A high-compact power drive device, system and power equipment

Abstract

The application provides a high-compact power driving device, system and power equipment, and relates to the technical field of hybrid power machinery. The high-compact power driving device has a first motor part and a second motor part. The first motor part is electrically connected with an energy storage structure and can be used as a motor. The second motor part is in transmission connection with an engine and can be used as a generator, that is, the high-compact power driving system provided by the embodiment is a dual-function power machinery integrated with a motor and a generator, and the cruising capability can be improved. The first motor part adopts a Halbach supplement structure, is sleeved outside the second motor part, is far away from the center of the device and has a large radius, so that the first motor part can be as thin as possible under the condition of meeting the magnetic load index, the occupied radial dimension is reduced, and the use amount of permanent magnets is reduced by adopting the Halbach permanent magnet, so that the effect of light weight is achieved. A slotless stator structure is adopted, the stator slot depth is saved, more design space is provided for coaxial design, and the demand of high compactness is met.

Description

Technical Field

[0001] This invention relates to the field of hybrid power machinery technology, and more specifically, to a highly compact power drive device, system, and power equipment. Background Technology

[0002] Currently, in motor vehicles powered by electricity, pure electric systems and hybrid power systems are commonly used. Pure electric systems use batteries as a power source, while hybrid power systems essentially use a fuel engine to generate electricity, resulting in the conservation of mechanical energy, although transmission losses also exist. However, electric motors have higher utilization efficiency and a wider efficient operating range, while traditional fuel engines are often inefficient at low speeds. For aviation electrification, the low power density of batteries currently makes it difficult to achieve all-electric aircraft with medium to large power outputs. Therefore, hybrid power technology is a transitional solution between traditional fuel-powered aircraft engines and all-electric aircraft engines. For aviation hybrid technology, the weight and size of its electrification system have very stringent requirements. Insufficient electric motor power density makes it difficult to replace traditional gas turbines, so the design of high-power-density hybrid power systems is a key technology. Traditional aviation hybrid configurations include series, parallel, and series-parallel configurations. Regardless of the connection method, a turboshaft generator is required, but turboshaft systems often introduce significant additional space and weight. Therefore, it is necessary to focus on the design of a compact power system for aviation hybrid systems. Summary of the Invention

[0003] The purpose of this invention is to provide a highly compact power drive device, system, and power equipment that can improve the technical problem of low power density in existing electrified drive devices.

[0004] Embodiments of the present invention can be implemented in the following ways:

[0005] A highly compact power drive device, the highly compact power drive device comprising:

[0006] A first motor section, configured to be electrically connected to an energy storage structure for operation using electrical energy supplied by the energy storage structure; the first motor section includes a first motor rotor and a first motor stator nested together, the first motor rotor having Halbach permanent magnets; and

[0007] The second motor section is disposed inside the first motor section, and the first motor section and the second motor section are coaxially arranged; the second motor section is used for transmission connection with the engine and for electrical connection with the energy storage structure; the second motor section includes a second motor rotor and a second motor stator nested together.

[0008] Both the first motor stator and the second motor stator are slotless structures.

[0009] Optionally, the first motor rotor is located radially outside the first motor stator.

[0010] Optionally, the first motor rotor further includes a carbon fiber sheath and a titanium alloy shell, wherein the Halbach permanent magnet, the titanium alloy shell, and the carbon fiber sheath are arranged sequentially in a radially outward direction along the first motor rotor;

[0011] The carbon fiber sheath is fixed to the titanium alloy shell by a winding technique.

[0012] Optionally, the first motor stator includes a first shaped Litz wire winding, a first stator core, and a stator heat sink, wherein the first shaped Litz wire winding, the first stator core, and the stator heat sink are arranged sequentially in a radially inward direction along the first motor stator; the Halbach permanent magnet and the first shaped Litz wire winding are arranged radially spaced along the first motor portion, and a first gap is formed between the Halbach permanent magnet and the first shaped Litz wire winding;

[0013] The first molded Litz wire winding is fixed to the surface of the first stator core by high-temperature adhesive.

[0014] Optionally, the second motor rotor is disposed radially inside the second motor stator.

[0015] Optionally, the high-compact power drive device further includes a motor shaft, which is located at the center of the high-compact power drive device, and the second motor rotor is connected to the motor shaft via a flat key.

[0016] Optionally, the high-compact power drive device further includes a shielding cover disposed between the first motor section and the second motor section; the second motor stator is fixedly connected to the shielding cover, and the shielding cover is rotatably supported on the motor shaft by a double tapered bearing;

[0017] The rotor of the first motor is rotatably supported on the shield by bearings.

[0018] Optionally, the second motor stator includes a second stator core and a second shaped Litz wire winding, wherein the second shaped Litz wire winding and the second stator core are arranged sequentially in a radially inward direction along the second motor stator.

