Dual-rotor machine

Abstract

A dual rotor machine (DRM) for selectively transferring mechanical power and / or generating electrical power in a driveline of a vehicle generally includes an input driveshaft, an input rotor, and an output rotor coupled to an output driveshaft. In a preferred variant, the dual-rotor machine comprises an input driveshaft for mechanically coupling the dual-rotor machine to an internal combustion engine, said input driveshaft extending in an axial direction into a housing of the dual-rotor machine. Generally, the input rotor is mechanically interconnected to the input driveshaft and is arranged inside the housing to be rotatable about a common axis of rotation. The output rotor is arranged to be rotatable about a common axis of rotation and is mechanically interconnected to an output drive shaft passing through the housing for mechanically coupling the dual-rotor machine to a mechanical power consuming device.

Description

Technical Field

[0001] The present disclosure relates to a dual-rotor machine for selectively transmitting mechanical power and / or generating electrical power, and a driveline for a vehicle including such a dual-rotor machine. Background Art

[0002] Conventional vehicles driven by an internal combustion engine (ICE) rarely operate at the optimal efficiency of the ICE. Depending on driver input and roadway requirements, the engine speed and torque of the ICE are determined and transmitted to the wheels via a mechanical transmission. However, the ICE operates with high efficiency only in a limited engine speed and torque region. In order to operate the ICE constantly with high efficiency, the generated engine speed and torque should be controlled to minimize CO2 emissions by remaining in the high-efficiency region. A four-quadrant transducer (4QT) system for achieving this typically includes an ICE, a battery, and a four-quadrant transducer arranged between the ICE and the wheels. Compared with a conventional vehicle, the four-quadrant transducer acts as a transmission, but also additionally acts as an electric motor and a generator to compensate for the over-supply / under-supply of engine speed and torque caused by the constant operation of the ICE with high efficiency.

[0003] Several types of four-quadrant transducers known from the prior art are described below.

[0004] FR2630868A1, published in 1989 in the name of Jean Paul Sibeud, relates to a device designed to be interposed between a rotating motor shaft and a rotating transmission shaft, i.e., on the transmission driveline of a motor vehicle. The device includes an electric machine which, on the one hand, combinatorially has two concentric rotors coaxial with a stator and arranged inside the stator, one of these rotors being integral with the motor shaft; and on the other hand, the other rotor being integral with the receiver shaft.

[0005] US2014292131A1, published in 2014 in the name of Caterpillar Inc., relates to a dual-rotor switched reluctance machine having a fixed stator and independent input and output rotors on either side of the fixed stator, for transmitting power between a power source such as a gas engine and a mechanical transmission unit such as wheels or tracks.

[0006] EP 3075587 A1, published in 2016 in the name of Marc Vetter, relates to a transmission arrangement for a motor vehicle, which includes an internal combustion engine having at least one output shaft for providing rotational movement to at least one wheel, in particular at least two wheels, which are driven by the internal combustion engine, wherein the wheel or each of the wheels includes a transmission shaft to which the rotational movement is provided in order to drive the corresponding wheel. The transmission arrangement further includes at least one electromechanical machine arranged between the output shaft and at least one of the transmission shafts such that, by means of the electromechanical machine, the corresponding transmission shaft can be engaged and disengaged from the output shaft, wherein when the electromechanical machine engages the output shaft and the transmission shaft, the rotational movement provided by the output shaft is directly or indirectly input into the electromechanical machine and is directly or indirectly output by the electromechanical machine to the transmission shaft. SUMMARY OF THE INVENTION

[0007] The motor - generator solution in a common and known four - quadrant transducer (4QT) driveline is a dual - rotor machine, typically a combination of a radial - flux permanent - magnet synchronous machine (RFPMSM) and a stator. Mechanical power from the ICE is transferred to the outer rotor of the RFPMSM coupled to the transmission shaft, or this mechanical power is converted to electrical power by the inner rotor and the windings of the stator of the RFPMSM. The engine speed and torque transferred to the outer rotor are controlled, resulting in a transmission shaft speed independent of the ICE.

[0008] A solution for implementing such a 4QT is a switched - reluctance motor (SRM) in a radial - flux (RF) configuration, which is simple to manufacture, robust, easy to maintain, efficient, operable under extreme conditions, low - cost and has fast acceleration. However, the SRMs known from the prior art have several drawbacks, including high noise and high torque ripple due to magnetic - force - related vibrations of the stator, and the driveline performance depends to a large extent on the control strategy. An object of the present disclosure is to solve at least one problem of the prior art.

