Electric drive system with switching clutch directly attached on disc motor

Abstract

The invention relates to an electric drive system (1) for a motor vehicle with electric or hybrid drive, having a disc motor (2), a transmission (3) and a switching clutch (6) which is operatively mounted between a disc rotor (4) of the disc motor (2) and an input (5a) of the transmission (3), wherein the switching clutch (6) has a first clutch component (7) with a carrier (8) which is directly attached to the rotor (4) and a plurality of friction elements (10) which are received on the carrier (8) in a torque-proof and movable manner relative to one another along an axis of rotation (9) of the rotor (4), and a second clutch component (11) which is connected to the input (5a) of the transmission (3).

Description

Technical Field

[0001] This invention relates to an electric drive system for motor vehicles (e.g., passenger cars, trucks, buses or other commercial vehicles) driven by pure electric or hybrid power. Summary of the Invention

[0002] In principle, the goal is to provide an electric drive module that is as compact as possible, which can be easily integrated into existing installation space to enable pure electric motor vehicles or hybrid vehicles.

[0003] This is solved by the electric drive system according to the invention. Therefore, an electric drive system for a motor vehicle driven by pure electric or hybrid power is proposed, equipped with a disc motor, a transmission, and a switching clutch operatively mounted between the disc rotor of the disc motor and the input end of the transmission. The switching clutch has a first clutch component and a second clutch component. The first clutch component has a carrier directly attached to the rotor and a plurality of friction elements received on the carrier in a torsionally resistant manner and movable relative to each other along the rotational axis of the rotor. The second clutch component is connected to the input end of the transmission. The switching clutch is normally switchable between a closed position and an open position, in which the two clutch components are connected in a torque-transmitting manner, and in the open position, no torque is transmitted between the clutch components.

[0004] A compact axial drive system is achieved through this construction of the disc motor according to the invention and its direct attachment to the carrier of the switching clutch.

[0005] Other advantageous implementation schemes are described in detail below.

[0006] If the carrier can be removed (without damage) and removably installed on the rotor, the components can be inspected independently of each other.

[0007] Advantageously, the carrier has at least one radially extending support region that rests against the axial side of the rotor. Thus, the carrier is supported as stably as possible relative to the rotor.

[0008] Furthermore, in this case, it is suitable that the carrier has at least one axially extending support area that abuts against the radially inner side of the rotor.

[0009] Therefore, the carrier is supported on the rotor in the radial direction in principle, so that the carrier is aligned with the rotation axis of the rotor.

[0010] If the rotor is supported on a support area that is fixed relative to the housing by rolling bearings arranged axially next to the carrier, then the carrier is also firmly supported.

[0011] It has also proven suitable in terms of carrier installation that the carrier (instead of removable mounting) is fixed to the rotor in a non-removable / non-destructive manner.

[0012] Furthermore, it has proven advantageous that the carrier is fixed to the rotor via a material-locking connection, preferably a welded connection. This achieves the most secure possible mounting of the carrier on the rotor side.

[0013] Furthermore, it is advantageous that the carrier is torsionally connected to the rotor via a shape-locking connector, which is preferably constructed with interlocking teeth. This allows for removable connectors to be assembled as easily as possible.

[0014] Instead of or attached to the shape-locking connection, it is advantageous that the carrier is fixed to the rotor by the force-locking connection, preferably by a press-fit connection or a pin connection. This also achieves a firm fixation of the carrier to the rotor.

[0015] It has also proven suitable that the carrier and / or the actuating unit associated with the switching clutch is at least partially arranged / inserted into the radial interior of the rotor. This further reduces the required axial installation space.

[0016] Furthermore, it is advantageous to have two switching clutches that preferably constitute a dual clutch and each of these switching clutches has a carrier, wherein these carriers are directly connected to the rotor or interconnected with each other. Attached Figure Description

[0017] The invention will now be described in detail below with reference to the accompanying drawings, in which various embodiments are also illustrated.

[0018] In the attached image:

[0019] Figure 1 The diagram shows a longitudinal sectional view of the electric drive system according to the invention based on a first embodiment. In addition to the basic attachment of the carrier of the switching clutch to the rotor of the disc motor, the coupling between the operating unit acting on the switching clutch and the rotating guide portion, which is constructed together with a bearing top (Lagerdom) fixed relative to the housing, is also visible.

[0020] Figure 2 The diagram shows a longitudinal sectional view of a drive system according to the invention based on a second embodiment, wherein the carriers of each of the two existing switching clutches are welded to the rotor, and the operating unit is implemented as a concentric driven cylinder.

[0021] Figure 3Shown in Figure 3 A detailed diagram of the attachment area between the carrier and the rotor of each switching clutch.

