High-compactness power driving device and system and power equipment

Abstract

The invention provides a high-compactness power driving device and system and power equipment, and relates to the technical field of hybrid power machinery. A highly compact power drive device has a first motor section and a second motor section. The first motor part is electrically connected with the energy storage structure and can be used as a motor. And the second motor part is in transmission connection with the engine and can be used as a generator, that is, the high-compactness power driving system provided by the embodiment is a dual-function power machine integrated with a motor and the generator, and the cruising ability can be improved. The first motor part adopts a Halbach topology structure, is sleeved outside the second motor part, is farther away from the center of the device and has a larger radius, so that the first motor part can be thinned as much as possible and the occupied radial size is reduced under the condition of meeting the magnetic load index, and the use amount of the permanent magnets can be reduced by adopting the Halbach permanent magnets to achieve the effect of light weight. And by adopting the slotless stator structure, the stator slot depth is saved, so that more design space is provided for coaxial design, and the requirement of high compactness is met.

Description

Technical Field

[0001] The present invention relates to the technical field of hybrid power machinery, and in particular to a highly compact power drive device, system and power equipment. Background Art

[0002] Currently, electric propulsion systems typically employ pure electric and hybrid systems. Pure electric systems use batteries as their power source, while hybrid systems essentially rely on fuel engines to generate electricity, generating mechanical energy conservation, though transmission losses are present. However, electric motors offer higher efficiency and a wider operating range, while traditional fuel engines often have low efficiency at lower speeds. Regarding aviation electrification, the low power density of current batteries makes it difficult to achieve fully electric aircraft with medium to large power outputs. Therefore, hybrid technology offers a transitional solution between traditional fuel-powered aircraft engines and fully electric aircraft engines. Aviation hybrid technology imposes stringent requirements on the weight and size of its electrified systems. The lack of high motor power density makes it difficult to replace traditional gas turbines, making the design of high-power-density hybrid systems a key technology. Traditional aviation hybrid configurations include series, parallel, and series-parallel. Regardless of the connection method, a turboshaft generator is required. Turboshaft generators often introduce additional space and weight, necessitating the development of compact powertrain designs for aviation hybrid systems. Summary of the Invention

[0003] The object of the present invention is to provide a highly compact power drive device, system and power equipment, which can improve the technical problem of low power density of electrified drive devices existing in the prior art.

[0004] The embodiments of the present invention can be implemented in the following ways:

[0005] A highly compact power drive device, comprising:

[0006] a first motor unit, the first motor unit being electrically connected to the energy storage structure to operate using the electric energy supplied by the energy storage structure; the first motor unit comprising a first motor rotor and a first motor stator nested with each other, the first motor rotor having a Halbach permanent magnet; and

[0007] a second motor portion, the second motor portion being disposed inside the first motor portion, and the first motor portion and the second motor portion being coaxially disposed; the second motor portion being configured to be transmission-connected to the engine and electrically connected to the energy storage structure; the second motor portion comprising a second motor rotor and a second motor stator being nested with each other;

[0008] Wherein, both the first motor stator and the second motor stator are slotless structures.

[0009] Optionally, the first motor rotor is located radially outside the first motor stator.

[0010] Optionally, the first motor rotor further includes a carbon fiber sheath and a titanium alloy shell, and the Halbach permanent magnet, the titanium alloy shell and the carbon fiber sheath are sequentially arranged in a radially outward direction of the first motor rotor;

[0011] The carbon fiber sheath is fixed on the titanium alloy shell by winding technology.

[0012] Optionally, the first motor stator includes a first formed Litz wire winding, a first stator core, and a stator heat sink, wherein the first formed Litz wire winding, the first stator core, and the stator heat sink are sequentially arranged in a radially inward direction of the first motor stator; the Halbach permanent magnet and the first formed Litz wire winding are spaced apart in a radial direction of the first motor portion, and a first gap is formed between the Halbach permanent magnet and the first formed Litz wire winding;

[0013] The first molded Litz wire winding is fixed to the surface of the first stator core by high-temperature adhesive.

[0014] Optionally, the second motor rotor is arranged radially inside the second motor stator.

[0015] Optionally, the highly compact power drive device further comprises a motor shaft, the motor shaft is arranged at the center of the highly compact power drive device, and the second motor rotor is connected to the motor shaft via a flat key.

[0016] Optionally, the highly compact power drive device further comprises a shielding cover arranged between the first motor part and the second motor part; the second motor stator is fixedly connected to the shielding cover, and the shielding cover is rotatably supported on the motor shaft through a double-cone bearing;

[0017] The first motor rotor is rotatably supported on the shielding cover through a bearing.

[0018] Optionally, the second motor stator includes a second stator core and a second shaped Litz wire winding, and the second shaped Litz wire winding and the second stator core are sequentially arranged along a radially inward direction of the second motor stator.

[0019] Optionally, the second motor rotor includes a rotor core and a rotor winding coil, the rotor core is provided with a plurality of mounting grooves distributed along the circumferential direction, and the rotor winding coil is embedded and installed in the mounting grooves.