[0009] A dual-rotor machine (DRM) according to the present disclosure for selectively transmitting mechanical power and / or generating electrical power in a vehicle's driveline can be mechanically interconnected to an electric machine of the driveline to form an advanced four-quadrant transducer. Omitting the stator of known methods can allow for the construction of a system providing both high torque density and high power density. Generally, the dual-rotor machine includes an input drive shaft, an input rotor, and an output rotor coupled to an output drive shaft. In a preferred variant, the dual-rotor machine includes an input drive shaft for mechanically coupling the dual-rotor machine to an engine, particularly an internal combustion engine, an electric engine, a turbine, or any other type of engine, the input drive shaft extending axially into the housing of the dual-rotor machine. Generally, the input rotor is mechanically interconnected to the input drive shaft and is arranged inside the housing to be rotatable about a common axis of rotation. The output rotor is arranged to be rotatable about the common axis of rotation and is mechanically interconnected to an output drive shaft passing through the housing for mechanically coupling the dual-rotor machine to a mechanical power consuming device. The mechanical power consuming device can include at least one of the following: a drive shaft for driving wheels, a hydraulic or pneumatic system, etc.

[0010] Depending on the design, the input rotor or the output rotor includes a disc-shaped first array of a number of ferromagnetic bodies and / or ferromagnetic material elements and a disc-shaped second array of a number of ferromagnetic bodies and / or ferromagnetic material elements, the disc-shaped second array being arranged adjacent to the first array, preferably axially adjacent to the first array or concentric therewith, and being spaced apart from the first array by a certain distance in the axial direction, wherein at least one spacer extends in the axial direction to fixedly interconnect the first and second arrays of ferromagnetic bodies and / or ferromagnetic material elements. Generally, the output rotor or the input rotor is respectively arranged to be rotatable about the common axis of rotation between the first and second disc-shaped arrays of ferromagnetic bodies. The ferromagnetic bodies and / or ferromagnetic material elements are made, for example, at least in part of iron or an iron alloy (steel), particularly of iron or steel laminations. The ferromagnetic bodies and / or ferromagnetic material elements provide, for example, a permanent magnetic field. In other words, the ferromagnetic bodies and / or ferromagnetic material elements are, for example, permanent magnets.

[0011] To transmit mechanical power and / or generate electrical power, the input rotor or the output rotor generally includes a disc-shaped array of electromagnets arranged adjacent to the first and second arrays of ferromagnetic bodies and / or ferromagnetic material elements, preferably axially adjacent to the first and second arrays or concentric therewith, for generating electrical power when rotating at an angular velocity lower than that of the input rotor.

[0012] The input rotor includes a disc-shaped first array and a disc-shaped second array, and the output rotor includes a disc-shaped array of a number of electromagnets; or the output rotor includes a disc-shaped first array and a disc-shaped second array, and the input rotor includes a disc-shaped array of a number of electromagnets.

[0013] Preferably, the dual-rotor machine has an axial-flux (AF) configuration. In other words, the magnetic flux between the electromagnets of the output rotor and the ferromagnetic bodies of the input rotor is generally oriented parallel to the common axis of rotation. This allows for a compact construction of the dual-rotor machine and increases the flexibility of the system. Additionally, compared to the prior art, the AF topology allows for an increase in the number of magnetic poles and thus an increase in power density, resulting in a DRM with higher performance. However, a radial-flux configuration is also possible. An additional benefit of the DRM according to the present disclosure is that no permanent magnets are required.

[0014] During operation, when electrical power is supplied to the output rotor, the output rotor can preferably be driven at an angular velocity higher than that of the input rotor. Another option or additionally, the output rotor can be driven at an angular velocity lower than that of the input rotor to generate electrical power. This allows the ICE to always operate in the high-efficiency region, resulting in a 15% to 40% reduction in fuel consumption compared to conventional vehicles. At similar performance, the reduced fuel consumption leads to a reduction in CO2 emissions.

[0015] Good results can be achieved when at least one ferromagnetic body in the first array and / or the second array has a substantially U-shaped or V-shaped cross-section. Preferably, all ferromagnetic bodies in the first array and / or the second array have a substantially U-shaped or V-shaped cross-section.

[0016] In a preferred variant, the input rotor is a multi-part design. Depending on the design, the input rotor includes: a first disc-shaped base on which, in the assembled state, a first array of ferromagnetic bodies is detachably arranged; and a second disc-shaped base on which, in the assembled state, a second array of ferromagnetic bodies is detachably arranged. This allows for a reduction in the complexity of manufacturing the input rotor as its parts can be produced individually and in an efficient manner. Preferably, the first base and / or the second base is at least partially made of a light material, particularly a non-magnetic material such as a metal or metal compound like aluminum. However, other materials are also possible, such as composite materials like fiber-reinforced plastics.