[0022] Figure 4 A detailed view is shown of the connection region between the rotor and the carrier of the first switching clutch in the drive system according to the invention according to a third embodiment, wherein the carrier is torsionally connected to the rotor via interlocking teeth.

[0023] Figures 5 to 7 Similar to Figure 4 Several detailed views of the connection areas according to different embodiments of the drive system of the present invention are shown, wherein retaining pins are used in different ways to secure the carrier to the rotor, and

[0024] Figure 8 A longitudinal sectional view of a drive system according to the invention, based on another embodiment, is shown, wherein, as Figure 2 As in the example, there is a welded connection between the carrier and the rotor in the clutch switching mechanism.

[0025] The accompanying drawings are merely illustrative and intended only for understanding the invention. The same elements are given the same reference numerals. The different features of these different embodiments can, in principle, be freely combined with each other. Detailed Implementation

[0026] Using according to the first embodiment Figure 1 The basic structure of the drive system 1 according to the present invention is clearly visible. The drive system 1 is constructed as a so-called electric axle / electric drive axle. Therefore, the drive system 1 is used to drive pure electric or hybrid-powered motor vehicles.

[0027] The drive system 1 has an electric drive motor in the form of a disc motor 2 that can be switched on as a drive unit. For clarity, only one rotor 4 of the disc motor 2 is shown in detail. The stator of the disc motor 2 is generally fixedly received in the housing 30 of the drive system 1.

[0028] The rotor 4 is torsionally supported relative to the housing 30. In this first embodiment, the rotor 4 is supported on the housing 30 by a rolling bearing 19, which is implemented as a double-row ball bearing. By means of the rolling bearing 19, the rotor 4 is supported not only (about its axis of rotation 9) in its radial direction but also (about its axis of rotation 9) in its axial direction relative to the support region 20 fixed relative to the housing.

[0029] Furthermore, the drive system 1 typically has a transmission device 3, shown only at its input ends 5a and 5b for clarity. This transmission device is preferably implemented as a planetary gear transmission mechanism or has a planetary gear transmission mechanism. In this embodiment, the transmission device 3 has two input shafts 31a and 31b arranged concentrically with each other, which respectively constitute the input ends 5a and 5b of the transmission device 3.

[0030] Therefore, the drive system 1 also has two switching clutches 6, 21, which are mounted between the rotor 4 and the corresponding input shafts 31a, 31b, respectively. The switching clutches 6, 21 are substantially identical in structure and function. In this embodiment, each switching clutch 6, 21 is implemented as a friction clutch.

[0031] Therefore, each switching clutch 6, 21 has two clutch components 7, 11 and 23, 25, which are connected to each other in a torque-transmitting manner (by frictional locking) in the closed position and are freely torsional relative to each other in the open position. Each first clutch component 7, 23 of the switching clutch 6, 21 has a first carrier 8, 22, which is implemented as an outer carrier and receives a plurality of first friction elements 10, 24 in a torsion-resistant and axially movable manner relative to each other. Each second clutch component 11, 25 of the switching clutch 6, 21 has a second carrier 26, 32, which is implemented as an inner carrier and receives a plurality of second friction elements 27, 33 in a torsion-resistant and axially movable manner relative to each other.

[0032] According to the present invention, the first switching clutch, indicated by reference numeral 6, is directly mounted on the rotor 4 with its first clutch component 7. The first clutch component 7 of the first switching clutch 6 is directly mounted / fixed to the rotor 4 with its first carrier 8. In this embodiment, the first clutch component 23 / first carrier 22 of the second switching clutch 21 is indirectly fixed to the rotor 4 via the first carrier 8.

[0033] Furthermore, as already mentioned, the first clutch component 7 of the first switching clutch 6 has a plurality of first friction elements 10 that are axially movable relative to each other and are received anti-torsionally on a first carrier 8. The second clutch component 11 has a second carrier 26 and a plurality of second friction elements 27 that are received anti-torsionally and axially movable relative to each other on the second carrier 26. The first carrier 8 forms an outer plate carrier and the second carrier 26 forms an inner plate carrier.

[0034] In a similar manner, the second switching clutch 21 has a first carrier 22 on which a plurality of first friction elements 24 are received anti-torsionally and axially movable relative to each other. The second clutch component 25 of the second switching clutch 21 further has a second carrier 32 and a plurality of second friction elements 33 on which the second friction elements are received anti-torsionally and axially movable relative to each other.

[0035] A first operating unit 18 is provided for operating the first switching clutch 6; a second operating unit 28 is provided for operating the second switching clutch 21. Each hydraulic operating unit 18, 28 has an axially movable piston 29a, 29b, which adjusts the clutches 6, 21 between their open and closed positions.