[0019] Optionally, the second motor rotor includes a rotor core and rotor winding coils. The rotor core is provided with a plurality of mounting slots distributed circumferentially, and the rotor winding coils are embedded in the mounting slots.

[0020] A high-compact power drive system, the high-compact power drive system comprising a gearbox, a clutch, and the aforementioned high-compact power drive device;

[0021] The gearbox has a first input section, a second input section, and an output section. The output section is used for transmission connection with a driven component. The first input section is transmissionally connected to the rotor of the first motor, and the second input section is transmissionally connected to the rotor of the second motor through the clutch to control the on / off of power transmission between the rotor of the second motor and the second input section.

[0022] Optionally, the gearbox includes a sun gear, planet gears, a planet carrier, and a ring gear; a plurality of planet gears mesh with the sun gear and are arranged around the sun gear; the plurality of planet gears are all mounted on the planet carrier; the ring gear is sleeved on the plurality of planet gears and meshes with the plurality of planet gears.

[0023] The sun gear forms the second input section, the gear ring forms the first input section, and the planet carrier forms the output section.

[0024] Optionally, the high-compact power drive system further includes a housing, which includes a first housing portion, a second housing portion, and a third housing portion connected in sequence. The first housing portion forms a first space for accommodating the high-compact power drive device, the second housing portion forms a second space for accommodating the clutch, and the third housing portion forms a third space for accommodating the gearbox.

[0025] A power device includes an engine, an energy storage structure, and the aforementioned high-compact power drive system. The engine is driven by a second motor rotor to drive the second motor rotor. The energy storage structure is electrically connected to the high-compact power drive system to supply power to the high-compact power drive system or store the electrical energy generated by the high-compact power drive system.

[0026] The beneficial effects of the highly compact power drive device, system, and power equipment provided by the embodiments of the present invention include:

[0027] Embodiments of the present invention provide a highly compact power drive device integrating a first motor section and a second motor section coaxially arranged. The first motor section functions as an electric motor, while the second motor section functions as a generator, thereby contributing to improved range. The first motor section employs a Halbach topology, which is located far from the device center and has a large radius. Therefore, it can be made as thin as possible while meeting magnetic load requirements, reducing the radial dimensions it occupies. Furthermore, the use of Halbach permanent magnets reduces the amount of permanent magnets used, resulting in weight reduction. The first and second motor stators adopt a slotless structure, eliminating stator slot depth and providing more design space for coaxial design, meeting the requirements of high compactness. Therefore, this highly compact power drive device meets the requirement of high power density within a small space.

[0028] Embodiments of the present invention also provide a highly compact power drive system having the aforementioned highly compact power drive device, thus also having the beneficial effects of small footprint and high power density.

[0029] Embodiments of the present invention also provide a power device that includes the aforementioned highly compact power drive system, and thus also has the technical effects of high power density and long range. Attached Figure Description

[0030] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals.

[0031] Figure 1 An overall framework diagram of a power device according to one aspect of the present invention is shown;

[0032] Figure 2 A side view of a power device according to one aspect of the present invention is shown;

[0033] Figure 3 A schematic diagram of the overall structure of a highly compact power drive device according to one aspect of the present invention is shown.

[0034] Figure 4 A top view schematic diagram of a highly compact power drive device according to one aspect of the present invention is shown.

[0035] Figure 5 A schematic diagram of the structure of the smallest unit in a highly compact power drive device according to one aspect of the present invention is shown;

[0036] Figure 6 A schematic diagram of the structure of the gearbox in a highly compact power drive system according to one aspect of the present invention is shown.

[0037] Figure 7 It shows Figure 6 A top view of the structure shown;

[0038] Figure 8 It shows Figure 6 A schematic diagram of the structure shown from below;

[0039] Figure 9 It shows Figure 6 The diagram shows the structure after removing the first housing portion.

[0040] Figure 10 A schematic diagram of the application structure of a highly compact power drive system according to one aspect of the present invention in the automotive field is shown.

[0041] Figure 11 A schematic diagram of the application structure of a highly compact power drive system according to one aspect of the present invention in an aviation electrified propulsion system is shown.

[0042] Figure 12 A schematic diagram of the structure in pure electric drive mode according to one aspect of the present invention is shown;

[0043] Figure 13 A schematic diagram of the structure in series drive mode according to one aspect of the present invention is shown;

[0044] Figure 14 A schematic diagram of the structure in parallel drive mode according to one aspect of the present invention is shown;

[0045] Figure 15 A schematic diagram of the structure in full power output mode according to one aspect of the present invention is shown;

[0046] Figure 16 A schematic diagram of the structure in energy recovery mode according to one aspect of the present invention is shown;

[0047] Figure 17 A schematic diagram of the structure in engine start-stop mode according to one aspect of the present invention is shown.