[0017] If appropriate, the ferromagnetic bodies of the first array and / or the second array are respectively positioned and fixed at the first disc-shaped base and / or the second disc-shaped base by support elements, in particular, these support elements are at least partially arranged inside the U-shape or V-shape of the respective ferromagnetic body in a cross-sectional view. Preferably, the first disc-shaped array and the second disc-shaped array have substantially the same diameter, in particular, the disc-shaped first array includes the same number of ferromagnetic bodies as the disc-shaped second array.

[0018] To achieve a high magnetic flux density, the output rotor includes a number of ferromagnetic cores, each of which has a first end section facing the first array of ferromagnetic bodies and a second end section facing the second array of ferromagnetic bodies in the axial direction. Preferably, the first end section and / or the second end section of each ferromagnetic core is at least partially surrounded by a winding in a set of windings respectively. To stabilize the array of electromagnets, spacers are preferably arranged between two adjacent cores. Similar to the first and second arrays of ferromagnetic bodies, this allows for a segmented structure / multi-part design of the output rotor. If appropriate, these spacers may have a substantially rectangular cross-section perpendicular to the axial direction, and these cores may have a corresponding substantially isosceles trapezoidal cross-section. The ferromagnetic cores are made of, for example, the same material as the ferromagnetic bodies or ferromagnetic material elements.

[0019] Generally, the ratio of the number of ferromagnetic bodies or ferromagnetic material elements to the number of electromagnets is from 1.1 to 1.5, particularly 1.2. Preferred number pairings of electromagnets and ferromagnetic bodies are 12 / 18 or 10 / 12 or 20 / 24, and most preferably 15 / 18 (electromagnets at the output rotor) / (ferromagnetic bodies at the input rotor, with 18 ferromagnetic bodies in each array). However, depending on the application field, this number can vary to account for the spatial dimensions of the input and output rotors.

[0020] If present, the disc-shaped array of electromagnets generally includes at least a set of windings that can be electrically interconnected to a battery for receiving electrical energy from and / or supplying electrical energy to the battery. In a preferred variant, the array of electromagnets includes three or more sets of windings. Good routing of these electrical interconnections is possible when the output shaft includes a central opening extending concentrically with the common axis of rotation in the axial direction for threading at least a set of electrical interconnections of the windings.

[0021] The input drive shaft and / or the output shaft are made of, for example, steel, particularly high-strength steel. In addition, at least some parts of the input rotor and / or the output rotor can be made of aluminum, particularly aerospace-grade aluminum.

[0022] The ferromagnetic bodies or ferromagnetic material elements of the first array are preferably arranged substantially mirror-symmetrically with respect to the ferromagnetic bodies or ferromagnetic material elements of the second array. This results in higher efficiency compared to a configuration in which the first array is circumferentially offset with respect to the ferromagnetic bodies or ferromagnetic material elements of the second array.

[0023] To achieve good performance, the distance between the output rotor and the input rotor in the axial direction (parallel to the common axis of rotation) is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1.5 mm, and particularly 1 mm.

[0024] Due to the high power density of the DRM according to the present disclosure, cooling devices can be arranged outside the housing. The cooling devices are fluidly interconnected to the interior of the housing to provide good thermal control of the components arranged therein. Preferably, the cooling device is formed as an oil spray cooling device, which includes at least one nozzle, in particular one or two nozzle units, interconnected to an oil sump, with two or three nozzles per unit.

[0025] Another aspect of the present disclosure relates to a powertrain for a vehicle, in particular a motor vehicle, which includes a dual-rotor machine as described above, wherein an electric machine is mechanically coupled, for example, to the output shaft of the dual-rotor machine to transmit torque therebetween. The electric machine is typically implemented as an electric motor / generator. In the powertrain, a four-quadrant transducer is formed by the dual-rotor machine and the electric machine mechanically coupled thereto, wherein the dual-rotor machine can be used to control the engine speed provided to the wheels, and the electric machine is used to control the torque. The electric machine can be the stator of the dual-rotor machine, which is, for example, part of the dual-rotor machine.

[0026] The vehicle of the present disclosure can include motor vehicles, heavy equipment, which can be mobile and / or stationary, for example configured for highway or non-highway applications. Other vehicles can also be contemplated.

[0027] If present, the electric machine is typically electrically interconnected to a battery, in particular interconnected to the same battery as the dual-rotor machine. In some variants, the electrical interconnection between the battery and the dual-rotor machine and / or the electric machine includes slip rings and / or power electronics between the dual-rotor machine and the battery. Preferably, the slip rings for each electrical interconnection of the dual-rotor machine and / or the electric machine are arranged in a common slip ring housing. To achieve a compact construction, the output drive shaft extends axially into the slip ring housing, thereby allowing a short wiring distance from the electromagnet to the slip rings.

