ELECTRIC MACHINE ARRANGEMENT

Abstract

An electric machine arrangement includes an electric machine having a stator and a rotor, a component supporting the stator, and an output element that is in contact with the rotor for conjoint rotation therewith. The stator is supported in the rotational direction via a length compensating element and is at least axially movably connected to the component supporting the stator.

Claims

1. An electric machine arrangement, comprising: an electric machine for driving an electrically drivable motor vehicle, having a stator and a rotor, a component supporting the stator, and an output element that is in contact with the rotor for conjoint rotation therewith, wherein the stator is supported with the interposition of a length compensating element in a rotational direction and is at least axially movably connected to the component supporting the stator.

2. The electric machine arrangement according to claim 1, wherein: the component supporting the stator is designed as a housing of the electric machine.

3. The electric machine arrangement according to claim 1, wherein: the stator is arranged to be supported relative to the rotor via at least a first bearing in such a way as to be decoupled from rotational movement of the rotor.

4. The electric machine arrangement according to claim 1, wherein the length compensating element is designed as an extension that extends in an axial direction or in direction, which is guided in regions in a corresponding recess, wherein the extension is connected either to the stator or to the component supporting the stator, and wherein the corresponding recess is formed in the supporting component or in the stator.

5. The electric machine arrangement according to claim 4, wherein: the extension is arranged in the corresponding recess via an elastic element( under the action of a force at least in one circumferential direction.

6. The electric machine arrangement according to claim 5, wherein: the elastic element designed as an elastomer or as a spiral or leaf spring.

7. The electric machine arrangement according to claim 1, wherein: the length compensating element designed as an individual leaf spring or as a leaf spring assembly.

8. The electric machine arrangement according to claim 7, the length compensating element is formed by a plurality of leaf springs distributed circumferentially to be connected to the stator or by a plurality of leaf spring assemblies distributed circumferentially to be connected to the stator.

9. The electric machine arrangement according to claim 1, wherein: the length compensating element is designed as a coupling rod.

10. The electric machine arrangement according to claim 9, wherein: the coupling rod has an articulated connection, or an elastic connection, on at least one of its free axial ends.

11. The electric machine arrangement according to claim 1, wherein: the length compensating element is designed as a supply line M-for coolant which extends in axial direction or in a radial direction.

12. The electric machine arrangement according to claim 11, wherein: the supply line is configured to compensate for an axial displacement of the stator that is permitted due to the interposition of the length compensating element between the stator and the component supporting the stator by a predetermined maximum distance.

13. The electric machine arrangement according to claim 1, wherein: a supply line designed as a coolant line is formed at least in sections by an elastic or displaceable seal, by an elastic corrugated tube, by an elastic bellows or by an elastic hose, such that a coolant supply to the stator is guaranteed in all axial positions that are made possible by the length compensating element between the stator and the component supporting the stator.

14. The electric machine arrangement according to claim 13, wherein: the supply line designed as a coolant line comprises a tube section which is designed with an elastic or displaceable seal at at least one axial end and is arranged displaceably guided in a receptacle.

15. The electric machine arrangement according to claim 9, wherein: the coupling rod is configured for supplying coolant to the stator is hollow on inside or is designed to be electrically conductive at least in regions for an electrical supply of the stator.

16. The electric machine arrangement according to claim 1, wherein: a supply line designed as a power line has, at least in regions, a length compensating section that enables the supply line be extended, wherein the length compensating section is formed by a cable, by an elastic busbar, by a spiral conductor or by an elastic, electrically conductive conductor mesh.

17. The electric machine arrangement according to claim 1, wherein: the supply line is formed by at least two leaf springs or leaf spring assemblies distributed circumferentially on the stator.

18. The electric machine arrangement according to claim 1, wherein: a supply line designed as a power line formed like a flat strip, wherein the power line is connected to the stator in such a way a trip plane of the power line extends perpendicularly to axial direction of movement of the stator.