[0048] Figure label:

[0049] 10-Power equipment; 11-Engine; 12-Energy storage structure; 13-Highly compact power drive system;

[0050] 100 - High-compact power drive unit; 110 - First motor section; 111 - First motor rotor; 112 - Halbach permanent magnet; 113 - Carbon fiber sheath; 114 - Titanium alloy housing; 115 - First motor stator; 116 - First molded Litz wire winding; 117 - First stator core; 118 - Stator heat sink; 120 - Second motor section; 121 - Second motor rotor; 122 - Rotor core; 123 - Mounting slot; 124 - Rotor winding coil; 125 - Second motor stator; 126 - Second stator core; 127 - Second molded Litz wire winding; 131 - Motor shaft; 132 - Shielding cover; 133 - Double tapered bearing; 134 - Bearing;

[0051] 200-Clutch;

[0052] 300 - Gearbox; 311 - Sun gear; 312 - Planetary gear; 313 - Planetary carrier; 314 - Ring gear;

[0053] 400 - Housing; 411 - First housing section; 412 - Second housing section; 413 - Third housing section;

[0054] 20-Driven component; 21-Hub; 22-External bypass fan. Detailed Implementation

[0055] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0056] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," "outer," or "vertical" appear, the orientation or positional relationship indicated is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed when in use, and does not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0057] At the same time, it should be noted that the terms "first" and "second" are used only for distinguishing descriptions and should not be interpreted as indicating or implying relative importance.

[0058] In the description of this invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0059] Definitions of relevant terms that may be mentioned in the description of this invention:

[0060] An electric motor is a device that converts electrical energy into mechanical energy. It utilizes a rotating magnetic field generated by a current-carrying coil (stator winding) that acts on a rotor (such as a squirrel-cage closed aluminum frame) to create magnetoelectric torque. Electric motors are classified into DC motors and AC motors based on the power source used. Most motors in power systems are AC motors, which can be synchronous or asynchronous (the stator magnetic field speed and rotor rotation speed are not synchronized). An electric motor mainly consists of a stator and a rotor. The direction of the force on a current-carrying conductor in a magnetic field depends on the direction of the current and the direction of the magnetic field lines. The working principle of an electric motor is that the magnetic field exerts a force on the current, causing the motor to rotate.

[0061] Generator: A mechanical device that converts mechanical energy into electrical energy. It is driven by a water turbine, steam turbine, diesel engine or other power machinery, which converts the energy generated by water flow, air flow, fuel combustion or nuclear fission into mechanical energy and then transmits it to the generator, which then converts it into electrical energy.

[0062] Distributed: This refers to distributing different modules in different locations. In contrast to centralized, distributed systems are a typical architecture for advanced intelligent systems.

[0063] Figure 1 This is an overall frame diagram of the power equipment 10 provided in this embodiment. Figure 2 This is an axle-side schematic diagram of the power equipment 10 provided in this embodiment. Figure 3 This is a schematic diagram of the overall structure of the highly compact power drive device 100 provided in this embodiment. Figure 4 This is a top view of the highly compact power drive device 100 provided in this embodiment. Figure 5 This is a schematic diagram of the smallest unit in the highly compact power drive device 100 provided in this embodiment. Please refer to the attached diagram. Figures 1-5 This embodiment provides a high-compact power drive device 100, a high-compact power drive system 13, and a power equipment 10.

[0064] The high-compact powertrain system 13 includes a high-compact powertrain unit 100, as well as a transmission 300 and a clutch 200. In operation, the high-compact powertrain system 13, together with the conventional engine 11 and energy storage structure 12, forms a hybrid integrated structure, thereby achieving the following: Figure 1 The power equipment 10 shown.

[0065] The high-compact power drive device 100 includes a first motor section 110 and a second motor section 120 coaxially arranged, with the first motor section 110 located radially outside the second motor section 120, meaning the radial dimension of the first motor section 110 is larger than that of the second motor section 120. It should be noted that since both the first motor section 110 and the second motor section 120 are cylindrical and coaxially arranged, and the axes of the first motor section 110, the second motor section 120, and the high-compact power drive device 100 coincide, in the description of this embodiment, when referring to the axial direction of a component in the high-compact power drive device 100, it can be considered as the axial direction of the high-compact power drive device 100. Correspondingly, the radial direction of a component can also be considered as a direction perpendicular to the axis of the high-compact power drive device 100.