[0020] A highly compact power drive system, comprising a gearbox, a clutch, and the highly compact power drive device described above;

[0021] The gearbox has a first input part, a second input part and an output part, the output part is used to be connected to the driven part; the first input part is connected to the first motor rotor, and the second input part is connected to the second motor rotor through the clutch to control the power transmission between the second motor rotor and the second input part.

[0022] Optionally, the gearbox includes a sun gear, planetary gears, a planetary carrier, and a ring gear, wherein the plurality of planetary gears are engaged with the sun gear and arranged around the sun gear; the plurality of planetary gears are mounted on the planetary carrier; the ring gear is sleeved outside the plurality of planetary gears and engaged with the plurality of planetary gears;

[0023] The sun gear forms the second input, the ring gear forms the first input, and the planet carrier forms the output.

[0024] Optionally, the highly compact power drive system further includes a casing, which includes a first casing part, a second casing part, and a third casing part connected in sequence, the first casing part forming a first space for accommodating the highly compact power drive device, the second casing part forming a second space for accommodating the clutch, and the third casing part forming a third space for accommodating the gearbox.

[0025] A power device, comprising an engine, an energy storage structure and the above-mentioned highly compact power drive system, wherein the engine is transmission-connected to a second motor rotor to drive the second motor rotor to operate; the energy storage structure is electrically connected to the highly compact power drive device to supply power to the highly compact power drive device or store the electrical energy generated by the highly compact power drive device.

[0026] The advantageous effects of the highly compact power drive device, system, and power equipment provided by the embodiments of the present invention include:

[0027] An embodiment of the present invention provides a highly compact power drive device, which integrates a first motor unit and a second motor unit that are coaxially arranged. The first motor unit can be operated as an electric motor, and the second motor unit can be operated as a generator, thereby helping to improve endurance. The first motor unit adopts a Halbach topology structure, which is far away from the center of the device and has a large radius. Therefore, it can be as thin as possible while meeting the magnetic load index, reducing the occupied radial dimension, and the use of Halbach permanent magnets can reduce the amount of permanent magnets and achieve a lightweight effect. The first motor stator and the second motor stator adopt a slotless structure, eliminating the stator slot depth, thereby providing more design space for the coaxial design and meeting the high compactness requirements. Therefore, the highly compact power drive device meets the requirements of having high power density in a smaller space.

[0028] An embodiment of the present invention further provides a highly compact power drive system having the highly compact power drive device described above, and thus also having the beneficial effects of occupying a small space and having a high power density.

[0029] An embodiment of the present invention further provides a power device, which includes the above-mentioned highly compact power drive system, and thus also has the technical effects of high power density and long endurance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above features and advantages of the present invention will be better understood after reading the detailed description of the embodiments of the present disclosure in conjunction with the following drawings. In the drawings, the components are not necessarily drawn to scale, and components with similar related properties or characteristics may have the same or similar reference numerals.

[0031] Figure 1 Shows an overall framework diagram of a power device provided according to one aspect of the present invention;

[0032] Figure 2 It shows an axle side schematic diagram of a power device provided according to one aspect of the present invention;

[0033] Figure 3 It shows a schematic diagram of the overall structure of a highly compact power drive device provided according to one aspect of the present invention;

[0034] Figure 4 A schematic top view of a highly compact power drive device according to one aspect of the present invention is shown;

[0035] Figure 5 It shows a schematic structural diagram of the smallest unit in a highly compact power drive device provided according to one aspect of the present invention;

[0036] Figure 6 A schematic structural diagram of a gearbox in a highly compact power drive system according to one aspect of the present invention is shown;

[0037] Figure 7 Shown Figure 6 A schematic diagram of the structure shown in the top view;

[0038] Figure 8 Shown Figure 6 a schematic diagram of the structure as viewed from above;

[0039] Figure 9 Shown Figure 6 The schematic diagram of the structure after removing the first housing portion is shown;

[0040] Figure 10 A schematic diagram of the application structure of a highly compact power drive system provided in accordance with one aspect of the present invention in the automotive field is shown;

[0041] Figure 11 A schematic diagram of the application structure of a highly compact power drive system provided in accordance with one aspect of the present invention in an aviation electrified propulsion system is shown;

[0042] Figure 12 A schematic diagram of the structure in a pure electric driving mode according to one aspect of the present invention is shown;

[0043] Figure 13 A schematic structural diagram of a serial drive mode according to one aspect of the present invention is shown;

[0044] Figure 14 A schematic diagram of a structure in a parallel driving mode according to one aspect of the present invention is shown;

[0045] Figure 15 A schematic diagram of the structure in full power output mode according to one aspect of the present invention is shown;

[0046] Figure 16 A schematic diagram of a structure in an energy recovery mode according to one aspect of the present invention is shown;

[0047] Figure 17 A schematic structural diagram of an engine start-stop mode according to one aspect of the present invention is shown.

