Motor combining electromagnetic connecting shaft and mechanical connecting shaft

Abstract

A motor combining an electromagnetic connecting shaft and a mechanical connecting shaft comprises a motor body, a driving shaft, a combined coupling assembly, a driven shaft and a coupling cover, one end of the driving shaft is connected with the output end of the motor, the other end of the driving shaft is connected with the combined coupling assembly, and the driven shaft is connected with the combined coupling assembly and transmits power to a load. The combined coupling assembly comprises a mechanical coupling part and an electromagnetic coupling part, the mechanical coupling part is connected with the driving shaft and the driven shaft through a first connecting part and a second connecting part, transmits mechanical torque and defines a center containing space, and the electromagnetic coupling part is arranged in the center containing space. The excitation part and the armature part are coaxially fixed to the first connecting part and the second connecting part respectively through key connection, electromagnetic torque is transmitted through electromagnetic interaction, the coupling cover seals the combined coupling assembly, rigid mechanical connection and controllable electromagnetic connection are compactly integrated, and adaptability and reliability of power transmission are improved.

Description

Technical Field

[0001] The invention relates to a motor combining an electromagnetic coupling with a mechanical coupling. Background Art

[0002] In modern automotive technology, efficiency, smoothness, reliability, and compactness of the powertrain (including the engine, electric motor, and transmission) are constantly pursued. The transfer and disconnection of power between various components (for example, between the engine and transmission, between the electric motor and transmission, or between the engine / motor and the driveshaft in hybrid systems) typically relies on various clutch or coupling technologies.

[0003] Coupling technology in existing automotive powertrains and its shortcomings:

[0004] Conventional friction clutches (manual / automatic / dual clutch): widely used in manual transmissions (MT), automated manual transmissions (AMT), and dual clutch transmissions (DCT). They transmit torque by compressing friction plates and disengage when disconnected.

[0005] Disadvantages: While relatively low-cost, they are subject to wear and require regular replacement. Smooth start and shifting rely on complex control strategies, which can still cause jerkiness. Highly precise torque control for active vibration reduction or sophisticated overload protection is difficult to achieve. In the semi-clutch state, there are efficiency losses and heat generation issues. They are essentially rigid (engaged) or disengaged, with limited flexibility and precision in between.

[0006] Torque converter (AT): Mainly used in traditional automatic transmissions (AT). It transmits torque through fluid flow, enabling smooth starting and a certain degree of torque amplification.

[0007] Disadvantages: There is a large slip and energy loss in the unlocked state, resulting in low transmission efficiency and affecting fuel economy; the structure is relatively complex and bulky, and occupies a large space; although locking (rigid connection) can be achieved, it is not as flexible and direct as electromagnetic control in switching between locked and unlocked states and flexible control at low speeds.

[0008] Coupling device in hybrid electric vehicle (HEV / PHEV): In order to achieve flexible combination and disconnection of engine, electric motor and transmission system, hybrid electric vehicle often uses specially designed clutch (such as wet multi-plate clutch) or coupling device.

[0009] Disadvantages: These devices require precise control to ensure smooth switching between different drive modes (pure electric, pure oil, hybrid drive, energy recovery, etc.), which places high demands on the control system; existing solutions may still rely mainly on friction transmission, or have a relatively complex structure and high cost; there may be a lack of a single compact unit that can provide both efficient direct mechanical drive and precise flexible electromagnetic control, making it difficult to perfectly balance the efficiency and smoothness requirements in all modes.

[0010] Therefore, the automotive industry urgently needs a new coupling technology that can integrate the advantages of rigid mechanical connection and controllable electromagnetic connection in a compact unit to achieve efficient, smooth, and reliable power transmission and control, thereby meeting increasingly stringent energy conservation and emission reduction regulations and consumers' high demand for driving experience. The present invention is proposed to address the shortcomings of the above-mentioned existing technologies.

[0011] To sum up, the technical background section of the present invention is intended to explain the current status of the prior art. The deficiencies of the prior art indicate that the content of this section will provide necessary background information for understanding the technical contributions and innovations of the present invention. The signals disclosed in this background technology section are only intended to increase the understanding of the overall background of the present invention and should not be regarded as implying any form of subjective consciousness. Summary of the Invention

[0012] In view of the above, an object of the present invention is to provide a motor that combines an electromagnetic coupling with a mechanical coupling.

[0013] The technical solution adopted to achieve the purpose of the present invention is a motor combining an electromagnetic coupling and a mechanical coupling, wherein the motor body has an output end and further includes a drive shaft, a combined coupling assembly, a driven shaft, and a coupling cover;

[0014] One end of the drive shaft is transmission-connected to the output end of the motor body, and the other end extends out;

[0015] The driven shaft is in driving connection with the combined coupling assembly for transmitting power to the load end;

[0016] The combined coupling assembly is arranged at the protruding end of the drive shaft;

[0017] Combined coupling components include: mechanical coupling components, electromagnetic coupling components,

[0018] The mechanical coupling component includes: a first connecting portion fixedly connected to the end of the drive shaft;

[0019] a second connecting portion fixedly connected to the starting end of the driven shaft;

[0020] The first connecting portion and the second connecting portion are interconnected via a mechanical structure and together define a central accommodation space located therebetween, and the mechanical structure transmits torque between the driving shaft and the driven shaft;

