Electromechanical device and transmission unit having the same and vehicle having the transmission unit

Abstract

The present disclosure relates to an electromechanical device (100) and a transmission unit for changing a motion parameter comprising the electromechanical device (100), and to a vehicle comprising the transmission unit, the electromechanical device (100) comprising a first rotating electromechanical machine (110) comprising a first stator (112) and a first rotor (120), a second rotating electromechanical machine (130) comprising a second stator (112) and a second rotor (120), and a second rotating electromechanical machine (130) having a smaller radial extension than the first rotating electromechanical machine (110) and comprising a second stator (132) and a second rotor (140), where the second rotating electromechanical machine (130) is arranged radially within the first rotating electromechanical machine (110) forming an interlaced region (176) of the electromechanical device (100), and where the first stator (112) and the second stator (132) are iron-free, and where the first stator (112) and the second stator (132) are non-ferrous. And wherein the first rotor (120) and the second rotor (140) are permanent magnet rotors or rotors comprising windings for electrical excitation.

Description

Technical Field

[0001] The present disclosure relates to an electromechanical device, a transmission unit including the electromechanical device, and a vehicle including the transmission unit. Specifically, the present disclosure relates to an electromechanical device, the electromechanical device including a first rotating electromechanical machine and a second rotating electromechanical machine coaxially arranged relative to each other, and wherein the second rotating electromechanical machine is radially arranged within the first rotating electromechanical machine, thereby forming an interleaved region of the electromechanical device. In addition, the present disclosure specifically relates to a transmission unit including an electromechanical machine having a first rotating electromechanical machine and a second rotating electromechanical machine, and a vehicle including the transmission unit. Background Art

[0002] Rotating electromechanical devices such as electric motors and generators are well known and used in many household, industrial and automotive applications and are available in many sizes and types depending on their intended use. An example of such an electromechanical device is a three-phase AC motor. In such an electric motor, an alternating current (AC) applied to the electrical windings of the stator generates a rotating electromagnetic field that induces torque in the rotor. The rotor has, for example, a set of permanent magnets that interact with the rotating electromagnetic field, rotor coils or rotor windings, rotor conductors through which an induced current passes to generate an electromagnetic field, or a soft magnetic material in which the non-permanent magnetic poles of the rotor are induced.

[0003] In the automotive industry, vehicles with internal combustion engines and conventional drive trains with discrete gear ratios constitute the majority of vehicle production. The internal combustion engine is mainly operated at a non-optimal operating point, because the rotational speed of the internal combustion engine is mechanically coupled to the speed of the wheels via the drive train. The starting of the internal combustion engine and the shifting between different gears require a clutch. Internal combustion engines are of vital importance because they use fossil fuels and therefore produce CO2. If the internal combustion engine could be operated at the best possible operating point, fuel consumption and CO2 output could be significantly reduced. One possible solution, namely a mechanical continuous gear, has not been used more widely in the automotive industry due to friction and wear problems.

[0004] Vehicles with fully electric drivetrains are being introduced to the market on a wide scale by various manufacturers. Their market penetration is limited by range, battery production and the availability of charging stations.

[0005] A hybrid vehicle comprises an internal combustion engine and an electric engine. The internal combustion engine is coupled to the wheels, for example, via a mechanical transmission unit. Mechanical gears with discrete transmission ratios can connect the internal combustion engine and the electric engine or the electric engine to the mechanical transmission unit. Other variants of hybrid vehicles are also conceivable.

[0006] An electric three-phase motor or generator typically has a stator having a stator iron and stator windings arranged inside the slots of the stator iron. The stator windings include conductors in many forms, such as, for example, litzwire, which is wound in the slots of the stator iron inside the stator, or individual hairpin wire segments, which are inserted into the slots of the stator iron and then electrically joined together, for example by using laser welding.

[0007] In conventional electromechanical devices, the stator iron comprises a stack of metal laminations or a stack of metal sheets. Electrical insulation between the sheets reduces eddy currents. The bundle of laminations or the stack of sheets conventionally comprises slots in which the stator windings are arranged.

[0008] Conventional electromechanical devices comprising a plurality of electric motors or generators may have a series or parallel connection between the various electric motors or generators. For example, one generator is powered by an internal combustion engine for generating electric current. This current is transmitted to the electric motors for driving the different shafts of the machine. The generator and the electric generator are in this case two different electromechanical machines, which are placed at different locations within the machine. The generator and the electric generator therefore require a lot of installation space within the machine.

[0009] Until now, it has not been possible to develop powerful electromechanical machines having small dimensions and high power output, in particular electromechanical machines combining the functionality of an electromechanical engine and an electromechanical generator.

[0010] The international patent application with international application number PCT / EP2021 / 057125 from the same applicant and titled “rotating electromechanical apparatus and method of manufacture of stator winding” is hereby incorporated by reference in its entirety. The international patent application with international application number PCT / EP2022 / 057160 from the same applicant and titled “ring cylindrical casing and method for producing a ring cylindrical casing of a rotating electromechanical apparatus” is hereby incorporated by reference in its entirety. Summary of the invention

[0011] The object of the present disclosure is to provide an electromechanical device, a transmission unit comprising the electromechanical device, and a vehicle comprising the transmission unit. In particular, the object of the present disclosure is to provide an electromechanical device, a transmission unit comprising the electromechanical device, and a vehicle comprising the transmission unit, which do not have at least some of the disadvantages of the prior art.

[0012] According to the present disclosure, these objects are achieved by the features of the independent claims.In addition, further advantageous embodiments can be derived from the dependent claims, claim combinations as well as the description and the drawings.

[0013] According to the present disclosure, a mechatronic device for changing a motion parameter is specified. The mechatronic device typically includes a first rotating mechatronic machine, the first rotating mechatronic machine including a first stator and a first rotor, the first rotor being arranged to be rotatable relative to a common rotation axis. The mechatronic device also includes a second rotating mechatronic machine, the second rotating mechatronic machine having a smaller radial extension than the first rotating mechatronic machine and including a second stator and a second rotor, the second rotor being arranged to be rotatable relative to the common rotation axis. In an embodiment, the first rotating mechatronic device is an electric motor or a generator and / or the second rotating mechatronic device is an electric motor or a generator. In a further embodiment, the mechatronic device includes a combination of an electric motor and a generator, wherein the first rotating mechatronic machine is an electric motor and the second rotating mechatronic machine is a generator, or vice versa.

[0014] According to the present disclosure, the rotating electromechanical machines are arranged so that their rotation axes are coaxially arranged, and the two rotors rotate around the common rotation axis. According to the present disclosure, the second rotating electromechanical machine is radially arranged inside the first rotating electromechanical machine, preferably completely inside the first rotating electromechanical machine, thereby forming an interleaved region of the electromechanical device. In other words, the first rotating electromechanical machine surrounds the second rotating electromechanical machine. The interleaved region is an axially extended portion of the electromechanical device, which includes the first rotating electromechanical machine and the second rotating electromechanical machine. Radially arranged therein means, for example, that the magnets of the rotor of the second rotating electromechanical machine and the windings or coils of the stator are surrounded by the first rotating electromechanical machine. Other components of the second rotating electromechanical machine, such as the input / output shaft, may be arranged outside or may extend outside.

[0015] According to the present disclosure, the first stator and the second stator are ironless. The ironless rotating electromechanical machine does not have a material with high magnetic permeability inside or extending into the area of ​​its coils / windings. The ironless rotating electromechanical machine preferably also includes a stator iron for guiding the magnetic flux. The stator iron typically has an annular cylindrical form, radially located inside or outside the windings or coils, opposite to the rotor. In other words, an ironless stator does not mean that the entire stator is iron-free; it only means that the portion including the coils or windings of the stator is iron-free. The ironless electromechanical machine is radially very compact, has a small radial dimension, and can provide high torque and high power output.

[0016] For example, an ironless rotating electromechanical machine has no material with high magnetic permeability within or extending into the region of its coils and / or windings, in particular within or extending into the region of the stator of the electromechanical machine including the coils and / or windings. In other words, iron-free means that the part including the coils and / or windings of the stator does not contain iron and / or ferromagnetic material, and / or does not contain material with a magnetic permeability of, for example, 4 or more, preferably 40 or more, more preferably 300 or more.