[0048] Reference numerals:

[0049] 10-Power equipment; 11-Engine; 12-Energy storage structure; 13-Highly compact power drive system;

[0050] 100 - Highly compact power drive device; 110 - First motor unit; 111 - First motor rotor; 112 - Halbach permanent magnet; 113 - Carbon fiber sheath; 114 - Titanium alloy housing; 115 - First motor stator; 116 - First molded Litz wire winding; 117 - First stator core; 118 - Stator heat sink; 120 - Second motor unit; 121 - Second motor rotor; 122 - Rotor core; 123 - Mounting slot; 124 - Rotor winding coil; 125 - Second motor stator; 126 - Second stator core; 127 - Second molded Litz wire winding; 131 - Motor shaft; 132 - Shield; 133 - Double-taper bearing; 134 - Bearing;

[0051] 200-clutch;

[0052] 300-gearbox; 311-sun gear; 312-planetary gear; 313-planet carrier; 314-ring gear;

[0053] 400 - housing; 411 - first housing portion; 412 - second housing portion; 413 - third housing portion;

[0054] 20-driven part; 21-wheel hub; 22-duct fan. DETAILED DESCRIPTION

[0055] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Note that the various aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention.

[0056] In the description of the present invention, it should be noted that if the terms "upper", "lower", "inner", "outer", "vertical" and the like appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the accompanying drawings, or is the orientation or position relationship in which the product of the invention is usually placed when in use, rather than indicating or implying that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0057] At the same time, it should be noted that the terms "first", "second", etc. are only used to distinguish and describe, and cannot be understood as indicating or implying relative importance.

[0058] It should also be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connection, integral connection, or detachable connection; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0059] Definitions of relevant terms that may be mentioned in the description of the present invention:

[0060] A motor is a device that converts electrical energy into mechanical energy. It uses energized coils (also known as stator windings) to generate a rotating magnetic field, which acts on a rotor (such as a squirrel-cage aluminum frame) to generate magneto-electrodynamic torque. Electric motors are categorized as DC and AC motors based on their power source. The majority of motors in power systems are AC motors, which can be synchronous or asynchronous (where the stator magnetic field speed and rotor rotation speed are not synchronized). An electric motor primarily consists of a stator and a rotor. The direction of the force exerted on a current-carrying conductor in a magnetic field is related to the direction of the current and the magnetic flux lines (magnetic field). The operating principle of an electric motor is that the magnetic field exerts a force on the current, causing the motor to rotate.

[0061] Generator: refers to a mechanical device that converts mechanical energy into electrical energy. It is driven by a turbine, steam turbine, diesel engine or other power machinery, and converts the energy generated by water flow, air flow, fuel combustion or nuclear fission into mechanical energy and transmits it to the generator, which then converts it into electrical energy.

[0062] Distributed: refers to the distribution of different modules in different locations. In contrast to centralized, distributed is a typical architecture for advanced intelligent systems.

[0063] Figure 1 This is the overall framework diagram of the power equipment 10 provided in this embodiment, Figure 2 This is a schematic diagram of the axial side of the power equipment 10 provided in this embodiment. Figure 3 This is a schematic diagram of the overall structure of the highly compact power drive device 100 provided in this embodiment. Figure 4 This is a schematic top view of the highly compact power drive device 100 provided in this embodiment. Figure 5 This is a structural diagram of the smallest unit in the highly compact power drive device 100 provided in this embodiment. Figure 1-Figure 5 This embodiment provides a highly compact power drive device 100 , and also provides a highly compact power drive system 13 and a power device 10 .

[0064] The highly compact power drive system 13 includes a highly compact power drive device 100, a gearbox 300 and a clutch 200. When in use, the highly compact power drive system 13 forms a hybrid integrated structure together with the conventional engine 11 and the energy storage structure 12, thereby obtaining the following: Figure 1 The power plant 10 is shown.

[0065] The highly compact power drive device 100 includes a first motor portion 110 and a second motor portion 120 that are coaxially arranged, and the first motor portion 110 is located radially outward of the second motor portion 120, that is, the first motor portion 110 has a larger radial dimension than the second motor portion 120. It should be noted that since the first motor portion 110 and the second motor portion 120 are both cylindrical and coaxially arranged, the axes of the first motor portion 110, the second motor portion 120, and the highly compact power drive device 100 coincide. Therefore, in the description of this embodiment, if the axial direction of a component in the highly compact power drive device 100 is mentioned, it can be regarded as the axial direction of the highly compact power drive device 100. Correspondingly, the radial direction of a component can also be regarded as a direction perpendicular to the axis of the highly compact power drive device 100.

[0066] The first motor unit 110 is electrically connected to the energy storage structure 12, so that the first motor unit 110 can operate using the electric energy supplied by the energy storage structure 12. In other words, the first motor unit 110 can be used as an electric motor. The second motor unit 120 is transmission-connected to the engine 11 and is used to be electrically connected to the energy storage structure 12. In this way, when the second motor unit 120 rotates and generates electricity under the drive of the engine 11, the electric energy generated by it can be stored by the energy storage structure 12. In other words, the second motor unit 120 can be used as a generator. That is, the highly compact power drive system 13 provided in this embodiment is a dual-function power machine integrating an electric motor and a generator.

