Electrified propulsion systems and equipment

Abstract

An electrified drivetrain system is described that maximizes power density, is easy to package, and improves driving performance. It includes a propulsion system with an axial flux rotary motor, a torque converter with a selectable one-way clutch, and an output component connectable to the drivetrain. The axial flux rotary motor includes a first rotor arranged coaxially with a first electric stator. The torque converter includes a fluid stator, a pump, a turbine, and a torque converter clutch. The axial flux rotary motor is arranged coaxially with the torque converter. The first rotor of the axial flux rotary motor is connected to the pump of the torque converter, and the turbine of the torque converter is rotatably connected to the output component.

Description

Technical Field

[0001] This disclosure relates to an electrified powertrain system for vehicles. Background Technology

[0002] Electrified powertrains for vehicles include, for example, battery electric vehicles, range-extended electric vehicles, plug-in hybrid electric vehicles, and fuel cell hybrid electric vehicles. As experienced practitioners understand, the design of an electrified powertrain involves optimizing and balancing traction power, weight, package size, range, driving performance, and other factors. Vehicle designers strive to achieve a fast, lightweight, and responsive powertrain system that can be integrated into the vehicle and travel long distances with minimal charging requirements.

[0003] An electric motor converts electrical energy into mechanical energy by generating torque. Electric vehicles (including hybrid vehicles) use electric motors (such as induction motors and permanent magnet motors) to propel the vehicle and capture braking energy when acting as a generator. Typically, an electric motor comprises a rotor that rotates during operation and a stationary stator. The rotor may contain multiple permanent magnets and rotates relative to the stationary stator. The rotor is connected to a shaft that also rotates with the rotor. The rotor, which includes the permanent magnets, is separated from the stator by a predetermined air gap. The stator comprises conductors in the form of wire windings. When electrical energy is applied through the conductive wire windings, a magnetic field is generated. When electrical energy or power is fed into the conductive windings of the stator, the power can generate torque through the air gap, which in turn acts on the permanent magnets in the rotor. In this way, mechanical energy can be transferred to or extracted from the rotating shaft. In electric vehicles, the rotor thus transmits torque to the vehicle's drive wheels via a gear set through the rotating shaft.

[0004] Two common types of electric motors include radial flux and axial flux motors. In a radial flux motor, the rotor and stator are typically arranged concentrically or nested, such that when the stator is energized, it generates a magnetic flux that extends radially from the stator to the rotor. Therefore, the conductive windings in the stator are typically arranged perpendicular to the axis of rotation, generating a magnetic field oriented radially from the axis of rotation. In an axial flux motor, a magnetic field parallel to the axis of rotation is generated by the conductive windings in the stator, thus the magnetic flux extends parallel to the axis of rotation. In some applications, axial flux motors are desirable because they are relatively lighter than radial flux motors, generate increased power, and have a compact size.

[0005] There is a need for an electrified powertrain system that maximizes power density, is easy to package, and improves driving performance. Summary of the Invention

[0006] An electrified powertrain system that maximizes power density, is easy to package, and improves driving performance is described. It includes a propulsion system with an axial flux rotary motor, a torque converter with a selectable one-way clutch, and an output component connectable to the powertrain. The axial flux rotary motor includes a first rotor arranged coaxially with a first electric stator. The torque converter includes a fluid stator, a pump, a turbine, and a torque converter clutch. The axial flux rotary motor is arranged coaxially with the torque converter. The first rotor of the axial flux rotary motor is connected to the pump of the torque converter, and the turbine of the torque converter is rotatably connected to the output component.

[0007] One aspect of this disclosure includes: the output component of the turbine coupled to the torque converter is rotatably coupled to the drivetrain.

[0008] Another aspect of this disclosure includes: the torque converter clutch is a normally closed clutch, which is controlled to be open during startup operation.

[0009] Another aspect of this disclosure includes: the axial flux rotary motor is a multiphase brushless permanent magnet DC rotary motor.

[0010] Another aspect of this disclosure includes: a first rotor being a plurality of radially oriented permanent magnets fixed to a disc-shaped back plate.

[0011] Another aspect of this disclosure includes: the first stator is a disc-shaped device having a plurality of radially oriented columns, wherein each of the columns has a conductive winding.

[0012] Another aspect of this disclosure includes: a first rotor having a plurality of radially oriented permanent magnets fixed to a disc-shaped back plate. The first stator is a disc-shaped device having a plurality of conductive windings, and the plurality of radially oriented permanent magnets are arranged adjacent to the plurality of radially oriented conductive windings in an axial orientation and separated by an air gap.

[0013] Another aspect of this disclosure includes: the torque converter clutch is one of a claw clutch, a preload friction clutch, or an electromagnetic clutch.

[0014] Another aspect of this disclosure includes: a second rotor arranged coaxially with the first rotor and the first stator, wherein the stator is inserted between the first rotor and the second rotor, and wherein the first rotor is connected to the second rotor via a shaft.

[0015] Another aspect of this disclosure includes: a first rotor comprising a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate, wherein a second rotor comprises a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate, wherein a first stator is a disc-shaped device having a plurality of conductive windings, wherein the first plurality of radially oriented permanent magnets are arranged adjacent to a first side of the plurality of radially oriented conductive windings in an axial orientation and separated by a first air gap, and wherein the second plurality of radially oriented permanent magnets are arranged adjacent to a second side of the plurality of radially oriented conductive windings in an axial orientation and separated by a second air gap.