[0028] In a preferred variant, the control unit is interconnected to at least one set of windings of the output rotor of the dual-rotor machine and is configured to receive an operator input and control the transfer of rotational speed from the input rotor to the output rotor based on the operator input. If appropriate, the control unit can be interconnected to the electric machine and is configured to determine the torque transmitted between the output drive shaft and the electric machine by controlling the electric machine. This allows control of both the torque and the engine speed provided to a mechanical power-consuming device, such as the wheels of a motor vehicle.

[0029] In a variant, the dual-rotor machine further includes at least one inverter that is electronically connected to the disk-shaped array of electromagnets and preferably to a battery, wherein the inverter is configured to convert the received current. The power supply of the dual-rotor machine is, for example, a battery that generates a DC voltage, and the dual-rotor machine itself is, for example, a three-phase AC motor. The inverter of the dual-rotor machine connects the two components by converting the DC side of the battery into a three-phase AC voltage used by the dual-rotor machine. In alternating current, when the voltage changes from positive to negative, the current flows in two directions in the circuit. The inverter regulates the flow of electric power so that the dual-rotor machine can operate in motor mode and generator mode. The inverter of the dual-rotor machine is a three-phase inverter, where 1 winding / coil is connected to 2 branches forming a half-bridge. There is an additional 7th branch in the inverter for braking.

[0030] The dual-rotor machine structure is preferably based on a switched reluctance machine because when power is applied to the windings of the outer rotor connected to the traction side, the reluctance of the outer rotor generates a force that aligns the inner rotor poles connected to the internal combustion engine with the nearest outer rotor poles. To maintain rotation, the electronic control system sequentially energizes the windings of successive stator poles so that the magnetic field of the stator "guides" the rotor poles, thus pulling them forward. The inverter achieves this switching sequence by appropriately turning on and off the transistors in its phase branches. Thus, the desired output waveform is delivered to the dual-rotor machine.

[0031] Advantageous assembly can be achieved when at least one of the input rotor or the output rotor includes a segmented rotor structure and is thus formed by a plurality of rotor segments.

[0032] For example, when the dual-rotor machine includes a plurality of disk-shaped first arrays, a plurality of disk-shaped second arrays, and a plurality of disk-shaped arrays of electromagnets, advantageous control of the enhanced rotational speed can be achieved, with these arrays arranged adjacent to each other, preferably axially adjacent or concentrically, and rotatable about a common axis of rotation.

[0033] Preferred mechanical connection of the rotating parts can be achieved when at least some of the rotating parts are interconnected via at least one prestressed tapered element configured to release stress during operation. The prestressed tapered element is, for example, arranged between a ferromagnetic / ferromagnetic material element and a support element of the rotor.

[0034] Improved mechanical coupling is possible when at least one bearing of the input drive shaft, preferably all bearings, are shrink-fitted onto the input drive shaft and / or when at least one bearing of the output drive shaft, preferably all bearings, are shrink-fitted onto the output drive shaft. These bearings are configured to support the respective shafts within the housing of the dual-rotor machine.

[0035] The number of magnetic poles that the disk-shaped first array combined with the disk-shaped second array can have is in the range of 15 to 20, preferably 18, and / or the number of magnetic poles that the disk-shaped array including an electromagnet can have is in the range of 10 to 20, preferably 15.

[0036] Advantageous stability is possible when the input drive shaft and / or the output shaft are made of a ferroalloy, preferably steel, especially high-strength steel.

[0037] Furthermore, when the input rotor and / or the output rotor are at least partially made of aluminum, especially aerospace-grade aluminum, an advantageous reduction in the rotating mass is possible. The support elements, the first base, and / or the second base are made of aluminum, for example.

[0038] The nominal DC link voltage of the dual-rotor machine is in the range of 250V to 400V, preferably 375V.

[0039] Preferably, the nominal speed of the input rotor is in the range of 2400 rpm to 3200 rpm, preferably 2700 rpm, and / or the nominal speed of the output rotor is in the range of 3600 rpm to 4500 rpm, preferably 4200 rpm.

[0040] It should be understood that both the foregoing general description and the following detailed description present several embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the present disclosure. Drawings are included to provide further understanding, and these drawings are incorporated into this specification and form a part of it. The drawings illustrate various embodiments and are used with the specification to explain the principles and operations of the disclosed concepts. Brief Description of the Drawings

[0041] The disclosure described herein will be more fully understood from the following detailed description and the accompanying drawings, which should not be regarded as limiting the disclosure described in the appended claims. The drawings show:

[0042] Figure 1 An exploded view of a first variant of a dual-rotor machine according to the present disclosure;

[0043] Figure 2 A partial cross-sectional view of a first variant of a dual-rotor machine;

[0044] Figure 3 Indicated by the circle O Figure 2 A detailed view of the dual-rotor machine;

[0045] Figure 4 Indicated by the section line MM Figure 2 A cross-sectional view of a first variant of the dual-rotor machine; and

[0046] Figure 5Schematic diagram of a first variant of a powertrain according to the present disclosure;

[0047] Figure 6 Schematic diagram of a second variant of a powertrain according to the present disclosure;

[0048] Figure 7 Cross-sectional view of a second variant of a dual-rotor machine. Detailed Description

[0049] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. In fact, the embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numerals will be used to refer to like components or parts.