19. The electric machine arrangement according to claim 10, wherein the articulated connection is a ball joint connection and the elastic connection is a connection head equipped with an elastomer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Both the disclosure and the technical field are explained in more detail below with reference to the figures. It should be noted that the disclosure is not intended to be limited by the exemplary embodiments shown. In particular, unless explicitly stated otherwise, it is also possible to extract partial aspects of the substantive matter outlined in the figures and to combine them with other components and knowledge from the present description and/or figures. In particular, it should be noted that the figures and in particular the proportions shown are only schematic in nature. Identical reference symbols indicate the same objects, so explanations from other figures can also be used.

[0034] In the figures:

[0035] FIG. 1 shows an axial section of an electric axial flux machine in an H arrangement, in a schematic representation,

[0036] FIG. 2 shows an axial section of an electric axial flux machine in an I arrangement, in a schematic representation,

[0037] FIG. 3 shows an axial section of the electric axial flux machine in an I arrangement according to FIG. 2 with a different arrangement of torque-supporting length compensating elements, in a schematic representation,

[0038] FIG. 4 shows an electric axial flux machine in an I arrangement with a torque support via leaf springs, a power supply via electric busbars and a coolant supply via movably mounted conduits in a perspective representation,

[0039] FIG. 5 shows an electric axial flux machine in an I arrangement with a torque support via a rigid coupling rod arranged approximately tangentially,

[0040] FIG. 6 shows an electric axial flux machine with a structurally simple torque support via a journal mounted in a recess, in a schematic representation, once in an axial top view (above) and once in a perspective view (below), wherein in the lower representation the journal is subjected to force in the circumferential direction via an elastic element designed as a leaf spring, and

[0041] FIG. 7 shows an axial section of an electric radial flux machine, in a schematic representation—and thus that the solutions presented using the example of various axial flux machines can also be transferred to radial flux machines.

DETAILED DESCRIPTION

[0042] FIG. 1 shows an axial section of an electric machine arrangement 1 with an electric machine 2 designed as an axial flux machine in an H arrangement, in a schematic representation. The illustration shows an axial flux motor in an H arrangement, the rotor shaft W of which (designed here as an integral part of the output element 100 designed as a drive shaft) is mounted in a housing 7 which surrounds the electric machine 2. For this purpose, the rotor shaft W is rotatably supported via a bearing 62 with one bearing 621, 622 each in the housing side walls of the housing 7 arranged on the right and left of the electric machine 2. The output element, which is designed in one piece with the rotor shaft W and is in the form of an output shaft, is connected to a gear stage 22 via an external toothing of the output shaft. The stator 3 is arranged between the two disk-shaped rotor halves of the rotor 4 and is supported on the rotor 4 via a further bearing 61 (in the figure consisting of two bearing points 611, 612 designed as angular ball bearings in an O arrangement). Due to this bearing point 61 arranged on the radially inner region of the stator 3 and the torque support preferably arranged on the radially outer region of the stator 3 by a length compensating element 8, the stator 3 is decoupled from the rotational movement of the rotor 4 and thus prevents the stator 3 from twisting or co-rotating in an impermissibly far manner. This torque support supports the reaction torque that always arises when the electric machine 2 generates a torque that is transmitted from the rotor shaft W to a downstream unit of the drive train. Viewed in the circumferential direction, the stator 3 is practically firmly connected to the housing 7 via the torque support, as is necessary for the functioning of the motor. For all other directions of movement, the torque support does not represent a significant restriction, so that the stator 3 can always align itself with the position of the rotor 4 thanks to the bearing 61 between the stator 3 and rotor 4 and can also follow changes in the position of the rotor 4, as can occur, for example, during driving operation due to elastic deformation or thermal expansion of the housing 7 and/or the rotor shaft W. In the exemplary embodiment shown in FIG. 1, the torque support or the length compensating element 8 is implemented by an elastic plastic or rubber sleeve, which is introduced into a recess 30 designed as a cylindrical bore in the stator housing and which is placed in the middle on an extension 81 designed as a pin, which is anchored in the housing 7. The bore in the stator housing, the rubber sleeve and the pin anchored in the housing 7 are arranged concentrically to one another and aligned coaxially with the axis of rotation of the electric machine 2. The torque of the electric machine 2 leads to a tangential force on the radial outer region of the stator 3, which is transmitted in the form of a force extending radially to the pin of the torque support from the stator housing bore through the rubber sleeve to the pin (and vice versa). Due to the elasticity of the rubber sleeve, slight axial and radial displacements and slight tilting between the pin and the cylindrical bore are possible. This displacement capacity between the housing 7 of the electric machine 2 and the stator 3 or the stator housing is negligible in terms of torque support in the circumferential direction—but it is sufficiently large with regard to all other movements that the stator 3 must perform in order to follow the position of the rotor 4. In the case of the stator 3 of the exemplary embodiment shown, the cooling liquid is supplied through the supply lines 9 designed as elastic elements (e.g., elastic connection lines). In FIG. 1, this is realized with the coolant supply indicated by a supply line 9 in the form of a corrugated bellows of the supply line between the housing 7 and the stator 3. This supply line 9 can be implemented, for example, by using a metal corrugated bellows tube or by using a rubber hose (possibly also in the form of a hydraulic hose with fabric reinforcement). In order to avoid undesired currents through the bearing points, a shaft grounding element 11 designed as a shaft grounding ring is arranged between the rotor 4 and the housing 7. This is arranged between an annular flange axially projecting from the housing wall and an annular flange axially projecting from the rotor body. A rotor position sensor 12 is also provided in order to be able to reliably detect the rotational rotor position at any time.