[0017] The portion of the first stator of the electromechanical machine including coils and / or windings has no material with high magnetic permeability and / or is iron-free inside, and the portion of the second stator of the electromechanical machine including coils and / or windings has no material with high magnetic permeability and / or is iron-free inside.

[0018] In an embodiment, the material of the first stator and / or the second stator within or extending into the region of its respective coil has a magnetic permeability μ less than 300, preferably less than 40, even more preferably less than 4. r The material within or extending into the area of ​​the coils of the ironless stator is, for example, a plastic material, a composite material, a resin material and / or a metal material having the magnetic permeability properties described above, which at least partially provides support for the coils and / or windings of the corresponding stator.

[0019] According to the present disclosure, the first rotor is a permanent magnet rotor or a rotor including a winding for electrical excitation, and the second rotor is a permanent magnet rotor or a rotor including a winding for electrical excitation. It is also important that the rotor has a small radial dimension so as not to hinder the advantages of a compact stator. The permanent magnet rotor enables the design of a rotor with a small radial dimension. In addition, the rotor having a rotor coil or winding for electrical excitation can be designed to have a small radial dimension. The radial dimension of the rotor is preferably in the same range as the radial dimension of the stator, more preferably smaller than the radial dimension of the stator, and even more preferably less than half of the radial dimension of the stator.

[0020] The ironless stator together with the radially compact rotor enables the design of an electromechanical machine with small radial dimensions, forming a "ring motor". The ring motors can be stacked on top of each other. Such a motor cascade, comprising for example a first rotating electromechanical machine and a second rotating electromechanical machine, has the same maximum outer dimensions as the outer dimensions of the first rotating electromechanical machine surrounding the second rotating electromechanical machine.

[0021] The extension of the effective gap between the corresponding stator and rotor determines the torque and power output of the corresponding rotating electromechanical machine. For example, at a relatively large diameter, more magnets can be placed in the circumference of the rotor, which increases the torque or power output of the rotating electromechanical machine. By using a first rotating electromechanical machine that is relatively small in the radial direction, a second electromechanical machine arranged inside the first rotating electromechanical machine can have an effective diameter that is still relatively large, thereby also allowing the second electromechanical machine to have high torque and power.

[0022] When two rotating electromechanical machines are arranged coaxially and staggered relative to each other as disclosed herein, this is very advantageous for the electromechanical device. The overall installation space of the disclosed electromechanical device is significantly smaller compared to conventional designs, in which two electromechanical machines are arranged, for example, next to each other. For applications in which installation space is very important, such as, for example, in automotive applications, the disclosed electromechanical device reduces the required installation space compared to conventional designs.

[0023] In particular, an electromechanical device as disclosed herein can be built in a compact form comparable or even smaller than a conventional mechanical gear unit of a vehicle such as a car or truck. This enables replacing a mechanical gear unit with an electromechanical device as disclosed herein.

[0024] A further advantage of the present disclosure is to provide a transmission unit for a vehicle which enables complete mechanical decoupling of the internal combustion engine from the drive train, which enables operation of the internal combustion engine at an optimized operating point during operation. Furthermore, a transmission unit for upgrading a conventional vehicle to a hybrid vehicle can be provided. In the case of being equipped with a transmission unit, it is possible to reduce fuel consumption, to enable partial operation as an all-electric drive vehicle, and / or to increase combustion power by additional battery power, without disadvantages in terms of space requirements.

[0025] According to an embodiment, the first rotating electromechanical machine and the second rotating electromechanical machine are both designed as inner rotor electromechanical machines, and wherein an input shaft configured to be coupled to one of the first rotor or the second rotor is coaxially arranged relative to an output shaft configured to be coupled to the other of the first rotor or the second rotor. The inner rotor electromechanical machine has a rotor arranged radially within a stator. This embodiment provides the advantage that the input shaft and the output shaft enter and / or leave the electromechanical device along a common rotation axis and coaxially with the common rotation axis in a rotation center. The input shaft and the output shaft are also coaxially arranged relative to each other. According to this embodiment, both rotors are surrounded by the outermost stators, both of which are arranged on the respective rotating electromechanical machines.

[0026] According to another embodiment, the first rotating electromechanical machine is designed as an inner rotor electromechanical machine and the second rotating electromechanical machine is designed as an outer rotor electromechanical machine, and wherein an input shaft configured to be coupled to one of the first rotor or the second rotor is arranged eccentrically relative to an output shaft configured to be coupled to the other of the first rotor or the second rotor. The inner rotor electromechanical machine has a rotor radially arranged inside the stator. The outer rotor electromechanical machine has a rotor radially arranged outside the stator. According to this embodiment, both rotors are surrounded by stators arranged at the innermost and outermost sides. For example, the permanent magnets of the second rotating electromechanical machine can be placed radially inside the rotor housing, which simplifies the arrangement of the magnets on the rotor housing because the centrifugal forces acting on the magnets are directly absorbed by the rotor housing. In this embodiment, the stator of the second electromechanical machine is placed inside the two rotors.

[0027] The topological advantage is that the second stator must enter the machine in the center along the axis of rotation so that the second rotor can be supported advantageously, preferably on both axial ends. The second stator must withstand the torque of the electromagnetic force and should be fed with a cooling fluid and, in some embodiments, additionally with a conductor for the current. Therefore, the second rotor of the second electromechanical machine cannot leave the device in the center because the center is filled by the second stator. In an embodiment, the second rotor may have the shape of a hollow shaft, which includes a gear arrangement and is configured to engage with an eccentrically arranged output shaft via the gear arrangement. In this embodiment, the output shaft may also include a gear arrangement. A gear stage, such as a spur gear stage or a bevel gear stage, is formed between the hollow shaft of the rotor and the output shaft. The gear stage has a gear ratio of, for example, 4:1.

[0028] In an embodiment, the input shaft is arranged on one axial end of the electromechanical device, and the output shaft is arranged on the other opposite axial end of the electromechanical device. For example, the input shaft is connected to the first rotor, and the output shaft is connected to the second rotor. This arrangement of the input shaft combined with the output shaft enables the bearings of the electromechanical device to be positioned relatively close to the axis of rotation, which reduces the wear of the bearings. The input shaft and / or the output shaft are, for example, integrally formed with the corresponding rotor, form-fitted, press-fitted, threaded, etc. or arranged on the corresponding rotor in a different manner.

[0029] According to an embodiment, the electromechanical device comprises a gear stage arranged between at least one of the following: the input shaft and the first rotor, the input shaft and the second rotor, the first rotor and the output shaft, and the second rotor and the output shaft. The gear stage creates the possibility of changing the rotation parameters between the input shaft and the first rotor and between the second rotor and the output stage directly within the electromechanical device, which is particularly advantageous in terms of installation space requirements. The gear stage also enables the rotation parameters to be changed for an ideal operation of the corresponding rotating electromechanical machine, in particular for operating a combustion engine providing the input power in an advantageous speed range. The gear stage is, for example, a spur gear stage or a bevel gear stage.

[0030] According to an embodiment, the first stator and the second stator each comprise a helical stack of laminations of a helically wound strip of a magnetically permeable material having a plurality of turns, wherein the strip comprises two main surfaces and two side surfaces, wherein at least one of the two main surfaces comprises an insulating coating. In a further embodiment, the first rotor and the second rotor each comprise a helical stack of laminations of a helically wound strip of a magnetically permeable material having a plurality of turns, wherein the strip comprises two main surfaces and two side surfaces, wherein at least one of the two main surfaces comprises an insulating coating. Before being formed into a helical shape, the strip has the shape of an extended cuboid, having two main surfaces, two side surfaces (typically smaller than the main surfaces) and two end surfaces, the ends. According to this embodiment, at least one of the two main surfaces of the extended cuboid comprises an insulating coating. In other words, it is possible that one of the two main surfaces comprises an insulating coating, such as the upper main surface or the lower main surface, or that both main surfaces may comprise an insulating coating. Typical for an ironless stator, the stator iron has a simple annular cylindrical form. This enables the use of a very cost-effective spiral lamination stack as described above, rather than a conventional lamination stack having a complex form including slots for the windings which have to be produced, for example, by pressing techniques or laser cutting.