[0067] In the highly compact power drive system 13, the gearbox 300 has a first input part, a second input part and an output part. The first input part is transmission-connected to the first motor rotor 111 of the first motor part 110, so that when the first motor part 110 is running, the mechanical energy generated by the first motor part 110 is input into the gearbox 300 through the first input part; the second input part is transmission-connected to the second motor rotor 121 of the second motor part 120 through the clutch 200, so as to control the power transmission between the second motor rotor 121 and the second input part through the clutch 200, that is, when the clutch 200 connects the second input part to the second motor part 120, the power transmission between the second motor rotor 121 and the second input part is connected, and at this time, the mechanical energy of the second motor part 120 is transmitted to the second input part through the clutch 200; when the clutch 200 disconnects the second input part from the second motor part 120, the power transmission between the second motor rotor 121 and the second input part is interrupted, and at this time, the second motor part 120 cannot transmit mechanical energy to the second input part. At the same time, when the clutch 200 connects the power transmission from the second input portion to the second motor portion 120, the first motor portion 110 and the second motor portion 120 simultaneously provide mechanical energy to the transmission 300. Therefore, in addition to achieving power transmission, the transmission 300 also needs to match the rated speeds of the first motor portion 110 and the second motor portion 120 according to actual usage requirements. The output portion is used to connect to the driven member 20, thereby transmitting the mechanical energy transmitted from the first motor portion 110 and / or the second motor portion 120 to the transmission 300 to the driven member 20, thereby driving the driven member 20 to operate.

[0068] The following combination Figure 3-Figure 5 The highly compact power drive device 100 provided in this embodiment is further described as follows:

[0069] In this embodiment, the first motor section 110 includes a first rotor 111 and a first stator 115 nested within each other. The first rotor 111 includes Halbach permanent magnets 112. Electromagnetic design in motors is essentially an interwoven design of electric and magnetic fields. Improving power density is closely related to the motor's high electromagnetic load. Therefore, in this outer rotor topology, the radius of the first motor section 110 is larger than that of the second motor section 120, resulting in a relatively higher material content for the Halbach permanent magnets 112. Therefore, the thickness of the Halbach permanent magnets 112 can be minimized while still meeting magnetic load requirements. Furthermore, Halbach permanent magnets are currently a high-magnetic-load design, and their use can further reduce the amount of permanent magnets used, thereby achieving a lightweight design.

[0070] Optionally, the first motor rotor 111 is located radially outward of the first motor stator 115. Disposing the first motor rotor 111 radially outward of the first motor stator 115 not only allows the radial dimension of the first motor rotor 111 located radially outward to be larger than the radial dimension of the first motor stator 115, but also allows the thickness of the Halbach permanent magnet 112 of the first motor rotor 111 to be further reduced. Furthermore, this helps meet the heat dissipation requirements of the first motor rotor 111, thereby reducing the number of heat dissipation structures and further improving the compactness of the device.

[0071] Furthermore, the first motor rotor 111 also includes a carbon fiber sheath 113 and a titanium alloy shell 114. The Halbach permanent magnet 112, the titanium alloy shell 114, and the carbon fiber sheath 113 are arranged in sequence along the radially outward direction of the first motor rotor 111, that is, the titanium alloy shell 114 is coated on the outside of the Halbach permanent magnet 112, and the carbon fiber sheath 113 is coated on the outside of the titanium alloy shell 114. Specifically, the carbon fiber sheath 113 is fixed to the titanium alloy shell 114 by a winding technology, so that the carbon fiber sheath 113 and the titanium alloy shell 114 are tightly fitted. By arranging a protective structure consisting of the carbon fiber sheath 113 and the titanium alloy shell 114 outside the Halbach permanent magnet 112, the protective structure is light and thin and has sufficient preload and containment effect, which can effectively avoid the catastrophic consequences caused by the rotor components contained therein flying off under high-speed rotation.

[0072] In this embodiment, the first motor stator 115 employs a slotless structure. Specifically, the first motor section 110 employs an outer rotor Halbach slotless topology. Specifically, the first motor stator 115 includes a first shaped Litz wire winding and a first stator core 117. The structure formed by the first shaped Litz wire winding 116 and the first stator core 117 is slotless. This slotless stator structure provides more space for the coaxial design of the dual motors. The first shaped Litz wire winding 116 is disposed outside the first stator core 117. As such, the first shaped Litz wire winding 116 is located at the outermost side of the first motor stator 115, adjacent to the first motor rotor 111. The innermost side of the first motor rotor 111 is the Halbach permanent magnet 112. The Halbach permanent magnet 112 and the first shaped Litz wire winding 116 are radially spaced apart from each other, forming a first gap C between the first shaped Litz wire winding 116. Using shaped Litz wire to form the stator winding effectively suppresses the motor's AC losses at high frequencies. Furthermore, the structural arrangement of the first motor portion 110 minimizes the size of the first gap C, thereby increasing the motor's output torque. The lead-out end windings of the first shaped Litz wire winding 116 can be led out and electrically connected to the energy storage structure 12. The specific layout of the lead-out structure can be configured as needed and is not described in detail here.