[0050] Figure 1 An exploded view showing a first variant of a dual-rotor machine 1 according to the present disclosure. Figure 2 A partial cross-sectional view showing a first variant of a dual-rotor machine 1, in which Figure 3 shown by circle O Figure 2 detailed view of the dual-rotor machine 1. In Figure 4 shown by cross-hatching MM Figure 2 cross-sectional view of a first variant of the dual-rotor machine 1; and in Figure 5 shown schematically a first variant of a powertrain 2 according to the present disclosure. Figure 6 Cross-sectional view showing a second variant of a dual-rotor machine 1.

[0051] As Figures 1 to 4 shown, a first variant of the dual-rotor machine 1 generally includes an input drive shaft 3, an input rotor 6, and an output rotor 11 coupled to an output drive shaft 12 for selectively transmitting mechanical power and / or generating electrical power in a powertrain 2 of a motor vehicle (not shown). The input drive shaft 3 may be mechanically interconnected to an ICE 4, while the output drive shaft 12 may be mechanically interconnected to the wheels 29 of a corresponding motor vehicle. As Figure 2 best seen in, the input drive shaft 3 extends axially in the z-direction into the housing 5 of the dual-rotor machine 1. The input rotor 6 attached to the input drive shaft 3 is arranged to be rotatable about a common rotational axis R inside the housing 5. The output rotor 11 is arranged to be rotatable about the same common rotational axis R and is mechanically interconnected to the output drive shaft 12 passing through the housing 5 opposite the input drive shaft 3.

[0052] As Figure 1As can be seen, the input rotor 3 includes a first disc-shaped array 8 of ferromagnetic bodies 7 and a second disc-shaped array 9 of ferromagnetic bodies 7. The second array 9 is concentrically arranged with the disc-shaped first array 8 (both of which rotate about the same common rotation axis R during operation), and is spaced apart from the first array 8 by a distance D1 in the axial direction z. A number of spacers 10 extend in the axial direction z, thereby fixedly interconnecting the first array 8 and the second array 9 of the ferromagnetic bodies 7. The first array 8 and the second array 9 of the ferromagnetic bodies 7 form a cage-like structure for accommodating the output rotor 11 therein. The output rotor 11 is arranged to be rotatable about the common rotation axis R between the first array 8 and the second array 9 of the ferromagnetic bodies 7. The output rotor 11 generally includes a disc-shaped array 14 of electromagnets 13, the disc-shaped array 14 being concentrically arranged with the first array 8 and the second array 9 of the ferromagnetic bodies 7 for generating electric power when rotating at an angular velocity lower than that of the input rotor 3.

[0053] Regarding the design of the input rotor 3 and the output rotor 11, as Figure 1 shown, compared with known rotors, both include a segmented / multi-part structure. The ferromagnetic bodies 7 of the first array 8 and the second array 9 have a substantially U-shaped or V-shaped cross-section in a plane parallel to the axial direction z. These ferromagnetic bodies 7 are respectively detachably arranged on the first base 15 or the second base 16 and are fixed thereto by support elements 17. The support elements 17 extend along the notches formed by the U-shaped or V-shaped cross-sections of the ferromagnetic bodies 7. The support elements 17 are attached to the corresponding bases 15, 16 by means of screws. Each of the two ferromagnetic body arrays 8, 9 of the first variant has eighteen (18) ferromagnetic bodies.

[0054] The output rotor 11 includes fifteen (15) electromagnets 13. Each electromagnet includes a first end section 21 facing the first array 8 of the ferromagnetic bodies 7 and a second end section 22 facing the second array 9 of the ferromagnetic bodies 7. In the shown variant, the distance D1 between the first end section 21 and the first array 8 of the ferromagnetic bodies 7 is about 1 mm. Similarly, in the shown variant, the distance D1 between the second end section 22 and the second array 9 of the ferromagnetic bodies 7 is about 1 mm.

[0055] As Figure 1As can be seen, the end sections 21, 22 of each core 20 are each wound with a winding 18. The windings 18 around the end sections 21, 22 of each core 20 do respectively belong to the common winding 18. The shown variant includes three sets of individual windings 18, thus allowing the output rotor 11 to operate in three phases. To electrically interconnect the windings 18 to the battery 19 for receiving electrical energy from the battery 19 and / or supplying electrical energy to the battery 19, the output drive shaft 12 includes a central opening 23 that extends concentrically with the common axis of rotation R in the axial direction z for threading the electrical interconnection of the windings 18. As an alternative or in addition, the input drive shaft 3 may include a corresponding central opening for threading the electrical interconnection of the windings 18.

