Motor Co Ltd Power generating device and braking device
CN102148544A (en) * 2010-02-09 2011-08-10 姚加章 Multigap series magnetic disc-embedded type motor
FR2981013A1 (en) * 2011-10-10 2013-04-12 Renault Sa Wheel motor for vehicle, has stator including crown portion extending according to angular sector of wheel such that space is released between ends of crown portion or between adjacent portions of crown of stator
ITPG20130020A1 (en) * 2013-05-08 2014-11-09 Rodolfo Bellaveglia DEVICE FOR A NEW BRAKING SYSTEM FOR ALL MOTOR VEHICLES, THAT COMPLETELY ELIMINATES FRICTION, IN BRAKING, BETWEEN THE WHEELS AND THE SOIL AND ITS RELATIVE STRENGTH OF INERTIA.
EP3807977A4 (en) * 2018-06-15 2022-06-29 Indigo Technologies, Inc. A sealed axial flux motor with integrated cooling
US11411450B2 (en) 2018-06-15 2022-08-09 Indigo Technologies, Inc. Sealed axial flux motor with integrated cooling
WO2021094078A1 (en) * 2019-11-14 2021-05-20 Fazua Gmbh Driving and braking device for a vehicle, and vehicle

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EP2043886B1 (en) 2017-02-08
GB0613570D0 (en) 2006-08-16
EP2043886A1 (en) 2009-04-08
JP2009542496A (en) 2009-12-03
EP2044677A2 (en) 2009-04-08
US20100071972A1 (en) 2010-03-25
US8008817B2 (en) 2011-08-30
JP5254967B2 (en) 2013-08-07
US8022593B2 (en) 2011-09-20
GB0709516D0 (en) 2007-06-27
WO2008003990A2 (en) 2008-01-10
WO2008003987A3 (en) 2011-06-30
GB0709628D0 (en) 2007-06-27
WO2008003990A3 (en) 2008-03-20
WO2008003987A2 (en) 2008-01-10

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