[0073] Optionally, the first shaped Litz wire winding 116 is fixed to the surface of the first stator core 117 using a high-temperature adhesive, thereby forming a slotless structure. The slotless structure can minimize torque ripple and, compared to a slotted structure, can utilize the space occupied by the slotted stator slots to accommodate more windings, thereby improving the slot fill rate to a certain extent. It is understood that in other embodiments, other methods can be used to achieve a fixed connection between the first shaped Litz wire winding 116 and the first stator core 117, and the connection can be a slotless structure.

[0074] Furthermore, the first motor stator 115 also includes a stator heat sink 118. The first molded Litz wire winding 116, the first stator core 117, and the stator heat sink 118 are arranged in sequence along the radially inward direction of the first motor stator 115, and the stator heat sink 118 is arranged on the inner side of the stator core. The stator heat sink 118 is a lightweight hollow structure having a channel extending axially through the highly compact power drive device 100, so that airflow through the channel effectively cools the first motor stator 115 in the first motor unit 110, which is seriously heated. In this way, the first motor unit 110 provided in this embodiment does not need to be cooled by oil cooling, thereby effectively avoiding the serious consequences of cooling oil leakage, while also avoiding the increase of additional weight, further improving the power-to-weight ratio of the entire system.

[0075] In this embodiment, the second motor rotor 121 is disposed radially inwardly of the second motor stator 125. That is, in this embodiment, the second motor rotor 121 is disposed near the center of the highly compact power drive device 100, and the second motor stator 125 is disposed near the first motor stator 115. Furthermore, the highly compact power drive device 100 further includes a motor shaft 131 disposed at the center of the highly compact power drive device 100. In this manner, the second motor rotor 121 can be directly and fixedly connected to the motor shaft 131 to achieve power transmission between the second motor rotor 121 and the motor shaft 131. Optionally, the second motor rotor 121 and the motor shaft 131 are connected via a flat key. It is understood that in other embodiments, other methods can also be used to achieve the connection between the second motor rotor 121 and the motor shaft 131.

[0076] Furthermore, the second motor rotor 121 includes a rotor core 122 and rotor winding coils 124. The rotor core 122 is provided with a plurality of circumferentially distributed mounting slots 123, into which the rotor winding coils 124 are embedded. Specifically, the mounting slots 123 are distributed axially along the rotor core 122 and form open slots on the outer circumference of the rotor core 122. Once installed in the mounting slots 123, the rotor winding coils 124 can interact electromagnetically with the first motor stator 115 located outside the second motor rotor 121. In this embodiment, the rotor core 122 is connected to the motor shaft 131 via a flat key.

[0077] Furthermore, the second motor stator 125 includes a second stator core 126 and a second shaped Litz wire winding 127. The second shaped Litz wire winding 127 and the second stator core 126 are arranged in sequence along the radially inward direction of the second motor stator 125, that is, the second shaped Litz wire winding 127 is located inside the second stator core 126 and is located close to the second motor rotor 121. The second motor stator 125 adopts a slotless structure. That is, in this embodiment, the second motor unit 120 adopts a slotless electrically excited synchronous topology. The use of an electrically excited synchronous topology structure that is easier to demagnetize helps improve the safety performance of the highly compact power drive device 100 and further enhances redundancy. In this embodiment, the second type Litz wire winding is fixed to the surface of the second stator core 126 using high-temperature adhesive. It is understood that in other embodiments, other slotless structures may also be used.

[0078] The lead wire end windings of the second formed Litz wire winding 127 and the rotor winding coil 124 can be led out and electrically connected to the energy storage structure 12. The specific arrangement of the lead-out structure can be set according to needs and is not described in detail here.

[0079] In this embodiment, the highly compact power drive device 100 further includes a shielding cover 132 disposed between the first motor unit 110 and the second motor unit 120. The second motor stator 125 is fixedly connected to the shielding cover 132, and thus the shielding cover 132 can also be considered a portion of the second motor stator 125. Since the first motor stator 115 is located inside the first motor unit 110, the first motor stator 115 is also fixedly connected to the shielding cover 132. In other words, in this embodiment, the first motor stator 115, the second motor stator 125, and the shielding cover 132 together form the stator portion of the highly compact power drive device 100. The shielding cover 132 is supported on the motor shaft 131 via a double-tapered bearing 133, and the first motor rotor 111 is rotatably supported on the shielding cover 132 via a bearing 134. The double-tapered bearings 133 and 134 ensure proper operation between the stator and rotor portions (the first motor rotor 111 and the second motor rotor 121). Specifically, the titanium alloy housing 114 of the first motor rotor 111 is rotatably connected to the shielding cover 132 via a bearing 134 .

