A hybrid electric motor

Abstract

The application provides a hybrid motor, which is an integrated shell compact hybrid motor, simple structure, cost saving and meeting functional requirements. It comprises an integrated main shell, which comprises an outer ring body, a web and a wire box, one axial end surface of the outer ring body is fixed with the web, the center part of the web is concave, the other axial end surface of the outer ring body is open and forms a positioning stop, the outer ring body is provided with an outer convex wire box, a front end cover, a wire box cover plate, a motor shaft, a shaft hub, a stator, a rotor and a pneumatic separation bearing. The upper surface of the outer convex wire box is covered with the wire box cover plate, the positioning stop of the outer ring body is covered with the front end cover, and the inner cavity formed by the combination of the outer ring body, the web and the front end cover is a motor cavity. The motor shaft is arranged through the center hole of the web and the front end cover, and the shaft hub is fixedly sleeved on the part of the motor shaft corresponding to the motor cavity.

Description

Technical Field

[0001] This invention relates to the technical field of motor structure, specifically a hybrid electric motor. Background Technology

[0002] The new energy vehicle industry has experienced rapid development, leading to increasingly stringent requirements for vehicle drive motors. High power density, integration, lightweight design, and low cost are becoming the dominant trends. In the commercial vehicle sector, the application of hybrid motors is gradually expanding from buses to light trucks, heavy trucks, and mining trucks. Existing hybrid motors are structurally complex, comprising individual components such as housings, front and rear end covers, and junction boxes, resulting in higher costs and longer axial installation dimensions. Current hybrid motors primarily use low-grade magnets such as 35UH and B35A300 laminations, resulting in lower power density and mediocre efficiency. Furthermore, the clutch actuators in hybrid motors mainly consist of release bearings, shift forks, and pneumatic / electric actuators, making the entire assembly complex, space-consuming, and with generally low reliability. Therefore, existing hybrid motors are increasingly unable to meet the demanding market requirements, necessitating the development of new hybrid motor products. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a hybrid electric motor, which is an integrated housing and a compact hybrid electric motor, with a simple structure, cost-effectiveness, and functional requirements.

[0004] A hybrid electric motor, characterized in that it comprises:

[0005] An integrated main housing includes an outer ring body, a web plate, and a wire box. The web plate is fixed to one axial end face of the outer ring body. The central part of the web plate is concave. The other axial end face of the outer ring body is open, forming a positioning stop. A protruding wire box is provided on the outer ring body.

[0006] Front cover;

[0007] Junction box cover;

[0008] Motor shaft;

[0009] Axle hub;

[0010] stator;

[0011] Rotor;

[0012] And pneumatic release bearings;

[0013] The upper surface of the protruding wire box is covered with a wire box cover plate, and the positioning stop cover of the outer ring body is covered with the front end cover. The inner cavity formed by the combination of the outer ring body, the web plate, and the front end cover is the motor cavity. The motor shaft is arranged through the central hole of the web plate and the front end cover. The part of the motor shaft corresponding to the motor cavity is fixedly fitted with a hub. The outer ring of the hub is fixedly fitted with a rotor. The stator is fixedly fitted to the corresponding inner ring wall of the outer ring body. The stator is connected to an external wire. The connector corresponding to the wire is placed inside the wire box. The corresponding lead-out end of the wire is exposed outside the outer ring body for external power supply.

[0014] A clutch cavity is formed at the corresponding position of the concave central part of the web, and the pneumatic release bearing is sleeved on the motor shaft corresponding to the clutch cavity.

[0015] Its further features are:

[0016] The mounting base of the pneumatic release bearing is fixedly mounted on the corresponding outer surface of the web plate. The inner ring of the pneumatic release bearing is fixedly sleeved on the motor shaft. The outer ring of the pneumatic release bearing is directly or indirectly connected to another power input structure. The inner and outer rings of the pneumatic release bearing are separated or combined to complete power mixing or independent power operation.

[0017] The other axial end face of the outer ring body is also provided with gearbox connection screw holes, which allows the outer ring body to be directly fixed to the gearbox body, ensuring that the axial space occupied is as small as possible.

[0018] The outer ring body has several annular water channels arranged along the axial length direction, specifically including the first ring, the second ring, ..., the Nth ring. Each ring includes an inlet and an outlet. An inclined baffle is provided between the inlet and the outlet. The outlet of each ring is connected to the inlet of the next ring. The first ring is the inlet ring, and the Nth ring is the end ring. The outer wall at the beginning of the inlet ring has a water inlet, and the outer wall at the end of the outlet of the end ring has a water outlet, which ensures sufficient and reliable cooling of the motor.