[0021] The electromagnetic coupling component is arranged inside the central accommodating space, and includes: an excitation portion, coaxially fixedly connected to the first connecting portion of the mechanical coupling component, and configured to generate a working magnetic field when energized; an armature portion, coaxially fixedly connected to the second connecting portion of the mechanical coupling component, and arranged opposite to the excitation portion, with a working air gap formed therebetween; the armature portion is capable of interacting with the magnetic field generated by the excitation portion to transmit electromagnetic torque, wherein a key connection structure is used between the excitation portion and the first connecting portion, and between the armature portion and the second connecting portion to achieve coaxial fixation and torque transmission; the key connection structure is arranged inside the central accommodating space;

[0022] The coupling cover seals the outside of the combined coupling assembly to form a relatively closed protective space to prevent external dust or impurities from entering; the coupling cover is provided with at least one air inlet and at least one air outlet; the air inlet and the air outlet can guide air to flow through the inside of the protective space to dissipate heat from the combined coupling assembly, and the air inlet and the air outlet are arranged at different positions of the coupling cover, and their layout is designed so that the air can form a predetermined flow path to maximize the heat dissipation efficiency.

[0023] Furthermore, the first connecting part of the mechanical coupling component is specifically a first hub, which has an inner hole structure for fixing to the end of the driving shaft; the second connecting part is specifically a second hub, which has an inner hole structure for fixing to the starting end of the driven shaft; the first hub and the second hub are arranged opposite to each other in the axial direction and together constitute a central accommodating space.

[0024] Furthermore, the mechanical structure of the mechanical coupling component is specifically a rigid direct engagement structure, which is arranged on opposite end faces between the first hub and the second hub for directly transmitting torque therebetween.

[0025] Furthermore, the first hub and the second hub are provided with a plurality of first shape features distributed along the circumferential direction on the end face of the first hub facing the second hub; and the second hub and the second hub are provided with a plurality of second shape features; the geometric shapes of the first shape features and the second shape features match each other, the shape feature of one of them is a protruding structure, and the shape feature of the other is a corresponding groove structure; when the first hub and the second hub are axially close to each other, the protruding structure can be embedded in the groove structure, thereby transmitting rotational torque between the first hub and the second hub, and the first shape feature and the second shape feature are both provided in the radially outer area of the respective end faces of the first hub and the second hub, which surrounds the periphery of the central accommodating space; so that the mechanical torque transmission path formed by the rigid direct meshing structure and the electromagnetic torque transmission path formed by the electromagnetic coupling component provided in the central accommodating space are spatially separated, allowing the two to work independently.

[0026] Further, the first hub is constructed with an inner cavity structure, which extends inward from its end close to the second hub along the central axis of the motor to form a part of the central accommodating space and provides a first mounting inner surface for mounting the excitation part; similarly, the second hub is also constructed with an inner cavity structure, which extends inward from its end close to the first hub along the central axis of the motor to form another part of the central accommodating space and provides a second mounting inner surface for mounting the armature part; the first and second mounting inner surfaces together constitute the central accommodating space.

[0027] Furthermore, the excitation part of the electromagnetic coupling component is coaxially and non-rotatably fixed on the first mounting inner surface relative to the first hub through a first key connection; the first key connection specifically includes: a first keyway opened on the first mounting inner surface, a matching first mating keyway opened on the corresponding mating surface of the excitation part, and a first key installed in the two keyways for fixation, and the armature part of the electromagnetic coupling component is coaxially and non-rotatably fixed on the second mounting inner surface relative to the second hub through a second key connection; the second key connection specifically includes: a second keyway opened on the second mounting inner surface, a matching second mating keyway opened on the corresponding mating surface of the armature part, and a second key installed in the two keyways for fixation.

[0028] Furthermore, the first mounting inner surface and the second mounting inner surface are both cylindrical inner surfaces or other regular inner surfaces having shapes that are adapted to the excitation part and the armature part, and the first keyway and the second keyway are opened along the direction of the central axis; the excitation part and the armature part are precisely mounted in the central accommodating space jointly defined by the inner cavity structures of the first and second hubs, ensuring the coaxiality and preset working air gap between them.

[0029] Furthermore, the excitation part includes an annular excitation coil and an iron core that accommodates and conducts magnetism to the excitation coil; the armature part is made of a magnetic conductive material, and its shape is adapted to the end face of the iron core of the excitation part to form an effective magnetic circuit, and also includes a power supply interface structure for conducting the excitation current into the excitation coil; the power supply interface structure includes: at least one conductive slip ring, which rotates with the first shaft hub and is electrically connected to the excitation coil; and at least one conductive brush that cooperates with it, which maintains continuous sliding contact with the conductive surface of the conductive slip ring to transmit current during rotation.

[0030] Furthermore, the coupling cover is an integral shell structure, and an air flow channel is left between its inner wall surface and the outer contour of the combined coupling assembly; the coupling cover is fixed on the end cover of the motor body, and is provided with a sealing structure that cooperates with the driven shaft outlet position, and the sealing structure includes a sealing gasket arranged at the joint surface between the coupling cover and the motor body end cover, and a rotating shaft seal arranged between the inner wall of the shaft outlet hole and the shaft surface, so as to jointly ensure the sealing of the protective space.