[0080] Figure 6 FIG. 1 shows a schematic structural diagram of the gearbox 300 in the highly compact power drive system 13 provided in this embodiment. Figure 7 Shown Figure 6 A schematic diagram of the top view of the structure shown, Figure 8 Shown Figure 6 A schematic diagram of the structure shown in FIG. Figure 9 for Figure 6 The structure shown is a schematic diagram of the structure after removing the first housing part 411. Figure 6-Figure 9 In the highly compact power drive system 13 provided in this embodiment, the mechanical energy provided by the highly compact power drive device 100 is transmitted outward through the gearbox 300, and the first input part of the gearbox 300 receives the mechanical energy from the first motor part 110, and the second input part receives the mechanical energy from the second motor part 120. Therefore, the gearbox 300 can achieve matching of the design parameters of the first motor part 110 and the second motor part 120, and achieve the rationality of the electromagnetic design of the first motor part 110 and the second motor part 120 in terms of size, speed, output torque, torque pulsation, and back electromotive force.

[0081] Specifically, the following describes the design considerations of the gearbox from the perspective of motor design:

[0082] The specific power density of the motor can be expressed as:

[0083] (1)

[0084] where K φis the ratio of the electrical load on the rotor and stator, m is the number of phases, m1 is the number of phases per stator, K e is the EMF factor, K i is the current shape factor, K p is the electric power waveform factor, η is the motor efficiency, B g is the air gap flux density, A is the total electrical load on the motor, f is the converter frequency, p is the number of motor pole pairs, D g is the air gap diameter, L e is the effective partial stack length, M is the mass of the motor. To simplify the expression, the specific power density can be defined omitting the constant factor as a dependency of the following parameters:

[0085] (2)

[0086] in, and D g , L e are proportional to the motor's rotational speed and volume, respectively. Therefore, the specific power density of a rotating motor is proportional to the air gap flux density, electrical load, and rotational speed. Average air gap flux density is a key parameter for increasing the power of any motor and, for aircraft applications, is typically between 0.4 and 1 T. This parameter is limited by the saturation of the stator and rotor magnets and the capacity of the magnets or field windings. However, the use of superconducting bulk magnets allows for much stronger electromagnetic field values, exceeding the maximum value of 17.6 T. The motor's electrical load, or linear current density, is closely related to the heat dissipation capacity and the slot current density. High electrical loads increase the air gap flux density, but also heat the windings, requiring larger cooling systems.

[0087] Based on the above formula (2), assuming that the electromagnetic load and air gap flux density remain unchanged within a certain speed range, the following assumptions can be made to simplify:

[0088] (3)

[0089] It can be seen from this that when the power is constant, the motor with a higher speed has a smaller size; for the same size, the motor with a higher speed has greater power, and the size and weight of the motor can be reduced by increasing the speed.

[0090] Please continue to refer to Figure 6-Figure 9In this embodiment, the gearbox 300 employs a planetary gear structure, comprising a sun gear 311, planetary gears 312, a planetary carrier 313, and a ring gear 314. The sun gear 311 is located in the middle of the gearbox 300 and forms the second input portion, which is transmission-connected to the motor shaft 131 via the clutch 200. A plurality of planetary gears 312 are disposed around the sun gear 311 and mesh with the sun gear 311. The plurality of planetary gears 312 are mounted on the planetary carrier 313. The planetary carrier 313 rotates through the combined action of the planetary gears 312, forming the output portion. Power output is achieved through the transmission connection between the planetary carrier 313 and the driven member 20. The ring gear 314 is disposed around the plurality of planetary gears 312 and meshes with the plurality of planetary gears 312. The ring gear 314 forms the first input portion, which is transmission-connected to the first motor unit 110. By adjusting the relative motion between the sun gear 311, the planetary gears 312, and the gears, different output speeds and torques can be achieved. Since the rotational speeds of the first motor unit 110 and the motor shaft 131 are different, the gear ratios thereof can be matched through the gearbox 300 .

[0091] It should be noted that the structure of the clutch 200 can adopt the current conventional structure, and the structure of the clutch 200 is not described in detail here. The clutch 200 can realize the power transmission between the motor shaft 131 and the sun gear 311. Furthermore, in order to clutch the output part before the motor fails and avoid the spread of the motor failure, the clutch 200 can also be set to a structure that can clutch the output part and the driven part 20, for example, two clutch parts are provided, one of which is connected between the motor shaft 131 and the sun gear 311, and the other is connected between the planetary carrier 313 and the driven part 20, or other clutch 20 structures can be adopted.

[0092] In this embodiment, the highly compact power drive system 13 further includes a housing 400, which comprises a first housing portion 411, a second housing portion 412, and a third housing portion 413, which are connected in sequence. The first housing portion 411 forms a first space for accommodating the highly compact power drive device 100, thereby protecting and containing the highly compact power drive device 100. The second housing portion 412 forms a second space for accommodating the clutch 200. In this embodiment, the clutch 200 is located in the second space. However, in other embodiments, the clutch 200 can be located in other locations, in which case the second housing portion 412 merely serves to connect the first housing portion 411 and the second housing portion 412. The third housing portion 413 forms a third space for accommodating the gearbox 300, which is secured and protected by the third housing portion 413. Thus, the highly compact power drive system 13 provided in this embodiment is integrated into a single structure, facilitating installation and use in actual machinery.