[0066] The first motor unit 110 is electrically connected to the energy storage structure 12, so that the first motor unit 110 can operate using the electrical energy supplied by the energy storage structure 12. In other words, the first motor unit 110 can be used as an electric motor. The second motor unit 120 is driven by the engine 11 and is used to be electrically connected to the energy storage structure 12. So that when the second motor unit 120 rotates and generates electricity under the drive of the engine 11, the electrical energy generated can be stored through the energy storage structure 12. In other words, the second motor unit 120 can be used as a generator. That is, the high-compact power drive system 13 provided in this embodiment is a dual-function power machine that integrates an electric motor and a generator.

[0067] In the high-compact power drive system 13, the gearbox 300 has a first input section, a second input section, and an output section. The first input section is driven by the first motor rotor 111 of the first motor section 110, so that when the first motor section 110 is running, the mechanical energy generated by the first motor section 110 is input into the gearbox 300 through the first input section. The second input section is driven by the second motor rotor 121 of the second motor section 120 through a clutch 200, so that the power transmission between the second motor rotor 121 and the second input section is controlled by the clutch 200. That is, when the clutch 200 connects the second input section and the second motor section 120, the power transmission between the second motor rotor 121 and the second input section is connected, and the mechanical energy of the second motor section 120 is transmitted to the second input section through the clutch 200. When the clutch 200 disconnects the second input section from the second motor section 120, the power transmission between the second motor rotor 121 and the second input section is interrupted, and the second motor section 120 cannot transmit mechanical energy to the second input section. Simultaneously, when the clutch 200 connects the power transmission between the second input section and the second motor section 120, the first motor section 110 and the second motor section 120 simultaneously provide mechanical energy to the gearbox 300. Therefore, in addition to power transmission, the gearbox 300 also needs to match the rated speeds of the first motor section 110 and the second motor section 120 according to actual usage requirements. The output section is used to connect with the driven member 20, thereby transmitting the mechanical energy transmitted from the first motor section 110 and / or the second motor section 120 to the gearbox 300 to the driven member 20, thereby driving the driven member 20 to operate.

[0068] The following is combined Figures 3-5 The highly compact power drive device 100 provided in this embodiment will be further described as follows:

[0069] In this embodiment, the first motor unit 110 includes a first motor rotor 111 and a first motor stator 115 nested together. The first motor rotor 111 has a Halbach permanent magnet 112. The electromagnetic design of a motor is essentially an interweaving of electric and magnetic fields. Improving power density is closely related to the high electromagnetic load of the motor. Therefore, in this outer rotor topology, the radius of the first motor unit 110 is larger than that of the second motor unit 120, resulting in a relatively increased material usage for the Halbach permanent magnet 112. Thus, it can be made as thin as possible while meeting the magnetic load requirements. Furthermore, the Halbach permanent magnet is currently a high magnetic load design material, and its use can further reduce the amount of permanent magnet used, thereby achieving a lightweight effect.

[0070] Optionally, the first motor rotor 111 is located radially outside the first motor stator 115. Positioning the first motor rotor 111 radially outside the first motor stator 115 has two advantages: firstly, the radial dimension of the first motor rotor 111 is larger than that of the first motor stator 115, allowing for a further reduction in the thickness of the Halbach permanent magnet 112 in the first motor rotor 111; secondly, it helps meet the heat dissipation requirements of the first motor rotor 111, thereby reducing the need for heat dissipation structures and further improving the compactness of the device.

[0071] Furthermore, the first motor rotor 111 also includes a carbon fiber sheath 113 and a titanium alloy shell 114. The Halbach permanent magnet 112, the titanium alloy shell 114, and the carbon fiber sheath 113 are arranged sequentially in a radially outward direction along the first motor rotor 111, that is, the titanium alloy shell 114 covers the outside of the Halbach permanent magnet 112, and the carbon fiber sheath 113 covers the outside of the titanium alloy shell 114. Specifically, the carbon fiber sheath 113 is fixed to the titanium alloy shell 114 by a winding technique, thus ensuring a tight fit between the carbon fiber sheath 113 and the titanium alloy shell 114. By providing a protective structure consisting of a carbon fiber sheath 113 and a titanium alloy shell 114 outside the Halbach permanent magnet 112, this protective structure is thin and lightweight, with sufficient preload and containment effect, effectively preventing the catastrophic consequences of the rotor components inside flying off under high-speed rotation.