[0031] In the spiral shape, the main surface of the first turn or winding of the spirally wound strip faces the main surface of the directly adjacent or next turn or winding of the spiral strip. One of the side surfaces faces radially inwards, i.e. towards the common rotation axis, and the other side surface faces radially outwards, i.e. away from the common rotation axis. In this way, each winding or turn of the spirally wound strip (if any) is in contact with the adjacent winding or turn only via the corresponding coated main surface. Therefore, the insulating coating has the effect of avoiding the induction current from one winding directly to the next winding, which reduces the eddy currents generated by the stator windings of the electromechanical device during its operation as required. Compared with the conventional lamination stack of annular cylindrical sheets, there is still an induction current flowing from one winding to the next winding, but the induction current does not flow directly in the axial direction to the next winding (for example 0.3mm), but must flow along the entire circumference and therefore has no significant impact on the performance of the rotating electromechanical machine. The spirally wound strip of magnetically permeable material follows the shape of the spiral to form a spiral lamination stack with a plurality of turns. Preferably, the spirally wound strip is made of an iron alloy.

[0032] The advantage of having an ironless stator is that the rotating electromechanical machine has a higher electrical efficiency and requires less space in radial dimensions, and in particular, the rotating electromechanical machine can be manufactured into an annular cylindrical shape with a reduced radial dimension. The increased electrical efficiency is caused by the smaller losses in the narrow stator iron. The small size of the annular cylindrical ironless stator also produces the beneficial effect of reducing the weight of the corresponding rotating electromechanical machine. In addition, the rotating electromechanical machine with an ironless stator does not have a significant cogging effect. However, to date, ironless stators are typically mainly used in electric motors of small size and power or requiring high positioning accuracy. Similar considerations also apply to the first rotor and the second rotor including the spiral lamination stack according to this embodiment. The first rotating electromechanical machine and the second rotating electromechanical machine according to this embodiment provide the desired electromagnetic characteristics for the use of ironless stators and corresponding rotors and high-power industrial or automotive applications.

[0033] According to an embodiment, the first stator and the second stator each include a continuous hairpin winding having at least two winding layers, or each include a continuous wavy winding having at least two winding layers. In another embodiment, the first rotor includes a permanent magnet or a continuous hairpin winding having at least two winding layers, or includes a continuous wavy winding having at least two winding layers. In another embodiment, the second rotor includes a permanent magnet or a continuous hairpin winding having at least two winding layers, or includes a continuous wavy winding having at least two winding layers. The coils for electrical excitation in the first stator and the second stator according to this embodiment may be continuous hairpin windings. The coils for electrical excitation in the first rotor and the second rotor according to this embodiment may be continuous hairpin windings.

[0034] The continuous hairpin winding comprises a wire which is hairpin-shaped and provides a straight segment extending parallel to a common axis of rotation. Next to the first straight segment, at one or both ends of the straight segment, the wire is folded and bent so that the subsequent second straight segment extends antiparallel at a certain distance (preferably a half-pole distance) to the first straight segment. The hairpin winding is continuous because each hairpin wire segment defined by one or two or more straight segments is continuous with the next hairpin wire segment. In particular, there is no need for an electrical connection between the hairpin wire segments by welding, soldering or similar techniques. However, the wires of the continuous hairpin winding (i.e., the input leads and / or the output leads) may eventually be connected at their ends by some welding or similar techniques, for example, for star-grounding or delta-connecting different phases of the continuous hairpin winding. When viewed in the radial direction, the continuous hairpin winding may have two layers of hairpin wires, one on top of the other. When looking around a continuous stator winding, a given wire changes position, for example from a first layer to a second layer or from a second layer to a first layer, so that a first straight segment is arranged in the first layer, and is then folded and bent so that a second or subsequent or next straight segment is arranged in the second layer.

[0035] Due to the superior layout of the wire segments, continuous hairpin windings are up to 30% more efficient in terms of torque and power compared to wave windings. In the hairpin design, the wire segments are parallel, for example in the region of the permanent magnets, conducting current parallel to the magnetic poles, while in the wave design the conductors only partially overlap the magnetic field, which can reduce the driving force exerted on the wave winding by the permanent magnetic field during motor operation, or can reduce the effective magnetic field by inducing counter currents in the wave winding during generator operation.

[0036] According to this embodiment, a continuous hairpin winding or a continuous wave winding is used as a coil of the corresponding rotating electromechanical machine and requires a relatively small radial installation space, which helps to arrange the first rotating electromechanical machine and the second rotating electromechanical machine coaxially and staggered relative to each other without requiring a large radial size of the resulting electromechanical device.

[0037] According to an embodiment, the first rotating electromechanical machine has a first machine thickness from its maximum radially outer extension at the staggered area to its minimum radially inner extension at the staggered area, which first machine thickness is in the range from 30 mm to 15 mm, preferably from 25 mm to 20 mm, more preferably 22 mm.

[0038] According to an embodiment, the second rotating electromechanical machine has a second machine thickness from its maximum radially outer extension at the staggered region to its minimum radially inner extension at the staggered region, which second machine thickness is in the range from 30 mm to 15 mm, preferably from 25 mm to 20 mm, and more preferably is 22 mm.

[0039] The machine thickness is the radial distance between the outer housing or casing of the outer rotor or stator of one of the rotating electromechanical machines and the inner housing or casing of the inner rotor or stator at the interleaved region of the electromechanical device. For example, a first rotating electromechanical machine comprises a stator casing including a cooling device, a spiral lamination stack, a continuous hairpin winding as a coil, a magnet and a rotor casing, wherein the stator casing, the spiral lamination stack and the coil form a stator, and the magnet or rotor coil and the rotor casing form a rotor. According to this embodiment, the radial distance between the radially outermost stator casing and the innermost rotor casing is the machine thickness. The components as described above enable the first rotating electromechanical machine and the second rotating electromechanical machine to be advantageously constructed with a small machine thickness as defined above without compromising power output.

[0040] According to an embodiment, the first rotating electromechanical machine has a maximum radial outer diameter at the staggered region in the range from 100 mm to 1000 mm, preferably from 150 mm to 350 mm, more preferably 300 mm. The maximum radial outer diameter of the first rotating electromechanical machine is the distance across the electromechanical device at the staggered region, and is therefore the overall required installation diameter of the electromechanical device.

[0041] According to an embodiment, the annular axially extending gap at the staggered area between the first rotating electromechanical machine and the second electromechanical machine has a thickness of less than 10 mm, preferably less than 5 mm. The annular axially extending gap defines the distance between the first rotating electromechanical machine and the second rotating electromechanical machine. Having a relatively small gap at the staggered area reduces the required radial installation space of the entire electromechanical device. In particular, only a relatively small gap of, for example, 5 mm can be achieved, because tolerances and support via bearings enable the different rotating components to rotate accurately during operation of the electromechanical device. In addition, it is required that the gap provides an air flow for cooling between the first rotating machine and the second rotating machine.

[0042] In an embodiment, the electromechanical device comprises at least one first bearing at a first axial end thereof and at least one second bearing at a second opposite axial end thereof, wherein the first bearing and the second bearing are arranged between two components selected from the group consisting of: a first stator, a second stator, a first rotor and a second rotor. According to this embodiment, the first stator, the second stator, the first rotor and the second rotor are coupled at both axial ends by bearings mounted concentrically relative to a common axis of rotation, which increases stability, reduces vibrations and helps to balance the different components of the electromechanical device, thereby enabling high torque and power output, especially at high rotation speeds of the electromechanical device.

[0043] According to an embodiment, the support of the first rotor comprises a first bearing arranged between a first stator and a first rotor at one axial end of the electromechanical device, and a second bearing arranged between a second rotor and the first rotor at another axial end of the electromechanical device. According to this embodiment, the first rotor is advantageously supported on both axial ends, which advantageously increases the stability and accuracy of the rotation, especially for high rotation speeds. This embodiment enables the first rotor to rotate relative to the first stator and the second stator about a common rotation axis. According to this embodiment, the first rotor is supported on the first stator and on the second rotor of the second rotating electromechanical machine by the first bearing and the second bearing. This makes it possible to support the first rotor on both axial ends of the first rotor, which increases the rotational stability and reliability during operation of the first rotating electromechanical machine.