[0016] Another aspect of this disclosure includes a second stator arranged coaxially with the first rotor and the first stator, wherein the first rotor is inserted between the first and second stators.

[0017] Another aspect of this disclosure includes: a first rotor comprising a first plurality of radially oriented permanent magnets fixed to a first side of a disc-shaped back plate, wherein the first rotor includes a second plurality of radially oriented permanent magnets fixed to a second side of the disc-shaped back plate, wherein the first stator includes a disc-shaped device having a first plurality of conductive windings, wherein the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the first plurality of conductive windings in an axial orientation and separated by a first air gap, and wherein the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the first plurality of conductive windings in an axial orientation and separated by a second air gap.

[0018] Another aspect of this disclosure includes a propulsion system comprising a first axial flux rotary motor and a second axial flux rotary motor arranged coaxially with a torque converter. The first axial flux rotary motor has a first rotor arranged coaxially with a first stator. The second axial flux rotary motor has a second rotor arranged coaxially with a second stator. The torque converter includes a fluid stator, a pump, a turbine, and a torque converter clutch. The first and second axial flux rotary motors are arranged coaxially with the torque converter, wherein the first and second rotors of the first axial flux rotary motor are coupled to the pump of the torque converter, and wherein the turbine of the torque converter is rotatably coupled to an output member.

[0019] Another aspect of this disclosure includes an optional one-way clutch coupled between a fluid stator and a mechanical grounding element.

[0020] Another aspect of this disclosure includes: the torque converter clutch is a normally closed clutch; wherein the torque converter clutch is controlled to open during start-up operation.

[0021] Another aspect of this disclosure includes: a first stator being a first disc-shaped device having a first plurality of radially oriented conductive windings, and a first rotor including a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate. A second stator includes a second disc-shaped device having a second plurality of radially oriented conductive windings; and a second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate. The first plurality of radially oriented permanent magnets are arranged adjacent to the first plurality of radially oriented conductive windings in an axial orientation and separated by a first air gap, and the second plurality of radially oriented permanent magnets are arranged adjacent to the second plurality of radially oriented conductive windings in an axial orientation and separated by a second air gap.

[0022] Another aspect of this disclosure includes a propulsion system having a first axial flux rotary motor, a second axial flux rotary motor, a first torque converter, and a second torque converter. The first axial flux rotary motor, the second axial flux rotary motor, the first torque converter, and the second torque converter are arranged coaxially. The first axial flux rotary motor includes a first rotor arranged coaxially with a first stator, and the second axial flux rotary motor includes a second rotor arranged coaxially with a second stator. The first torque converter includes a first fluid stator, a first pump, a first turbine, and a first torque converter clutch. The second torque converter includes a second fluid stator, a second pump, a second turbine, and a second torque converter clutch. The first rotor of the first axial flux rotary motor is coupled to the first pump of the first torque converter, and the second rotor of the second axial flux rotary motor is coupled to the second pump of the second torque converter. The first turbine of the first torque converter is rotatably coupled to a first output member, and the second turbine of the second torque converter is rotatably coupled to a second output member.

[0023] Another aspect of this disclosure includes: a first stator being a first disc-shaped device having a first plurality of radially oriented conductive windings; a first rotor including a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate; and a second stator including a second disc-shaped device having a second plurality of radially oriented conductive windings.

[0024] The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate. A first plurality of radially oriented permanent magnets are arranged adjacent to the first plurality of radially oriented conductive windings in an axial orientation and separated by a first air gap. A second plurality of radially oriented permanent magnets are arranged adjacent to the second plurality of radially oriented conductive windings in an axial orientation and separated by a second air gap.

[0025] This invention provides the following technical solutions:

[0026] 1. A propulsion system, comprising:

[0027] An axial flux rotary electric motor, comprising a first rotor arranged coaxially with a first stator;

[0028] A torque converter, comprising a fluid stator, a pump, a turbine, and a torque converter clutch;

[0029] A one-way clutch may be selected, which is connected to the fluid stator;

[0030] The axial flux rotary motor is arranged coaxially with the torque converter.

[0031] The first rotor of the axial flux rotary motor is connected to the pump of the torque converter;

[0032] The turbine of the torque converter is rotatably connected to the output component.

[0033] 2. The propulsion system according to claim 1, wherein the output component of the turbine connected to the torque converter is rotatably connected to the transmission system.

[0034] 3. The propulsion system according to claim 1, wherein the torque converter clutch includes a normally closed clutch; and wherein, during start-up operation, the torque converter clutch is controlled to be in an open state.

[0035] 4. The propulsion system according to Scheme 1, wherein the axial flux rotary motor includes a multiphase brushless permanent magnet DC rotary motor.

[0036] 5. The propulsion system according to Scheme 1, wherein the first rotor includes a plurality of radially oriented permanent magnets fixed to a disc-shaped backplate.

[0037] 6. The propulsion system according to Scheme 1, wherein the first stator includes a disc-shaped device having a plurality of radially oriented columns, wherein each of the columns has a conductive winding.