[0056] To provide cooling, in particular, to the electromagnets 13 of the output rotor 11, a cooling device 24 is arranged outside the housing 5. In the shown variant, the cooling device 24 is formed as an oil spray cooling device 24 that is fluidly interconnected to the interior of the housing 5. The oil spray cooling device 24 includes a number of nozzles that are supplied with oil from an oil sump to spray oil onto the rotors 3, 11.

[0057] In Figure 5 a first variant of the powertrain 2 is shown, which generally includes an ICE 4 or any other engine that is mechanically interconnected to the DRM 1 via an input drive shaft 3. The DRM 1 is mechanically interconnected to the electric machine 25 on the other side via a transmission 30 that is mechanically coupled to the output drive shaft 12. The electric machine 25 is generally electrically interconnected to the battery 19, in particular to the same battery 19 as the dual-rotor machine 1.

[0058] Figure 5 The solid lines in indicate the interconnections for transferring energy (mechanical or electrical energy). The dashed lines indicate signal paths. In the shown variant, the control unit 26 is interconnected to at least one set of windings 18 of the output rotor 11 of the dual-rotor machine 1. The control unit 26 is configured to receive operator input and control the transfer of rotational speed from the input rotor 3 to the output rotor 11 based on that operator input. Additionally, the control unit 26 is generally interconnected to the electric machine 25 and is configured to determine the torque transferred between the output drive shaft 12 and the electric machine 25 by controlling the electric machine 25. The output drive shaft 12 may also be mechanically interconnected directly or indirectly to the wheels 29 of the corresponding motor vehicle in a known manner.

[0059] In the shown variant, the electrical interconnections between the battery 19 and the dual-rotor machine 1 and / or the electric machine 25 each include slip rings 27. As Figure 2 and Figure 4Best visible in, the slip rings 27 for each electrical interconnection of the dual rotor machine 1 and / or the electric machine 25 are arranged in a common slip ring housing 28. Preferably, the output drive shaft 12 extends axially in the direction z into the slip ring housing 28, thus allowing a short wiring distance from the electromagnet 13 to the slip rings 27. The dual rotor machine 1 may further include at least one inverter configured to convert the received current, depending on the usage, from the electrical winding 18 or from the battery 19.

[0060] In Figure 6 is shown a second variant of the powertrain 2, which generally includes an ICE 4 or any other engine that is mechanically interconnected to the DRM 1 via an input drive shaft 3. The DRM 1 is mechanically interconnected to the electric machine 25 on the other side via a transmission 30 that is mechanically coupled to the output drive shaft 12. The electric machine 25 is generally electrically interconnected to the battery 19, in particular to the same battery 19 as the dual rotor machine 1. Figure 6 Also schematically shown is a control unit 26 configured to control different parts of the powertrain 2. Figure 6 Also shown are two inverters, where the first inverter is arranged between the battery 19 and the electric machine 25, while the second inverter is arranged between the battery 19 and the dual rotor machine 1. These inverters are configured to convert the received direct current from the battery 19 into alternating current for the dual rotor machine 1 or the electric machine 25, or vice versa. Figure 6 Also shown is that the electric machine 25 is mechanically coupled to the dual rotor machine 1 via the transmission 30 (thus forming, for example, part of the dual rotor machine 1). In addition, the dual rotor machine 1 and the electric machine 25 are coupled to the wheels 29 via the transmission 30.

[0061] Figure 7 A second variant of the dual rotor machine 1 is shown in a longitudinal sectional view. This variant mainly differs in the bearing concept from Figure 4 the variant shown in. The input drive shaft 3 is supported by two bearings arranged between the input drive shaft 3 and the housing 5. These bearings are, for example, shrink-fitted onto the input drive shaft 3. The bearing arranged near the input end of the input drive shaft 3 is, for example, a double-roller bearing arranged in an O-shape, while the bearing arranged near the output drive shaft 12 is, for example, a double-roller bearing arranged in an X-shape. Having such a bearing arrangement advantageously increases the rotational stability of the input drive shaft 3 and the input rotor 3. According to as Figure 4 shown in and as Figure 6In the variant shown, the output transmission shaft 12 is supported by two bearings. The bearing arranged near the input transmission shaft 3 is arranged between the housing 5 of the DRM 1 and the output transmission shaft 12. This bearing is, for example, a double roller bearing arranged in an X shape. The bearing arranged away from the interior of the DRM 1 is arranged between the slip ring housing 27 and the output transmission shaft 12. This bearing is, for example, a single roller bearing. Both bearings are, for example, shrink-fitted onto the output transmission shaft 12. Figure 7 and Figure 4 also differs in different embodiments of the output rotor 12, compared with Figure 4 the single output rotor 12 of Figure 7 the output rotor 12 of

[0062] Instead, the words used in the specification are descriptive, not restrictive, words, and it should be understood that various changes can be made without departing from the scope of the present disclosure.

