Electric Machine for Driving a Motor Vehicle
20220200373 · 2022-06-23
Inventors
Cpc classification
B60K2001/001
PERFORMING OPERATIONS; TRANSPORTING
B60K1/00
PERFORMING OPERATIONS; TRANSPORTING
H02K5/207
ELECTRICITY
H02K9/19
ELECTRICITY
International classification
B60K1/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An electric machine (1) for driving a motor vehicle includes a stator (2) having at least one winding overhang (9, 10). Cooling fluid is flowable in the area of the at least one winding overhang (9, 10) to receive heat from the at least one winding overhang (9, 10). Air is flowable in the area of the at least one winding overhang (9, 10) to receive heat from the cooling fluid.
Claims
1-10. (canceled)
11. An electric machine (1) for driving a motor vehicle (6; 38), comprising a stator (2) with at least one winding overhang (9, 10), wherein cooling fluid is flowable proximate the at least one winding overhang (9, 10) in order to receive heat from the at least one winding overhang (9, 10), and air is flowable proximate the at least one winding overhang (9, 10) in order to receive heat from the cooling fluid.
12. The electric machine (1) of claim 11, further comprising: a first fluid duct (15) configured such that the cooling fluid flowable in the first fluid duct (15) receives heat from the first winding overhang (9), the first fluid duct (15) arranged adjacent to an end surface of the first winding overhang (9) in an axial direction (x); and a second fluid duct (20) configured such that the cooling fluid flowable in the second fluid duct (20) receives heat from the second winding overhang (10), the second fluid duct (20) arranged adjacent to an end surface of the second winding overhang (10) in the axial direction (x).
13. The electric machine (1) of claim 12, further comprising: a first air duct (54) arranged separated from the first fluid duct (15) and adjacent to the first fluid duct (15), the first air duct (54) configured such that the air flowable in the first air duct (54) receives heat from the cooling fluid in the first fluid duct (15); and a second air duct (55) arranged separated from the second fluid duct (20) and adjacent to the second fluid duct (20), the second air duct (55) configured such that the air flowing in the second air duct (55) receives heat from the cooling fluid in the second fluid duct (55).
14. The electric machine (1) of claim 13, further comprising a housing (4), wherein: the housing (4) has an end-surface housing part (19) that at least partially closes the electric machine (1) on a first axial end surface (S1) of the electric machine (1); and the housing part (19) at least partially forms a portion of the first air duct (54).
15. The electric machine (1) of claim 13, further comprising a housing cover (5), wherein: the housing cover (5) at least partially closes the electric machine (1) on a second axial end surface (S2) of the electric machine (1); and the housing cover (5) at least partially forms a portion of the second air duct (55).
16. The electric machine (1) of claim 13, further comprising: a closed air circuit (37); and a fan (53) arranged within the closed air circuit (37), wherein the first air duct (54) and the second air duct (55) form a section of the closed air circuit (37), and the fan (53) is operable to induce circulation of air within the closed air circuit (37).
17. The electric machine (1) of claim 16, further comprising a rotor (3) with a rotor shaft (36), wherein: the air circuit (37) comprises a rotor air duct (57); the rotor air duct (57) extends along the rotor shaft (36) or through the rotor shaft (36) in the axial direction (x); the rotor air duct (57) is connected to the first air duct (54) at one axial end of the rotor air duct (57) and to the second air duct (55) on the other axial end of the rotor air duct (57), air is flowable out of the second air duct (55) into the rotor air duct (57), and air is flowable out of the rotor air duct (57) into the first air duct (54); and wherein the rotor air duct (57) is configured such that the air flowable in the rotor air duct (57) receives heat from the rotor shaft (36).
18. The electric machine (1) of claim 16, further comprising a stator cooling bush (8), wherein: the air circuit (37) comprises a stator air duct (58); the stator cooling bush (8) surrounds the stator (2) in a radial direction (r); the housing (4) surrounds the stator cooling bush (8) in the radial direction (r); the stator air duct (58) extends along an outer circumference (31) of the stator cooling bush (8) in the axial direction (x); the stator air duct (58) is connected to the first air duct (54) at one axial end of the stator air duct (58) and to the second air duct (55) at the other axial end of the stator air duct (58), air is flowable out of the first air duct (54) into the stator air duct (58), and air is flowable out of the stator air duct (58) into the second air duct (55); and the housing (4) is configured for receiving heat from the air flowable in the stator air duct (58) and for rejecting the heat to external surroundings (32) of the electric machine (1).