[0038] 7. The propulsion system according to Scheme 1, wherein the first rotor includes a plurality of radially oriented permanent magnets fixed to a disc-shaped back plate;

[0039] The first stator includes a disc-shaped device having multiple conductive windings; and

[0040] The plurality of radially oriented permanent magnets are arranged adjacent to the plurality of radially oriented conductive windings in the axial orientation and separated by an air gap.

[0041] 8. The propulsion system according to Scheme 1, wherein the torque converter clutch includes one of a claw clutch, a preload friction clutch, or an electromagnetic clutch.

[0042] 9. The propulsion system according to claim 1 further includes a second rotor arranged coaxially with the first rotor and the first stator; wherein the first stator is inserted between the first rotor and the second rotor; and wherein the first rotor is shaft-connected to the second rotor.

[0043] 10. The propulsion system according to claim 9, wherein the first rotor includes a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate;

[0044] The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate;

[0045] The first stator includes a disc-shaped device with multiple conductive windings.

[0046] Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the plurality of radially oriented conductive windings in an axial orientation and separated by a first air gap; and

[0047] In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the plurality of radially oriented conductive windings in the axial orientation and separated by a second air gap.

[0048] 11. The propulsion system according to Scheme 1 further includes a second electric stator arranged coaxially with the first rotor and the first electric stator; wherein the first rotor is inserted between the first electric stator and the second electric stator.

[0049] 12. The propulsion system according to Scheme 11,

[0050] The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first side of a disc-shaped back plate;

[0051] The first rotor includes a second plurality of radially oriented permanent magnets fixed to a second side of the disc-shaped back plate;

[0052] The first stator includes a disc-shaped device having a first plurality of conductive windings;

[0053] Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the first plurality of conductive windings in an axial orientation and separated by a first air gap; and

[0054] In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the first plurality of conductive windings in the axial orientation and separated by a second air gap.

[0055] 13. A propulsion system, comprising:

[0056] A first axial flux rotary motor and a second axial flux rotary motor are arranged coaxially with the torque converter;

[0057] The first axial flux rotary motor includes a first rotor arranged coaxially with the first stator;

[0058] The second axial flux rotary motor includes a second rotor arranged coaxially with the second stator;

[0059] The torque converter includes a fluid stator, a pump, a turbine, and a torque converter clutch;

[0060] The first and second axial flux rotary motors are arranged coaxially with the torque converter;

[0061] Wherein, the first rotor and the second rotor of the first axial flux rotary motor are connected to the pump of the torque converter; and

[0062] The turbine of the torque converter is rotatably connected to the output component.

[0063] 14. The propulsion system according to claim 13 further includes a selectable one-way clutch connected between the fluid stator and the mechanical grounding element.

[0064] 15. The propulsion system according to claim 13, wherein the torque converter clutch includes a normally closed clutch; wherein the torque converter clutch is controlled to open during start-up operation.

[0065] 16. The propulsion system according to Scheme 13,

[0066] The first stator includes a first disc-shaped device having a first plurality of radially oriented conductive windings;

[0067] The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate;

[0068] The second stator includes a second disc-shaped device having a second plurality of radially oriented conductive windings; and

[0069] The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate;

[0070] Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first plurality of radially oriented conductive windings in an axial orientation and separated by a first air gap; and

[0071] In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second plurality of radially oriented conductive windings in the axial orientation and separated by a second air gap.

[0072] 17. A propulsion system, comprising:

[0073] A first axial flux rotary motor, a second axial flux rotary motor, a first torque converter, and a second torque converter;

[0074] The first axial flow rotary motor, the second axial flow rotary motor, the first torque converter, and the second torque converter are arranged coaxially.

[0075] The first axial flux rotary motor includes a first rotor arranged coaxially with the first stator;

[0076] The second axial flux rotary motor includes a second rotor arranged coaxially with the second stator;

[0077] The first torque converter includes a first fluid stator, a first pump, a first turbine, and a first torque converter clutch;

[0078] The second torque converter includes a second fluid stator, a second pump, a second turbine, and a second torque converter clutch;

[0079] Wherein, the first rotor of the first axial flux rotary motor is connected to the first pump of the first torque converter;

[0080] The second rotor of the second axial flux rotary motor is connected to the second pump of the second torque converter;

[0081] Wherein, the first turbine of the first torque converter is rotatably connected to the first output component; and

[0082] The second turbine of the second torque converter is rotatably connected to the second output component.

[0083] 18. The propulsion system according to claim 17, wherein the first torque converter clutch includes a normally closed clutch; and wherein the first torque converter clutch is controlled to open during start-up operation.

[0084] 19. The propulsion system according to claim 17, wherein the second torque converter clutch includes a normally closed clutch; and wherein the second torque converter clutch is controlled to open during start-up operation.

[0085] 20. The propulsion system according to Scheme 17,

[0086] The first stator includes a first disc-shaped device having a first plurality of radially oriented conductive windings;

[0087] The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first disc-shaped back plate;

[0088] The second stator includes a second disc-shaped device having a second plurality of radially oriented conductive windings;

[0089] The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate;

[0090] Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first plurality of radially oriented conductive windings in an axial orientation and are separated by a first air gap; and

[0091] In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second plurality of radially oriented conductive windings in the axial orientation and separated by a second air gap.