[0043] FIG. 2 shows an axial section of an electric machine 2 designed as an electric axial flux machine in an I arrangement, in a schematic representation. It is well illustrated here that the functional principle already presented in FIG. 1 can also be transferred to an axial flux motor in an I arrangement. The same components are provided with identical reference symbols in all figures.

[0044] FIG. 3 shows the electric axial flux machine in an I arrangement according to FIG. 2, wherein the torque support by means of the longitudinal compensating element 8 and/or the supply lines 9 do not necessarily have to be arranged radially above the stator 3. These elements can also be arranged completely or partially axially next to the electric machine 2. This can be implemented particularly well in the case of axial flux motors in an I arrangement, since the two stator halves of the stator 3 which surround the rotor 4 form the axially outer components of the electric machine 2. In FIG. 3, the torque support is again realized by the rubber sleeve already known from FIG. 1. In this case, however, it is arranged axially next to the stator 3. In the exemplary embodiment, the torque support is arranged relatively far radially outwards, despite the arrangement next to the stator 3, in order to reduce the forces introduced into the torque support by the motor torque. The position shown here for the torque support is also very well suited for the alternative embodiments of the torque support described above. FIG. 3 shows a supply line 9 designed as a coolant supply line, which is connected radially on the inside to the right-hand end face of the stator. This supply line 9 is connected to the stator 3 via an angle piece, which is adjoined by an elastic region which extends in the radial direction and which merges into a tube. Connecting the connecting elements (e.g., cables, busbars, tubes or hoses) to the stator 3 as far inside as possible is particularly useful, since the displacements caused by the tilting movements of the stator 3 are smaller there than radially outwards and thus the resulting elastic deformations of the connecting elements can be reduced.

[0045] A further supply line is arranged in the axial direction on the left-hand end face of the stator 3. Any number of electric and hydraulic lines can also be arranged on this side in different radial positions and in different orientations.

[0046] Only the housed stator 3 of the axial flux machine is shown in the I arrangement in FIGS. 4-6, wherein the rotor 4 is covered by the stator halves which are connected to one another radially on the outside and housed in the stator housing.

[0047] FIG. 4 shows an electric machine 2 designed as an electric axial flux machine in an I arrangement with a length compensating element 8 designed as a torque support via leaf springs 84, a power supply via electric busbars and a coolant supply via movably mounted tube sections 90 in a perspective view. The length compensating element 8 is formed from a total of three leaf springs 84 or leaf spring assemblies 840 connected circumferentially to at least one axial end face of the stator 3.