[0044] According to an embodiment, the support of the second rotor includes a first bearing arranged between the first stator and the second rotor on one axial end of the electromechanical device, and a second bearing arranged between the second rotor and the first rotor on the other axial end of the electromechanical device. The support of the second rotor also includes a second bearing arranged between the second rotor of the second rotating electromechanical machine and the first rotor of the first rotating electromechanical machine. The second rotor is supported on the second stator of the second rotating electromechanical machine and on the first rotor of the first rotating electromechanical machine by the first bearing and the second bearing. According to this embodiment, the second rotor is supported on both axial ends, which increases the rotational stability and reliability during operation of the second rotating electromechanical machine.

[0045] According to an embodiment, the radially innermost component of the second rotating electromechanical machine is at least at the staggered area designed as a hollow shaft, thereby forming a cavity radially inside the second rotating electromechanical machine. The cavity is a result of the radially compact first and second electromechanical machines. Even without further calculations, it turns out that the electromechanical device has a low weight, because a considerable volume is empty and not filled with heavy metal. Low weight is a further advantage of the disclosed device. For many applications, in particular in the automotive industry, low weight is an important advantage.

[0046] In an embodiment, the first rotating electromechanical machine and the second rotating electromechanical machine are both configured to operate as electric engines in engine mode. In this embodiment, the output shaft of the first rotating electromechanical machine and the output shaft of the second rotating electromechanical machine can be driven completely independently. The application of such a device is, for example, in high-end automotive technology with a separate power source for each wheel of the power axle. In an embodiment, the first rotating electromechanical machine and the second rotating electromechanical machine are controlled so that the resulting rotation speed and the resulting power of the corresponding power wheel driven by the corresponding output shaft are selected depending on the current path and the current position of the wheel on the path to achieve optimal cornering stability / track alignment. In an embodiment, the electrical energy required to drive the first rotating electromechanical machine and the second rotating electromechanical machine is supplied, for example, by a battery and / or by an internal combustion engine mechanically connected to a generator. According to this embodiment, it is possible to improve cornering stability by applying, for example, a higher torque to the outer wheel via the first rotating electromechanical machine or the second rotating electromechanical machine. Compared with the prior art solution with two separate engines that requires about twice as much installation space, the disclosed device has significant advantages.

[0047] In an embodiment, the first stator comprises a first stator housing, a first stack of laminations, preferably comprising a first helically wound strip, and a first coil, preferably comprising a first continuous hairpin winding, and wherein the second stator comprises a second stator housing, a second stack of laminations, preferably comprising a second helically wound strip, and a second coil, preferably comprising a second continuous hairpin winding. According to this embodiment, the first stator housing has a different radial extension (radius) compared to the second stator housing, so that other components of the electromechanical device can be arranged between the first stator and the second stator. In a further embodiment, at least one of the rotors, preferably both rotors, of the electromechanical device are arranged between the first stator and the second stator.

[0048] According to another aspect of the present disclosure, a transmission unit for changing a motion parameter is specified. The motion parameter is, for example: rotational speed, acceleration and / or deceleration of rotation, torque, or any combination of such parameters. The transmission unit includes an electromechanical device and an electrical component as described above and below, the electrical component being configured to receive a current generated during operation of the first rotating electromechanical machine or the second rotating electromechanical machine, and being configured to transmit the current to the other of the first rotating electromechanical machine or the second rotating electromechanical machine to drive an output shaft. In other words, the electrical component of the transmission unit is configured to transfer the received electrical energy from the first rotating electromechanical machine or the second rotating electromechanical machine operating in generator mode to the other of the first rotating electromechanical machine or the second rotating electromechanical machine operating in engine mode.

[0049] The transmission unit further comprises a transmission unit battery connected to the electrical components and configured to store the electric power received from the electromechanical device and configured to provide the electric power to the electromechanical device, in particular to the rotating electromechanical device configured to drive the output shaft. The transmission unit battery may also be configured to at least one of: buffer the difference in power requirements of the two rotating electromechanical machines, supply power to the output shaft, start the combustion engine, enable a pure electric driving mode of a vehicle including the transmission unit, recover power in a break mode, charge by a fixed external power station, and any combination of these features.

[0050] According to an embodiment, the electrical component includes a converter configured to convert a received current having a first electrical characteristic (particularly a first AC frequency) into a desired current having a second electrical characteristic (particularly a second AC frequency) for a rotating electromechanical machine configured to drive an output shaft. According to this embodiment, the electrical component not only transmits the received current to the corresponding rotating electromechanical machine, but also modifies the electrical characteristics of the received current into the desired current for the corresponding rotating electromechanical machine configured to operate in a generator mode.

[0051] The first rotating electromechanical machine and the second rotating electromechanical machine can be operated completely independently in terms of rotational speed. They are not connected by a mechanical transmission with fixed or discrete ratio steps, such as in a gear connection. Although the two machines are arranged inside each other, they can be operated completely independently of each other at their optimized operating points. Therefore, the transmission unit operates as a continuous "gearbox", which is not limited by mechanical requirements, but only by electrical power and frequency conversion. In automotive applications, the internal combustion engine that can drive the input shaft of the electromechanical device can be operated at its optimal operating point for achieving low fuel consumption and CO2 emissions independent of the speed of the wheels. As long as power from the transmission unit battery and / or from the vehicle battery is available, the internal combustion engine can be turned off.

[0052] According to an embodiment, the electrical component comprises a control unit for controlling the characteristics of the current transmitted to the first rotating electromechanical machine or the second rotating electromechanical machine so that a desired transmission ratio, in particular a variable or continuously variable transmission ratio, between the input shaft of the first rotating electromechanical machine and the output shaft of the second rotating electromechanical machine is achieved. The transmission ratio is, for example, the ratio of the rotational speed of the output shaft to the rotational speed of the input shaft. According to this embodiment, the electrical component is configured to modify the characteristics of the current, which is transmitted to the rotating electromechanical machine operating in the motor mode, for example by changing the frequency of the current. The desired transmission ratio is determined, for example, by an input parameter received in the control unit, which is converted by the control unit into a control command for the electrical component.

[0053] According to a further aspect of the disclosure, a vehicle is specified, such as a passenger car or a truck or a motorcycle or a powered aircraft, in particular a vehicle comprising an internal combustion engine or a hybrid vehicle or an electric vehicle, comprising a transmission unit as described above or hereinafter.

[0054] According to an embodiment, a vehicle comprises an internal combustion engine, a transmission system, the internal combustion engine being configured to propel an input shaft of an electromechanical device, the transmission system being mechanically connected to an output shaft of the electromechanical device and being configured to propel the vehicle. The vehicle may also comprise a vehicle battery, the vehicle battery being electrically connected to the electrical components and being configured to store the electric power received from the electromechanical device and being configured to provide the electric power to the vehicle, in particular to the electromechanical device. In an embodiment, the vehicle battery is the same battery as the transmission unit battery. In another embodiment, the vehicle battery is an additional battery. The battery is electrically connected to the electromechanical device and is configured to at least temporarily receive a portion of the current generated by a rotating electromechanical machine operating in generator mode and / or to provide electric energy to a rotating electromechanical machine operating in engine mode. According to this embodiment, the vehicle battery is configured to work as an electric buffer for the vehicle. In addition, the vehicle battery may additionally provide electric energy to a rotating electromechanical machine operating in engine mode.

[0055] In additional or alternative embodiments, a vehicle battery may be used as a storage medium for electrical energy, which may be charged from an external power source such as an electricity grid and / or photovoltaic cells.