19. The electric machine (1) of claim 18, wherein: the stator cooling bush (8) forms a stator fluid duct (30.1, 30.2, 30.3) separated from the stator air duct (58); a fluid is flowable through the stator fluid duct (30.1, 30.2, 30.3) for receiving heat from the stator (2); the stator air duct (58) is arranged between the stator cooling bush (8) and the housing (4); and the stator fluid duct (30.1, 30.2, 30.3) is configured such that the fluid flowable through the stator fluid duct (30.1, 30.2, 30.3) receives heat from the air flowable through the stator air duct (58).
20. The electric machine (1) of claim 12, wherein: the first fluid duct (15) comprises a rigid element (16) and a flexible element (17), the rigid element (16) and the flexible element (17) jointly define the first fluid duct (15); the flexible element (16) rests against an outer contour of the axial end surface of the first winding overhang (9); and the flexible element (17) is configured for adapting to the outer contour of the axial end surface of the first winding overhang (9).
21. The electric machine (1) of claim 12, wherein: the second fluid duct (20) comprises a rigid element (16) and a flexible element (17); the rigid element (16) and the flexible element (17) jointly define the second fluid duct (20); the flexible element (17) rests against an outer contour of the axial end surface of the second winding overhang (10); and the flexible element (17) is configured for adapting to the outer contour of the axial end surface of the second winding overhang (10).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Exemplary embodiments of the invention are explained in greater detail in the following with reference to the diagrammatic drawings, wherein identical or similar elements are labeled with the same reference numbers, wherein
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
DETAILED DESCRIPTION
[0041] Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.
[0042]
[0043] When the electric machine 1 is operated as a motor, a time-varying voltage can be applied to the stator 2 and to the windings located therein, in order to generate a time-varying magnetic field, which acts in the rotor 3 to induce a torque and, thereby, generate a turning motion. When the electric machine 1 is operated as a generator, electrical energy can be generated by inducing a changing magnetic field (for example, by rotating the rotor 3) in a looped or coiled conductor of the stator 2, in order to induce a current in the conductor.
[0044] The stator 2 includes a stator core 7, a stator cooling bush 8, and a first winding overhang 9 on a first end surface S1 of the electric machine 1 and a second winding overhang 10 on a second end surface S2 of the electric machine 1. The stator core 7 and the stator cooling bush 8 are fixedly (i.e., the stator core 7 and the stator cooling bush system 8 do not rotate) accommodated in the housing 4. The stator core 7 has a cylindrical inner cavity, in which the rotor 3 is arranged. The rotor 3 is mounted in a first antifriction bearing 11 and in a second antifriction bearing 12 so as to be rotatable about a longitudinal axis L of the electric machine 1. The longitudinal axis L extends in the axial direction x of the electric machine 1.
[0045] The first winding overhang 9 is arranged within a first winding overhang space 13, which is represented on the left in
[0046] The first winding overhang space 13 is a hollow space. In an axial direction x of the electric machine 1, the first winding overhang space 13 is delimited by a housing part 19 of the housing 4, wherein the housing part 19 closes the electric machine 1 on the first end surface S1. The first winding overhang space 13 is also delimited externally, in a radial direction r of the electric machine 1, by the housing 4. Internally, in the radial direction r, the winding overhang space 13 transitions into a first rotor space 25. The first winding overhang space 13 and the first rotor space 25 are dry, i.e., no cooling fluid is located within the first winding overhang space 13 and within the first rotor space 25.
[0047] The second winding overhang space 14 is also a hollow space. In the axial direction x of the electric machine 1, the second winding overhang space 14 is delimited by the housing cover 5, which closes the electric machine 1 toward the outside on the second end surface S2. The second winding overhang space 14 is also delimited externally, in a radial direction r of the electric machine 1, by the housing 4. Internally, in the radial direction r, the second winding overhang space 14 transitions into a second rotor space 27. The second winding overhang space 14 and the second rotor space 27 are dry, i.e., no cooling fluid is located within the second winding overhang space 14 and within the second rotor space 27.
[0048] An annular first fluid duct 15 is arranged within the first winding overhang space 13 and includes a rigid element 16, for example, a sheet-metal pressed part, and a flexible element 17, for example, made of rubber. The rigid element 16 is annular and has a U-shaped cross-section. A longer inner leg of the rigid element 16 delimits the annular first cooling duct 15 in the axial direction x on the second end surface S2 of the electric machine 1. Two smaller legs delimit the first fluid duct 15 internally and externally, respectively, in the radial direction r.