[0048] In the illustrated embodiment, a total of three approximately tangentially aligned leaf spring assemblies 840 distributed around the circumference are shown. The leaf spring assemblies 840 consist of several leaf springs 84 lying one above the other and fixed to the neighboring components with the same fastening means (rivets). The leaf springs 84 are made from thin spring steel sheet and are mounted in such a way that their sheet metal planes are aligned (approximately) orthogonally to the axis of rotation of the electric machine 2 (axial direction). One end of each of the leaf spring assemblies 840 is fastened to the stator 3 of the electric machine 2 and the other end to an element supporting the electric machine 2 (e.g., a housing 7—not shown in the figure). If the stator 3 is displaced axially, the leaf spring assemblies 840, which are axially soft due to their structure, can participate in the displacement and at the same time support the electric machine 2 in the circumferential direction, so that the motor torque can be transmitted through the leaf springs 84 to the element supporting the electric machine 2. The three leaf spring assemblies 840 arranged around the circumference also have a radially centering effect on the stator 3. Therefore, the electric machine 2 must be mounted with its axis of rotation exactly coaxial to the axis of rotation of the output element 100—for example, the transmission input shaft (or the differently configured downstream unit). This can be done by making the fastening holes, using which the leaf spring 84 is screwed to the housing 7 or to the stator 3, slightly larger than the screws, so that there is enough play to be able to align the electric machine 2 exactly during assembly. Alternatively, the electric machine 2 can also be precisely aligned with its neighboring unit via pinned centering holes. For this purpose, centering holes must then be drilled on the housing 7 precisely aligned with the axis of rotation of the neighboring unit (transmission), and centering holes must be drilled on the leaf springs 84 precisely aligned with the axis of rotation of the rotor 4, which are then pinned together. If the leaf springs 84 are part of the transmission housing in terms of assembly, the precisely drilled centering holes must of course be introduced into the stator 3 and the leaf spring assemblies 840. Fastening elements are shown in the lower and left part of the illustration, which are riveted to the leaf springs 84 and have fastening holes or in which the centering holes can be drilled, via which the leaf spring assemblies 840 are then screwed to the housing 7. Alternatively, this exemplary embodiment can also be equipped with only a single leaf spring assembly 84. A single leaf spring assembly 840 cannot radially center the electric machine 2 and therefore does not require such precise alignment during assembly. The centering of the stator 3 is then only implemented via the bearing of the stator 3 on the rotor 4 or the rotor shaft W.

[0049] FIG. 5 shows an electric machine 2 designed as an electric axial flux machine in an I arrangement with a torque support via a length compensating element 8 by means of an approximately tangentially arranged rigid coupling rod 85. The coupling rod 85 shown is connected to the stator 3 and a component supporting the stator 3 via fastening points at both axial ends. As can be seen in the enlarged detailed illustration above, these fastening points are each designed as ball heads that allow rotational movements in several spatial directions. As a result, the torque support can prevent the stator 3 from also rotating unintentionally and at the same time adapt to radial and axial displacements of the stator 3 without impeding these movements.

[0050] In the exemplary embodiment shown in FIG. 5, the cooling liquid (or a fluid that fulfills a different task) is supplied and discharged through two supply lines 9 designed as elastic corrugated bellows tubes. These corrugated bellows tubes can be made of metal or plastic, for example. Alternatively, the fluid can also be supplied via hoses, for example via hoses with fabric reinforcement, as is the case with hydraulic hoses, for example. Several elastic elements can also be arranged one behind the other. For example, it makes sense to arrange a rigid connecting element such as a piece of tube between two elastic elements, via which it is then connected to the stator 3 and to the component providing the fluid. Due to the rigid element between the two elastic elements, most movements of the stator 3 result in only small angular movements in the elastic elements. This reduces the deformation of the elastic elements, so that smaller and less expensive elastic elements can be used.