[0093] Figure 10 FIG. 1 shows a schematic diagram of the application structure of the highly compact power drive system 13 provided in this embodiment in the automotive field. Figure 10 As shown, the highly compact power drive device 100 provided in this embodiment can be used as a hub motor of a car. In this case, the highly compact power drive device 100 can be directly highly integrated with the wheel hub 21, thereby helping to improve the power density of the electric drive system.

[0094] Figure 11 A schematic diagram of the application structure of the highly compact power drive system 13 provided in this embodiment in an aviation electrified propulsion system is shown. In this case, the highly compact power drive device 100 can be directly meshed with the fan blades of the ducted fan 22 to form an integrated design.

[0095] The highly compact power drive system 13 provided in this embodiment is an integrated modular structure. When it is applied in other structures, it can form a distributed architecture with other structures.

[0096] The following describes different working modes of the highly compact power drive system 13 in actual use, taking its application in an aviation electrified propulsion system as an example:

[0097] Table 1

[0098]

[0099] Table 1 shows the status of various components in different working modes of the high-compact power drive system 13 provided in this embodiment. Specifically:

[0100] When in pure electric driving mode (such as Figure 12 As shown), the engine 11 does not work, and the highly compact power drive system 13 only provides mechanical energy through the first motor unit 110. At this time, the clutch 200 disconnects the second motor unit 120 from the gearbox 300.

[0101] When in series drive mode (such as Figure 13 As shown in the figure, the first motor unit 110 acts as an electric motor to convert electrical energy into mechanical energy and uses the gearbox 300 for power output. The engine 11 works to drive the second motor unit 120 to work. At this time, the second motor unit 120 acts as a generator to convert the mechanical energy transmitted by the engine 11 into electrical energy, and transmits the electrical energy to the energy storage structure 12 or directly supplies it to the first motor unit 110. At the same time, the clutch 200 disconnects the second motor unit 120 from the gearbox 300, that is, only the first motor unit 110 supplies mechanical energy to the gearbox 300.

[0102] When in parallel drive mode (such as Figure 14 As shown), at this time, the clutch 200 connects and couples the motor shaft 131 with the gearbox 300, that is, at this time, the engine 11 is directly connected to the gearbox 300 through the motor shaft 131, and the mechanical energy generated by the engine 11 is directly input into the second input part. At this time, the second motor part 120 is actually not working. At the same time, the first motor part 110 works to convert electrical energy into mechanical energy and inputs it into the gearbox 300 through the first input part.

[0103] When in full power output mode (such as Figure 15 As shown, transmission 300 can be considered the power distributor for the entire system. Its function is to match the rotational speeds of first motor unit 110 and second motor unit 120 to their respective rated optimal speeds for power output. However, first motor unit 110 is controlled by energy storage structure 12 via the electronically controlled PCM, while second motor unit 120 functions solely as an electric motor, coaxially with engine 11, for torque superposition. The torque output of engine 11 and both motors is applied to driven component 20 via clutch 200, allowing the entire hybrid system's energy to be used for driving.

[0104] When in energy recovery mode (e.g. Figure 16 As shown in FIG, at this time, the engine 11 and the second motor unit 120 are not working, and the clutch 200 disconnects the second motor unit 120 from the gearbox 300, thereby preventing the mechanical energy generated by the gearbox 300 driven by the driven member 20 from being transmitted to the second motor unit 120. At the same time, the gearbox 300 drives the first motor rotor 111 to rotate, so that the first motor unit 110 acts as a generator to generate electricity.

[0105] When in the engine 11 start-stop mode (such as Figure 17As shown), at this time, the engine 11 is not working, and the first motor unit 110 and the second motor unit 120 are both operating under the action of the electric energy supplied by the energy storage structure 12, thereby converting the electric energy into mechanical energy. The mechanical energy generated by the first motor unit 110 is transmitted to the gearbox 300 through the first input unit; at the same time, the clutch 200 couples the second motor unit 120 with the gearbox 300, and the mechanical energy generated by the second motor unit 120 is transmitted to the gearbox 300 through the second input unit. The gearbox 300 operates under the joint drive of the first motor unit 110 and the second motor unit 120.

[0106] The highly compact power drive device 100, system, and power equipment 10 provided by the embodiments of the present invention have the functions of both an electric motor and a generator, which can effectively improve the endurance of the electric drive system, thereby suppressing mileage anxiety. The first motor part 110 and the second motor part 120 are coaxially arranged, and an outer rotor Halbach slotless topology structure is adopted as the first motor part 110, and a slotless electric excitation synchronous topology structure is adopted at the internal coaxial part as the second motor part 120, which helps to improve the power density and make the structure more compact. In addition, the slotless stator structure eliminates the stator slot depth, thereby providing more design space for the coaxial design of the dual motors. More design space can ensure the rational use of electromagnetic materials, thereby ensuring design performance. The more compact structure helps to achieve miniaturization of the device and occupy less space. When applied to equipment such as aircraft, it helps to increase the driving force and perform distributed redundancy design by arranging a larger number of the devices.