[0056] According to an additional aspect of the present disclosure, a conversion kit is specified, which includes an electromechanical device as described above and in the following text or includes a transmission unit as described above and in the following text. The conversion kit is used to convert a conventional internal combustion engine vehicle into a hybrid vehicle. The electromechanical device replaces, for example, a conventional gearbox of a conventional transmission system. For example, the input shaft of the electromechanical device is connected to the internal combustion engine, and the rest of the vehicle's transmission system (without the gearbox) is connected to the output shaft of the electromechanical device. The internal combustion engine can operate at its optimal operating point, and the required transmission is performed by the newly installed transmission unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] By way of example, the present disclosure will be explained in more detail with reference to the accompanying drawings, in which:

[0058] Figure 1 A longitudinal cross-sectional view schematically shows an electromechanical device according to a first embodiment of the present disclosure,

[0059] Figure 2 schematically shows a cross-sectional view of an electromechanical device in a radial plane according to a first embodiment of the present disclosure,

[0060] Figure 3 A longitudinal cross-sectional view schematically shows an electromechanical device according to a second embodiment of the present disclosure,

[0061] Figure 4 shows a side view of an electromechanical device according to a second embodiment of the present disclosure,

[0062] Figure 5 Schematically showing a spiral lamination stack according to a first exemplary embodiment in a perspective view,

[0063] Figure 6 schematically illustrates an electromechanical device according to an embodiment of the present disclosure in a perspective view with cutaway sections showing the interior of the device,

[0064] Figure 7 schematically shows a cylindrical continuous hairpin winding according to a first exemplary embodiment in a perspective view,

[0065] Figure 8 schematically illustrates a transmission unit comprising an electromechanical device according to an exemplary embodiment,

[0066] Fig. 9 A vehicle including a transmission unit according to an exemplary embodiment is schematically shown. DETAILED DESCRIPTION

[0067] Figure 1 and Figure 2 A mechatronic device 100 according to a first exemplary embodiment is schematically shown. Figure 1 shows a longitudinal cross-sectional view, and Figure 2 1 shows a radial cross-sectional view of an electromechanical device 100. The electromechanical device 100 includes a first rotating electromechanical machine 110 and a second rotating electromechanical machine 130. The first rotating electromechanical machine 110 includes a first stator 112 and a first rotor 130. The first stator 112 includes a first stator housing 113, a first lamination stack 114 preferably including a first helically wound strip 115, and a first coil 116 preferably including a first continuous hairpin winding 117. The first rotor 120 includes a first rotor housing 121 and a first magnet 118. The second rotating electromechanical machine 130 includes a second stator 132 and a second rotor 140. The second stator 132 includes a second stator housing 133, a second lamination stack 134 preferably including a second helically wound strip 135, and a second coil 136 preferably including a second continuous hairpin winding 137. The second rotor 140 includes a second rotor housing 141 and a second magnet 138.

[0068] According to another embodiment (not shown in the figure), the first rotor includes a winding for electrical excitation instead of the first magnet 118, and the winding for electrical excitation is preferably a continuous hairpin winding. It is also preferred that the second rotor includes a winding for electrical excitation instead of the second magnet 138, and the winding for electrical excitation is preferably a continuous hairpin winding. In this embodiment, the first rotor and the second rotor may also each include a corresponding lamination stack, which includes a spirally wound strip.

[0069] like Figure 1 , Figure 2 and Figure 3 The first rotating electromechanical machine 110, and in particular the first rotor 120, best shown in the figures, is configured to rotate about a common rotation axis 122 during operation. The second rotating electromechanical machine 130, and in particular the second rotor 140, is configured to rotate about a common rotation axis 122 during operation. In addition, these figures show that the first rotating electromechanical machine 110 and the second rotating electromechanical machine 130 are arranged staggered relative to each other, thereby forming a staggered area 176. The staggered area 176 is an axial extension of the electromechanical device 100 in which the first rotating electromechanical machine 110 and the second rotating electromechanical machine 130 overlap. Arranging the two rotating electromechanical machines 110, 130 coaxially and in a staggered manner advantageously reduces the required installation space. These figures also show that the second rotating electromechanical machine 130 is arranged completely within the first rotating electromechanical machine 110.

[0070] The stators 112, 132 of the respective rotating electromechanical machines 110, 130 are configured to guide a magnetic field within the respective rotating electromechanical machines 110, 130. The stator housings 113, 133 are configured to serve as a housing for the stators 112, 132 and to hold other components of the stators 112, 132 in place during operation of the electromechanical device 100. The stator housings 113, 133 may additionally include cooling devices (not shown in the figures) for cooling the respective electromechanical machines 110, 130. The lamination stacks 114, 134 include helically wound bars 115, 135 configured to reduce eddy currents and increase the efficiency of the rotating electromechanical machines 110, 130. The coils 116, 136 are configured to guide current through the respective stators 112, 132. In the embodiment presented in the figures, the coils 116, 136 preferably include continuous hairpin windings 117, 137.

[0071] like Figure 6 and Figure 7As best shown in , the continuous hairpin winding 117, 137 has at least two layers 1171, 1172, which at least two layers 1171, 1172 include wires, which are hairpin-shaped and provide straight segments extending parallel to the common rotation axis 122. Next to the first straight segment, at one or both ends of the straight segment, the wire is folded and bent so that the subsequent second straight segment extends antiparallel at a certain distance to the first straight segment. The hairpin winding 117, 137 is continuous because each hairpin wire segment defined by one or two or several straight segments is continuous with the next hairpin wire segment, i.e., in one piece. In particular, no electrical connection between the hairpin wire segments by welding, soldering or similar techniques is required. However, the wires of the continuous hairpin windings 117 , 137 may eventually be joined at their ends by some welding or similar technique, for example for star-grounding or delta-connecting the different phases of the continuous hairpin windings.

[0072] When viewed in the radial direction, the continuous hairpin windings 117, 137 have two layers 1171, 1172 of hairpin wires one above the other. When viewed around the continuous hairpin windings 117, 137, a given wire changes position, for example, from the first layer 1171 to the second layer 1172 or from the second layer 1172 to the first layer 1171, so that the first straight segment is arranged in the first layer 1171, and is then folded and bent so that the second or subsequent or next straight segment is arranged in the second layer 1172. According to this embodiment, the continuous hairpin windings 117, 137 or continuous wave windings are used as coils 116, 136 of the corresponding rotating electromechanical machines 110, 130, which require a relatively small radial installation space, which helps to arrange the first rotating electromechanical machine 110 and the second rotating electromechanical machine 130 coaxially and in a staggered manner relative to each other without requiring a huge radial dimension.

[0073] The first rotating electromechanical machine 110 is configured to operate as an electric motor or a generator, depending on the desired application of the electromechanical device 100 . The second rotating electromechanical machine 130 is also configured to operate as an electric motor or a generator, depending on the desired application of the electromechanical device 100 .

[0074] Figure 1 and Figure 2A first variant of the electromechanical device 100 is shown. In this variant, the first rotating electromechanical machine 110 and the second rotating electromechanical machine 130 are designed as inner rotor electromechanical machines. In other words, the respective rotor 120, 140 is arranged radially within the respective stator 112, 132. According to this embodiment, the input shaft 160 of the electromechanical device 100 is formed integrally with the second rotor housing 141. Different couplings between the input shaft 160 and the second rotor housing 141 are also conceivable. According to this embodiment, the output shaft 170 of the electromechanical device 100 is formed integrally with the first rotor housing 121. Different couplings between the output shaft 170 and the first rotor housing 121 are also conceivable. The first output shaft 160 and the second output shaft 170 are arranged coaxially relative to each other and relative to the common rotation axis 122.

[0075] Figure 1 Also shown is a support concept 150 of different bearings of a first embodiment of the electromechanical device 100. As can be seen, all bearings are arranged relatively close to the common axis of rotation 122, which advantageously reduces the rolling speed of the bearings and thus increases the life of the bearings. The bearings include a first bearing 151 arranged on one axial end of the electromechanical device 100 and a second bearing 152 arranged on the other opposite axial end of the electromechanical device 100. Having bearings 151, 152 on both axial ends increases the stability and accuracy of rotation, which enables relatively high rotation speeds of the rotors 120, 140. According to this embodiment, all components of the electromechanical device 100 are rotatably connected via bearings concentric with the common axis of rotation 122, which increases stability, reduces vibrations and imbalances, and enables high torque and power output, especially at high rotation speeds.

[0076] Figure 1 A first bearing 151 is shown as a support 150 for the first rotor 120, which is arranged between the first rotor housing 121 and the first stator housing 113. In other words, the support 150 is a bearing concept. In this embodiment, the first stator housing 113 is coupled to the second stator housing 133, and the first bearing 151 of the first rotor 120 is arranged at the coupling portion. Figure 1 Also shown is a second bearing 152 which is arranged on the opposite axial end between the first stator housing 113 and the first rotor housing 121 , in particular the output shaft 170 which is coupled to the first rotor housing 121 according to this embodiment.

[0077] Figure 1Also shown is a first bearing 151 as a support 150 for the second rotor 140, which is arranged between the second rotor housing 141 and the first stator housing 121, in particular between the coupling portion of the first stator housing 121 and the second stator housing 133. A second bearing 152 is arranged at the opposite axial end of the electromechanical device 100, between the second rotor housing 141 and the first rotor housing 121, in particular the output shaft 170, which is coupled to the first rotor housing 121 according to this embodiment.