[0092] When taken in conjunction with the accompanying drawings, as defined in the appended claims, the above-described features and advantages of the present teachings, as well as other features and advantages, will become apparent from the following detailed description of some preferred modes and other embodiments for carrying out the present teachings. Attached Figure Description

[0093] One or more embodiments will now be described by way of example with reference to the accompanying drawings, in which:

[0094] Figure 1 An embodiment of a propulsion system for an electrified drive system according to the present disclosure is illustrated, the electrified drive system including an axial flux rotary motor coupled to a torque converter.

[0095] Figure 2 The references to this disclosure are shown schematically. Figure 1 Elements of an embodiment of an axial flux rotary motor described.

[0096] Figure 3 A propulsion system for an electrified drive system according to the present disclosure is schematically shown, the electrified drive system including another embodiment of an axial flux rotary motor coupled to a torque converter.

[0097] Figure 4 The references to this disclosure are shown schematically. Figure 3 Elements of an embodiment of an axial flux rotary motor described.

[0098] Figure 5 A propulsion system for an electrified drive system according to the present disclosure is schematically shown, the electrified drive system including another embodiment of an axial flux rotary motor coupled to a torque converter.

[0099] Figure 6 The references to this disclosure are shown schematically. Figure 5 Elements of an embodiment of an axial flux rotary motor described.

[0100] Figure 7 A propulsion system for an electrified drive system according to the present disclosure is schematically shown, the electrified drive system including another embodiment of an axial flux rotary motor coupled to a torque converter.

[0101] Figure 8 A propulsion system for an electrified drive system according to the present disclosure is schematically shown, the electrified drive system including another embodiment of an axial flux rotary motor coupled to a torque converter.

[0102] The accompanying drawings are not necessarily drawn to scale and may present slightly simplified representations of the various features of this disclosure as disclosed herein, including, for example, specific dimensions, orientations, positions, and shapes. Details associated with such features will be determined in part by the specific intended application and environment of use. Detailed Implementation

[0103] Referring now to the accompanying drawings, which are shown for illustrative purposes and not for limitation, Figure 1 and Figure 2 Elements of an embodiment of a propulsion system 100 are schematically shown, including an axial flux rotary motor 10 coupled to a drivetrain 60 via a novel torque converter 50 and controlled by a controller 70. The same figures refer to the same elements throughout the description. This description is provided in the context of an axial orientation with an axial reference line 15 and a radial reference line 16. An axial flux rotary motor is a form of electric motor structure in which the gap between the rotor and stator, and thus the direction of the magnetic flux between them, is aligned parallel to the axis of rotation. In one embodiment, and as described herein, the axial flux rotary motor 10 is configured as a brushless permanent magnet direct current (DC) motor. In one embodiment, the propulsion system may include an internal combustion engine coupled to the axial flux rotary motor 10 and coupled to the drivetrain 60 via the torque converter 50.

[0104] In one embodiment, the propulsion system 100 is disposed on the vehicle, and the drivetrain 60 terminates at one or more wheels to provide traction. The vehicle may be a mobile platform in the form of, but is not limited to, commercial vehicles, industrial vehicles, agricultural vehicles, passenger vehicles, aircraft, ships, trains, all-terrain vehicles, personal mobile devices, robots, etc., to achieve the purposes of this disclosure.

[0105] In one embodiment, the drivetrain 60 includes a fixed-gear transmission or a continuously variable transmission (CVT) coupled to the wheels via a drive shaft, drive axle, or differential. In one embodiment, the propulsion system 100 is arranged as a stationary device, and the drivetrain 60 terminates at an actuator such as a fluid pump.

[0106] The axial flux rotary motor 10 is a high-voltage multiphase electric motor / generator configured to convert stored electrical energy into mechanical energy and then into electrical energy that can be stored in a high-voltage energy storage device (battery) 90. The battery 90 can be a high-voltage energy storage device, such as a multi-cell lithium-ion device, a supercapacitor, or another device, without limitation. Monitoring parameters associated with the battery 90 may include state of charge (SOC), temperature, and others. In one embodiment, the battery 90 may be electrically connected to a remote external power source via an onboard battery charger (not shown) for charging when the vehicle is stationary. The battery 90 is electrically connected to an inverter module 80 via a high-voltage DC bus to deliver high-voltage DC power to the axial flux rotary motor 10 via three-phase conductors in response to control signals originating from the controller 70.

[0107] Refer again Figure 1 and Figure 2This embodiment of the axial flux rotary motor 10 includes a single rotor 20 and a single stator 30. The stator 30 is electrically connected to a battery 90 via an inverter module 80 and a high-voltage bus. The inverter module 80 is configured with control circuitry including power transistors (e.g., IGBTs) for converting high-voltage DC power to high-voltage AC power and vice versa. The inverter module 80 may employ pulse-width modulation (PWM) control of the IGBTs to convert stored DC power from the battery 90 into AC power to drive the axial flux rotary motor 10 to generate torque. Similarly, the inverter module 80 converts mechanical energy delivered to the axial flux rotary motor 10 into DC power to generate electrical energy that can be stored in the battery 90, including as part of a regenerative braking control strategy. The inverter module 80 receives motor control commands and controls the inverter state to provide motor drive and regenerative braking functions. In one embodiment, a DC / DC power converter is electrically connected to the high-voltage bus to provide power to a low-voltage battery via a low-voltage bus. The low-voltage battery is electrically connected to the auxiliary power system to provide low-voltage power to low-voltage systems in the vehicle, including, for example, power windows, HVAC fans, seats, and other devices. A controller 70 is operatively connected to an inverter module 80 to control the power transfer between the battery 90 and multiple radially oriented conductive windings 32 of the stator 30. The controller 70 controls the inverter module 80 to sequentially electrically activate the radially oriented conductive windings 32 to apply rotational magnetic force to multiple permanent magnets 24 fixed to the rotor 20 to achieve rotation of the rotor 20, or to provide a counter-torque to slow down the rotation of the rotor 20.