[0072] In this embodiment, the first motor stator 115 adopts a slotless structure, that is, the first motor section 110 in this embodiment adopts an external rotor Halbach slotless topology. Specifically, the first motor stator 115 includes a first shaped Litz wire winding and a first stator core 117, that is, the structure composed of the first shaped Litz wire winding 116 and the first stator core 117 is a slotless structure. The use of a slotless stator structure provides more space for the coaxial design of dual motors. The first shaped Litz wire winding 116 is located outside the first stator core 117, so the first shaped Litz wire winding 116 is located on the outermost side of the first motor stator 115, close to the first motor rotor 111. The innermost side of the first motor rotor 111 is a Halbach permanent magnet 112. The Halbach permanent magnet 112 and the first shaped Litz wire winding 116 are arranged radially spaced along the first motor section 110, and a first gap C is formed between the first shaped Litz wire windings 116. Using shaped Litz wire to form the stator winding can effectively suppress AC losses in the motor at high frequencies. Furthermore, the structure of the first motor section 110 allows for minimizing the size of the first gap C, thereby increasing the motor's output torque. The lead-out end winding of the first shaped Litz wire winding 116 can be led out and electrically connected to the energy storage structure 12. The specific arrangement of its lead-out structure can be configured according to requirements and is not detailed here.

[0073] Optionally, the first molded Litz wire winding 116 is fixed to the surface of the first stator core 117 using a high-temperature adhesive, thus forming a slotless structure. This slotless structure minimizes torque pulsation, and compared to a slotted structure, the space occupied by the stator slots can be used to lay more windings, improving the slot fill factor to some extent. It is understood that in other embodiments, other methods can be used to achieve the fixed connection between the first molded Litz wire winding 116 and the first stator core 117, and this connection can also be a slotless structure.

[0074] Furthermore, the first motor stator 115 also includes a stator heat sink 118. The first shaped Litz wire winding 116, the first stator core 117, and the stator heat sink 118 are arranged sequentially in a radially inward direction along the first motor stator 115, with the stator heat sink 118 located inside the stator core. The stator heat sink 118 is a lightweight hollow structure with a channel extending axially along the high-compact power drive device 100, facilitating airflow through this channel to effectively cool the first motor stator 115, which generates significant heat in the first motor section 110. Thus, the first motor section 110 provided in this embodiment does not require oil cooling, effectively avoiding the serious consequences of cooling oil leakage and preventing additional weight gain, further improving the power-to-weight ratio of the entire system.

[0075] In this embodiment, the second motor rotor 121 is disposed radially inside the second motor stator 125. Specifically, in this embodiment, the second motor rotor 121 is positioned close to the center of the high-compact power drive device 100, and the second motor stator 125 is positioned close to the first motor stator 115. Further, the high-compact power drive device 100 also includes a motor shaft 131, which is disposed at the center of the high-compact power drive device 100. Thus, the second motor rotor 121 can be directly and fixedly connected to the motor shaft 131 to achieve power transmission between the second motor rotor 121 and the motor shaft 131. Optionally, the second motor rotor 121 and the motor shaft 131 are connected by a flat key. It is understood that in other embodiments, other methods can also be used to connect the second motor rotor 121 and the motor shaft 131.

[0076] Furthermore, the second motor rotor 121 includes a rotor core 122 and rotor winding coils 124. The rotor core 122 has multiple mounting slots 123 distributed circumferentially, and the rotor winding coils 124 are embedded in these mounting slots 123. Specifically, the mounting slots 123 are distributed axially along the rotor core 122 and form open slots on the outer circumferential surface of the rotor core 122. After the rotor winding coils 124 are installed in the mounting slots 123, they can interact electromagnetically with the first motor stator 115 located outside the second motor rotor 121. In this embodiment, the rotor core 122 is connected to the motor shaft 131 via a flat key.

[0077] Furthermore, the second motor stator 125 includes a second stator core 126 and a second shaped Litz wire winding 127. The second shaped Litz wire winding 127 and the second stator core 126 are arranged sequentially in a radially inward direction along the second motor stator 125, that is, the second shaped Litz wire winding 127 is located inside the second stator core 126, close to the second motor rotor 121. The second motor stator 125 adopts a slotless structure, that is, in this embodiment, the second motor section 120 is a slotless electrically excited synchronous topology. The use of a synchronous topology structure that makes demagnetization easier to achieve helps to improve the safety performance of the high-compact power drive device 100 and further enhances redundancy. In this embodiment, the second type of Litz wire winding is fixed to the surface of the second stator core 126 by high-temperature adhesive. It is understood that in some other embodiments, other slotless structures may also be used.

[0078] The lead-out end windings of the second-formed Litz wire winding 127 and the rotor winding coil 124 can be led out and electrically connected to the energy storage structure 12. The specific arrangement of the lead-out structure can be set according to requirements, which is not detailed here.

