ELECTRIC VEHICLE

Abstract

The invention relates to an electric vehicle (10) with an electric motor (18) wherein the electric motor (18) comprises (a) a first electric motor module (38.1) that features a first rotor (42.1) with a first rotor shaft (40.1) and whose rotor shaft (40.1) has a first shaft coupling structure (46a), and (b) at least a second electric motor module (38.2) that features a second rotor (42.2) with a second rotor shaft (40.2) and whose second rotor shaft (40.2) has a second shaft coupling structure (46b), and (c) a rotational bearing (68) by means of which the first rotor shaft (40.1) is mounted, wherein (d) the first rotor shaft (40.1) and the second rotor shaft (40.2) are positively coupled with one another by means of the shaft coupling structures (46). According to the invention, the shaft coupling structures (46) are at least partially surrounded by the rotational bearing (68).

Claims

1. An electric vehicle with an electric motor wherein the electric motor comprises a plurality of electric motor modules, comprising a first electric motor module, comprising a first rotor, which has a first rotor shaft, wherein the first rotor shaft has a first shaft coupling structure, and at least a second electric motor module, comprising a second rotor, which has a second rotor shaft, wherein the second rotor shaft has a second shaft coupling structure, and a rotational bearing by which the first rotor shaft is mounted, wherein the first rotor shaft and the second rotor shaft are positively coupled with one another via the first and second shaft coupling structures, and wherein the first and second shaft coupling structures are at least partially surrounded by the rotational bearing.

2. The electric vehicle according to claim 1, wherein each rotor of each electric motor module is supported by two pivot bearings such that the first and second electric motor modules are capable of functioning independently of one another, and at least two electric motor modules of the plurality of electric motor modules are structurally identical.

3. The electric vehicle according to claim 1, wherein at least two electric motor modules of the plurality of electric motor modules are permanently excited synchronous motors.

4. The electric vehicle according to claim 1, wherein the rotational bearing comprises a first pivot bearing, which comprises a first set of rolling elements arranged annularly, and the rotational bearing comprises a second pivot bearing which comprises a second set of rolling elements that are arranged annularly and at an offset to the first set of rolling elements, and the first and second shaft coupling structures are at least partially surrounded by the first pivot bearing and the second pivot bearing.

5. The electric vehicle according to claim 1, wherein the first shaft coupling structure comprises a projection that extends in an axial direction, the second shaft coupling structure has a recess that extends in the axial direction so that the first shaft coupling structure and the second shaft coupling structure abut one another in the axial direction along a contact surface, and the contact surface forms an angle of at most 5° with an angle measurement plane which contains a rotational axis of the first or second rotor.

6. The electric vehicle according to claim 1, wherein the electric motor further comprises a rotary encoder which comprises a rotary encoder coupling structure with a projection that extends in an axial direction, and the rotary encoder is positively connected to either the first or second shaft coupling structure of an electric motor module.

7. The electric vehicle according to claim 6, wherein the electric motor has a brake which comprises a brake coupling structure with a projection that extends in an axial direction, and the brake is positively connected to the first or second shaft coupling structure of an electric motor module or the rotary encoder.

8. The electric vehicle according to claim 1, wherein the first rotor shaft and the second rotor shaft have a cooling duct.

9. An electric vehicle with an electric motor wherein the electric motor comprises a first electric motor module, comprising a first rotor, which has a first rotor shaft, and a rotational bearing by which the first rotor shaft is mounted, and wherein the first rotor shaft has a first shaft coupling structure, and at least a second electric motor module, comprising a second rotor, which has a second rotor shaft, wherein the second rotor shaft has a second shaft coupling structure, wherein the first rotor shaft and the second rotor shaft are positively coupled with one another via the first and second shaft coupling structures, wherein the first and second shaft coupling structures are at least partially surrounded by the rotational bearing, wherein the first rotor shaft and the second rotor shaft have a cooling duct, and wherein the cooling duct extends through the first rotor and the second rotor.

10. The electric vehicle according to claim 1, further comprising a stator, wherein the rotor shaft comprises a central cooling duct that extends in an axial direction, a feed branch duct that extends radially outwards and is connected to the central cooling duct, and a discharge branch duct that extends outwards and is connected to the central cooling duct, wherein the stator comprises a cooling fluid feed for supplying cooling fluid to the feed branch duct, and a cooling fluid discharge for discharging cooling fluid from the discharge branch duct.