[0019] The front cover has a concealed structure. The outer ring of the front cover is embedded in the positioning stop and is fastened to the outer ring body by connecting bolts.

[0020] The outer ring body is provided with two suspension bosses on both sides. The suspension bosses are used to directly connect the hybrid motor to the vehicle frame, making the connection simple and reliable.

[0021] The motor shaft is fitted with bearings at the positions corresponding to the center holes of the web plate and the front end cover, respectively.

[0022] The wire box is located directly above the outer ring and protrudes upwards, and it is integrally cast with the outer ring body;

[0023] The junction box cover extends axially outward and is fixed to the device, and the external three-phase wire is correspondingly fixed to the fixing device.

[0024] With this invention, the front end of the integrated main housing is positioned and connected to the front cover through the positioning stop, and the center of the cover at the axial rear end is recessed to form a clutch cavity. The pneumatic release bearing is sleeved on the motor shaft corresponding to the clutch cavity, thereby replacing the shift fork structure. This makes the overall axial length of the hybrid motor short, and the integrated main housing integrates the structure of the junction box and the web plate. It is an integrated housing and a compact hybrid motor, which has a simple structure, saves costs, and meets functional requirements. Attached Figure Description

[0025] Figure 1 This is a three-dimensional structural schematic diagram of the present invention;

[0026] Figure 2 This is a half-sectional side view of the present invention;

[0027] Figure 3 This is a top view of the present invention with the junction box cover removed.

[0028] Figure 4 This is a schematic cross-sectional view of the waterway of the present invention;

[0029] The names corresponding to the serial numbers in the diagram are as follows:

[0030] Integrated main housing 1, outer ring 101, web plate 102, junction box 103, positioning stop 104, gearbox connecting screw hole 105, suspension boss 106, front end cover 2, inner stop 201, motor shaft 3, bearing 4, bearing 5, shaft hub 6, rotor 7, stator 8, cedar head cable tie 9, external three-phase line 10, junction box cover plate 11, L-shaped insulating block assembly 12, copper busbar 1201, terminal 13, pneumatic separation bearing 14, bolt 15, water passage 16, first ring 161, second ring 162, third ring 163, fourth ring 164, oblique baffle 17, water inlet 18, water outlet 19. Detailed Implementation

[0031] A hybrid electric motor, see Figures 1-4 It includes: an integrated main housing 1, a front cover 2, a wire box cover 11, a motor shaft 3, a shaft hub 6, a stator 8, a rotor 7, and a pneumatic separation bearing 14.

[0032] The integrated main housing 1 includes an outer ring body 101, a web plate 102, and a wire box 103. The web plate 102 is fixed on one of the axial rear end faces of the outer ring body 101. The central part of the web plate 102 is concave. The other axial end face of the outer ring body 101 is open, forming a positioning stop 104. The wire box 103 is provided on the outer ring body 101.

[0033] The upper surface of the protruding junction box 103 is covered with a junction box cover plate 11. The positioning stop 104 of the outer ring body 101 is covered with a front end cover 2. The center of the end of the front end cover 2 is provided with a protruding inner stop 201. The inner stop 201 can cooperate with the outer stop of the gearbox and be fitted with a sealing ring to play a positioning and sealing role. The inner cavity formed by the combination of the outer ring body 101, the web plate 102, and the front end cover 2 is the motor cavity. The motor shaft 3 is arranged through the central hole of the web plate 102 and the front end cover 2. The part of the motor shaft 3 corresponding to the motor cavity is fixedly fitted with a hub 6. The outer ring of the hub 6 is fixedly fitted with a rotor 7. The stator 8 is fixedly fitted to the corresponding inner ring wall of the outer ring body 101. The stator 8 is connected to a wire. The connector of the wire is placed inside the junction box 103. The corresponding lead-out end of the wire is exposed outside the outer ring body 101 for external power supply.

[0034] The central part of the web plate 102 is recessed to form a clutch cavity, and the pneumatic release bearing 14 is sleeved on the motor shaft 3 corresponding to the clutch cavity.

[0035] In specific implementation, the mounting base of the pneumatic release bearing 14 is fixedly mounted on the corresponding outer surface of the web plate, the inner ring of the pneumatic release bearing 14 is fixedly sleeved on the motor shaft 3, and the outer ring of the pneumatic release bearing 14 is directly or indirectly connected to another power input structure. The inner and outer rings of the pneumatic release bearing 14 are separated or combined to complete the power mixing or individual power operation.