[0036] Depend on Figure 1 It is also concluded that the first carrier 8 of the first switching clutch 6 forms a multi-stage tank. Here, the first carrier 8 has two support regions 12a and 12b that are axially and radially offset and configured for axial support, and two support regions 12c and 12d that are axially and radially offset and configured for radial support. The first carrier 8 directly abuts against the axially raised portion 34 of the rotor 4 with the first support region 12a. This first support region 12 is connected to the sleeve region 35 of the first carrier 8 that receives the first friction element 10 and extends radially inward from the sleeve region 35. In addition to the first support region 12a, there is another second support region 12b in its radial interior, through which the first carrier 8 also axially abuts against the rotor 4. The third support region 12c extends radially between the two support regions 12a and 12b, and the third support region is supported on the radially inner side 14 of the rotor 4. In addition, there is a fourth support region 12d, which is also radially supported on the rotor 4 from the inside.

[0037] Therefore, the first carrier 8 of the first switching clutch 6 is arranged axially offset from the rotor 4 with its sleeve region 35, but its support regions 12a, 12b, 12c, and 12d are directly abutting and partially arranged within the radial interior of the rotor 4. In this configuration, the first carrier 8 is also connected to a fluid guide sleeve 36, which is further supported on a bearing top 37 when a rotational guide portion is constructed. The bearing top 37 is a direct component of the housing 30.

[0038] The different connection types between the first carrier 8 and the rotor 4 are described below with reference to different embodiments of the drive system 1 according to the present invention. It should be noted that... Figures 2 to 8 Other embodiments are substantially corresponding in structure and function to those according to Figure 1 The first embodiment is described below, therefore for the sake of brevity, only the differences between these embodiments will be described below.

[0039] according to Figures 1 to 8 Connections 15, 16, and 17, which can achieve different material locking, shape locking, and force locking, are provided between the first carrier 8 and the rotor 4.

[0040] exist Figure 1 The diagram shows a force-locking connection 17, in which a plurality of connecting pins / fixing pins 38 distributed circumferentially directly fix the first carrier 8 to the rotor 4. The fixing pins 38 are respectively anchored in the axial protrusions 34 of the rotor 4 and fixed / supported on the first carrier 8, and fixed / supported on the first support region 12a.

[0041] Other connecting parts using fixing pin 38 Figures 5 to 7 An example is shown. In Figure 5 In, similar to Figure 1 The retaining pin 38 is pressed into the (first) receiving hole 40a of the first carrier 8 and the (second) receiving hole 40b of the rotor 4 and is thus implemented as a pressing pin. The two receiving holes 40a and 40b are implemented as blind holes.

[0042] exist Figure 6 In, with Figure 5 In contrast, the first receiving hole 40a is implemented as a through hole. Here, the retaining pin 38 extends from the first receiving hole 40a, such that the retaining pin is preferably shaped in this area when constructing a rivet pin.

[0043] exist Figure 7 In, with Figure 6 In contrast, the fixing pin 38 terminates flush with the end of the first receiving hole 40a and therefore does not protrude from the first receiving hole.

[0044] use Figure 2 and 3 It can also be seen that, advantageously, the first carrier 8 is material-locked and installed, i.e., welded, to the rotor 4. The first carrier 8 is installed directly on the axial side 13 of the rotor 4 through the material-locked connection part 15 / welding part.

[0045] Alternatively, in place of the material-locking connection 15 or the force-locking connection 17, it can also be implemented according to... Figure 4 The shape-locking connection part 16. Here, there is a toothed part between the first carrier 8 and the rotor 4 so as to connect the first carrier 8 and the rotor 4 in a torsion-resistant manner.

[0046] In other embodiments according to the invention, a shape- and force-locking connection is also implemented, preferably as a press-fit connection.

[0047] As by Figure 1 and 2It is evident that, in the comparison of the embodiments, the first carrier 22 of the second switching clutch 21 is installed in a different manner. This first carrier 22 is... Figure 1 The first carrier 22 is connected to the first carrier 8 of the first switching clutch 6 via a shape-locking connection part 39 (tooth part) and is therefore indirectly connected to the rotor 4, while the first carrier 22 is in Figure 2 The intermediate part is directly mounted on rotor 4.

[0048] exist Figure 2 In order to mount the first carrier 22 of the second switching clutch 21 onto the rotor 4, a material-locking connection 15 was selected. However, it should be noted that the first carrier 22 can also be mounted in other ways, such as by shape-locking or force-locking as the first carrier 8 of the first switching clutch 6.