11. The electric vehicle according to claim 10, wherein the cooling fluid feed has a first shaft seal and a second shaft seal, which form a shaft annular duct, and a feed line that is configured to feed cooling fluid to the annular duct.

12. The electric vehicle according to claim 10, wherein the first rotor comprises a magnet carrier, a plurality of permanent magnets fixed to the magnet carrier, and a secondary duct which extends in the axial direction through the magnet carrier and is connected to the central cooling duct.

13. The electric vehicle according to claim 12, wherein the stator comprises stator electromagnets, the permanent magnets of the first rotor are arranged radially outside of the stator electromagnets, the rotor shaft has a first sleeve section that extends in a first axial direction and a second sleeve section that extends in a direction opposite to the first axial direction, the first and second sleeve sections are symmetrical, and the first and second sleeve sections contain cooling ducts.

14. The electric vehicle according to claim 13, wherein the first and second sleeve sections are configured on a tubular component, the tubular component is fixed to a web, and the web has a connection duct that extends radially outwards which connects the central cooling duct to an external duct in the tubular component.

15. The electric vehicle according to claim 13, wherein the stator comprises cooling nozzle, which is arranged to cool the stator electromagnets.

16. An electric vehicle with an electric motor wherein the electric motor comprises a first electric motor module comprising a first rotor which has a first rotor shaft that comprises a first shaft coupling structure and a first cooling duct, and at least a second electric motor module, comprising a second rotor which has a second rotor shaft that comprises a second shaft coupling structure (46b) and a second cooling duct, wherein the first rotor shaft and the second rotor shaft are positively coupled with one another via the first and second shaft coupling structures, and wherein the first and second cooling ducts are connected to one another.

17. The electric vehicle according to claim 16, wherein the first electric motor module has a first module housing, comprising a first housing coupling structure, the second electric motor module has a second module housing, comprising a second housing coupling structure, the first and second electric motor modules are positively connected to one another via the first and second housing coupling structures, and the first and second housing coupling structures radially surrounds the first pivot bearing.

18. The electric vehicle according to claim 17, wherein the first housing coupling structure is at least partially formed by a first tapered housing ring, the second housing coupling structure is at least partially formed by a second tapered housing ring, and the first and second tapered housing rings are connected via a coupling clamp, which has an at least partially tapered inner surface.

19. The electric vehicle according to claim 10, wherein the cooling fluid is coolant.

Description

[0043] In the following, the invention will be explained in more detail by way of the attached figures. All figures show the invention on one of several types of electric motor, namely as permanently excited synchronous motors, which are a preferred embodiment of the invention. However, other types of electric motor can be used, such as asynchronous motors or brushless direct current motors. What is shown in the drawings is in

[0044] FIG. 1a an electric vehicle according to the invention with an electric motor according to the invention,

[0045] FIG. 1b an electric vehicle according to the invention in a view from behind,

[0046] FIG. 1c an electric vehicle according to a second embodiment with two clutches and two driven axles in a perspective view,

[0047] FIG. 1d an electric vehicle according to a third embodiment with two electric motors according to the invention, whose rotors extend parallel to one another, with four clutches in a perspective view,

[0048] FIG. 2a a scaled perspective view of an electric motor module, which is designed as an internal rotor and may form part of an electric motor according to the invention,

[0049] FIG. 2b the rotor of the electric motor module of the internal rotor version according to FIG. 2a in a perspective view,

[0050] FIG. 3a a cross-section through an electric motor according to the invention in the form of an internal rotor from two electric motor modules according to FIGS. 2a and 2b,

[0051] FIG. 3b a detailed view of the electric motor module according to FIG. 3a,

[0052] FIG. 4 in the partial FIG. 4a, a perspective, scaled view of an electric motor according to the invention according to a fourth embodiment, which comprises electric motor modules, and in the partial FIG. 4b, a partially exploded view of the electric motor according to partial FIG. 4a,

[0053] FIG. 5 a cross-section through an electric motor module, which represents an electric motor in the form of an internal rotor,