[0031] Further, comprising the following steps,

[0032] (a) State determination and mode decision: Obtaining operating instructions for the drive system, wherein the parameters at least indicate a desired power transmission method (e.g., requiring a rigid connection, requiring a soft start, requiring torque limitation, or requiring a disconnection); based on the desired power transmission method, selecting at least one of the following operating modes:

[0033] Mode 1 (Mechanical Connection Mode): Select this mode to utilize the mechanical coupling component to provide the primary torque transmission path;

[0034] Mode 2 (electromagnetic connection): Select this mode to use the electromagnetic coupling component to provide the main torque transmission path;

[0035] (b) Mode execution - excitation current control:

[0036] If the decision is to select mode 1 (mechanical connection mode), the excitation current applied to the excitation part of the electromagnetic coupling component is controlled to zero or maintained below a preset safety level that is insufficient to generate effective electromagnetic torque through the power supply interface structure. At this time, power is mainly transmitted by the structure of the mechanical coupling component;

[0037] If the decision is to select mode 2 (electromagnetic connection), determining the target operating state of the electromagnetic coupling component based on a pre-set control strategy, real-time monitored load conditions, system operating mode (e.g., soft start mode, synchronous operation mode, energy-saving mode, disconnection mode), or operator input, wherein the target operating state at least defines whether the electromagnetic coupling should be in a state of substantially disengagement, fully engagement, or operating at a specific electromagnetic torque or slip ratio;

[0038] Electromagnetic coupling execution steps: by precisely controlling the power supply interface, applying, cutting off or adjusting the excitation current to the excitation coil of the excitation part of the electromagnetic coupling component: if the target state is separation, cutting off the excitation current; if the target state is engagement, applying an excitation current sufficient to generate a saturated attraction force or a rated electromagnetic torque; if the target state is a specific electromagnetic torque or slip rate, adjusting the magnitude and duty cycle of the excitation current to control the generated electromagnetic force or the allowable relative speed difference, thereby realizing active control of the torque transmitted through the electromagnetic path or the connection flexibility.

[0039] Beneficial effects of the present invention:

[0040] Multi-mode working capability and high adaptability: The present invention integrates a rigid mechanical coupling component (direct engagement structure) and a controllable electromagnetic coupling component in the same coupling assembly, so that the motor (especially in automotive applications, such as hybrid systems or electric drive axles) can flexibly select the working mode according to the actual working conditions (such as starting, cruising, acceleration, brake energy recovery, mode switching, etc.). It can use the mechanical path to achieve high-efficiency, high-rigidity direct drive (mode one), which is suitable for stable operating conditions that require efficient power transmission (such as high-speed cruising); it can also use the electromagnetic path to achieve flexible connection (mode two), completing smooth soft start / soft loading, precise torque limitation (overload protection, gear shift shock suppression), controllable slip operation (such as torque assistance or smooth transition in special modes) or active disconnection of power transmission (such as disconnecting the engine during pure electric driving). This multi-mode capability greatly improves the adaptability of the vehicle drive system to complex and changeable working conditions and the driving experience.

[0041] Compact Structure, Space Savings: This invention cleverly positions the electromagnetic coupling components (excitation and armature) within a central housing space defined by the mechanical coupling components (first and second hubs). This allows for a highly integrated spatial arrangement of the two functional components, significantly reducing the axial and radial dimensions of the entire coupling. In space-critical automotive powertrain systems, this invention offers a more compact structure than traditional, standalone, bulky clutches (such as torque converters and multi-plate wet clutches) or a combination of mechanical and electromagnetic units, facilitating powertrain layout and weight reduction.

[0042] Reliable transmission and secure connection: The mechanical coupling utilizes a direct end-face meshing structure, capable of transmitting high torque, with excellent connection rigidity and high efficiency, making it suitable for automotive applications requiring high torque and high-efficiency transmission. The excitation and armature components of the electromagnetic coupling are coaxially and non-rotatably secured to their respective hubs via keyed connections, ensuring efficient torque transmission, precise positioning between components, and a stable working air gap. This combination of two transmission paths and secure fixing ensures long-term reliable operation of the vehicle's transmission system.

[0043] Good protection and heat dissipation performance: The coupling cover not only provides effective sealing protection for the internal precision combined coupling components, but also prevents the intrusion of dust, oil, moisture and other common in the vehicle operating environment, thereby extending the service life; at the same time, the air inlet and outlet openings on the coupling cover constitute an effective heat dissipation channel, which can guide air to flow through the heat-generating components (especially the electromagnetic coil), dissipate heat in time, and ensure the thermal stability of the coupling under conditions such as frequent starting and stopping of the vehicle and high-load operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0045] Figure 1 It is a structural schematic diagram of the present invention;

[0046] Figure 2 This is a view of the coupling of the present invention;

[0047] Figure 3 This is a view of the excitation portion of the present invention;

[0048] Figure 4 This is a view of the coupling cover of the present invention;

[0049] Figure 5 is a side view of the coupling cover of the present invention;

[0050] Figure 6 This is a view of the electromagnetic coupling of the present invention;

[0051] In the figure, 101 - driving shaft, 102 - driven shaft, 103 - first connecting part, 104 - second connecting part, 105 - first shape feature, 106 - inner cavity structure, 107 - excitation part, 108 - coupling cover, 109 - rotary shaft seal, 100 - working air gap. DETAILED DESCRIPTION

[0052] The present invention will be described in this embodiment with reference to the accompanying drawings and some implementation methods.

[0053] It should be noted that, unless there is a conflict, the embodiments in this application and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in combination with the embodiments.

[0054] The following further describes the motor combining an electromagnetic coupling and a mechanical coupling of the present invention with reference to the accompanying drawings and embodiments, which is intended to help understand the technical concept and specific implementation of the present invention, but this description should not be understood as limiting the scope of protection of the present invention.