[0079] In this embodiment, the high-compact power drive device 100 further includes a shield 132 disposed between the first motor section 110 and the second motor section 120. The second motor stator 125 is fixedly connected to the shield 132, so the shield 132 can also be regarded as part of the second motor stator 125. Since the first motor stator 115 in the first motor section 110 is located on the inner side, the first motor stator 115 can also be fixedly connected to the shield 132. That is, in this embodiment, the first motor stator 115, the second motor stator 125, and the shield 132 are connected to form the stator part of the high-compact power drive device 100. The shield 132 is supported on the motor shaft 131 by a double tapered bearing 133, and the first motor rotor 111 is rotatably supported on the shield 132 by a bearing 134. In this way, the double tapered bearing 133 and the bearing 134 ensure the normal operation between the stator part and the rotor part (the first motor rotor 111 and the second motor rotor 121). Specifically, the titanium alloy housing 114 of the first motor rotor 111 is rotatably connected to the shield 132 via a bearing 134.

[0080] Figure 6 This diagram shows a structural schematic of the gearbox 300 in the high-compact power drive system 13 provided in this embodiment. Figure 7 It shows Figure 6 A top view of the structure shown. Figure 8 It shows Figure 6 A schematic diagram of the structure shown from below. Figure 9 for Figure 6 The diagram shown is a structural schematic after removing the first housing portion 411. Please refer to the reference diagram. Figures 6-9 In the high-compact power drive system 13 provided in this embodiment, the mechanical energy provided by the high-compact power drive device 100 is transmitted outward through the gearbox 300. Moreover, the first input part of the gearbox 300 receives mechanical energy from the first motor part 110, and the second input part receives mechanical energy from the second motor part 120. Therefore, the gearbox 300 can match the design parameters of the first motor part 110 and the second motor part 120, and realize the rationality of the electromagnetic design of the first motor part 110 and the second motor part 120 in terms of size, speed, output torque, torque pulsation and back electromotive force.

[0081] Specifically, the design considerations for the gearbox will be explained below from the perspective of the motor design:

[0082] The specific power density of an electric motor can be expressed as:

[0083] (1)

[0084] Where K φIt is the ratio of electrical load on the rotor to that on the stator, m is the number of phases, m1 is the number of phases per stator, and K e It is the EMF factor, K i It is the current waveform factor, K p It is the electrical power waveform coefficient, η is the motor efficiency, and B g Here, A is the air gap flux density, f is the total electrical load of the motor, p is the converter frequency, and D is the number of pole pairs of the motor. g It is the air gap diameter, L e Where is the effective stack length and M is the mass of the motor. To simplify the expression, specific power density can be defined, omitting the constant factor as a dependency on the following parameters:

[0085] (2)

[0086] in, and D g L e The specific power density of a rotating electrical machine is directly proportional to its air gap flux density, electrical load, and rotational speed, respectively. The average air gap flux density is a key parameter for increasing the power of any motor; for aircraft applications, it is typically between 0.4 and 1 T. This parameter is limited by the saturation of the stator and rotor magnets and the capability of the magnet or magnetic field windings. However, by using superconducting bulk magnets, much stronger electromagnetic field values ​​can be achieved, exceeding the maximum value of 17.6 T. The electrical load, or linear current density, of the motor is closely related to its heat dissipation capacity and the current density of the slots. High electrical loads increase air gap flux density but also heat the windings, requiring a larger cooling system.

[0087] Based on the above equation (2), assuming that the electromagnetic load and air gap magnetic flux density remain unchanged within a certain speed range, the following simplification can be made:

[0088] (3)

[0089] Therefore, it can be seen that, for a given power, a motor with a higher rotational speed has a smaller size; for the same size, a motor with a higher rotational speed has greater power, and the size and weight of the motor can be reduced by increasing the rotational speed.

[0090] Please continue to refer to the reference. Figures 6-9In this embodiment, the gearbox 300 adopts a planetary gear structure, including a sun gear 311, planetary gears 312, a planet carrier 313, and a ring gear 314. The sun gear 311 is located in the middle of the gearbox 300 and forms a second input section, which is connected to the motor shaft 131 via a clutch 200. Multiple planetary gears 312 are arranged around the sun gear 311 and mesh with it. Simultaneously, all planetary gears 312 are mounted on the planet carrier 313. Thus, the planet carrier 313 rotates through the combined action of the multiple planetary gears 312, forming an output section. Power output is achieved through the transmission connection between the planet carrier 313 and the driven component 20. The ring gear 314 is sleeved on the multiple planetary gears 312 and meshes with them, forming a first input section that is connected to the first motor section 110. By adjusting the relative motion between the sun gear 311, planetary gears 312, and the gears, different output speeds and torques can be achieved. Since the first motor unit 110 and the motor shaft 131 rotate at different speeds, their speed ratios can be matched by the gearbox 300.

[0091] It should be noted that the structure of clutch 200 can adopt a conventional structure, and the structure of clutch 200 is not described in detail here. Clutch 200 is sufficient to enable and disable power transmission between motor shaft 131 and sun gear 311. Furthermore, in order to engage the output unit before a motor failure occurs and prevent the motor failure from spreading, clutch 200 can be configured to engage and disengage the output unit and the driven component 20. For example, two clutches can be provided, one connected between motor shaft 131 and sun gear 311, and the other connected between planetary carrier 313 and driven component 20. Alternatively, other clutch 200 structures can be used.