[0049] Furthermore, it should be noted in principle that in other implementations, only the first switching clutch 6 is configured as the sole switching clutch.

[0050] In addition, by Figure 2 and 8 It is also concluded that the operating units 18 and 28 are implemented as dual driven cylinders, that is, as (concentric) driven cylinders respectively. Here, a portion of the corresponding pistons 29a and 29b are always arranged radially inside the rotor 4 and axially at the same height as the rotor 4.

[0051] In other words, different connection methods according to the invention are achieved, which enable the disc rotor 2 to directly carry the torque of the switching clutch 6. Detachable and non-detachable connection portions 15, 16, and 17 are shown here. Detachable connection portions 16 and 17 are preferred when components should be configured and inspected independently of each other. All connections that ensure torque carrying can be considered as connection methods. This can be pin connections, toothed connections, press-fit connections, welded connections, etc. It should be noted that in the detachable plug-in connection portion 17, this connection portion also has axial shear force.

[0052] List of reference numerals

[0053] 1. Drive System

[0054] 2. Disc motor

[0055] 3. Transmission device

[0056] 4 rotors

[0057] 5a First Input Terminal

[0058] 5b Second Input Terminal

[0059] 6. Shift the clutch

[0060] 7. First clutch components of the first switching clutch

[0061] 8 First carrier of the first switching clutch

[0062] 9. Rotation axis

[0063] 10 First friction element of the first switching clutch

[0064] 11 The second clutch component of the first switching clutch

[0065] 12a First Support Area

[0066] 12b Second Support Area

[0067] 12c Third Support Area

[0068] 12d Fourth Support Area

[0069] 13 Axial side

[0070] 14. Inner side

[0071] 15. Material locking connection part

[0072] 16. Shape-locking connection part

[0073] 17. Force-locking connection part

[0074] 18 First Control Unit

[0075] 19 Rolling bearings

[0076] 20 Support Area

[0077] 21 Second switching clutch

[0078] 22 The first carrier of the second switching clutch

[0079] 23 The first clutch component of the second switching clutch

[0080] 24 The first friction element of the second switching clutch

[0081] 25 The second clutch component of the second switching clutch

[0082] 26 The second carrier of the first switching clutch

[0083] 27 The second friction element of the first switching clutch

[0084] 28 Second Control Unit

[0085] 29a First Piston

[0086] 29b Second Piston

[0087] 30 Casing

[0088] 31a First Input Axis

[0089] 31b Second Input Axis

[0090] 32 The second carrier of the second switching clutch

[0091] 33 Second friction element of the second switching clutch

[0092] 34. Raised section

[0093] 35 Sleeve Area

[0094] 36 Fluid Guide Sleeve

[0095] 37 Bearing Top

[0096] 38 Fixed pins

[0097] 39 Shape-locking connection part

[0098] 40a First receiving hole

[0099] 40b Second receiving port

Claims

1. An electric drive system (1) for a motor vehicle driven by pure electric or hybrid power, comprising a disc motor (2), a transmission (3), and a switching clutch (6), the switching clutch being mounted operatively between the disc rotor (4) of the disc motor (2) and the input end (5a) of the transmission (3), wherein, The switching clutch (6) has a first clutch component (7) and a second clutch component (11). The first clutch component has a carrier (8) directly attached to the rotor (4) and a plurality of friction elements (10). The friction elements are received on the carrier (8) in a torsional manner and are movable relative to each other along the rotation axis (9) of the rotor (4). The second clutch component is connected to the input end (5a) of the transmission device (3).

2. The electric drive system (1) according to claim 1, characterized in that, The carrier (8) can be detached and installed on the rotor (4) again.

3. The electric drive system (1) according to claim 1, characterized in that, The carrier (8) has at least one radially extending support area that abuts against the axial side (13) of the rotor (4).

4. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The carrier (8) has at least one axially extending support area that abuts against the radially inner side (14) of the rotor (4).

5. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The rotor (4) is supported on a support area (20) that is fixed relative to the housing by rolling bearings (19) arranged axially next to the carrier (8).

6. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The carrier (8) is fixed to the rotor (4) by a material locking connection.

7. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The carrier (8) is torsionally connected to the rotor (4) through a shape-locking connection.

8. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The carrier (8) is fixed to the rotor (4) by a force-locking connection.

9. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, The carrier (8) and / or the operating unit (18) associated with the switching clutch (6) are arranged at least partially in the radial interior of the rotor (4).

10. The electric drive system (1) according to any one of claims 1 to 3, characterized in that, There are two switching clutches (6, 21), each equipped with a carrier (8, 22), wherein the carriers (8, 22) are connected to the rotor (4).

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