[0078] Figure 1 Also shown is an additional third bearing 153 which is arranged between the second stator housing 133 and the first rotor housing 121 , in particular the output shaft 170 , for additionally or alternatively supporting the second stator housing 133 relative to the first rotor housing 121 .

[0079] Figure 2 Shown by Figure 1 A cross section of a modified staggered portion 176 is shown in FIG. Figure 2 The thicknesses of the different rotating electromechanical machines 110, 130 are advantageously shown. The first rotating electromechanical machine 110 has a first machine thickness 200 extending from the first stator housing 113 to the first rotor housing 121. The second rotating electromechanical machine 130 has a second machine thickness 201 extending from the second stator housing 133 to the second rotor housing 141. An axially extending gap 124 is arranged between the first rotating electromechanical machine 110 and the second rotating electromechanical machine 130. The electromechanical device 100 has an overall thickness 202 extending from the first stator housing 113 to the second rotor housing 141. In other words, the overall thickness is the sum of the first machine thickness 200, the second machine thickness 201 and the axially extending gap 124. Figure 1 and Figure 2 Also shown is a cavity 210 arranged radially within the staggered portion 176. This cavity is a result of the radially compact electromechanical machines 110, 130. Even without further calculations, it is demonstrated that the electromechanical device 100 has a low weight, since a considerable volume is empty and not filled with heavy metal.

[0080] Figure 3 and Figure 4A second variant of the electromechanical device 100 is shown. According to this embodiment, the first rotating electromechanical machine 110 is designed as an inner rotor electromechanical machine and the second rotating electromechanical machine 130 is designed as an outer rotor electromechanical machine. In other words, the second rotor 140 is arranged radially outside the second stator 132. According to this embodiment, the input shaft 160 of the electromechanical device 100 is formed integrally with the first rotor housing 121. Different couplings between the input shaft 160 and the first rotor housing 121 are also conceivable. According to this embodiment, the output shaft 170 of the electromechanical device 100 is coupled to the second rotor housing 131 via a mechanical gear stage 180, in particular a spur gear stage. The first output shaft 160 and the second output shaft 170 are not arranged coaxially with respect to each other; instead, they have axes that are offset with respect to each other. The gear stage 180 makes it possible to modify the rotational characteristics between the second rotor 140 and the output shaft 170.

[0081] Figure 3 The second stator 132 of the second electromechanical machine 130 is shown entering the electromechanical device 100 at the center of one axial end. The second stator 132 is located inside the two rotors 120, 140, but is not movable according to this embodiment. The second stator 132 is configured to absorb the torque of the electromechanical device 100 and to provide access to the electrical connectors and cooling, such as water cooling. The output shaft 170 therefore cannot leave the electromechanical device 100 coaxially with respect to the common rotation axis 122, as shown in FIG. Figure 1 , because the center is occupied by the second stator 132. As disclosed, this problem is solved by adding an eccentrically arranged gear stage 180. With the gear stage 180, the output shaft 170 is shifted away from the center, as shown in FIG. Figure 4 Best shown in .

[0082] Figure 3 Also shown is a support concept 150 of different bearings of a second embodiment of the electromechanical device 100. As can be seen, all bearings are arranged relatively close to the axis of rotation 122, 142, which advantageously reduces the rolling speed of the bearings and thus increases the life of the bearings. The bearings include a first bearing 151 arranged on one axial end of the electromechanical device 100 and a second bearing 152 arranged on the other opposite axial end of the electromechanical device 100. Having bearings 151, 152 on both axial ends increases the accuracy and stability of the rotation, which enables relatively high rotation speeds.

[0083] Figure 3A first bearing 151 is shown as a support 150 for the first rotor 120, which is arranged between the first rotor housing 121 and the first stator housing 113. The first bearing 151 of the first rotor 120 is arranged on an input shaft 160, which is coupled to the first rotor housing 121 according to this embodiment. Figure 3 Also shown is a second bearing 152 which is arranged between the first rotor housing 121 and the second rotor housing 141 at the opposite axial end of the electromechanical device 100 .

[0084] Figure 3 Also shown is a first bearing 151 as a support 150 for the second rotor 140, which is arranged between the second rotor housing 141 and the second stator housing 133. A second bearing 152 is arranged between the second rotor housing 141 and the second stator housing 133 on the opposite axial end of the electromechanical device 100.

[0085] Figure 3 Also shown is a third bearing 153 arranged between the second stator housing 133 and the first rotor housing 121, in particular the input shaft 160, for additionally or alternatively supporting the second stator housing 133 relative to the first rotor housing 121. Figure 1 As shown in the embodiment of the present invention, the first stator 112, the second stator 132, the first rotor 120 and the second rotor 140 are connected at both axial ends by bearings concentric with respect to the common rotation axis 122, which increases stability, reduces vibration levels and loss of balance, thereby enabling high torque and power output even at high rotation speeds.

[0086] Figure 4 A particularly advantageous offset of the output shaft 170 relative to the common axis of rotation 122 is shown in a side view of the second exemplary embodiment.

[0087] Figure 5A perspective view of a first lamination stack 114 or a second lamination stack 134 as used, for example, in a first rotating electromechanical machine 110 or a second rotating electromechanical machine 130 is shown. The spiral lamination stack 114, 134 is formed by a spirally wound strip 115, 135 of a magnetically permeable material (e.g., an iron alloy). The strip 115, 135 preferably has a rectangular cross-section. Thus, the strip 115, 135 has two main surfaces 1151 and two side surfaces 1152. The main surfaces 1151 are arranged parallel to each other and form the surfaces with the largest extension in terms of area. The side surfaces 1152 are also arranged parallel to each other. In addition, the side surfaces 1152 are arranged perpendicular to the main surfaces 1151 and connect the two main surfaces 1152 to each other. The main surfaces 1151 and the side surfaces 1152 define the cover of the strip 115, 135. The thickness of the strip 115, 135 is the short extension between the side surfaces 1152. The width of the strip 115, 135 is the short extension between the main surfaces 1151. The other extension or long extension of the main surface 1151 and the side surface 1152 defines the length of the strip 115, 135. The strip 115, 135 is closed or terminated by two end surfaces, which form the ends of the strip 115, 135. Figure 5 Also shown is an insulating coating 1153 arranged on at least one of the two main surfaces 1151. The insulating coating 1153 is configured to electrically insulate two adjacent main surfaces 1151 of different turns or windings of the spiral lamination stack 114, 134. In another embodiment, the insulating coating 1153 is arranged at both main surfaces 1151. In an embodiment, the spiral lamination stack 114, 134 forms a segment, which is arranged on the stator housing 113, 133, for example together with other segments.

[0088] In an embodiment, the spiral lamination stacks 114, 134 are multi-gear lamination stacks ( Figure 5 ). The multi-gear lamination stack is formed by a plurality of helically wound strips 115, 135 having the same inclination angle or pitch angle. Different strips 115, 135 may have different thicknesses, may include different materials and / or may have different insulating coatings.

[0089] Figure 6 An electromechanical device 100 according to an embodiment of the present disclosure is schematically illustrated with cutaway sections to illustrate the interior of the electromechanical device 100 . Figure 6 An embodiment of a first rotating electromechanical machine 110 is partially shown. Figure 6A first stator housing 113, a first lamination stack 114 with a first helically wound strip 115, a first coil 116 including a first continuous hairpin winding 117, and a first magnet 118 arranged on a first rotor housing 121 are shown. In addition, a common rotation axis 122 is shown. The first continuous hairpin winding 117 includes a first winding layer 1171 and a second winding layer 1172. Within the first rotor housing 121, a second rotating electromechanical machine 130 ( Figure 6 not shown).

[0090] In this embodiment, the spiral lamination stack 114 is connected to the first stator housing 113 via a permanent connection. The connection is formed, for example, via a form fit, a press fit, a force fit or a chemical connection. The spiral lamination stack 114 is, for example, press fit, screw connection, shrink fit and / or glued into or onto the first stator housing 113.