[0107] Furthermore, the clutch 200's engagement and disengagement function enables different hybrid power modes to meet the needs of different phases of use. For example, during high-power phases like takeoff and climb, an aircraft (e.g., an airplane) utilizes engine 11 for high-power direct drive. During cruising, multiple dual-function motors are selected to operate at the high-efficiency rated cruise state, significantly improving the overall hybrid system's output performance and range. Furthermore, this structure utilizes the abundant cooling resources in the air to cool the motors, providing increased reliability without adding additional weight, further enhancing the power-to-weight ratio of the entire hybrid system.

[0108] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technology in this field within the technical scope disclosed by the present invention should be covered by the scope of protection of the present invention.

Claims

1. A highly compact power drive device, characterized in that: The highly compact power drive device comprises: a first motor unit, the first motor unit being electrically connected to the energy storage structure to operate using the electric energy supplied by the energy storage structure; the first motor unit comprising a first motor rotor and a first motor stator nested with each other, the first motor rotor having a Halbach permanent magnet; and a second motor portion, the second motor portion being disposed inside the first motor portion, and the first motor portion and the second motor portion being coaxially disposed; the second motor portion being configured to be transmission-connected to the engine and electrically connected to the energy storage structure; the second motor portion comprising a second motor rotor and a second motor stator being nested with each other; Wherein, both the first motor stator and the second motor stator are slotless structures.

2. The highly compact power drive device according to claim 1, characterized in that: The first motor rotor is located radially outside the first motor stator.

3. The highly compact power drive device according to claim 2, characterized in that: The first motor rotor further includes a carbon fiber sheath and a titanium alloy shell, and the Halbach permanent magnet, the titanium alloy shell and the carbon fiber sheath are sequentially arranged in a radially outward direction of the first motor rotor; The carbon fiber sheath is fixed on the titanium alloy shell by winding technology.

4. The highly compact power drive device according to claim 2, characterized in that: The first motor stator includes a first shaped Litz wire winding, a first stator core, and a stator heat sink, wherein the first shaped Litz wire winding, the first stator core, and the stator heat sink are sequentially arranged in a radially inward direction of the first motor stator; the Halbach permanent magnet and the first shaped Litz wire winding are spaced apart in a radial direction of the first motor portion, and a first gap is formed between the Halbach permanent magnet and the first shaped Litz wire winding; The first molded Litz wire winding is fixed to the surface of the first stator core by high-temperature adhesive.

5. The highly compact power drive device according to claim 1, characterized in that: The second motor rotor is arranged radially inward of the second motor stator.

6. The highly compact power drive device according to claim 5, characterized in that: The highly compact power drive device further includes a motor shaft, which is disposed at the center of the highly compact power drive device, and the second motor rotor is connected to the motor shaft via a flat key.

7. The highly compact power drive device according to claim 6, characterized in that: The highly compact power drive device further includes a shielding cover disposed between the first motor portion and the second motor portion; the second motor stator is fixedly connected to the shielding cover, and the shielding cover is rotatably supported on the motor shaft via a double-cone bearing; The first motor rotor is rotatably supported on the shielding cover through a bearing.

8. The highly compact power drive device according to claim 5, characterized in that: The second motor stator includes a second stator core and a second shaped Litz wire winding. The second shaped Litz wire winding and the second stator core are sequentially arranged in a radially inward direction of the second motor stator.

9. The highly compact power drive device according to claim 5, characterized in that: The second motor rotor includes a rotor core and a rotor winding coil. The rotor core is provided with a plurality of mounting grooves distributed along the circumferential direction, and the rotor winding coil is embedded and installed in the mounting grooves.

10. A highly compact power drive system, characterized in that: The highly compact power drive system comprises a gearbox, a clutch, and a highly compact power drive device according to any one of claims 1 to 9; The gearbox has a first input part, a second input part and an output part, the output part is used to be connected to the driven part; the first input part is connected to the first motor rotor, and the second input part is connected to the second motor rotor through the clutch to control the power transmission between the second motor rotor and the second input part.

11. The highly compact power drive system according to claim 10, characterized in that: The gearbox includes a sun gear, planetary gears, a planetary carrier, and a ring gear, wherein a plurality of planetary gears are engaged with the sun gear and arranged around the sun gear; the plurality of planetary gears are mounted on the planetary carrier; The gear ring is sleeved outside the plurality of planetary gears and meshes with the plurality of planetary gears; The sun gear forms the second input, the ring gear forms the first input, and the planet carrier forms the output.

12. The highly compact power drive system according to claim 10, characterized in that: The highly compact power drive system also includes a casing, which includes a first casing part, a second casing part and a third casing part connected in sequence, the first casing part forming a first space for accommodating the highly compact power drive device, the second casing part forming a second space for accommodating the clutch, and the third casing part forming a third space for accommodating the gearbox.

13. A power equipment, characterized in that: The power equipment includes an engine, an energy storage structure and a highly compact power drive system as described in any one of claims 10-12, wherein the engine is transmission-connected to the second motor rotor to drive the second motor rotor to operate; the energy storage structure is electrically connected to the highly compact power drive device to supply power to the highly compact power drive device or store the electrical energy generated by the highly compact power drive device.

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