[0108] The rotor 20 includes a disc-shaped backplate 22 concentric with and fixed to a rotatable shaft member (shaft) 12. The backplate 22 includes a plurality of radially oriented permanent magnets 24 arranged near its outer periphery. The permanent magnets 24 may have alternating polarities. Adjacent pairs of permanent magnets 24 define a channel between them, which may extend radially along a face of the rotor 20. In this way, the permanent magnets 24 and the channel can together define a plurality of magnetic poles. As will be understood by those skilled in the art, the number, shape, arrangement, and orientation of the permanent magnets 24 may differ from those shown. The rotor 20 is supported on the shaft 12 and by bearings housed in a fixed frame member 35. The center of the shaft 12 is arranged on and defines an axial reference line 15. The rotor 20 rotates together with the shaft 12 during operation. The stator 30 is a disc-shaped device concentric with the shaft 12. The stator 30 is fixed to the fixed frame member 35. The stator 30 includes a plurality of electromagnetic components in the form of radially oriented conductive windings 32 that are spaced apart from each other to form electromagnetic poles.

[0109] A radially oriented conductive winding 32 and a radially oriented permanent magnet 24 are arranged adjacent to the radially oriented conductive winding 32 in the axial direction and separated by an air gap 17. The radially oriented conductive winding 32 is electrically connected to the inverter module 80 in a multiphase arrangement to generate an electromagnetic force applied to the radially oriented permanent magnet 24 to cause the rotor 20 to rotate in electric mode to generate torque in traction operation, and to resist the rotation of the rotor 20 in reaction mode to generate electricity in regenerative operation. In one embodiment, the radially oriented conductive winding 32 may be electrically connected in a three-phase configuration, but the concept described herein is not limited to three-phase. Other phase arrangements, such as two-phase, four-phase, etc., may be used.

[0110] The torque converter 50 may be a fluid torque coupling device coaxially arranged between the axial-flux rotary motor 10 and the drivetrain 60. The torque converter 50 includes a pump 56 rotatably coupled to the shaft 12, a fluid stator 57, and a turbine 58 rotatably coupled to an output member 59, which is rotatably coupled to the drivetrain 60. The torque converter 50 also includes a controllable torque converter clutch 52 and a selectable one-way clutch (SOWC) 55. The torque converter clutch 52 may be configured as a claw clutch, a preload friction clutch, or an electromagnetic clutch. The torque converter clutch 52 is arranged as a normally closed clutch, which is controlled to be open under certain operating conditions (e.g., during start-up operations).

[0111] The torque converter 50 operates to provide a fluid torque coupling between the pump 56 and the turbine 58 when the clutch 52 is disengaged or released, and a mechanical torque coupling between the pump 56 and the turbine 58 when the clutch 52 is activated. Because a difference in rotational speeds between the pump 56 and the turbine 58 may exist when the clutch 52 is not actuated or released during fluid torque coupling, this is referred to as torque converter clutch slippage. Torque converter clutch slippage can be measured using a rotational speed sensor. The SOWC 55 is arranged to selectively engage the fluid stator 57 to the fixed frame member 35, and thus facilitates reverse operation when activated.

[0112] Shaft 12 is connected to pump 56 of torque converter 50 to transmit torque to output member 59, which in one embodiment is connected to drivetrain 60.

[0113] The drivetrain 60 includes, for example, a transmission. In one embodiment, the transmission may be arranged in a stepped gear configuration and may include one or more differential gear sets and an active clutch configured to transmit torque in one of a plurality of fixed gear states within a speed ratio range between the output member 59 of the torque converter 50 and the drivetrain components. The transmission may be one of various configurations and may be an automatic transmission that automatically shifts between fixed gear states.

[0114] In one embodiment, drivetrain 60 may include a gear set mechanically coupled to one or more axles, which in turn are mechanically coupled to one or more wheels. The drivetrain transmits traction power to the road surface. The gear set of drivetrain 60 may be in the form of a front drive axle and half-shafts (not shown) that rotatably connect output member 59 to one or more wheels. Alternatively, the gear set may be in the form of a rear differential and axle that rotatably connects output member 59 to one or more wheels. Alternatively, the gear set may be in the form of a front drive axle and a rear drive shaft combined, the rear drive shaft being coupled to a differential that rotatably connects output member 59 to one or more wheels. Alternatively or additionally, a power take-off (PTO) gearbox (not shown) may be rotatably coupled to output member 59. Propulsion system 100 is illustrative, and the concepts described herein are applicable to other propulsion systems with similar configurations.

[0115] In one embodiment, the fluid system 85 is arranged to supply hydraulic fluid to the torque converter 50 and is also fluidly connected to heat exchange elements arranged on the axial flux rotary motor 10 and the inverter module 80. As a non-limiting example, the fluid system 85 includes a fluid pump, an oil tank, cooling elements, and associated pumping loop elements, and is configured to supply hydraulic fluid to the torque converter 50 and also remove heat from the motor 10 and the inverter module 80.

