Rotor frame for electric motors

Abstract

The present invention relates to a rotor frame for a rotor (2.2) of an electric motor (2) and a hybrid module having the rotor frame, wherein the rotor frame comprises a tubular base body (13), wherein a receiving portion for a portion of a clutch (7) is provided on an inner circumferential surface facing away from the rotor (2.2), and wherein the base body (13) is connected to a hub (4) by means of a connecting element (14) arranged adjacent to the receiving portion, characterized in that the connecting element (14) is formed by a radially extending annular flange; and the radially extending annular flange is arranged in the axial direction between the receiving portion and the end of the base body (13), or characterized in that the base body (13) is formed integrally with a torque converter housing (5.1); and the connecting element (14) is formed by a radially extending housing wall or housing cover of the torque converter housing (5.1).

Description

Technical Field

[0001] The invention relates to a rotor carrier for an electric motor, in particular in a hybrid drive train of a vehicle. Background Art

[0002] In the prior art, in addition to solid rotors, annular rotors arranged around a rotation axis are also known in electric motors. For example, DE 10 2005 053 887 A1 or US 2013 / 0192947 A1 disclose that the lamination stack of a rotor is received on a sleeve and that the sleeve is directly connected to a subsequent torque converter. Summary of the invention

[0003] The object of the present invention is to provide an alternative to the prior art which has an improved rotor support and an optimized utilization of the installation space and which can be produced simply and cost-effectively.

[0004] This object is achieved by the rotor frame according to the invention. Advantageous embodiments are apparent from the description and the drawings.

[0005] According to the present invention, a rotor frame for a rotor of an electric motor, wherein the rotor frame includes a tubular base body, wherein the base body has a device on an outer circumferential surface facing the rotor, and the device can achieve a shape-fitting and / or force-fitting connection between the base body and the rotor, wherein on an inner circumferential surface facing away from the rotor, a receiving portion for a clutch portion is provided on a portion of an axially extending portion, and wherein the base body is connected to the hub by a connecting element arranged adjacent to the receiving portion, characterized in that the connecting element is composed of a radially extending annular flange, and the radially extending annular flange is arranged in the axial direction between the receiving portion and the end of the base body.

[0006] In order to establish a connection between the base body and the rotor, for example, a contour portion is provided on the base body, wherein at least on the outer circumferential surface, projections and / or recesses are provided, which cooperate with corresponding counterparts on the inner surface of the rotor to establish a form-fitting connection. Alternatively or cumulatively, projections or recesses, such as shoulders or annular grooves, can also be provided in the circumferential direction, which can be used for a form-fitting or force-fitting connection. Instead of a form-fitting connection, a force-fitting connection can also be provided, in which the rotor is connected to the base body by means of clamping devices, threaded connections, rivets, etc. In principle, it can also be a material-fitting connection, in which the rotor is welded to the base body. It can also be a combination, in which different connection methods are used to map or fix the connection in different directions.

[0007] The base body is connected to the hub via a connecting element so that the torque can be transmitted. In this regard, in addition to the hub usually mounted on the shaft, the hub also refers to and includes a direct connection with the shaft or a connection with subsequent components in the drive train (such as a torque converter housing).

[0008] The connection to the hub is effected via a flange region of the connecting element which is correspondingly formed in the radial direction.

[0009] Receptacles for parts of the clutch are provided on the inner circumferential surface of the base body. These parts are preferably grooves or projections in the axial direction, which serve as receptacles for the plates of the multi-disc clutch. The base body thus simultaneously forms the outer plate carrier of the clutch. The clutch can be used, for example, to disconnect the force flow from or relative to a combustion engine located upstream in the drive train.