[0054] FIG. 6 a cross-section through an electric motor module of an electric motor according to the invention or an electric motor according to the invention that represents an internal rotor electric motor,

[0055] FIG. 7 in the partial FIG. 7a, the rotor of the electric motor module according to FIG. 6 in an isometric perspective view and in partial FIG. 7b, a rotor shaft and a web of the rotor according to partial FIG. 7a,

[0056] FIG. 8 a cross-section through an electric motor according to the invention with two electric motor modules that are designed as internal rotor electric motors,

[0057] FIG. 9 in the partial FIG. 9a, a cooling nozzle for an electric motor according to the invention in an isometric perspective glass body view, and FIG. 9b a cross-section through the stator cap 50 of the cooling nozzle according to partial FIG. 9b, and in

[0058] FIG. 10 a further embodiment of an electric motor module 38.

[0059] FIG. 1a depicts an electric vehicle 10 according to the invention in the form of an electric car, which comprises a first axle 12 in the form of a front axle and a second axle 14 in the form of a rear axle. Wheels 16.1, 16.2 are fixed to the first axle 12; wheels 16.3, 16.4 are fixed to the second axle 14. An electric motor 18 drives the wheels 16.1, 16.2 of the first axle 12 via a differential gearbox 20, which may also be referred to as a differential.

[0060] The electric motor 18 is supplied with power from a battery 22. The battery 22 comprises at least two—in the present case eight—battery units 24.1, 24.2, . . . , 24.8. The term battery should be understood here to mean any kind of unit of galvanic elements that serves to store electrical energy or convert into electrical energy to supply the electric motor 18.

[0061] It is clear to see that a motor rotational axis D.sub.18 extends between the battery units 24.1, 24.3, 24.5, 24.7 on one side and 24.2, 24.4, 24.6 and 24.8 on the other. A mass m.sub.r of the battery units 24.1, 24.3, 24.5 and 24.7 arranged to the right of the motor rotational axis D.sub.18 corresponds to a mass m.sub.l of the battery elements to the left of the motor rotational axis D.sub.18, i.e. in the present case of the battery elements 24.2, 24.4, 24.6 and 24.8.

[0062] The feature that the two masses m.sub.r, m.sub.l correspond to each other should be understood particularly to mean that the two masses deviate from one another by a maximum of 20%, preferably a maximum of 15%.

[0063] The electric vehicle 10 has a vehicle floor 26. In the present embodiment, both the battery 22 and the electric motor 18 are mounted on the vehicle floor 26. The electric vehicle 10 also has components that are not depicted, such as an outer casing, in particular made of sheet metal, seats and a steering system.

[0064] FIG. 1b shows the electric vehicle 10 in a view from behind. It should be recognised that an electric motor overall height h.sub.M corresponds to a battery overall height h.sub.B. The electric motor overall height h.sub.M is the height of the conceived cuboid Q.sub.1 of minimal volume, which encloses 90% of the mass of the battery 22. FIG. 1b also shows a body 28 of the electric vehicle 10. A driver's seat 30 and a front passenger's seat 32 are also depicted, both of which are arranged on an even floor 34 of a passenger area 36.

[0065] In the embodiment shown in FIG. 1a, the electric motor 18 is composed of three electric motor modules 38.1, 38.2, 38.3 that are coupled behind one another. All three electric motor modules 38.1, 38.2, 38.3 are structurally identical and comprise rotor shafts 40.1, 40.2, 40.3 that are coupled with one another. The electric motor modules 38.1 (i=1, . . . N; N: number of electric motor modules) are structurally identical.

[0066] FIG. 1c shows a scaled perspective view of an electric vehicle 10 according to the invention without its vehicle body, comprising a first clutch 77.1 and a second clutch 77.2. The first clutch is located in a torque path between the electric motor 18 and the wheels 16.1, 16.2 of the first axis 12. The second clutch 72 is located in a torque path between the electric motor 18 and the wheels 16.3, 16.4 of the second axis 14. The clutches 77.1, 77.2 can preferably be switched electrically. In this way, it is possible for the electric vehicle 10 to have either a purely front-wheel drive, a purely rear-wheel drive or 4-wheel drive.