[0116] Figure 3 and Figure 4 Another embodiment of the propulsion system 200 is shown. In this embodiment, the axial flux rotary motor 210 includes a single stator 30 arranged coaxially with and inserted between the first rotor 220 and the second rotor 221. The first rotor 220 and the second rotor 221 are connected together via a shaft 12 and spaced apart from the single stator 30 by respective first air gaps 17 and second air gaps 18. The radially oriented conductive windings 32 of the stator 30 are electrically connected to the battery 90 via an inverter module 80 and a high-voltage bus. Operation is controlled by a controller 70. The shaft 12 is coupled to a pump 56 of a torque converter 50 to transmit torque to an output member 59, which in one embodiment is coupled to an embodiment of a drivetrain 60.

[0117] The first rotor 220 includes a first back plate 222 having a first set or plurality of radially oriented permanent magnets 224 fixed thereon. The second rotor 221 includes a second back plate 223 having a second set or plurality of radially oriented permanent magnets 225 fixed thereon.

[0118] Figure 5 and Figure 6 Another embodiment of the propulsion system 300 is shown. In this embodiment, the axial flux rotary motor 310 includes a first stator 330 and a second stator 331 arranged coaxially with a rotor 320, with the rotor 320 inserted between them. The rotor 320 is coupled to a shaft 12. The first stator 330 and the second stator 331 are spaced apart from the rotor 320 by respective first air gaps 317 and second air gaps 318. The shaft 12 is coupled to a pump 56 of a torque converter 50 to transmit torque to an output member 59, which, in one embodiment, is coupled to an embodiment of a drivetrain 60.

[0119] The rotor 320 includes a disc-shaped back plate 322 having a first set or more radially oriented permanent magnets 24 fixed to a first side 321, and a second set or more radially oriented permanent magnets 24 fixed to a second opposite side 323 of the back plate 322.

[0120] The first stator 330 has a first plurality of radially oriented conductive windings 332, and the second stator 331 has a second plurality of radially oriented conductive windings 333.

[0121] The first radially oriented conductive winding 332 of the first stator 330 is electrically connected to the battery 90 via the first inverter module 380 and the high-voltage bus. The second radially oriented conductive winding 333 of the second stator 331 is electrically connected to the battery 90 via the second inverter module 382 and the high-voltage bus. Operation is controlled by the controller 70.

[0122] In one embodiment, the first radially oriented conductive winding 332 of the first stator 330 is rotatably aligned with the second radially oriented conductive winding 333 of the second stator 331. This helps to maximize the electromagnetic force exerted on the rotor 320 by the first stator 330 and the second stator 331. In another embodiment, the first radially oriented conductive winding 332 of the first stator 330 is rotatably offset from the second radially oriented conductive winding 333 of the second stator 331 by 180 degrees of electrical rotation angle. This helps to minimize fluctuations caused by the electromagnetic forces exerted on the rotor 320 by the first stator 330 and the second stator 331.

[0123] Figure 7Another embodiment of the propulsion system 400 is shown. In this embodiment, a first axial flux rotary motor 410 and a second axial flux rotary motor 450 are arranged coaxially and coaxial with the torque converter 50. The first axial flux rotary motor 410 and the second axial flux rotary motor 450 are arranged in a manner similar to that of the reference model. Figure 1 The first axial flux rotary motor 10 is configured in such a manner that the shaft 12 is connected to the pump 56 of the torque converter 50 to transmit torque to the output member 59, which in one embodiment is connected to an embodiment of the drivetrain 60.

[0124] A first axial-throughput rotary motor 410 includes a first stator 430 arranged coaxially with a first rotor 420. The first rotor 420 is coupled to a shaft 412. The first stator 430 is separated from the first rotor 420 by a first air gap 417. A second axial-throughput rotary motor 450 includes a second stator 465 arranged coaxially with a second rotor 460. The second rotor 460 is also coupled to a shaft 412. The second stator 465 is separated from the second rotor 460 by a second air gap 418. The first stator 430 is electrically connected to a battery 90 via a first inverter module 480 and a high-voltage bus. The second stator 465 is electrically connected to the battery 90 via a second inverter module 482 and a high-voltage bus. Operation is controlled by a controller 70.

[0125] Figure 8 Another embodiment of the propulsion system 800 is shown. In this embodiment, a first axial flux rotary motor 810 and a second axial flux rotary motor 863 are arranged coaxially and coaxial with a first torque converter 850 and a second torque converter 840. The first axial flux rotary motor 810 and the second axial flux rotary motor 863 are arranged in a manner similar to that of the reference model. Figure 1 The configuration of the first axial flux rotary motor 10 is described.

[0126] The first axial flux rotary motor 810 includes a first stator 830 arranged coaxially with a first rotor 820, which is coupled to a first shaft 812. The first stator 830 is separated from the rotor 820 by a first air gap 816. The first shaft 812 is coupled to a first pump 848 of a first torque converter 840 to transmit torque to a first output member 849, which is coupled to a drivetrain 870 in one embodiment, which may be a half-shaft coupled to a wheel in one embodiment. The first torque converter 840 is similar to the torque converter 50 and includes a pump 846, a fluid stator 847, and a turbine 848 rotatably coupled to the first output member 849, which is rotatably coupled to the first drivetrain 870. The first torque converter 840 also includes a controllable torque converter clutch 842 and a selectable one-way clutch (SOWC) 845.