[0036] The other axial end face of the outer ring body 101 is also provided with gearbox connection screw holes 105, which allows the outer ring body 101 to be directly fixed to the gearbox body, ensuring that the axial space occupied is as small as possible.

[0037] The outer ring body 101 has several annular water channels 16 arranged along its axial length, which flow sequentially in stages. Specifically, these include the first ring 161, the second ring 162, ..., the Nth ring. Each stage of the ring includes an inlet and an outlet. An inclined baffle 17 is provided between the inlet and outlet. The outlet of each stage of the ring connects to the inlet of the next stage of the ring. The first ring 161 is the inlet ring, and the Nth ring is the end ring. The outer wall at the starting position of the inlet ring has a water inlet. The outer wall of the outlet portion of the final loop is provided with an outlet 19 to ensure sufficient and reliable cooling of the motor. In a specific embodiment, the outer ring body 101 is provided with a first loop 161, a second loop 162, a third loop 163, and a fourth loop 164 along the axial length direction. Each of the four loops includes an inlet portion and an outlet portion. The outer wall of the first loop 161 at the starting position is provided with an inlet 18, and the outer wall of the outlet portion of the fourth loop 164 at the end is provided with an outlet 19.

[0038] The front cover 2 has a hidden structure. The outer ring of the front cover 2 is embedded in the positioning stop 104 and is fastened to the outer ring body 101 by connecting bolts.

[0039] The outer ring body 101 is provided with two suspension bosses 106 on both sides. The suspension bosses 106 are used to directly connect the hybrid motor to the frame, making the connection simple and reliable.

[0040] Bearings 4 and 5 are respectively fitted onto the motor shaft 3 at the positions corresponding to the center holes of the web plate 102 and the front end cover 2.

[0041] The rotor 7 and stator 8 are arranged axially aligned. The rotor 7 is made of high-grade magnets 42UH and 48UH. The laminations of the rotor 7 are made of B30AHV1500. The enameled wire of the stator 8 is made of grade 3 or grade 4 enamel film.

[0042] The pneumatic release bearing 14 used to control the clutch action is sleeved on the input end of the motor shaft 3 and fixed to the center of the web plate 102 by bolts. The pneumatic release bearing 14 is recessed in the clutch cavity of the motor along the axial direction. In order to leave enough space to accommodate the pneumatic release bearing 14, the inner ring of the shaft hub 6 and the web plate 102 are arranged towards the output end.

[0043] The junction box 103 is located directly above the outer ring body 101 and protrudes upwards. It is integrally cast with the outer ring body 101. The bottom of the inner cavity of the junction box 103 is equipped with an L-shaped insulating block assembly 12, which is fixed to the bottom plate of the junction box by bolts 15. The long side of the L-shaped insulating block assembly 12 extends downwards into the motor cavity. The copper busbar 1201 on the long side of the L-shaped insulating block assembly 12 connects to the three-phase wires and terminals 13 of the motor stator and is fixed by bolts. The short side of the other side of the L-shaped insulating block assembly 12 connects to the terminals of the external three-phase wires 10 and is fastened with bolts. The external three-phase wires 10 are fixed axially to the junction box 103 through the three-in-one through-hole connector on it.

[0044] The junction box cover 11 extends outward axially and is fixed to the device. The external three-phase wires are fixed to the fixing device. In specific implementation, the fixing device is a fir tree head tie 9.

[0045] This hybrid motor features an integrated design for the clutch housing, junction box, and motor housing, with suspension feet on both sides of the housing, resulting in a simple and compact overall structure. The distribution of the water channels optimizes the housing weight and heat dissipation performance. The output end cap has a concealed design, its contour matching one side of the housing, allowing the gearbox connection bolts to be directly fixed to the main housing, increasing connection strength and creating a seamless hybrid system appearance. The integrated design of the motor junction box and housing simplifies the structure and saves costs, while maintaining normal heat conduction between the junction box and housing. An insulating block seals the bottom cavity of the junction box, preventing internal motor moisture from entering and causing condensation. The extended junction box allows for the placement of three-phase wire fixing ties, eliminating the need for additional wire clamps. Through in-depth simulation optimization, higher-grade magnets, laminations, and thicker enameled wire are used, while the core length is minimized, increasing power density and reducing losses. A pneumatic release bearing replaces the traditional shift fork and release bearing structure; its unique design allows the pneumatic release bearing to be concealed within the motor's underside, significantly saving axial space.

[0046] Its beneficial effects are as follows:

[0047] The integrated design of the clutch housing, motor housing, and junction box saves on parts and costs, resulting in a more compact motor structure.