[0010] Another rotor frame for a rotor of an electric motor according to the present invention, wherein the rotor frame includes a tubular base body, wherein the base body has a device on an outer circumferential surface facing the rotor, and the device can achieve a shape-fitting and / or force-fitting connection between the base body and the rotor, wherein on an inner circumferential surface facing away from the rotor, a receiving portion for a clutch portion is provided on a part of the axially extending portion, and wherein the base body is connected to the hub by a connecting element arranged adjacent to the receiving portion, characterized in that the base body is formed integrally with the torque converter housing, and the connecting element is formed by a radially extending housing wall or housing cover of the torque converter housing.

[0011] The basic structure is as described above, wherein the base body is formed integrally with the torque converter housing. In this case, the connecting element is formed by a radially extending housing wall or housing cover, which is arranged axially adjacent to the receiving portion for the clutch part. In other words, the torque converter housing has a sleeve-shaped base body, the rotor is fastened to the sleeve-shaped base body, the housing wall implemented as a radial connecting element extends in this base body, and the torque converter housing has an axially open receiving portion for the clutch formed by the base body. With such a design, the rotor carrier can be implemented with a smaller structural space.

[0012] The embodiment of the rotor frame is characterized in that the annular flange is composed of separate components, which are fixedly connected to the inner circumferential surface in the axial direction and in the circumferential direction. By designing the base body and the connecting element as separate components, the geometry of the components is simplified and thus the manufacturing is also simplified. In particular, welding, riveting, snap-fit ​​connection or threaded connection are suitable as the connection between the base body and the annular flange, wherein other form-fit connections can also be used, wherein corresponding protrusions on the base body or the connecting element engage in corresponding hollowing-outs on the counterpart. Combinations of different connection methods are also possible.

[0013] An alternative embodiment of the rotor frame is characterized in that the annular flange is formed integrally with the base body. In an integral embodiment of the base body and the connecting element, the force flow within the component is improved and the assembly effort for the connection is avoided. In particular, manufacturing processes from the range of deformation, flow forming or shaping are suitable for producing such a rotor frame.

[0014] The rotor frame according to an embodiment is characterized in that the base body is designed to be longer than the rotor at least at an axial end portion.

[0015] The length here refers in particular to the length of the lamination stack of the rotor. The base body protruding beyond the rotor can improve the positioning of the component by means of shoulders, projections, etc., on the one hand, and in a corresponding design can improve cooling on the other hand. In addition, the protruding rotor frame, more precisely the protruding base body, provides a certain degree of mechanical protection for the rotor.

[0016] The protruding base body can also be used, in particular, for balancing the rotor by attaching balancing weights to the protruding base body or by removing local material.

[0017] An embodiment of the rotor frame is characterized in that the base body has at least one recess which is continuous in the radial direction and is used to allow oil to pass through. At least one recess is provided in order to conduct the oil for lubrication and cooling from the inside to the outside. Preferably, this recess is arranged in a flow-through manner in the region of an axial end of the lamination stack or in a flow-through manner in an oil channel formed between the rotor frame and the lamination stack.

[0018] A preferred embodiment of the rotor frame is characterized in that the hollowing portion is arranged in the bottom area of ​​the groove arranged on the inner circumferential surface. In addition to the hollowing portion, other guide elements can also be provided at the connecting element or the base body to guide the oil generated inside to the hollowing portion or to be able to discharge it to the outside in a targeted manner. These guide elements can be implemented as channels, annular grooves, depressions or other grooves that are preferably inclined toward the hollowing portion. Alternatively, it can also be a guide element that is raised as a pillar, protrusion or shoulder. Preferably, these guide elements can also be used as a receiving portion of a part of the clutch at the same time, and / or in another axial direction for establishing a form-fitting connection between the connecting element and the base body.

[0019] The rotor frame according to a preferred embodiment is characterized in that a plurality of recesses are arranged distributed in the circumferential direction. In order to distribute the oil more evenly and avoid imbalance, a plurality of recesses are preferably distributed symmetrically in the circumferential direction.

[0020] The preferred embodiment of the rotor frame is characterized in that a plurality of recesses are arranged in different, axially spaced planes. Here, a plurality of recesses can also be provided at different axial positions, thereby, for example, improving cooling on both sides in the axial direction.