[0055] See also Figure 1-6 As shown, this embodiment discloses a motor that combines an electromagnetic coupling with a mechanical coupling. The motor mainly includes a motor body, a drive shaft 101, a combined coupling assembly, a driven shaft 102, and a coupling cover 108.

[0056] In this embodiment, the motor body is the source of power and can be a conventional electric motor, such as an AC motor, a DC motor, a servo motor, etc. The specific type is selected according to the application scenario. The motor body has an output end, usually the end of the motor rotor shaft, for outputting rotational power.

[0057] In this embodiment, one end of the drive shaft 101 is drivingly connected to the output end of the motor body. This connection can be direct (for example, the drive shaft 101 itself is an extension of the motor rotor shaft) or via a key, spline, interference fit, or other standard shaft connection method. The other end of the drive shaft 101 extends beyond the end cap of the motor body for connection to a modular coupling assembly.

[0058] In this embodiment, the driven shaft 102 is used to ultimately transmit power to a load end (not shown), such as a pump, fan, compressor, or other mechanical equipment that needs to be driven. The starting end of the driven shaft 102 is drivingly connected to the combined coupling assembly, and the end thereof is connected to the load.

[0059] In this embodiment, the combined coupling assembly is the core component of the present invention, which integrates the mechanical coupling component and the electromagnetic coupling component. The assembly is arranged between the extended end of the driving shaft 101 and the starting end of the driven shaft 102, and is responsible for selectively transmitting torque.

[0060] In this embodiment, the coupling cover 108 seals the exterior of the combined coupling assembly, forming a relatively closed protective space. The main function of this space is to protect the delicate coupling assembly inside from the external environment (such as dust, moisture, oil, accidental impact, etc.) to ensure its long-term stable operation. It is fixed to the end cover of the motor body. The coupling cover 108 has an open end, the shape and size of which are adapted to the outer edge of the end cover of the motor body; the coupling cover 108 is fixedly connected to the end cover of the motor body by a plurality of fasteners (such as bolts or screws) provided on its open end.

[0061] In this embodiment, the combined coupling assembly includes a mechanical coupling component and an electromagnetic coupling component.

[0062] In this embodiment, the mechanical coupling component is mainly responsible for providing a rigid and direct torque transmission path and includes a first connection portion 103 and a second connection portion 104 .

[0063] In this embodiment, the first connecting portion 103 is embodied as a first hub. This first hub has an inner hole structure for achieving a secure, torque-transmitting fixed connection with the end of the drive shaft 101. Similarly, the second connecting portion 104 is embodied as a second hub. This second hub also has an inner hole structure for achieving a secure, torque-transmitting fixed connection with the beginning of the driven shaft 102. The first hub and the second hub are arranged opposite each other along the central axis of the motor. Together, they define a central accommodation space located between them, which is a key area for accommodating the electromagnetic coupling components.

[0064] In this embodiment, the mechanical coupling component further includes a mechanical structure for transmitting torque between the first connection portion 103 (first hub) and the second connection portion 104 (second hub). The mechanical structure is preferably a rigid direct engagement structure.

[0065] In this embodiment, this rigid direct meshing structure is specifically arranged on the opposite end faces between the first hub and the second hub. Specifically, on the end face of the first hub facing the second hub, a plurality of first shape features 105 (for example, convex teeth) are evenly distributed along the circumferential direction. Correspondingly, on the end face of the second hub facing the first hub, a plurality of second shape features (for example, grooves corresponding to the convex teeth) whose geometric shapes match are provided. When the first hub and the second hub are axially close to and meshed, the first shape feature 105 (convex structure) can be precisely embedded in the second shape feature (groove structure). This meshing forms a direct mechanical connection, so that the torque transmitted from the drive shaft 101 can be transmitted to the driven shaft 102 through the first hub, the meshing structure, the second hub, and finally.

[0066] It is noteworthy that these first shape features 105 and the second shape features are preferably located in the radially outer region of the respective end faces of the first and second hubs. This region surrounds the periphery of the central receiving space. This layout design is of great significance: it spatially separates the mechanical torque transmission path formed by the rigid direct meshing structure from the electromagnetic torque transmission path formed by the electromagnetic coupling component disposed within the central receiving space. This spatial separation allows the mechanical and electromagnetic connections to operate independently to a certain extent or to be switched as needed, and is one of the key structural foundations for achieving the functionality of the present invention.

[0067] In this embodiment, the electromagnetic coupling component is disposed inside the central accommodation space defined by the first hub and the second hub, and is primarily responsible for providing a controllable and flexible torque transmission path. The component includes an excitation portion 107 and an armature portion.

[0068] In this embodiment, the excitation portion 107 is coaxially fixedly connected to the first connecting portion 103 (i.e., the first hub) of the mechanical coupling component. The excitation portion 107 typically includes an annular excitation coil and an iron core (typically made of a soft magnetic material such as electrical pure iron or silicon steel sheet) for accommodating and conducting the magnetism of the coil. When an excitation current is applied to the excitation coil, the iron core becomes magnetized, generating an operating magnetic field.