[0127] The second axial flux rotary motor 863 includes a second stator 865 arranged coaxially with the second rotor 860. The second rotor 860 is coupled to a second shaft 813. The second stator 865 is separated from the second rotor 860 by a second air gap 817. The second stator 865 is electrically connected to the battery 90 via a second inverter module 882 and a high-voltage bus. Operation is controlled by a controller 70.

[0128] The second shaft 813 is coupled to the second pump 856 of the second torque converter 850 to transmit torque to the second output member 859, which is coupled to a drivetrain 871 in one embodiment, which may be a half-shaft coupled to a wheel in another embodiment. The second torque converter 850 is similar to the torque converter 50 and includes the second pump 856, the second fluid stator 857, and the second turbine 858 rotatably coupled to the second output member 859, which is rotatably coupled to the second drivetrain 871. The second torque converter 850 also includes a controllable torque converter clutch 852 and a selectable one-way clutch (SOWC) 855.

[0129] The terms controller, control module, module, control, control unit, processor, and similar terms refer to one or various combinations of application-specific integrated circuits (ASICs), electronic circuits, central processing units (e.g., microprocessors), and associated non-transitory memory components in the form of memory and storage devices (read-only, programmable read-only, random access, hard disk drives, etc.). Non-transitory memory components are capable of storing machine-readable instructions in the form of one or more software or firmware programs or routines, combinational logic circuits, input / output circuitry and devices, signal conditioning and buffering circuitry, and other components accessible by one or more processors to provide the aforementioned functionality. Input / output circuitry and devices include analog-to-digital converters and associated devices for monitoring inputs from sensors, such inputs being monitored at a preset sampling frequency or in response to trigger events. Software, firmware, program, instructions, control routines, code, algorithms, and similar terms refer to the set of instructions executable by the controller, including calibration and lookup tables. Each controller executes control routines to provide the required functionality, including monitoring inputs from sensing devices and other networked controllers, and executing control and diagnostic routines to control the operation of actuators. Routines can be executed periodically at regular intervals, such as every 100 microseconds or 3.125, 6.25, 12.5, 25, and 100 milliseconds during ongoing operation. Alternatively, routines can be executed in response to the occurrence of a triggering event. Communication between controllers, and between controllers, actuators, and / or sensors, can be implemented using direct wired links, networked communication bus links, wireless links, serial peripheral interface buses, or other communication links. Communication includes the exchange of data signals in various forms, including, for example, electrical signals via conductive media, electromagnetic signals via air, optical signals via optical waveguides, etc. Data signals can include signals representing inputs from sensors, signals representing actuator commands, and communication signals between controllers. As used herein, the terms "dynamic" and "dynamically" describe a step or process executed in real time, characterized by monitoring or otherwise determining the state of parameters and regularly or periodically updating the state of parameters during routine execution or between cycles of routine execution.

[0130] As used herein, the term "system" may refer to one or a combination of mechanical and electrical actuators, sensors, controllers, application-specific integrated circuits (ASICs), combinational logic circuits, software, firmware, and / or other components arranged to provide the said functionality.

[0131] The concepts described herein relate to embodiments of the propulsion system described herein, employing an axial flux rotary motor 10 to reduce NVH-related parameters and improve packaging.

[0132] This means that the flux path is much shorter compared to radial flux machines, allowing for smaller motors with higher power density and efficiency for the same power output. Because the flux path in an axial flux machine is one-dimensional, grain-oriented electrical steel can be used. This steel makes flux flow more easily, resulting in efficiency gains. Furthermore, due to the short axial length of the axial flux motor, packaging benefits can be achieved.

[0133] The components of an electric motor can be built on a planar structure, such as a printed circuit board, with the addition of coils and bearings.

[0134] The coil winding process, as well as the connection between the coil and the core, is likely to be much simpler. Because the coil is flat, rectangular copper bars can be more easily used, allowing for simplified high-current windings. The rotor weight can be significantly reduced. The rotor-stator gap can be smaller than that of a radial flux motor because it is unaffected by centrifugal force and can be adjusted after construction. A shorter magnetic path length can be achieved compared to radial flux motors. Many structural components are flat and can be manufactured without specialized casting or stamping tools, thus reducing costs. The magnetic path through the windings is generally straight, allowing the use of grain-oriented electrical steel, which offers advantages such as higher permeability and lower core losses compared to non-electrical steel. Arranging the axial flux rotary motor close to the torque converter is advantageous and allows the use of a transmission fluid as the cooling medium for the axial flux rotary motor.

[0135] The detailed description and accompanying drawings are intended to support and describe this teaching, but the scope of this teaching is defined only by the claims. While some preferred modes and other embodiments for carrying out this teaching have been described in detail, various alternative designs and embodiments exist for practicing the teaching as defined in the appended claims.