[0092] In this embodiment, the high-compact power drive system 13 further includes a housing 400, which includes a first housing portion 411, a second housing portion 412, and a third housing portion 413 connected in sequence. The first housing portion 411 forms a first space for accommodating the high-compact power drive device 100, thereby protecting and containing the high-compact power drive device 100. The second housing portion 412 forms a second space for accommodating the clutch 200. In this embodiment, the clutch 200 is located in the second space. It is understood that in some other embodiments, the clutch 200 may be located in other positions, in which case the second housing portion 412 only serves to connect the first housing portion 411 and the second housing portion 412. The third housing portion 413 forms a third space for accommodating the gearbox 300, thereby fixing and protecting the gearbox 300. Thus, the high-compact power drive system 13 provided in this embodiment is integrated into a single structure, facilitating installation and use in actual machinery.

[0093] Figure 10 This diagram illustrates the application structure of the highly compact power drive system 13 provided in this embodiment in the automotive field. (See attached diagram.) Figure 10 As shown, the high-compact power drive device 100 provided in this embodiment can be used as a wheel hub motor for automobiles. In this case, the high-compact power drive device 100 can be directly and highly integrated with the wheel hub 21, thereby helping to improve the power density of the electric drive system.

[0094] Figure 11 The diagram shows the application structure of the high-compact power drive system 13 provided in this embodiment in an aviation electrified propulsion system. In this case, the high-compact power drive device 100 can be directly meshed with the fan blades of the outer bypass fan 22 in an integrated design.

[0095] The highly compact power drive system 13 provided in this embodiment is an integrated modular structure. When it is applied in other structures, it can form a distributed architecture with other structures.

[0096] The following section uses the application of the high-compact power drive system 13 in an aviation electrified propulsion system as an example to illustrate the different operating modes of the high-compact power drive system 13 in actual use:

[0097] Table 1

[0098]

[0099] Table 1 shows the status of each component in different operating modes of the high-compact power drive system 13 provided in this embodiment during actual use. Specifically:

[0100] When in pure electric drive mode (such as) Figure 12 As shown), the engine 11 is not working, and the high-compact power drive system 13 provides mechanical energy only through the operation of the first motor unit 110. At this time, the clutch 200 disconnects the second motor unit 120 from the gearbox 300.

[0101] When in series drive mode (e.g.) Figure 13 As shown), the first motor unit 110 converts electrical energy into mechanical energy as an electric motor and outputs power through the gearbox 300. The engine 11 works, thereby driving the second motor unit 120 to work. At this time, the second motor unit 120 acts as a generator, converting the mechanical energy transmitted from the engine 11 into electrical energy and delivering the electrical energy to the energy storage structure 12 or directly supplying it to the first motor unit 110. At the same time, the clutch 200 disconnects the second motor unit 120 from the gearbox 300, that is, only the first motor unit 110 supplies mechanical energy to the gearbox 300.

[0102] When in parallel drive mode (such as) Figure 14 As shown), at this time, the clutch 200 connects and couples the motor shaft 131 with the gearbox 300. That is, at this time, the engine 11 is directly connected to the gearbox 300 through the motor shaft 131. The mechanical energy generated by the engine 11 is directly input to the second input section. At this time, the second motor section 120 is not actually working. At the same time, the first motor section 110 works to convert electrical energy into mechanical energy and inputs it into the gearbox 300 through the first input section.

[0103] When in full power output mode (such as) Figure 15 As shown, the gearbox 300 can be considered the power distributor of the entire system. Its function is to match the speeds of the first motor unit 110 and the second motor unit 120 to their respective rated optimal speeds for power output. However, at this time, the first motor unit 110 is controlled by the energy storage structure 12 through the electronically controlled PCM, while the second motor unit 120 only acts as an electric motor, coaxially with the engine 11 to superimpose torque. Through the clutch 200, the torque output of the engine 11 and the torque output of the two motors are all applied to the driven component 20. At this time, all the energy of the entire hybrid system is used for driving.

[0104] When in energy recovery mode (such as) Figure 16 As shown), at this time, neither the engine 11 nor the second motor unit 120 is working. At the same time, the clutch 200 disconnects the second motor unit 120 from the gearbox 300, thereby preventing the mechanical energy generated by the rotation of the gearbox 300 under the drive of the driven member 20 from being transmitted to the second motor unit 120. Meanwhile, the gearbox 300 drives the first motor rotor 111 to rotate, thereby making the first motor unit 110 act as a generator to generate electricity.