[0051] In order to supply the electric machine 2 with electric current, three electric supply lines 9 designed as bent electric conductors are provided in the exemplary embodiment in FIG. 5. The conductors connect the stator 3 to a component providing the electric current (not shown in the figure). Due to the arching of the bent conductors, the conductors become more flexible and can elastically compensate for movements of the stator 3 relative to the adjacent component in all spatial directions. The longer the conductor and the more it is arched or curved, the more flexible it becomes. Conductors bent in a spiral shape or conductors bent in a meandering shape are particularly well suited for accommodating a sufficiently elastic conductor in a small installation space. The conductors can be solid (e.g., in the form of a straight or bent rod) or they can be composed of thinner wires, such as is the case with cables or metal mesh.

[0052] FIG. 6 shows an electric machine 2 designed as an electric axial flux machine with a structurally simple torque support via a journal mounted in a recess, in a schematic representation, once in an axial top view (above) and once in a perspective view (below), wherein in the lower representation the journal is subjected to force in the circumferential direction via an elastic element designed as a leaf spring. The torque support is handled here via a stop acting in the circumferential direction or a form fit between the stator 3 of the electric machine 2 and the housing 7 (or another element supporting the electric machine 2). In the exemplary embodiment, an extension 81 connected to the stator 3 projects into a slot in the housing 7. Depending on the direction in which the electric machine 2 exerts torque on the wheels, one side or the other of the extension lies tangentially against the corresponding contact surface of the slot in the housing 7. If the torque direction changes, the stator 3 rotates minimally until the tangential play is overcome and the previously unloaded stop surfaces of the stator 3 and housing 7 come into contact and can thus transmit the tangential force caused by the torque. Radial and axial movements of the stator 3 are still possible since the extension 81 can be displaced radially and axially in the slot. With this design of the torque support, it makes particular sense to position it radially as far outside as possible on the stator 3 of the electric machine 2 in order to create the greatest possible distance between the axis of rotation of the electric machine 2 and the contact point of the torque support. Due to this large distance between the axis of rotation of the electric machine 2 and the contact point of the torque support, the tangential support force is lowered and thus the sliding friction that occurs during axial or radial displacements of the stator 3 when torque is transmitted at the same time is also reduced. In order to further reduce the friction that occurs or to reduce wear at the contact points, the contact points can also be coated or additional components made of friction-reducing and/or wear-resistant material can be arranged between the extension of the electric machine 2 and the housing 7.

[0053] Alternatively, other contours forming a tangential form fit can also be used as torque support. For example, the housing 7 can also have an extension which projects into the stator 3 instead of the stator 3 projecting into the housing 7 with an extension 81.

[0054] Alternatively, the torque support subject to play can also be provided with a spring mechanism that exerts a tangential force on the stator 3, the electric machine 2 and/or the torque support (illustration below). Due to the tangential spring force, the spring exerts a torque on the stator 3, which torque is superimposed on the torque with which the stator 3 must be supported on the torque support in order to drive the rotor shaft W. The flank change, which occurs in the torque support subject to play when the torque crosses zero, can be shifted to other motor torques by the spring mechanism. With the correct dimensioning of the spring mechanism, the flank change can thus be placed in a motor torque range in which the flank change is not disruptive. For example, it is possible to place the flank change in a torque range that is rarely passed through in order to reduce the number of flank changes. As a result, the wear on the torque support can be reduced. For example, it is also possible to place the flank change in a torque range in which possible rattling noises from the torque support do not disturb, since they are masked by other driving noises. If the spring mechanism is strong enough, the motor can also be pressed so hard in one direction against a contact surface (flank) of the torque arm that the motor torque in the opposite direction is never, or almost never, large enough to overcome the force of the spring mechanism and cause a flank change in the torque support.

[0055] The spring mechanism shown consists of a bent leaf spring which is fastened to the housing 7 and whose free resilient end lies between the extension 81 and the adjacent contact surface of the housing gap. The free end of the spring can thus exert a tangentially acting force on the extension 81 of the stator 3, which presses it against the opposite contact surface of the housing gap. Since the spring is arranged between the extension 81 and one of the two contact surfaces of the housing 7, it also protects the contact surface of the housing 7 behind the spring from wear. This effect can also be used for the opposite contact point between the extension 81 and slot by mounting a high-strength or hardened sheet metal part between the extension 81 and slot there as well. It is even possible to use an identical spring for this if it is installed in such a way that it does not exert any force in the direction of the extension 81 or is significantly weaker than the opposite spring.