[0067] FIG. 1d depicts a reduced, perspective and scaled view of an electric vehicle according to the invention according to a further embodiment, which features two electric motors 18.1, 18.2. Both electric motors 18.1, 18.2 are composed of at least two modules, the rotational axes of which extend parallel to one another. However, this refers to parallelism in the technical sense, which is to say that it is possible but not essential for the two axes to extend parallel to one another in the mathematical sense. In particular, the rotational axes can form an angle with one another that is smaller than, for instance, 3°.

[0068] FIG. 2a shows an electric motor module 38 of the internal rotor version, which comprises a first rotor 42 (see FIG. 2b) and a module housing 44. A first coupling structure 46a is configured on the rotor shaft 40 of the rotor 42. The module housing 44 comprises a housing ring 48, which may also be described as a coupling ring. In the present case, the housing ring 48 is designed on a stator cap 50a. The module housing 44 also features a second stator cap 50b and a stator carrier 52, which is connected to both stator caps 50a, 50b and arranged between the two in the embodiment of the internal rotor version shown.

[0069] It should be recognised that the shaft coupling structure 46 partially protrudes axially beyond the module housing 44 and partially returns behind the module housing 44.

[0070] FIG. 2b depicts the rotor 42 with the shaft coupling structure 46a.1 and a second shaft coupling structure 46b.1, which is arranged opposite the first coupling structure 46a. The rotor 42 has a magnet carrier 54, by means of which permanent magnets 56.1, 56.2 are arranged. The permanent magnets 56.j (j=1, 2, . . . ) are arranged in such a way that the north pole and south pole point outwards on an alternating basis.

[0071] FIG. 2b also shows that the first coupling structure 46a has a projection 58.1 that extends in the axial direction. When mounted, this projection 58.1 lies along two contact surfaces K1, K2 on a complementary coupling structure of the adjacent electric motor module. In the present case, the contact surfaces K1, K2 form an angle of between 0° and 1° with an angle measurement plane E. The angle measurement plane E is the plane which contains a rotational axis D of the rotor 42 and touches or intersects the respective contact surface K at at least one point.

[0072] The rotor 42 also has a first bearing seating surface 60.1 and a second bearing seating surface 60.2.

[0073] FIG. 3a shows a cross-section through an embodiment of an electric motor 18 according to the invention, composed of electric motor modules 38.1, 38.2, which are structurally identical.

[0074] The first electric motor module 38.1 has a first pivot bearing 62a.1 in the form of a ball bearing and a second pivot bearing 62b.1. The second electric motor module 38.2 has a pivot bearing 62a.2 and a second pivot bearing 62b.2. The first pivot bearing 62a.1 has a first set of rolling elements 64.1, 64.2, . . . , which are arranged annularly. The second pivot bearing 62b.2 also features rolling elements 66.1, 66.2, . . . , arranged along a second ring which is at an offset to the first ring. Both pivot bearings 62a.1 and 62b.2 form a pivot bearing 68. It should be recognised that the coupling structure 46a of the first electric motor module 38.1 forms a positive-locking fit with a coupling structure 46b.2 of the second electric motor module 38.2, and that the coupling structures 46a.1, 46b.2 are surrounded by the rotational bearing 68.

[0075] FIG. 3a shows that the coupling structure 46a.1 of the first electric motor module 38.1 extends to below the pivot bearing 62b.2 of the second electric motor module 38.2. Regardless of other properties of the embodiment described here, this represents a generally preferred embodiment. The coupling structure 46b.2 also extends to below the pivot bearing 62a.1.

[0076] If the present description contains a reference to an axial length, this refers to a position along a schematically depicted x-axis, which extends towards the rotational axis D. In particular, the coupling structures 46a.1 and 46b.2 are thus arranged at the same axial height as the rotational bearing 38.

[0077] FIG. 3b depicts a section from FIG. 3a. It should be recognised that the module housing 44.1 has a first housing coupling structure 70a.1, which forms a first tapered housing ring. The second module housing 44.2 has a second housing coupling structure 70b.2, which also forms a second tapered housing ring. The two housing coupling structures 70a.1, 70a.2 are positively connected by means of a connector in the form of a coupling clamp 72. The coupling clamp 72 features a tapered inner surface 74, which has respective surface contacts with the housing coupling structures 70a.1, 70b.2, thereby effecting a positive-locking fit.