[0021] The rotor frame according to an embodiment is characterized in that the base body has a different thickness in the region of the receiving portion than in the region of the connecting element in the axial direction. Therefore, the base body has a cross-section that changes in the radial direction at at least one position along the axial extension. This can be used, for example, as a stop for positioning the base body and the connecting element relative to each other so that the position can be easily and quickly determined when assembling the base body and the connecting element. It is therefore advantageous to use circumferential shoulders or protrusions, because stops can be formed in the axial direction by these shoulders or protrusions, and the corresponding counterparts can be pushed against these stops. In addition, the amount of material can be adapted to the load by different wall thicknesses so as to be constructed as lightly as possible.

[0022] An embodiment of the rotor frame is characterized in that the base body is made of a shaped tube segment. Since the basic shape of the base body is given in the tube segment, the base body is advantageously made of a tube segment, which is formed into the base body by a corresponding shaping step and / or processing step. Alternatively, the base body can also be formed from a plate.

[0023] The rotor frame according to an embodiment is characterized in that the connecting element has an axial section, which extends parallel to the base body and is connected to the base body. In addition to the butt contact of the connecting element with the base body, the connecting region of the connecting element can be shaped, for example, so as to form a section extending coaxially with the base body, which extends within the base body. By means of this connecting region, positioning in the base body and establishing the connection can be simplified. The coaxial direction also increases the stability of the connecting element.

[0024] Preferably, the axial section abuts against the base body. The stability of the rotor frame can be further improved by the contact between the connecting element and the base body along the axial section. In addition, the contact area can additionally serve as a connecting area or a part of a connecting area.

[0025] Preferably, an axial section of the connecting region is arranged on that side of the connecting element which faces away from the receptacle for the clutch portion.

[0026] Preferably, the connecting element is arranged in the region of the middle half of the base body. The coaxial region of the connecting element is designed to be shorter than the base body, wherein preferably the axial section of the connecting element has an axial length in the range of at least 33% of the axial length of the base body. As a result, the force flow and load of the connecting element can be reduced and axial installation space can be saved overall, because the subsequent components on the driven shaft can be arranged at least partially in the rotor protruding outside the connecting element.

[0027] Another advantageous aspect of the two-part embodiment of the rotor carrier with the base body and the connecting element is that the same connecting element can be used for different base bodies of different rotors, which is advantageous in terms of production and costs. This effect also applies analogously to the base body, since different connecting elements can be used to construct the same base body, depending on the drive train.

[0028] Another aspect of the invention is a hybrid module, comprising an input shaft, a clutch, an electric motor, a torque converter and a driven shaft, wherein the hybrid module is characterized in that a rotor carrier according to one of the described embodiments is provided. As a result, the hybrid module can benefit from the advantages described in terms of axial structural space and the like.

[0029] The embodiments are not limited to the above examples, but can be implemented by other corresponding design methods. The features of the embodiments can be combined with each other arbitrarily. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will be described in detail below with the aid of the accompanying drawings. The same or similar elements are represented by unified reference numerals. In the accompanying drawings:

[0031] Figure 1 A schematic cross section of an embodiment of a hybrid module is shown.

[0032] Figure 2 A schematic cross-sectional view of a partial area of ​​a hybrid module of an exemplary embodiment in the region of the rotor carrier is shown.

[0033] Figure 3 A schematic cross-sectional view of a partial area of ​​a hybrid module of an exemplary embodiment in the region of the rotor is shown.

[0034] Figure 4 A schematic cross-sectional view of a partial area of ​​a hybrid module of an exemplary embodiment in the region of the rotor is shown. DETAILED DESCRIPTION

[0035] Figure 1A hybrid module according to an embodiment is shown in a schematic sectional view, wherein half is omitted for reasons of symmetry. The hybrid module comprises a housing (1) in which an electric motor (2) is arranged, which has a stator (2.1) which is rotationally fixed relative to the housing (1) and a rotatable rotor (2.2).