Claims

1. A propulsion system, comprising: An axial flux rotary electric motor, comprising a first rotor arranged coaxially with a first stator; A second electric stator arranged coaxially with the first rotor and the first electric stator; A torque converter, comprising a fluid stator, a pump, a turbine, and a torque converter clutch; A one-way clutch may be selected, which is connected to the fluid stator; The axial flux rotary motor is arranged coaxially with the torque converter. The first rotor of the axial flux rotary motor is connected to the pump of the torque converter; The turbine of the torque converter is rotatably connected to the output component; The first rotor is inserted between the first stator and the second stator; The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first side of a disc-shaped back plate; The first rotor includes a second plurality of radially oriented permanent magnets fixed to a second side of the disc-shaped back plate; The first stator includes a disc-shaped device having a first plurality of conductive windings; Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the first plurality of conductive windings in an axial orientation and separated by a first air gap; and In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the first plurality of conductive windings in the axial orientation and separated by a second air gap.

2. The propulsion system according to claim 1, wherein, The output component of the turbine connected to the torque converter is rotatably connected to the drivetrain.

3. The propulsion system according to claim 1, wherein, The torque converter clutch includes a normally closed clutch; And during startup, the torque converter clutch is controlled to be in an open state.

4. The propulsion system according to claim 1, wherein, The axial flux rotary motor includes a multiphase brushless permanent magnet DC rotary motor.

5. The propulsion system according to claim 1, wherein, The first stator includes a disc-shaped device having a plurality of radially oriented columns, wherein each of the columns has a conductive winding.

6. The propulsion system according to claim 1, wherein, The torque converter clutch includes one of a claw clutch, a preload friction clutch, or an electromagnetic clutch.

7. The propulsion system according to claim 1, further comprising a second rotor arranged coaxially with the first rotor and the first stator; wherein, The first stator is inserted between the first rotor and the second rotor; and wherein the first rotor is connected to the second rotor via a shaft.

8. The propulsion system according to claim 7, wherein, The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate.

9. A propulsion system, comprising: A first axial flux rotary motor and a second axial flux rotary motor are arranged coaxially with the torque converter; The first axial flux rotary motor includes a first rotor arranged coaxially with the first stator; The second axial flux rotary motor includes a second rotor arranged coaxially with the second stator; The torque converter includes a fluid stator, a pump, a turbine, and a torque converter clutch; The first and second axial flux rotary motors are arranged coaxially with the torque converter; Wherein, the first rotor and the second rotor of the first axial flux rotary motor are connected to the pump of the torque converter; and The turbine of the torque converter is rotatably connected to the output component; The first rotor is inserted between the first stator and the second stator; The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first side of a disc-shaped back plate; The first rotor includes a second plurality of radially oriented permanent magnets fixed to a second side of the disc-shaped back plate; The first stator includes a disc-shaped device having a first plurality of conductive windings; Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the first plurality of conductive windings in an axial orientation and separated by a first air gap; and In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the first plurality of conductive windings in the axial orientation and separated by a second air gap.

10. The propulsion system of claim 9, further comprising a selectable one-way clutch connected between the fluid stator and the mechanical grounding element.

11. The propulsion system according to claim 9, wherein, The torque converter clutch includes a normally closed clutch; wherein the torque converter clutch is controlled to open during start-up operation.

12. The propulsion system according to claim 9, in, The second stator includes a second disc-shaped device having a second plurality of radially oriented conductive windings; and The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate.

13. A propulsion system, comprising: A first axial flux rotary motor, a second axial flux rotary motor, a first torque converter, and a second torque converter; The first axial flow rotary motor, the second axial flow rotary motor, the first torque converter, and the second torque converter are arranged coaxially. The first axial flux rotary motor includes a first rotor arranged coaxially with the first stator; The second axial flux rotary motor includes a second rotor arranged coaxially with the second stator; The first torque converter includes a first fluid stator, a first pump, a first turbine, and a first torque converter clutch; The second torque converter includes a second fluid stator, a second pump, a second turbine, and a second torque converter clutch; Wherein, the first rotor of the first axial flux rotary motor is connected to the first pump of the first torque converter; The second rotor of the second axial flux rotary motor is connected to the second pump of the second torque converter; Wherein, the first turbine of the first torque converter is rotatably connected to the first output component; and The second turbine of the second torque converter is rotatably connected to the second output component; and The second stator is arranged coaxially with the first rotor and the first stator; The first rotor is inserted between the first stator and the second stator; The first rotor includes a first plurality of radially oriented permanent magnets fixed to a first side of a disc-shaped back plate; The first rotor includes a second plurality of radially oriented permanent magnets fixed to a second side of the disc-shaped back plate; The first stator includes a disc-shaped device having a first plurality of conductive windings; Wherein, the first plurality of radially oriented permanent magnets are arranged adjacent to the first side of the first plurality of conductive windings in an axial orientation and separated by a first air gap; and In this configuration, the second plurality of radially oriented permanent magnets are arranged adjacent to the second side of the first plurality of conductive windings in the axial orientation and separated by a second air gap.

14. The propulsion system according to claim 13, wherein, The first torque converter clutch includes a normally closed clutch; and wherein the first torque converter clutch is controlled to open during start-up operation.

15. The propulsion system according to claim 13, wherein, The second torque converter clutch includes a normally closed clutch; and wherein the second torque converter clutch is controlled to open during start-up operation.

16. The propulsion system according to claim 13, in, The second stator includes a second disc-shaped device having a second plurality of radially oriented conductive windings; The second rotor includes a second plurality of radially oriented permanent magnets fixed to a second disc-shaped back plate.

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