[0069] In this embodiment, the armature portion is coaxially fixedly connected to the second connecting portion 104 (i.e., the second hub) of the mechanical coupling component. It is positioned opposite the excitation portion 107, forming a predetermined working air gap 100 between them. The armature portion's material and structural design enable effective interaction with the magnetic field generated by the excitation portion 107. The armature portion is made of a magnetically conductive material (such as soft iron) and is fabricated from a soft magnetic material with high magnetic permeability, such as soft iron, low-carbon steel, or silicon steel laminated together to form an armature disc. When the excitation portion 107 generates a magnetic field, this field interacts with the armature portion, generating a magnetic attraction force, thereby generating or transmitting electromagnetic torque between the two. When torque is required to be transmitted through the electromagnetic coupling component, an excitation current is applied to the excitation coil. This current generates a strong magnetic field in the iron core. This magnetic field passes through the working air gap 100 and enters the magnetically conductive armature portion, magnetizing it. According to the principles of electromagnetic induction and magnetic circuit laws, the magnetized armature portion is strongly attracted to the magnetic field generated by the excitation portion 107. This magnetic attraction acts between the end faces of the excitation element 107 and the armature. When the excitation current is cut off, the magnetic field generated by the excitation element 107 rapidly disappears, along with the magnetization of the armature, and the magnetic attraction between the two drops to almost zero. Consequently, the electromagnetic coupling components quickly separate, terminating the electromagnetic torque transmission path.

[0070] In order to ensure that the electromagnetic coupling components can reliably transmit torque and maintain precise coaxiality and working air gap 100, the connection method between them and the corresponding shaft hub is crucial.

[0071] In this embodiment, the first hub is constructed with an inner cavity structure 106. This inner cavity extends inward along the motor's central axis from its end proximal to the second hub, forming a portion of the central accommodating space and providing a first mounting inner surface for mounting the excitation element 107. Similarly, the second hub is constructed with an inner cavity structure 106. This inner cavity extends inward along the motor's central axis from its end proximal to the first hub, forming another portion of the central accommodating space and providing a second mounting inner surface for mounting the armature element. These two inner cavities together constitute the main body of the central accommodating space.

[0072] In this embodiment, the excitation portion 107 is coaxially and non-rotatably fixed to the first hub on the first mounting inner surface via a first key connection. Specifically, the first key connection includes: a first keyway defined on the first mounting inner surface, a matching first mating keyway defined on a corresponding mating surface of the excitation portion 107 (e.g., the outer cylindrical surface of the core), and a first key installed in these two aligned keyways for torque transmission and fixation.

[0073] Similarly, the armature portion is coaxially and non-rotatably fixed to the second mounting inner surface relative to the second hub via a second key connection. The second key connection has a structure similar to the first key connection, including: a second keyway defined in the second mounting inner surface, a matching second mating keyway defined in a corresponding mating surface of the armature portion, and a second key mounted in these two keyways for securing the armature portion.

[0074] The keyed connection (primary and secondary) offers several advantages: simple structure, low cost, high standardization, reliable torque transmission, and guaranteed coaxiality and circumferential fixation of the excitation portion 107 and the armature portion with the primary and secondary hubs, respectively. This connection structure, located within the central housing, is compact.

[0075] In this embodiment, in order to facilitate processing and installation, the first mounting inner surface and the second mounting inner surface are preferably designed as cylindrical inner surfaces. Of course, if the outer shape of the excitation part 107 or the armature part is not a standard cylindrical shape, these mounting inner surfaces can also be designed into other regular shapes (such as polygons) to adapt thereto. Accordingly, the first keyway and the second keyway are usually straight keyways opened along the direction of the central axis of the motor. Through this precise inner cavity structure 106 and key connection method, the excitation part 107 and the armature part are precisely installed in the central accommodation space jointly defined by the inner cavity structure 106 of the first hub and the second hub. This not only ensures strict coaxiality between them, but is also crucial to ensuring the size and uniformity of the preset working air gap 100 between the two, thereby ensuring the stability and reliability of the performance of the electromagnetic coupling components.

[0076] In order for the excitation part 107 to generate a working magnetic field as required, it is necessary to provide an excitation current to the excitation coil thereof.

[0077] The power supply interface structure in this embodiment adopts a classic slip ring-brush structure. Specifically, it includes:

[0078] At least one (usually two or more, depending on the coil windings and power requirements) conductive slip ring. These slip rings are typically annular and made of a conductive material (such as copper or a copper alloy). They are fixed to the first hub and rotate with it. Each slip ring is electrically connected to one end of the excitation coil via a wire.

[0079] At least one (corresponding to each slip ring) conductive brush is used in conjunction with it. The brush is usually made of a graphite-containing composite material with good conductivity and wear resistance. The brush is fixed to a stationary component (for example, the motor end cover) so that its conductive end face maintains continuous and reliable sliding contact with the conductive surface of the corresponding conductive slip ring. The external power supply is connected to the stationary brush through a wire, and the current is transmitted to the rotating slip ring through the brush and then introduced into the excitation coil. This slip ring-brush structure is a mature technology for realizing power supply of rotating components, which can ensure the stable transmission of excitation current during rotation.

[0080] In this embodiment, the coupling cover 108 not only serves as a protective function but also has a heat dissipation function. The coupling cover 108 is preferably designed as a one-piece housing structure formed by stamping. An appropriate gap is left between its inner wall and the internal combined coupling assembly (especially its outer contour when rotating) to form a channel for air flow. To ensure the sealing of the protective space, multiple sealing measures are adopted:

[0081] A sealing gasket (such as a rubber ring or a flat sealing gasket) is provided at the joint surface between the coupling cover 108 and the end cover of the motor body.

[0082] A rotating shaft seal 109 (such as an oil seal or a labyrinth seal) is provided between the inner wall of the hole for the shaft to pass through on the coupling cover 108 and the surface of the shaft.