[0063] List of reference numerals

[0064] 1 Dual Rotor Machine (DRM) 16 Second base (input rotor)

[0065] 2 Transmission system 17 Support element (input rotor)

[0066] 3 Input transmission shaft 18 Winding

[0067] 4 Internal Combustion Engine (ICE) 19 Battery

[0068] 5 Housing (dual rotor machine) 20 Core (ferromagnetic, output rotor)

[0069] 6 Input rotor 21 First end section

[0070] 7 Ferromagnet 22 Second end section

[0071] 8 First array of ferromagnets 23 Central opening (output transmission shaft)

[0072] 9 Second array of ferromagnets 24 Cooling device

[0073] 10 Spacer 25 Electric machine

[0074] 11 Output rotor 26 Control unit

[0075] 12 Output transmission shaft 27 Slip ring

[0076] 13 Electromagnet 28 Slip ring housing

[0077] 14 Array of electromagnets (output rotor) 29 Wheel

[0078] 15 First base (input rotor) 30 Transmission device

[0079] R Common rotation axis D1 distance (between the first and second arrays of ferromagnetic bodies)

[0081] D2 distance (between the input rotor and the output rotor)

Claims

1. A dual-rotor machine (1) for selectively transmitting mechanical power and / or generating electrical power in a driveline (2) of a vehicle, the dual-rotor machine (1) comprising: a. An input drive shaft (3) for mechanically coupling the dual-rotor machine (1) to an engine (4), the input drive shaft (3) extending axially into a housing (5); b. An input rotor (6) mechanically interconnected to the input drive shaft (3) and arranged to be rotatable about a common axis of rotation (R) inside the housing (5); c. An output rotor (11) arranged to be rotatable about the common axis of rotation (R) and mechanically interconnected to an output drive shaft (12) passing through the housing (5) for mechanically coupling the dual-rotor machine (1) to a mechanical power consuming device, wherein d. The input rotor (6) or the output rotor (11) comprises: i. A disc-shaped first array (8) comprising a plurality of ferromagnetic bodies (7) and / or ferromagnetic material elements; ii. A disc-shaped second array (9) comprising a plurality of ferromagnetic bodies (7) and / or ferromagnetic material elements, the disc-shaped second array (9) being arranged adjacent to the first array (8) and spaced apart from the first array (8) by a distance (D1) in the axial direction (R, z), wherein iii. At least one spacer (10) extending in the axial direction for fixedly interconnecting the first array (8) and the second array (9); e. The input rotor (6) or the output rotor (11) comprises: i. A disc-shaped array (14) comprising a plurality of electromagnets (13), the disc-shaped array (14) being arranged adjacent to the first array (8) and the second array (9) of ferromagnetic bodies (7) and / or ferromagnetic material elements and arranged to be rotatable about the common axis of rotation (R), wherein the disc-shaped array (14) of electromagnets (13) is respectively arranged between the first array (8) and the second array (9) of the input rotor (6) or the output rotor (11).

2. The twin-rotor machine (1) according to claim 1, wherein, When electrical power is supplied to the output rotor (11), the output rotor (11) can be driven at an angular velocity higher than that of the input rotor (6), and / or wherein, When electrical power is removed from the output rotor (11), the output rotor (11) can be driven at an angular velocity lower than that of the input rotor (6).

3. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, At least one ferromagnetic body (7) and / or at least one ferromagnetic material element in the first array (8) and / or the second array (9) has a substantially U-shaped or V-shaped cross-section, in particular, all ferromagnetic bodies (7) and / or all ferromagnetic material elements in the first array (8) and / or the second array (9) have a substantially U-shaped or V-shaped cross-section.

4. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The disc-shaped first array (8) comprises a disc-shaped first base (15), on which, in the assembled state, the ferromagnets (7) and / or ferromagnetic material elements of the first array (8) are detachably arranged, and wherein the disc-shaped second array (9) comprises a disc-shaped second base (16), on which, in the assembled state, the ferromagnets (7) and / or ferromagnetic material elements of the second array (9) are detachably arranged.

5. The twin-rotor machine (1) according to claim 4, wherein, The ferromagnets (7) and / or ferromagnetic material elements of the first array (8) and / or the second array (9) are respectively positioned and fixed at the first base (15) and / or the second base (16) by support elements (17), and in particular, the support elements (17) are at least partially arranged inside the U-shape or V-shape of the corresponding ferromagnets (7) and / or ferromagnetic material elements in a cross-sectional view.

6. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The disc-shaped array (14) of the electromagnet (13) comprises at least one set of windings (18), which can be electrically interconnected to a battery (19) for receiving electrical energy from and / or supplying electrical energy to the battery (19).

7. The twin-rotor machine (1) according to claim 6, wherein, The disc-shaped array (14) of the electromagnet (13) comprises a number of ferromagnetic cores (20), each of which has a first end section (21) facing the first array (8) and a second end section (22) facing the second array (9) in the axial direction, and wherein the first end section (21) and / or the second end section (22) of each ferromagnetic core (20) are at least partially surrounded by in-phase windings (18).

8. The twin-rotor machine (1) according to one of the preceding claims 2 to 7, wherein, The output transmission shaft (12) comprises a central opening (23), which extends concentrically with the common rotation axis (R) in the axial direction (R, z).

9. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The disc-shaped first array (8) comprises the same number of ferromagnets (7) and / or ferromagnetic material elements as the disc-shaped second array (9).

10. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The ferromagnets (7) and / or ferromagnetic material elements of the first array (8) are arranged substantially mirror-symmetrically with respect to the ferromagnets (7) and / or ferromagnetic material elements of the second array (9).

11. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The distance (D2) between the output rotor (11) and the input rotor (6) in the axial direction (R, z) is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1.5 mm, and in particular 1 mm.

12. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, A cooling device (24) is arranged outside the housing (5), and the cooling device (24) is fluidly interconnected to the inside of the housing (5).

13. The twin-rotor machine (1) according to claim 12, wherein, The cooling device (24) comprises an oil spraying cooling device, which comprises at least one nozzle interconnected to an oil sump, in particular one or two nozzle units, with two or three nozzles per unit.

14. The twin-rotor machine (1) according to at least one of the preceding claims, further comprising an inverter which is electronically connected to the disk-shaped array (14) of the electromagnets (13) and preferably to the battery (19), wherein, The inverter is configured to convert the received current.

15. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, At least one of the input rotor (6) and the output rotor (11) comprises a segmented rotor structure and is thus formed by a plurality of rotor segments.

16. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The twin-rotor machine (1) includes a plurality of the disc-shaped first arrays (8), a plurality of the disc-shaped second arrays (9), and a plurality of the disc-shaped arrays (14) of the electromagnets (13), which are arranged adjacent to each other and are rotatable about the common axis of rotation.

17. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, At least some of the rotating parts are interconnected via at least one prestressed tapered element configured to release stress during operation.

18. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The ferromagnetic body (7) and / or the ferromagnetic material element is made of an iron alloy, in particular of laminated iron alloy.

19. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, At least one bearing, preferably all bearings, of the input transmission shaft (3) are shrink-fitted onto the input transmission shaft (3), and / or wherein at least one bearing, preferably all bearings, of the output transmission shaft (12) are shrink-fitted onto the output transmission shaft (12). The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The combined number of magnetic poles of the disc-shaped first array (8) and the disc-shaped second array (9) is in the range of 15 to 20, preferably 18, and / or wherein The disc-shaped array (14) including the electromagnet (13) has a number of magnetic poles in the range of 10 to 20, preferably 15.

21. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The input transmission shaft (3) and / or the output shaft (12) are made of steel, in particular high-strength steel, and / or wherein the input rotor (6) and / or the output rotor (11) are at least partially made of aluminum, in particular aerospace-grade aluminum.

22. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The nominal DC link voltage is in the range of 250 V to 400 V, preferably 375 V.

23. The twin-rotor machine (1) according to at least one of the preceding claims, wherein, The nominal speed of the input rotor (6) is in the range of 2400 rpm to 3200 rpm, preferably 2700 rpm, and / or wherein The nominal speed of the output rotor (11) is in the range of 3600 rpm to 4500 rpm, preferably 4200 rpm.

24. A driveline (2) for a vehicle, the driveline comprising a dual-rotor machine (1) according to at least one of claims 1 to 12, wherein, The electric machine (25) is mechanically coupled to the output transmission shaft (12) of the twin-rotor machine (1) to transmit torque therebetween.

25. The powertrain (2) according to claim 24, wherein, The control unit (26) is interconnected to at least one set of windings (18) of the output rotor (11) or the input rotor (6) of the twin-rotor machine (1) and is configured to receive operator input and control the rotational speed from the input rotor (6) to the output rotor (11), or vice versa, based on the operator input.

26. The drive train (2) according to claim 25, wherein, The control unit (26) is interconnected to the electric machine (25) and is configured to determine the torque transmitted between the output transmission shaft (12) and the electric machine (25) by controlling the electric machine (25).

27. The powertrain (2) according to claim 25 or 26, wherein, The control unit (26) is configured to use a control algorithm to control the twin-rotor machine (1) to selectively transmit / generate mechanical power and / or selectively transmit / generate electrical power.

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