[0049] The rigid element 16 therefore forms the first fluid duct 15 in such a way that the first fluid duct 15 is closed, in the axial direction x, on the first end surface S1. In the direction of the second end surface S2, however, the first fluid duct 15 formed by the rigid element 16 is open (
[0050] The rigid element 16 is inserted, in the direction of the first end surface S1, into a recess 26 (cf.
[0051] The rigid element 16 includes an input-side port 28 (
[0052] The rigid element 16 also includes an output-side port 56, via which a flow of cooling fluid, which has previously absorbed heat from the first winding overhang 9, can be discharged from the first fluid duct 15. The output-side port 56 can also be arranged at the inner leg of the rigid element 16 and include a bore in the inner leg as well as a hollow cylindrical connection piece. The output-side port can be connected in a fluid-tight manner to a line element of the cooling water circuit of the electric machine 1 extending through the housing part 19, for example, via clamping, adhesive bonds, vulcanization, welding, or other suitable joining methods that enable a fluid-tight connection between the output-side port and the line element of the cooling water circuit of the electric machine 1.
[0053] In the exemplary embodiment shown, a second fluid duct 20 is arranged within the second winding overhang space 14 with mirror symmetry with respect to the first fluid duct 15. The second fluid duct 20, having one further rigid element 16 and one further flexible element 17 in the exemplary embodiment shown, has the same configuration, in principle, as the first fluid duct 15. The second fluid duct 20 and/or the further rigid element 16 and further flexible element 17 are arranged mirror symmetrically with respect to the first fluid duct 15 and are connected to the cooling water circuit.
[0054] The further rigid element 16 includes an input-side port 29, via which a flow of cooled cooling fluid can be routed to the second fluid duct 20. In the exemplary embodiment shown, the input-side port 29 is arranged at the inner leg of the further rigid element 16 and includes a bore in the inner leg. The housing cover 5 includes a bore 22 (inlet hole) extending in the axial direction, which is connected to the cooling water circuit of the electric machine 1 and/or is a part of this cooling water circuit. The bore 22 in the housing cover 5 is connected to the bore in the inner leg of the further rigid element 16, and so cooled cooling fluid from the cooling water circuit of the electric machine 1 can be guided into the second fluid duct 20 in order to cool the second winding overhang 10. The further rigid element 16 also includes an output-side port 23, via which a flow of cooling fluid, which has previously absorbed heat from the second winding overhang 10, can be discharged from the second fluid duct 20. The output-side port 23 is connected to an outflow hole 24 within the housing cover 5. The outflow hole 24 is connected to the cooling water circuit of the electric machine 1 and/or is a part of this cooling water circuit.
[0055]
[0056] In addition to the aforementioned cooling of the electric machine 1 by way of the cooling fluid, a rotor shaft 36 of the rotor 3 as well as the two winding overhangs 9, 10 are cooled by an air circulation that circulates within the electric machine 1 in a closed manner. The course of the air circulation is illustrated in
[0057] The air circuit 37 has a first air duct 54 (
[0058] The housing cover 5 and a surface of the longer inner leg of the further rigid element 16 of the second fluid duct 20 facing away from the second fluid duct 20 jointly delimit the second air duct 55, and so the second air duct 55 is arranged separated from the second fluid duct 20 and adjacent to the second fluid duct 20. In the exemplary embodiment shown, the air duct sections of the second air duct 20 are separated from one another by the centering and fixing elements 18 (cf.
[0059] The air circuit 37 includes a rotor air duct 57 for cooling the rotor shaft 36. The rotor air duct 57 extends through the rotor shaft 36 in the axial direction x of the electric machine 1. The rotor shaft 36 forms the rotor air duct 57, for example, in that the rotor shaft 36 has a star-shaped cross-section. On the second end surface S2, the second air duct 55 opens into the second rotor space 27, which opens into the rotor air duct 57 (
[0060] The air circuit 37 includes a stator air duct 58 in the area of the stator cooling bush 8 in order to cool the air that has previously absorbed heat from the second winding overhang 10, from the rotor shaft 36, and from the first winding overhang 9 (in this order and/or flow direction), so that the air can subsequently absorb heat again from the aforementioned components (in the aforementioned order and/or flow direction), in order to cool these components. The stator air duct 58 extends, in the axial direction x of the electric machine 1, along the outer circumference 31 of the stator cooling bush 8 between the stator cooling bush 8 and the housing 4 of the electric machine 1. On the first end surface S1, the first air duct 54 opens into the first winding overhang space 13, which opens into the stator air duct 58. In this way, the stator air duct 58 is connected to the first air duct 54 via the first winding overhang space 13. Therefore, air can flow out of the first air duct 54 into the stator air duct 58 via the first winding overhang space 13.