[0078] FIG. 3b also shows that an axial structural length L1 is less than twice the length, in this case less than 1.5-times the length, of an axial structural length L2 of a coupling section. The axial structural length L2 corresponds to the axial length of the shaft coupling. An axial structural length L3 of the coupling clamp 72 is slightly shorter than the axial length L2.

[0079] The coupling clamp 72 is designed in such a way that it can be released and tightened from the outside. It is therefore possible to connect two electric motor modules 38.1, 38.2 by first connecting the rotor shafts to one another by means of their respective shaft coupling structures. The housings are then connected to one another via the connector, i.e. the coupling clamp 72 in this case. To release the connection between the two electric motor modules 38.1, 38.2, the coupling clamp 72 must simply be removed; the rotor shafts can then be pulled apart axially.

[0080] FIG. 4a depicts an electric motor according to the invention, which comprises three electric motor modules 38.1, 38.2 and 38.3 as well as a rotary encoder 76, a clutch 77 and a brake 78. The rotary encoder 76 and the brake 78 each have a shaft, which extends coaxially to the rotor shafts of the electric motor modules 38.i.

[0081] FIG. 4b depicts a partial exploded view of the electric motor 18 according to FIG. 4a. It should be recognised that the rotary encoder 76 features rotary encoder coupling structures 80a, 80b, which correspond to the coupling structures 46 of the electric motor modules 38.

[0082] The brake 78 has at least one brake coupling structure 82a, which is designed like the other coupling structures, so that the brake 78 can be positively connected to both the rotary encoder 76 and each electric motor module 38. The coupling 77 has the same coupling structure as the brake 78, such that it can be coupled with each electric motor module, like the brake 78.

[0083] FIG. 5 depicts a cross-section through the electric motor module 38.1, which can also be considered as an independent electric motor. It should be recognised that a cooling duct 84 is arranged in the rotor shaft 40. In the present form, the cooling fluid 86 in the form of a liquid coolant is supplied through a cooling fluid feed 88. A sealing bush 90 rotates with the rotor shaft and is connected to the rotor shaft 40 via seals.

[0084] At least one, but preferably two, partition walls 92a, 92b are arranged in the rotor shaft 40 which cause the cooling fluid 86 to flow through a first secondary duct 94a, a second secondary duct 94b or another secondary duct, not depicted. The secondary ducts 94a, 94b, . . . extend in both the axial and radial direction, and thus largely parallel to the cooling duct 84. The cooling fluid in the secondary duct 94 cools the magnet carrier 54 and thus the permanent magnets 56.

[0085] A laminated stator core 96 is arranged radially outside the permanent magnets 56. The laminated stator core 96 is cooled in a stator cooling duct 98 using cooling fluid. It is possible that the stator cooling duct 98 does not extend across the full width of the laminated stator core, in particular winding heads 100a, 100b need not lie on an axial length on which the stator cooling duct 98 also extends.

[0086] FIG. 6 shows a further embodiment of an electric motor module 38 according to the invention, which also represents an independent embodiment of an electric motor according to the invention. As the electric motor according to FIG. 5 is an internal rotor, the electric motor 38 according to FIG. 6 is an external rotor, where the permanent magnets 56 are arranged radially outside of the laminated stator core 96. The laminated stator cores 96a, 96b engage in a space between the rotor shaft 40 and a tubular component 102, which features a first sleeve section 104 and a second sleeve section 106. The tubular component 102 is fixed to a bar 108, which can also be described as a rotor hub. The tubular component 102 and the web 108 form a T-shaped rotor element.

[0087] The rotor shaft 40 features a feed branch duct 110, by means of which the cooling fluid 86 can be guided into the cooling duct 84. The partition walls 92a, 92b, 92c cause the cooling fluid from the branch duct 110 to first cover a part in the cooling duct 84 and then flow into a first web duct 112, from where it can flow into an unmarked duct in the tubular component 102. The cooling fluid heats up here and flows through a second web duct 114 in the web 108 back into the duct 84. Via a discharge branch duct 115, the cooling fluid flows out of the rotor 42 into a shaft annular duct 129 between the stator housing 121 and the rotor shaft 40, and from there into a cooling fluid discharge 118.