[0091] The continuous hairpin winding 117 may have two groups of three phase windings U1, V1, W1, U2, V2, W2, wherein the phase winding U1 of the first group and the corresponding phase winding U2 of the second group have the same electrical phase (and may be connected together, for example, Figure 7 1 ). The continuous hairpin winding 117 has an input lead for each of the phase windings U1, V1, W1, U2, V2, W2 in the same area of ​​the electromechanical device 100, the input lead comprising a wire, so that the electrical connection of the continuous hairpin winding 114 is efficient and uncomplicated. In particular, all input leads are within a common, preferably small azimuth area. The end of each phase winding U1, V1, W1, U2, V2, W2 is electrically connected to at least one other phase winding of the phase windings U1, V1, W1, U2, V2, W2, for example to form a star ground 24 or a delta connection. The continuous hairpin winding 114 includes straight segments extending parallel to the axis 122, curved segments including offset bends, and folded segments.

[0092] like Figure 6 As can be seen in the figure, the first stator housing 113 forms part of the ironless stator of the rotating electromechanical machine 110. In particular, the first spiral lamination stack 114, the first stator housing 113 and the first hairpin winding 117 are comprised by the first ironless stator 112. The first continuous hairpin winding 117 is covered by the spiral lamination stack 114 along its entire axial extension (i.e. its extension parallel to the axis of rotation 122). The inner surface of the first spiral lamination stack 114 is arranged adjacent to the first continuous hairpin winding 117 and holds the continuous hairpin winding 117 in place. The continuous hairpin winding 117 is completely arranged within the first stator housing 113 and is thereby protected from mechanical damage, impacts and contamination.

[0093] The first stator 112 has an advantageously small radial extension and at the same time a high efficiency and is suitable for large industrial or automotive applications.

[0094] Figure 7 Schematically illustrated are cylindrical continuous hairpin windings 117, 137 according to a first exemplary embodiment as used, for example, in a first rotating electromechanical machine 110 or a second rotating electromechanical machine 130. As shown, all phase windings U1, V1, W1, U2, V2, W2 have input leads on the same side of the continuous hairpin windings 117, 137 and within the same relatively small azimuth range, which facilitates the continuous hairpin windings, for example, to be electrically connected to a power source and / or a motor controller. In addition, the opposite ends of the wires from the input leads are also in the same area, allowing for easy formation of a star ground or delta connection between the phase windings U1, V1, W1, U2, V2, W2. Each phase winding U1, V1, W1 of the first group and each corresponding phase winding U2, V2, W2 of the second group have the same phase. Such optimally shaped continuous hairpin windings 117, 137 are particularly desirable for electromechanical machines 110, 130 having very small gaps 124 between the continuous hairpin windings 117, 137 and the respective rotors 120, 140. Having a small gap is obviously advantageous for achieving higher electromagnetic efficiency, and particularly for embodiments of the electromechanical device 100.

[0095] In an embodiment, the continuous hairpin windings 117, 137 may be potted with a curable potting material. The strong mechanical and thermal bonding of the hairpin windings 117, 137 to the lamination stacks 114, 134 facilitates reliable transfer of torque and optimal conduction of heat. It also provides additional structural support and increases electrical insulation between wires, and improves heat transfer away from the wires.

[0096] Figure 8 A block diagram of a transmission unit 10 according to an exemplary embodiment is schematically shown. The transmission unit 10 comprises an electromechanical device 100 having a first rotating electromechanical machine 110 and a second rotating electromechanical machine 130 which are coaxially arranged and staggered with respect to each other. Figure 8Also shown are an input shaft 160 and an output shaft 170. The transmission unit 10 further comprises an electrical component 300 configured to receive an electric current generated during operation of the first rotating electromechanical machine 110 or the second rotating electromechanical machine 130 and configured to transmit the electric current to the other of the first rotating electromechanical machine 110 or the second rotating electromechanical machine 130 to drive the output shaft 170. According to this embodiment, the electrical component 300 comprises a converter 302 configured to convert the received electric current having a first electrical characteristic (particularly a first AC frequency) into a desired electric current having a second electrical characteristic (particularly a second AC frequency) for the rotating electromechanical machine 110, 130 configured to drive the output shaft 170 as desired.

[0097] According to this embodiment, the transmission unit 10 further comprises a control unit 304 for controlling the characteristics of the current transmitted to the first rotating electromechanical machine 110 or the second rotating electromechanical machine 130 so that a desired transmission ratio between the first rotor 120 of the first rotating electromechanical machine 110 and the second rotor 140 of the second rotating electromechanical machine 130 is achieved. The transmission ratio is, for example, the ratio of the rotation speed of the output shaft 170 to the rotation speed of the input shaft 160. According to this embodiment, the electrical component 300 is configured to modify the characteristics of the current transmitted to the rotating electromechanical machines 110, 130 operating in the generator mode, for example by changing the frequency. The desired transmission ratio is determined, for example, by input parameters received by the control unit 304, and these input parameters are converted by the control unit 304 into control commands for the electrical component 300.

[0098] like Figure 8 The transmission unit 10 shown in FIG. 1 also shows a transmission unit battery 303 configured to store and provide electrical energy for the transmission unit 10. The transmission unit 10 is configured to transfer mechanical input energy received via the input shaft 160 of the electromechanical device 100 into mechanical output energy that is transmitted to different components of a vehicle (such as a drive train of the vehicle) via the output shaft 170 of the electromechanical device 100. The desired characteristics of the mechanical output energy can be achieved by modifying the electrical characteristics of the current supplied to the rotating electromechanical machines 110, 130 of the electromechanical device 100 operating in the engine mode.

[0099] The transmission unit battery 303 electrically connected to the electromechanical device 100 may be configured such that at least a portion of the current generated by the rotating electromechanical machines 110, 130 operating in the generator mode is at least temporarily transferred to the transmission unit battery 303. Alternatively or in addition, the transmission unit battery 303 may also be configured such that at least a portion of the current required by the rotating electromechanical machines 110, 130 operating in the engine mode is at least temporarily provided by the transmission unit battery 303. According to this embodiment, the transmission unit battery 303 is configured to operate as an electric buffer of the transmission unit 10.

[0100] Fig. 9 A vehicle 400 including a transmission unit 10 according to an exemplary embodiment is schematically shown. The vehicle 400 additionally comprises an internal combustion engine 401, a vehicle battery 402 and a drive train 403. According to this embodiment, the internal combustion engine 401 is mechanically connected to the input shaft 160 of the transmission unit 10 and is configured to drive the first rotating electromechanical machine 110 or the second rotating electromechanical machine 130 operating in generator mode. The output shaft 170 of the transmission unit 10 is mechanically connected to the drive train 403. The transmission unit 10 replaces a conventional gearbox, for example. The transmission unit 10 can be installed in the vehicle 400 as a replacement kit. In another embodiment, the transmission unit 10 is directly installed during the manufacture of the vehicle 400.

[0101] Reference numerals list 10 Transmission unit 100 Mechanical and electrical equipment 110 First Rotating Electromechanical Machine 112 First stator 113 First stator housing 114 First lamination stacking 115 Spiral Wrap Strip 1151 Main surface 1152 Side surface 1153 Insulation coating 116 First Coil 117 First Continuous Hairpin Winding 1171 First winding layer 1172 Second winding layer 118 First Magnet 120 First rotor 121 First rotor housing 122 Common axis of rotation 124 Axial extension clearance 130 Second Rotating Electromechanical Machine 132 Second stator 133 Second stator housing 134 Second lamination stack 135 Second spiral winding strip 136 Second coil 137 Second continuous hairpin winding 138 Second Magnet 140 Second rotor 141 Second rotor housing 150 Support 151 First Bearing 152 Second bearing 153 Third bearing 160 Input shaft 170 Output shaft 176 Interlaced Area 180 gear stages 200 First machine thickness 201 Second machine thickness 202 Overall thickness and radial thickness of electromechanical equipment 210 cavity, hollow inner machine volume 300 Electrical components 302 Converters, AC-AC converters 303 Transmission unit battery 304 Control Unit 400 Transportation 401 Internal combustion engine 402 Vehicle Batteries U1,U2,V1,V2,W1,W2 phase windings.