[0061] In this way, air that flows out of the first air duct 54 via the first winding overhang space 13 into the stator air duct 58 can, on the one hand, give off heat to the housing 4, which can at least partially give off the absorbed heat to the external surroundings 32 of the electric machine 1. On the other hand, the air that flows through the stator air duct 58 can give off heat to the cooling fluid that flows through the stator fluid duct 30.1, 30.2, 30.3. In this way, the air that flows through the stator air duct 58 is cooled down or re-cooled in both radial directions r (namely, radially inward and radially outward). On the second end surface, the stator air duct 58 opens into the second winding overhang space 14, which opens into the second air duct 55. In this way, the stator air duct 58 is connected to the second air duct 55 via the second winding overhang space 14. Therefore, air can flow out of the stator air duct 58 into the second air duct 55 via the second winding overhang space 14. Since the air cools down while the air flows through the stator air duct 58, cool air is available once again downstream from the stator air duct 58 in order to cool, in particular, the second winding overhang 10, the rotor shaft 36, and the first winding overhang 9.
[0062]
[0063] The transmission 34 can therefore be a hybrid transmission, wherein the internal combustion engine 33 and/or the electric machine 1 can be coupled to the transmission 34. The transmission 34 can be an automatic transmission. A drive of the motor vehicle 6 can take place either via the internal combustion engine 33, the electric motor 1 (i.e., the electric machine 1 operated as a motor), or via a combination of both prime movers 1, 33. The purely exemplary drive train including the transmission 34 is a parallel hybrid having a P2 architecture in the exemplary embodiment shown, wherein the electric machine 1 is arranged between the internal combustion engine 33 and the transmission 34. The internal combustion engine 33 can be separated from the electric machine 1 and from the transmission 34 via a separating clutch 35.
[0064]
[0065] Alternatively or additionally to the described front axle drive, the drive train 39 can include an engageable and disengageable electric axle drive 47, which, in the exemplary embodiment shown, includes an electric machine 1 according to
[0066] Modifications and variations can be made to the embodiments illustrated or described herein without departing from the scope and spirit of the invention as set forth in the appended claims. In the claims, reference characters corresponding to elements recited in the detailed description and the drawings may be recited. Such reference characters are enclosed within parentheses and are provided as an aid for reference to example embodiments described in the detailed description and the drawings. Such reference characters are provided for convenience only and have no effect on the scope of the claims. In particular, such reference characters are not intended to limit the claims to the particular example embodiments described in the detailed description and the drawings.
REFERENCE CHARACTERS
[0067] L longitudinal axis of the electric machine [0068] S1, S2 first/second end surface of the electric machine [0069] x/r axial/radial direction [0070] 1 electric machine [0071] 2 stator [0072] 3 rotor [0073] 4 housing [0074] 5 housing cover [0075] 6 motor vehicle [0076] 7 stator core [0077] 8 stator cooling bush [0078] 9 first winding overhang [0079] 10 second winding overhang [0080] 11 first rotor bearing [0081] 12 second rotor bearing [0082] 13 first winding overhang space [0083] 14 second winding overhang space [0084] 15 first fluid duct [0085] 16 rigid element [0086] 17 flexible element [0087] 18 centering and fixing elements [0088] 19 housing part on the first end surface [0089] 20 second fluid duct [0090] 22 inlet hole [0091] 23 output-side port of rigid element of second fluid duct [0092] 24 outflow hole [0093] 25 first rotor space [0094] 26 housing recess [0095] 27 second rotor space [0096] 28 input-side port of first fluid duct [0097] 29 input-side port of second fluid duct [0098] 30.1 stator cooling bush recess [0099] 30.2 stator cooling bush recess [0100] 30.3 stator cooling bush recess [0101] 31 outer circumference of stator cooling bush [0102] 32 external surroundings of the electric machine [0103] 33 internal combustion engine [0104] 34 transmission [0105] 35 separating clutch [0106] 36 rotor shaft [0107] 37 air circuit [0108] 38 motor vehicle [0109] 39 drive train [0110] 40 drive unit [0111] 41 prime mover [0112] 42 transmission [0113] 43 front differential gear [0114] 44 front wheel [0115] 45 front wheel [0116] 46 front axle [0117] 47 electric axle drive [0118] 48 rear differential gear [0119] 49 first rear wheel [0120] 50 first sideshaft [0121] 51 second rear wheel [0122] 52 second sideshaft [0123] 53 fan [0124] 54 first air duct [0125] 55 second air duct [0126] 56 output-side port [0127] 57 rotor air duct