[0083] These sealing structures work together to effectively prevent external dust, moisture, oil, etc. from invading the protective space and protect the combined coupling components.

[0084] At the same time, considering that electromagnetic coupling components generate heat during operation (especially when the excitation coil is energized), and that mechanical coupling components may also generate heat due to friction or material damping at high speeds or high torques, effective heat dissipation of the combined coupling assembly is required. To this end, the coupling cover 108 is specifically provided with at least one air inlet and at least one air outlet.

[0085] In this embodiment, the positions of the air inlet and the air outlet. For example, the air inlet can be set at a lower position of the cover body on the side close to the motor body, and the air outlet can be set at a higher or lateral position of the cover body on the side away from the motor body. This layout is intended to utilize the airflow disturbance (fan effect) generated when the combined coupling assembly rotates, or cooperate with external forced ventilation to guide the cooling air (usually ambient air) into the protective space from the air inlet, flow through the air flow channel, blow over the surface of the combined coupling assembly (especially the electromagnetic coupling component with higher heat generation), absorb heat, and then discharge from the air outlet. The cooling air can exchange heat with the heat-generating components as fully as possible, thereby maximizing the heat dissipation efficiency and ensuring that the coupling assembly does not overheat under rated operating conditions.

[0086] The present invention also provides a control method for the motor combining the electromagnetic coupling and the mechanical coupling. The core of the method is to intelligently select and control the working states of the mechanical connection path and the electromagnetic connection path according to system requirements.

[0087] The control method mainly includes the following steps:

[0088] Step 1: State determination and mode decision

[0089] First, it is necessary to obtain operating instructions from the upper control system or operator, or monitor the current system status through sensors. These instructions or status information should at least indicate the specific requirements for the power transmission method. For example:

[0090] Do you need the most direct and efficient rigid connection? (Corresponding to mechanical connection mode)

[0091] Do you need a smooth, impact-free soft start or acceleration process? (You may need the soft start function of the electromagnetic connection mode)

[0092] Is it necessary to provide protection against overload by limiting the transmitted torque? (A torque limiting function in the electromagnetic connection mode may be required)

[0093] Is it necessary to completely disconnect the power transmission? (corresponding to the separation state of the electromagnetic connection mode)

[0094] Do you need to adjust the connection characteristics under specific operating conditions (such as energy-saving operation)?

[0095] Based on the analysis and judgment of these requirements, the control system decides to select at least one of the following working modes:

[0096] Mode 1 (Mechanical Connection Mode): Select this mode to utilize the mechanical coupling components (rigid direct engagement structure) to provide the primary and only torque transmission path. This mode provides the highest transmission efficiency and the most rigid connection.

[0097] Mode 2 (Electromagnetic Connection Mode): Select this mode to utilize the electromagnetic coupling component to provide the primary torque transmission path.

[0098] Step 2: Mode Execution - Excitation Current Control

[0099] According to the working mode selected in step 1, the control system will accurately control the excitation current of the electromagnetic coupling components.

[0100] If you decide to choose mode 1 (mechanical connection mode):

[0101] At this point, the system's goal is to allow power to be transmitted entirely through the mechanical coupling components. To prevent the electromagnetic coupling components from generating unnecessary electromagnetic forces (which may cause heating, energy consumption, or interference), the control system will control the excitation current applied to the excitation part (excitation coil) to zero (i.e., power off) through the power supply interface structure, or maintain it at a preset safety level that is far below the rated torque. In this state, the torque transmission between the drive shaft and the driven shaft mainly relies on a purely mechanical path formed by the first hub, the rigid direct meshing structure, and the second hub.

[0102] If the decision is to select mode 2 (electromagnetic connection mode):

[0103] In this mode, the control system needs to first determine the target working state required by the electromagnetic coupling components based on more specific control objectives. These objectives may come from:

[0104] Pre-set control strategies: For example, a soft start procedure is always executed when the system starts.

[0105] Real-time monitoring of load conditions: For example, when the load torque exceeds a threshold, the system enters the torque limiting state.

[0106] System operation mode switching instructions: For example, switching from high-speed operation to energy-saving mode may require adjusting the electromagnetic coupling strength.

[0107] Direct input from the operator: for example, manually triggering an emergency disconnect.

[0108] The target operating state at least defines whether the electromagnetic coupling should be in a state of essentially disengagement, fully engaged, or operating with a specific electromagnetic torque or slip ratio (the speed difference between the driving shaft and the driven shaft). Subsequently, the electromagnetic coupling execution steps are performed: the control system applies, cuts off, or fine-tunes the magnitude of the excitation current to the excitation coil by precisely controlling the power supply interface structure (for example, by controlling the output voltage and current of the power module driving the slip ring-brush):

[0109] If the target state is separated (open): the control system will cut off the excitation current (set to zero).

[0110] If the target state is fully engaged (synchronized), the control system applies a sufficiently high excitation current (e.g., rated current or saturation current) to generate a strong magnetic attraction between the magnetic field generated by the excitation element and the armature (magnetic conductive material). This attraction acts between the excitation and armature components, directly transmitting torque through magnetic flux linkage. This is sufficient to transmit the rated load torque and ensures that there is almost no relative speed difference between the driving and driven shafts (i.e., synchronous rotation). At this point, the electromagnetic coupling component assumes the primary responsibility for torque transmission.