Claims

1. An electromechanical device (100) for changing a motion parameter, the electromechanical device (100) comprising: a. a first rotating electromechanical machine (110), the first rotating electromechanical machine (110) comprising a first stator (112) and a first rotor (120), the first rotor (120) being arranged to be rotatable relative to a common rotation axis (122), b. a second rotating electromechanical machine (130) having a smaller radial extension than the first rotating electromechanical machine (110) and comprising a second stator (132) and a second rotor (140), the second rotor (140) being arranged to be rotatable relative to the common rotation axis (122), wherein the second rotating electromechanical machine (130) is arranged radially within the first rotating electromechanical machine (110) so as to form an interleaved region (176) of the electromechanical device (100), wherein the first stator (112) and the second stator (132) are ironless so as not to have a material with high magnetic permeability within or extending into the region of their coils (116, 136), and wherein the first rotor (120) is a permanent magnet rotor or a rotor including windings for electrical excitation, and wherein the second rotor (140) is a permanent magnet rotor or a rotor including windings for electrical excitation.

2. The electromechanical device (100) according to claim 1, wherein: The first rotating electromechanical machine (110) and the second rotating electromechanical machine (130) are designed as inner rotor electromechanical machines, and wherein an input shaft (160) configured to be coupled to one of the first rotor (120) or the second rotor (140) is coaxially arranged relative to an output shaft (170) configured to be coupled to the other of the first rotor (120) or the second rotor (140).

3. The electromechanical device (100) according to claim 1, wherein: The first rotating electromechanical machine (110) is designed as an inner rotor electromechanical machine, and the second rotating electromechanical machine (130) is designed as an outer rotor electromechanical machine, and wherein an input shaft (160) configured to be coupled to one of the first rotor (120) or the second rotor (140) is arranged eccentrically with respect to an output shaft (170) configured to be coupled to the other of the first rotor (120) or the second rotor (140).

4. The electromechanical device (100) according to any one of claims 2 or 3, wherein: The input shaft (160) is arranged on one axial end of the electromechanical device (100), and the output shaft (170) is arranged on the other opposite axial end of the electromechanical device (100).

5. The electromechanical device (100) according to any one of claims 2 to 4, wherein: The electromechanical device (100) comprises a gear stage (180) arranged between at least one of: the input shaft (160) and the first rotor (120), the input shaft (160) and the second rotor (120), the first rotor (120) and the output shaft (170), and the second rotor (140) and the output shaft (170).

6. An electromechanical device (100) according to any one of the preceding claims, wherein: a. the first stator (112) and the second stator (132) each comprising a spiral lamination stack (114, 134) of a helically wound strip (115, 135) of magnetically permeable material having a plurality of turns, wherein the strip (115, 135) comprises two main surfaces (1151) and two side surfaces (1152), wherein at least one of the two main surfaces (1151) comprises an insulating coating (1153), and / or b. wherein the first rotor (120) and the second rotor (140) each comprise a spiral lamination stack (114, 134) of a helically wound strip (115, 135) of magnetically permeable material having a plurality of turns, wherein the strip (115, 135) comprises two main surfaces (1151) and two side surfaces (1152), wherein at least one of the two main surfaces (1151) comprises an insulating coating (1153).

7. An electromechanical device (100) according to any one of the preceding claims, wherein: a. The first stator (112) and the second stator (132) each include a continuous hairpin winding (116, 117, 136, 137) having at least two winding layers (1171, 1172), or each include a continuous wave winding having at least two winding layers, and b. wherein the first rotor (120) comprises a permanent magnet or a continuous hairpin winding (117, 137) having at least two winding layers (1171, 1172), or a continuous wave winding having at least two winding layers, and c. wherein the second rotor (140) comprises a permanent magnet or a continuous hairpin winding (117, 137) having at least two winding layers (1171, 1172), or comprises a continuous wave winding having at least two winding layers.

8. An electromechanical device (100) according to any one of the preceding claims, wherein: The first rotating electromechanical machine (110) has a first machine thickness (200) from its maximum radially outer extension at the staggered area (176) to its minimum radially inner extension at the staggered area (176), the first machine thickness (200) being in the range from 30 mm to 15 mm, preferably from 25 mm to 20 mm, more preferably 22 mm.

9. An electromechanical device (100) according to any one of the preceding claims, wherein: The second rotating electromechanical machine (130) has a second machine thickness (201) from its maximum radially outer extension at the staggered area (176) to its minimum radially inner extension at the staggered area (176), the second machine thickness (201) being in the range from 30 mm to 15 mm, preferably from 25 mm to 20 mm, more preferably 22 mm.

10. An electromechanical device (100) according to any one of the preceding claims, wherein The first rotating electromechanical machine (110) has a maximum radial outer diameter at the staggered region (176) in the range from 100 mm to 1000 mm, preferably from 150 mm to 350 mm, more preferably 300 mm.

11. An electromechanical device (100) according to any one of the preceding claims, wherein An annular axially extending gap (124) at the staggered region (176) between the first rotating electromechanical machine (110) and the second electromechanical machine (130) has a thickness of less than 10 mm, preferably less than 5 mm, more preferably 3 mm.

12. An electromechanical device (100) according to any one of the preceding claims, wherein: The electromechanical device (100) comprises a first bearing (151) at a first axial end thereof and a second bearing (152) at a second opposite axial end thereof, wherein the first bearing (151) and the second bearing (152) are arranged between two components selected from the group consisting of: the first stator (112), the second stator (132), the first rotor (120) and the second rotor (140).

13. The electromechanical device (100) according to claim 12, wherein: The support member (150) of the first rotor (120) comprises: a. a first bearing (151), the first bearing (151) being arranged between the first stator (112) and the first rotor (120) at one axial end of the electromechanical device (100), and b. A second bearing (152), which is arranged between the second rotor (140) and the first rotor (120) at the other axial end of the electromechanical device (100).

14. The electromechanical device (100) according to any one of claims 12 or 13, wherein: The support member (150) of the second rotor (140) comprises: a. a first bearing (151), the first bearing (151) being arranged between the first stator (112) and the second rotor (140) at one axial end of the electromechanical device (100), and b. A second bearing (152), which is arranged between the second rotor (140) and the first rotor (120) at the other axial end of the electromechanical device (100).

15. An electromechanical device (100) according to any one of the preceding claims, wherein The first stator (112) includes a first stator housing (113), a first lamination stack (114) and a first coil (116), and wherein the second stator (132) includes a second stator housing (133), a second lamination stack (134) and a second coil (136).

16. An electromechanical device (100) according to any one of the preceding claims, wherein The material of the first stator (112) and / or the second stator (132) within the region of its coils (116, 136) or extending into the region of its coils (116, 136) has a magnetic permeability of less than 300, preferably less than 40.

17. A transmission unit (10) for changing a motion parameter, the transmission unit (10) comprising: a. An electromechanical device (100) according to any one of the preceding claims, b. an electrical component (300) configured to receive current generated during operation of the first rotating electromechanical machine (110) or the second rotating electromechanical machine (130), and configured to transmit the current to the other of the first rotating electromechanical machine (110) or the second rotating electromechanical machine (130) to drive an output shaft (170), and c. a transmission unit battery (303), which is connected to the electrical component (300) and is configured to store the electric power received from the electromechanical device (100) and to provide the electric power to the electromechanical device (100), in particular to the rotating electromechanical machine (110, 130) configured to drive the output shaft (170).

18. The transmission unit (10) according to claim 15, wherein: The electrical component (300) comprises a converter (302) configured to convert the received electric current having first electrical characteristics, in particular a first AC frequency, into a desired electric current having second electrical characteristics, in particular a second AC frequency, for the rotating electromechanical machine (110, 130) configured to drive the output shaft (170).

19. The transmission unit (10) according to claim 15 or 16, wherein: The electrical component (300) comprises a control unit (304) for controlling the characteristics of the current transmitted to the first rotating electromechanical machine (110) or the second rotating electromechanical machine (130) so that a desired transmission ratio, in particular a continuously variable transmission ratio, between the first rotor (120) and the second rotor (140) is achieved.

20. A vehicle comprising a transmission unit (10) according to any one of claims 15 to 17, wherein: The transportation means also include: a. an internal combustion engine configured to propel an input shaft (160) of the electromechanical device (100); b. a drive train mechanically connected to an output shaft (170) of the electromechanical device (100) and configured to propel the vehicle; and c. A vehicle battery electrically connected to the electrical component (300) and configured to store the electric power received from the electromechanical device (100) and to provide the electric power to the vehicle, in particular the electromechanical device (100).

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