[0036] The hybrid module has a torque converter (5). The torque converter housing (5.1) is connected to the hub (4). The pump wheel (5.3) of the torque converter (5) is fixedly connected to the torque converter housing (5.1) of the torque converter (5). The guide wheel (5.4) of the torque converter (5) is supported in a rotationally fixed manner by the flywheel in one rotation direction. The turbine (5.5) of the torque converter (5) is connected to the turbine shaft (5.2) of the torque converter (5). The hybrid module also has an additional optional torsional vibration damper (10), which is arranged in the torque converter housing (5.1) and is arranged on the torque converter housing. The turbine shaft (5.2) is connected to the driven shaft (6) of the automatic transmission (not shown in detail). In addition, a lockup clutch (11) is arranged in the torque converter housing (5.1). By closing the lockup clutch (11), the torque converter housing (5.1) can be directly connected to the turbine shaft (5.2).

[0037] The hub (4) is designed as a hollow shaft, which is coaxial with the driven shaft (6) and is arranged to enclose the driven shaft. The input shaft (3) is also implemented as a hollow shaft in the example shown and is arranged coaxially with the hub (4). A plurality of bearings (12) are arranged between the driven shaft (6) and the hub (4), between the hub (4) and the input shaft (3) and between the input shaft (3) and the housing (1), which support these components to each other. On the outside of the hub (4), the hub is connected to the torque converter housing (5.1) and is connected to one side of the clutch (7) via a rotor carrier.

[0038] A vibration damper (8) is arranged on the input shaft (3), which is connected to a combustion engine (not shown). Possible torsional vibrations are reduced by means of the vibration damper (8) in order to supply the hybrid module with a torque or rotational movement that is as uniform as possible. At the same time, position tolerances and orientation tolerances between the combustion engine and the hybrid module can be compensated by means of the vibration damper (8). The input shaft (3) is further connected to a part of a clutch (7).

[0039] The housing (1) separates the wet space from the dry space of the hybrid module. The wet space is sealed relative to the dry space by means of a seal (9), which is preferably arranged directly next to the bearing (12).

[0040] A clutch (7) is also arranged in the housing (1), with which the combustion engine can be disconnected from another drive train. For this purpose, the clutch (7) is arranged in the force flow between the input shaft (3) and the hub (4). More precisely, parts of the clutch (7) are connected to the input shaft (3) and to the rotor carrier respectively. In the illustrated embodiment, the clutch (7) is designed as a multi-plate clutch.

[0041] The rotor (2.2) of the electric motor (2) is connected to the base (13) of the rotor frame. The base (13) has a tubular structure, and the rotor (2.2) is mounted on the outer circumferential surface of the tubular structure. In the illustrated embodiment, the axial end of the base (13) facing the torque converter (5) is formed outward to form a flange, which partially covers the rotor (2.2) in the radial direction. Therefore, the flange provides protection for the rotor (2.2) and can be used as a stop for positioning the rotor (2.2). Through corresponding hollowing parts or balancing elements not shown, the flange can also be used to guide oil for lubrication and cooling the electric motor (2) or for balancing the electric motor (2). The opposite axial ends of the base (13) are implemented flush with the outer circumferential surface so that the rotor (2.2) can be assembled. In order to fix the axial position of the rotor (2.2) on the base (13), a fixing element (15) is arranged in a groove. The fixing element ( 15 ) can be embodied to be at least partially elastic in order to compensate for manufacturing tolerances or the like.

[0042] In addition to the base body (13), the rotor frame also includes a connecting element (14). In the illustrated embodiment, the connecting element (14) is largely designed as a radially extending, tubular structure. A shorter axial section of the connecting element (14) extending coaxially with the base body (13) forms a connecting region, via which the connecting element (14) is connected to the base body (13). The base body (13) has a shoulder on its inner circumferential surface, which serves as a stop and positioning aid for the connecting element (14). The outer circumferential surface of the connecting region is preferably firmly connected to the inner circumferential surface of the base body (13) by welding, wherein other connection methods are also possible.