[0056] FIG. 7 shows an axial section of an electric machine 2 designed as an electric radial flux machine, in a schematic representation—thus illustrating that the solutions presented using the example of various axial flux machines can also be transferred to radial flux machines. FIG. 7 shows a radial flux machine which is supported with its stator housing via corresponding length compensating elements 8 for torque support of the stator 3 against the housing 7 of the electric machine 2. The rotor 4 is supported on the stator via the bearing point 61 and the rotor 4 is supported with its rotor shaft W on opposite sides of the housing 7 in housing walls. Otherwise, the properties described above with regard to axial flux machines also apply analogously to the radial flux machine shown—or they can be implemented accordingly.

[0057] The axially elastic elements (length compensating elements 8) shown in the exemplary embodiments, which serve torque support purposes or are part of the flexible lines between the stator 3 and the components surrounding the stator 3, are always only shown as examples of elements with these properties. In all of the exemplary embodiments, differently designed elements can always be used if they have comparable properties to the detailed solutions shown.

[0058] The bearing of the stator 3 on the rotor 4 or the rotor shaft W presented here is particularly useful for axial flux motors, since these electric motors are particularly sensitive to axial forces acting on them or long tolerance chains that affect the air gaps between rotor and stator due to their slim, disk-shaped design. However, the bearing of the stator 3 on the rotor 4 is also useful for all other electric motors in order to reduce the axial force load on the structure of the electric motors and to be able to ensure a very precise alignment between the stator 3 and the rotor 4 over the long term.

[0059] The bearing variants described here are not only applicable to e-axles. The bearing variants can also be used for electric motors that are arranged at other points in a motor vehicle. The bearing can also be used independently of the type of units driven by the electric motors. A spur gear stage 22 is always shown in the illustrations, which is intended to indicate a transmission that absorbs the torque of the electric machine 2. However, other units or drive train components can also be driven. For example, it is also possible for the electric motor to be connected directly to a drive wheel.

[0060] In the context of this application, the drive train is understood to mean all components of a motor vehicle that generate the power for driving the motor vehicle and transmit it to the road via the vehicle wheels.

[0061] The terms “radial”, “axial”, “tangential” and “circumferential direction” used in this disclosure always refer to the axis of rotation of the electric machine. The terms “left”, “right” and “above”, “below” are used here only to clarify which areas of the illustrations are currently being described in the text. The later embodiment of the disclosure can also be arranged differently.

[0062] The disclosure is not limited to the embodiments shown in the figures. The above description is therefore not to be regarded as limiting, but rather as explanatory. The following claims are to be understood as meaning that a named feature is present in at least one embodiment of the disclosure. This does not exclude the presence of further features. If the patent claims and the above description define ‘first’ and ‘second’ features, this designation serves to distinguish between two features of the same type without defining an order of precedence.

LIST OF REFERENCE SYMBOLS

[0063] 1 Machine arrangement

[0064] 2 Electric machine

[0065] 3 Stator

[0066] 4 Rotor

[0067] 6 Component supporting the stator

[0068] 7 Housing

[0069] 8 Length compensating element

[0070] 9 Supply line

[0071] 11 Shaft grounding element

[0072] 12 Rotor position sensor

[0073] 22 Gear wheel/gear stage

[0074] 30 Recess (stator)

[0075] 50 Recess (housing)

[0076] 31 Abutment (stator)

[0077] 41 Abutment (rotor)

[0078] 61 Bearing (rotor/stator)

[0079] 611 First bearing point

[0080] 612 Second bearing point

[0081] 62 Bearing (rotor shaft/housing)

[0082] 621 First bearing point

[0083] 622 Second bearing point

[0084] 80 Elastic element

[0085] 81 Extension

[0086] 83 Corrugated tube

[0087] 84 Leaf spring

[0088] 840 Leaf spring assembly

[0089] 85 Coupling rod

[0090] 90 Tube section

[0091] 91, 92 Receptacle (for tube section)

[0092] 100 Output element