[0111] If the target state is a specific electromagnetic torque or slip ratio (flexible control), the control system needs to more finely adjust the excitation current. Soft start / soft load: By gradually increasing the excitation current during the startup process, the electromagnetic torque can be slowly increased from zero to a level sufficient to drive the load, achieving a smooth startup and reducing the impact on the motor and load. Torque limit: By setting a maximum excitation current value, the maximum torque that the electromagnetic coupling can transmit can be limited, thereby protecting the motor and drive chain from overload damage.

[0112] Summarize

[0113] The present invention achieves the following advantages by cleverly integrating a rigid mechanical coupling component and a controllable electromagnetic coupling component into the same combined coupling assembly, which is arranged between the motor drive shaft and the driven shaft:

[0114] Multi-mode working capability: rigid mechanical connection (high efficiency, high stiffness) or flexible electromagnetic connection (controllable torque, soft start, overload protection, disconnection) can be selected according to needs.

[0115] Compact structure: The electromagnetic components are accommodated in the central space formed by the mechanical components (hub), saving axial space.

[0116] Reliable connection: The mechanical components adopt a direct meshing structure, and the electromagnetic components and the shaft hub are key-connected, ensuring the reliability of torque transmission.

[0117] Good protection and heat dissipation: The coupling cover provides sealed protection and is equipped with vents for heat dissipation, ensuring long-term stable operation.

[0118] Intelligent control: The supporting control method can automatically select the operating mode according to system requirements and accurately control the electromagnetic coupling state, improving the adaptability and performance of the system.

[0119] This motor design, which combines the advantages of both couplings, is particularly suitable for industrial transmission fields that have high requirements for starting performance, overload protection, and operating mode switching.

[0120] The above specific embodiments are typical examples of the present invention, but the present invention is not limited thereto. Without departing from the core technical concept of the present invention, reasonable changes can be made to its structure, materials and control logic, and all improvements based on this fall within the scope of protection of the present invention.

[0121] The specific embodiments of the present invention are merely illustrative and do not limit the scope of protection of the present invention. Various changes and modifications may be made to the specific embodiments of the present invention without departing from the gist and spirit of the present invention. Such changes and modifications are within the scope of the present invention.

[0122] It is worth noting that: in the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly defined and specified. In the present invention, unless otherwise clearly specified and defined, the terms "install", "connect", "connect", "fix" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection; the circuits described in the present invention are all commonly used circuits in the art, and other related components are all existing commonly used components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0123] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and it is intended that all variations within the meaning and scope of the appended claims be encompassed. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A motor combining an electromagnetic coupling and a mechanical coupling, wherein the motor body has an output end and is characterized in that: It also includes a drive shaft, a combined coupling assembly, a driven shaft, and a coupling cover; One end of the drive shaft is transmission-connected to the output end of the motor body, and the other end extends out; The driven shaft is in driving connection with the combined coupling assembly for transmitting power to the load end; The combined coupling assembly is arranged at the protruding end of the drive shaft; Combined coupling components include: mechanical coupling components, electromagnetic coupling components, The mechanical coupling component includes: a first connecting portion fixedly connected to the end of the drive shaft; a second connecting portion fixedly connected to the starting end of the driven shaft; The first connecting portion and the second connecting portion are interconnected via a mechanical structure and together define a central accommodation space located therebetween, and the mechanical structure transmits torque between the driving shaft and the driven shaft; The electromagnetic coupling component is arranged inside the central accommodating space, and includes: an excitation portion, coaxially fixedly connected to the first connecting portion of the mechanical coupling component, and configured to generate a working magnetic field when energized; an armature portion, coaxially fixedly connected to the second connecting portion of the mechanical coupling component, and arranged opposite to the excitation portion, with a working air gap formed therebetween; the armature portion is capable of interacting with the magnetic field generated by the excitation portion to transmit electromagnetic torque, wherein a key connection structure is used between the excitation portion and the first connecting portion, and between the armature portion and the second connecting portion to achieve coaxial fixation and torque transmission; the key connection structure is arranged inside the central accommodating space; The coupling cover seals the outside of the combined coupling assembly to form a relatively closed protective space to prevent external dust or impurities from entering; the coupling cover is provided with at least one air inlet and at least one air outlet; the air inlet and the air outlet can guide air to flow through the inside of the protective space to dissipate heat from the combined coupling assembly, and the air inlet and the air outlet are arranged at different positions of the coupling cover, and their layout is designed so that the air can form a predetermined flow path to maximize the heat dissipation efficiency.

2. The motor combining electromagnetic coupling and mechanical coupling according to claim 1, characterized in that: The first connecting part of the mechanical coupling component is specifically a first hub, which has an inner hole structure for fixing to the end of the driving shaft; the second connecting part is specifically a second hub, which has an inner hole structure for fixing to the starting end of the driven shaft; the first hub and the second hub are arranged opposite to each other in the axial direction and together constitute a central accommodating space.

3. The motor combining electromagnetic coupling and mechanical coupling according to claim 2, characterized in that: The mechanical structure of the mechanical coupling component is specifically a rigid direct engagement structure, which is arranged on opposite end faces between the first hub and the second hub for directly transmitting torque therebetween.