[0048] 2. By maximizing the length of the water channels on the main housing, the motor's heat dissipation capacity is enhanced, and the housing is made lighter;

[0049] The three-end cap concealed design makes the hybrid system look seamless, while the gearbox can be directly bolted to the motor main housing, making the connection safer and more reliable;

[0050] 4. The main housing has built-in mounting bosses on both sides, allowing the motor to be directly mounted on the frame without the need for additional mounting plates, which is simple and reliable;

[0051] The 5-wire junction box features an integrated design, resulting in a simple structure and cost-effectiveness. It utilizes a three-phase cable with a three-in-one through-hole connector for easy installation.

[0052] The outer edge of the 6-phase junction box cover has built-in binding points to fix the three-phase wires, eliminating the need for wire clamps and other components.

[0053] 7. Through in-depth simulation optimization, higher grade magnets, laminations, and thicker enameled wire coatings are used while the core length is compressed to the maximum extent to meet the requirements of higher power density, higher efficiency, larger voltage platform, and charging rate;

[0054] The 8 pneumatic release bearings replace the traditional plug-in + release bearing structure. The unique concave semi-hidden design makes the axial installation length of the motor 1 / 3 shorter than that of existing hybrid motors, which greatly improves the adaptability of the hybrid system to vehicles.

[0055] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0056] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A hybrid electric machine characterized by, It includes: Integrated main shell, including outer ring body, web, wire box, one of the axial end surface of the outer ring body is fixed with the web, the center part of the web is concave, the other axial end surface of the outer ring body is open and forms a positioning stop, the outer ring body is provided with an outer convex wire box; Front end cover; Wire box cover plate; Motor shaft; Shaft hub; Stator; Rotor; And pneumatic separation bearing; The upper surface of the outer convex wire box is covered with a wire box cover plate, the positioning stop of the outer ring body is covered with the front end cover, the inner cavity formed by the combination of the outer ring body, the web and the front end cover is a motor cavity, the motor shaft passes through the center hole of the web and the front end cover, the corresponding part of the motor shaft is sleeved with the shaft hub, the outer ring of the shaft hub is fixed with the rotor, the stator is fixed to the corresponding inner ring wall of the outer ring body, the stator is circumscribed with the wire, the corresponding joint of the wire is placed in the wire box, and the corresponding lead-out end of the wire is exposed outside the outer ring body for external connection of the power supply. The corresponding position of the concave center part of the web forms a clutch cavity, and the pneumatic separation bearing is sleeved on the corresponding motor shaft of the clutch cavity.

2. A hybrid electric machine as claimed in claim 1, wherein: The mounting seat body of the pneumatic separation bearing is fixed to the corresponding outer surface of the web, the inner ring of the pneumatic separation bearing is sleeved on the motor shaft, and the outer ring of the pneumatic separation bearing is directly or indirectly connected to another power input structure. The inner ring and the outer ring of the pneumatic separation bearing are separated or combined to complete power mixing or separate power operation.

3. The hybrid electric machine of claim 1, wherein: The other axial end surface of the outer ring body is also provided with a gearbox connection screw hole, which allows the outer ring body to be directly and fixedly connected with the gearbox body.

4. The hybrid electric machine of claim 1, wherein: The ring wall of the outer ring body is provided with a plurality of ring-shaped waterways along the axial length direction, which are sequentially arranged in stages, and specifically include a first ring, a second ring, …, and an Nth ring. Each stage of ring includes an inlet portion and an outlet portion, and a diagonal baffle is arranged between the inlet portion and the outlet portion. The outlet portion of each stage of ring is communicated with the inlet portion of the next stage of ring. The first ring is an inlet ring, and the Nth ring is a terminal ring. The outer wall of the starting position of the inlet ring is provided with a water inlet, and the outer wall of the terminal end of the outlet portion of the terminal ring is provided with a water outlet.

5. The hybrid electric machine of claim 1, wherein: The front end cover is of a hidden structure, and the outer ring of the front end cover is embedded in the positioning stop and is tightly connected with the outer ring body through connecting bolts.

6. The hybrid electric machine of claim 1, wherein: The outer ring body is provided with suspension bosses on both sides, which are used to directly connect the hybrid motor to the frame.

7. The hybrid electric machine of claim 1, wherein: The motor shaft is sleeved with a bearing at the position corresponding to the center hole of the web and the front end cover.

8. The hybrid electric machine of claim 1, wherein: The wire box is located directly above the outer ring and is convexly arranged, and is integrally cast with the outer ring body.

9. The hybrid electric machine of claim 1, wherein: The wire box cover plate extends axially outward and is fixed to the fixing device, and the three-phase wire is fixed to the fixing device.

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