[0043] The base body (13) is provided with a contour on the side facing away from the torque converter (5) to form projections and depressions distributed in the circumferential direction in the form of spline teeth. These projections and depressions serve as receiving parts of the clutch (7), in the example shown as receiving parts of the outer plate of the clutch (7), whereby the base body (13) forms the outer plate carrier of the clutch (7).

[0044] Figure 2 , Figure 3 and Figure 4 They show similar Figure 1 Partial area of ​​the hybrid module in the clutch area for different exemplary embodiments. Figures 2 to 4 The invention relates to a clutch (7) and a clutch (13). The clutch (13) and a clutch (14) have in common that the input shaft (3) is connected to the clutch (7), more precisely to the input side of the clutch. Part of the clutch, more precisely to the output side, is connected to a base body (13), which also forms an outer plate carrier. The connecting element (14) is connected to the hub (4) and thus to the further drive train. Furthermore, the connecting element (14) is connected to the base body (13), and the base body (13) receives the rotor (2.2) on the outer circumferential surface. Therefore, the connecting element (14) and the base body (13) together form a rotor frame.

[0045] The connection area of ​​the connection element (14) is Figure 2 In the embodiment of the present invention, the connecting element (14) is designed as a section which is formed coaxially with the base body (13) in the direction of the torque converter (5). In this case, the connecting region has, for example, one quarter of the length of the base body (13) in the axial direction. This length can prevent the connecting element (14) from tilting relative to the base body (13) during assembly and a larger surface is available for establishing the connection. In particular, the connection can be achieved by spot welding, riveting or clinching.

[0046] exist Figure 3 In principle, Figure 1 The rotor frame is designed as in the example shown in , wherein, however, the rotor frame consisting of the base body (13) and the connecting element (14) is implemented in one piece. The one-piece embodiment increases the manufacturing costs of the rotor frame, but the force flow in the rotor frame can be improved and the assembly costs for connecting the base body (13) and the connecting element (14) can be reduced.

[0047] exist Figure 4 In the embodiment of the invention, the base body (13) is formed integrally with the torque converter housing (5.1). In this example, the sleeve-shaped base body (13) is formed by the axial end of the torque converter housing (5.1). The connecting element (14) is embodied as a separate component, but it is also possible to embodied as an integral component as an alternative. The connecting element (14) thus forms part of the torque converter housing (14) in the form of a housing cover. In order to position the connecting element (14), a shoulder is provided on the inner circumferential surface of the base body (13), against which the connecting element (14) is pushed.

[0048] The base body (13) or the torque converter housing (5.1) has a region protruding beyond the connecting element (14) in the axial direction, in which a receptacle for a portion of the clutch (7) is received outside the torque converter (5). Within the torque converter (5), the inner circumferential surface of the base body (13) serves as a receptacle for a portion of the lockup clutch (11), thereby achieving a higher utilization of the installation space and thus being able to reduce the required axial installation space.

[0049] The present invention is not limited to the above-described embodiments. It can be implemented in the manner described above, and only individual advantageous features can be provided, or different features of different examples can be combined with each other.