4. The motor combining electromagnetic coupling and mechanical coupling according to claim 3, characterized in that: On the end face of the first hub facing the second hub, multiple first shape features are distributed along the circumferential direction; and on the end face of the second hub facing the first hub, multiple second shape features are arranged; the geometric shapes of the first shape features and the second shape features match each other, the shape feature of one is a protruding structure, and the shape feature of the other is a corresponding groove structure; when the first hub and the second hub are axially close to each other, the protruding structure can be embedded in the groove structure, thereby transmitting rotational torque between the first hub and the second hub, the first shape feature and the second shape feature are both arranged in the radially outer area of the respective end faces of the first hub and the second hub, which surrounds the periphery of the central accommodating space; the mechanical torque transmission path formed by the rigid direct meshing structure and the electromagnetic torque transmission path formed by the electromagnetic coupling component arranged in the central accommodating space are spatially separated, allowing the two to work independently.

5. The motor combining an electromagnetic coupling and a mechanical coupling according to claim 2, characterized in that: The first shaft hub is constructed with an inner cavity structure, which extends inwardly from an end thereof close to the second shaft hub along the central axis of the motor to form a part of the central accommodating space and provides a first mounting inner surface for mounting the excitation part; similarly, the second shaft hub is also constructed with an inner cavity structure, which extends inwardly from an end thereof close to the first shaft hub along the central axis of the motor to form another part of the central accommodating space and provides a second mounting inner surface for mounting the armature part; The first and second mounting inner surfaces together form a central receiving space.

6. The motor combining an electromagnetic coupling and a mechanical coupling according to claim 5, characterized in that: The excitation part of the electromagnetic coupling component is coaxially and non-rotatably fixed on the first mounting inner surface relative to the first hub through a first key connection; the first key connection specifically includes: a first keyway opened on the first mounting inner surface, a matching first mating keyway opened on the corresponding mating surface of the excitation part, and a first key installed in the two keyways for fixation, and the armature part of the electromagnetic coupling component is coaxially and non-rotatably fixed on the second mounting inner surface relative to the second hub through a second key connection; the second key connection specifically includes: a second keyway opened on the second mounting inner surface, a matching second mating keyway opened on the corresponding mating surface of the armature part, and a second key installed in the two keyways for fixation.

7. The motor combining an electromagnetic coupling and a mechanical coupling according to claim 6, characterized in that: The first mounting inner surface and the second mounting inner surface are both cylindrical inner surfaces or other regular inner surfaces having shapes that are adapted to the excitation part and the armature part, and the first keyway and the second keyway are opened along the direction of the central axis; the excitation part and the armature part are precisely mounted in the central accommodating space jointly defined by the inner cavity structures of the first and second hubs, ensuring the coaxiality and preset working air gap between them.

8. The motor combining electromagnetic coupling and mechanical coupling according to claim 1, characterized in that: The excitation part includes an annular excitation coil and an iron core that accommodates and conducts magnetism to the excitation coil; the armature part is made of magnetic conductive material, and its shape is adapted to the end face of the iron core of the excitation part to form an effective magnetic circuit. It also includes a power supply interface structure for conducting the excitation current into the excitation coil; the power supply interface structure includes: at least one conductive slip ring, which rotates with the first hub and is electrically connected to the excitation coil; and at least one conductive brush that cooperates with it, which maintains continuous sliding contact with the conductive surface of the conductive slip ring to transmit current during rotation.

9. The motor combining electromagnetic coupling and mechanical coupling according to claim 1, characterized in that: The coupling cover is an integral shell structure, with an air flow channel between its inner wall and the outer contour of the combined coupling assembly; the coupling cover is fixed to the end cover of the motor body and is provided with a sealing structure that matches the position where the driven shaft passes through. The sealing structure includes a sealing gasket arranged at the joint surface between the coupling cover and the end cover of the motor body, and a rotating shaft seal arranged between the inner wall of the shaft outlet hole and the shaft surface, so as to jointly ensure the sealing of the protective space.

10. The control method of a motor combining an electromagnetic coupling and a mechanical coupling according to claims 1 to 9, characterized in that: The following steps are included: (a) State determination and mode decision: Obtaining operating instructions for the drive system, wherein the parameters at least indicate the power transmission mode required; based on the requirement, selecting at least one of the following operating modes: Mode 1: Mechanical connection mode, this mode is selected to utilize the mechanical coupling component to provide the main torque transmission path; Mode 2: electromagnetic connection, select this mode to use the electromagnetic coupling component to provide the main torque transmission path; (b) Mode Execution - Field Current Control: If the decision is made to select mode 1: mechanical connection mode, the excitation current applied to the excitation portion of the electromagnetic coupling component is controlled to zero or maintained below a preset safety level that is insufficient to generate effective electromagnetic torque through the power supply interface structure. At this time, power is mainly transmitted by the structure of the mechanical coupling component; If the decision is to select mode 2: electromagnetic connection, determining a target operating state of the electromagnetic coupling component based on a pre-set control strategy, a real-time monitored load condition, a system operating mode, or an operator input, wherein the target operating state at least defines whether the electromagnetic coupling should be in a state of substantially disengagement, fully engagement, or operating at a specific electromagnetic torque or slip ratio; Electromagnetic coupling execution step: applying, cutting off or adjusting the excitation current to the excitation coil of the excitation part of the electromagnetic coupling component by precisely controlling the power supply interface: if the target state is separation, cutting off the excitation current; if the target state is engagement, applying an excitation current sufficient to generate a saturated attractive force or a rated electromagnetic torque; If the target state is a specific electromagnetic torque or slip rate, the magnitude and duty cycle of the excitation current are adjusted to control the generated electromagnetic force or the allowable relative speed difference, thereby achieving active control of the torque transmitted through the electromagnetic path or the connection flexibility.

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