[0088] The cooling fluid 86 reaches the feed branch duct 110 via a cooling fluid feed 120, wherein the cooling fluid feed 120 is also configured in a stator housing 121; in the present case, it is configured in the stator cap 50b1. The cooling fluid feed 120 comprises a first shaft seal 122 and a second shaft seal 124. In the present embodiment, the second shaft seal 124 also serves to seal the pivot bearing 62b.1. However, the second shaft seal can of course also be arranged in another position.

[0089] FIG. 7a shows an isometric view of the rotor 42 of the module 38.1. It should be recognised that the tubular component 102 is fixed to the web 108 via screws 126.1, 126.2 (see FIG. 7b).

[0090] FIG. 7b depicts the web ducts 112, 114, between which a web annular duct 128 is arranged. Cooling fluid flows from the web annular duct 128 into the open component 102 and back, such that it ends up in the second web duct 114.

[0091] FIG. 8 depicts a cross-section through an electric motor 18 according to the invention, which is composed of two electric motor modules 38.1, 38.2 of the external rotor version.

[0092] FIG. 9a shows a part of the stator housing 121, consisting of a stator cap 50 and stator carrier 52, which features an inflow 132 for cooling fluid and an outflow 133 for cooling fluid and which comprises a cooling nozzle 130. FIG. 9 also shows the cooling nozzles of the electric motor 18, which are labelled with the counting suffixes “a” and “b” as well as “1” and “2”, as is also the case for other components of which there is more than one. The purpose of this counting system is to designate multiple objects as easily as possible as being of the same type. Stator electromagnets 134 (see FIGS. 7 and 9) of the electric motors, which are external rotors, are cooled via cooling nozzles 130.

[0093] FIG. 9b depicts a cross-section through the stator cap 50 and the rotor shaft 40 to represent the shaft annular duct 129.

[0094] FIG. 10 shows a further embodiment of an electric motor module 38, the shaft coupling structure 46 of which is designed to have multiple teeth.

REFERENCE LIST

[0095]

TABLE-US-00001 10 electric vehicle 12 first axle 14 second axle 16 wheels 18 electric motor 20 differential 22 battery 24 battery unit 26 vehicle floor 28 body 30 driver's seat 32 front passenger's seat 34 base 36 passenger area 38 electric motor module 40 rotor shaft 42 rotor 44 module housing 46 shaft coupling structure 48 housing ring 50 stator cap 52 stator carrier 54 magnet carrier 56 permanent magnet 58 projection 60 bearing seating surfac 62 pivot bearing 64 rolling element 66 rolling element 68 rotational bearing 70 housing coupling structure 72 coupling clamp 74 inner surface 76 rotary encoder 77 clutch 78 brake 79 coupling mechanism 80 rotary encoder coupling structure 81 clutch coupling structure 82 brake coupling structure 84 cooling duct 86 cooling fluid 88 cooling fluid feed 90 sealing bush 92 partition wall 94 secondary duct 96 laminated stator core 98 stator cooling duct 100 winding head 102 tubular component 104 first sleeve section 106 second sleeve section 108 web 110 feed branch duct 112 web duct 114 second web duct 115 discharge branch duct 116 stator 118 cooling fluid discharge 120 cooling fluid feed 121 stator housing (composed of stator cap 50 and stator carrier 52) 122 first shaft seal 124 second shaft seal 126 screw 128 web annular duct 129 shaft annular duct 130 cooling nozzle 132 inflow 133 outflow 134 stator electromagnet A wheelbase D rotational axis D.sub.18 motor rotational axis E angle measurement plane i, j running index K.sub.i contact surface L1 axial structural length of rotational bearing L2 axial structural length of shaft coupling structure L3 axial structural length of housing coupling structure m.sub.l left battery mass m.sub.r right battery mass Q central percentile Q1, Q2 cuboids S.sub.10 vehicle mass centre of gravity S.sub.18 electric motor mass centre of gravity S.sub.22 battery mass centre of gravity