[0050] List of Reference Numerals

[0051] 1 Housing

[0052] 2 Electric motor

[0053] 2.1 Stator

[0054] 2.2 Rotor

[0055] 3 Input shaft

[0056] 4 Hub

[0057] 5 Torque converter

[0058] 5.1 Torque converter housing

[0059] 5.2 Turbine shaft

[0060] 5.3 Impeller

[0061] 5.4 Guide wheel

[0062] 5.5 Turbine

[0063] 6 Driven shaft

[0064] 7 Clutch

[0065] 8 Vibration damper

[0066] 9 Seals

[0067] 10 Torsional vibration damper

[0068] 11 Lock-up clutch

[0069] 12 Bearings

[0070] 13 Matrix

[0071] 14 Connecting elements

[0072] 15 Fixing elements

Claims

1. A rotor frame for a rotor (2.2) of an electric motor (2), wherein the rotor frame comprises a tubular base body (13), wherein the base body (13) has a device on an outer peripheral surface facing the rotor (2.2), wherein the device can realize a form-fitting and / or force-fitting connection between the base body (13) and the rotor (2.2), wherein on the inner peripheral surface facing away from the rotor (2.2), a receiving portion for a portion of a clutch (7) is provided on a part of the axial extension, and wherein the base body (13) is connected to the hub (4) by means of a connecting element (14) arranged adjacent to the receiving portion, characterized in that The connecting element (14) is composed of a radially extending annular flange; the radially extending annular flange is arranged in the axial direction between the receiving portion and the end of the base (13); the base (13) has at least one hollow portion continuous in the radial direction for allowing oil to pass through; and multiple hollow portions are arranged in different, axially spaced apart planes, wherein the connecting element (14) has an axial section, which extends parallel to the base (13) and is connected to the base.

2. The rotor frame according to claim 1, characterized in that: The annular collar is formed by a separate component which is fixedly connected to the inner circumferential surface in the axial direction and in the circumferential direction.

3. The rotor frame according to claim 1, characterized in that: The annular flange is formed integrally with the base body (13).

4. The rotor frame according to claim 1, characterized in that: The base body (13) is designed to be longer than the rotor (2.2) at least at the axial end.

5. The rotor frame according to claim 1, characterized in that: The recess is arranged in a bottom region of a groove provided on the inner circumferential surface.

6. The rotor frame according to claim 1, characterized in that: The plurality of hollow portions are arranged to be distributed in the circumferential direction.

7. The rotor frame according to any one of the preceding claims 1 to 6, characterized in that The base body (13) has a different thickness in the axial direction in the region of the receptacle than in the region of the connecting element (14).

8. The rotor frame according to any one of the preceding claims 1 to 6, characterized in that The base body (13) is produced from a shaped tube section.

9. A rotor frame for a rotor (2.2) of an electric motor (2), wherein the rotor frame comprises a tubular base body (13), wherein the base body (13) has a device on an outer peripheral surface facing the rotor (2.2), wherein the device can realize a form-fitting and / or force-fitting connection between the base body (13) and the rotor (2.2), wherein on the inner peripheral surface facing away from the rotor (2.2), a receiving portion for a portion of a clutch (7) is provided on a part of the axial extension, and wherein the base body (13) is connected to the hub (4) by means of a connecting element (14) arranged adjacent to the receiving portion, characterized in that The base body (13) is formed integrally with the torque converter housing (5.1); the connecting element (14) is formed by a radially extending housing wall or housing cover of the torque converter housing (5.1); the base body (13) has at least one hollow portion which is continuous in the radial direction for oil to pass through; and a plurality of hollow portions are arranged in different, axially spaced-apart planes, wherein the connecting element (14) has an axial section which extends parallel to the base body (13) and is connected to the base body.

10. The rotor frame according to claim 9, characterized in that The base body (13) is designed to be longer than the rotor (2.2) at least at the axial end.

11. The rotor frame according to claim 9, characterized in that: The recess is arranged in a bottom region of a groove provided on the inner circumferential surface.

12. The rotor frame according to claim 9, characterized in that: The plurality of hollow portions are arranged to be distributed in the circumferential direction.

13. The rotor frame according to any one of the preceding claims 9 to 12, characterized in that The base body (13) has a different thickness in the axial direction in the region of the receptacle than in the region of the connecting element (14).

14. The rotor frame according to any one of the preceding claims 9 to 12, characterized in that The base body (13) is produced from a shaped tube section.

15. A hybrid power module, comprising an input shaft (3), a clutch (7), an electric motor (2), a torque converter (5) and a driven shaft (6), characterized in that: A rotor frame according to one of claims 1 to 14 is provided.

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