[0105] When in engine start-stop mode (e.g.) Figure 17As shown), at this time, the engine 11 is not working. The first motor unit 110 and the second motor unit 120 both operate under the action of electrical energy supplied by the energy storage structure 12, thereby converting electrical energy into mechanical energy. The mechanical energy generated by the first motor unit 110 is transmitted to the gearbox 300 through the first input unit. At the same time, the clutch 200 couples the second motor unit 120 with the gearbox 300. The mechanical energy generated by the second motor unit 120 is transmitted to the gearbox 300 through the second input unit. The gearbox 300 operates under the joint drive of the first motor unit 110 and the second motor unit 120.

[0106] The highly compact power drive device 100, system, and power equipment 10 provided in the embodiments of the present invention simultaneously possess the functions of an electric motor and a generator, which can effectively improve the range of the electric drive system and thus suppress range anxiety. The first motor section 110 and the second motor section 120 are coaxially arranged. The first motor section 110 uses an external rotor Halbach slotless topology, while the second motor section 120 uses a slotless electrically excited synchronous topology at its internal coaxial section. This helps to increase power density, resulting in a more compact structure. Furthermore, the slotless stator structure eliminates stator slot depth, providing more design space for the coaxial design of the two motors. This increased design space allows for the rational use of electromagnetic materials, thereby ensuring design performance. The more compact structure facilitates the miniaturization of the device, reducing its footprint. Consequently, when applied to equipment such as aircraft, it allows for the deployment of a larger number of these devices, thereby increasing driving force and enabling distributed redundancy design.

[0107] Furthermore, through the clutch function of clutch 200, it can achieve different hybrid power modes to meet the needs of different stages of use. For example, during the high-power phases of takeoff and climb, the high-power direct drive of engine 11 is used; during the cruise phase, multiple dual-function motors are selected to operate in the high-efficiency rated cruise state, greatly improving the output performance and range of the entire hybrid system. Moreover, this structure can also utilize the abundant air resources in the air to cool the motors, making it more reliable and further improving the power-to-weight ratio of the entire hybrid system without adding extra weight.

[0108] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A highly compact power drive device, characterized in that, The high-compact power drive unit includes: A first motor section, configured to be electrically connected to an energy storage structure for operation using electrical energy supplied by the energy storage structure; the first motor section includes a first motor rotor and a first motor stator nested together, the first motor rotor having Halbach permanent magnets; and The second motor section is disposed inside the first motor section, and the first motor section and the second motor section are coaxially arranged; the second motor section is used for transmission connection with the engine and for electrical connection with the energy storage structure; the second motor section includes a second motor rotor and a second motor stator nested together. Both the first motor stator and the second motor stator are slotless structures.

2. The highly compact power drive device according to claim 1, characterized in that, The rotor of the first motor is located radially outside the stator of the first motor.

3. The highly compact power drive device according to claim 2, characterized in that, The first motor rotor also includes a carbon fiber sheath and a titanium alloy shell, wherein the Halbach permanent magnet, the titanium alloy shell and the carbon fiber sheath are arranged sequentially in the radial outward direction of the first motor rotor; The carbon fiber sheath is fixed to the titanium alloy shell by a winding technique.

4. The highly compact power drive device according to claim 2, characterized in that, The first motor stator includes a first shaped Litz wire winding, a first stator core, and a stator heat sink. The first shaped Litz wire winding, the first stator core, and the stator heat sink are arranged sequentially in a radially inward direction along the first motor stator. The Halbach permanent magnet and the first shaped Litz wire winding are arranged radially spaced along the first motor section, and a first gap is formed between the Halbach permanent magnet and the first shaped Litz wire winding. The first molded Litz wire winding is fixed to the surface of the first stator core by high-temperature adhesive.

5. The highly compact power drive device according to claim 1, characterized in that, The rotor of the second motor is located on the radial inner side of the stator of the second motor.

6. The highly compact power drive device according to claim 5, characterized in that, The high-compact power drive device also includes a motor shaft, which is located at the center of the high-compact power drive device, and the second motor rotor is connected to the motor shaft by a flat key.

7. The highly compact power drive device according to claim 6, characterized in that, The high-compact power drive device also includes a shielding cover disposed between the first motor section and the second motor section; the second motor stator is fixedly connected to the shielding cover, and the shielding cover is rotatably supported on the motor shaft by a double tapered bearing; The rotor of the first motor is rotatably supported on the shield by bearings.

8. The high-compact power drive device according to claim 5, characterized in that, The second motor stator includes a second stator core and a second shaped Litz wire winding, which are arranged sequentially in the radial direction inward of the second motor stator.

9. The high-compact power drive device according to claim 5, characterized in that, The second motor rotor includes a rotor core and rotor winding coils. The rotor core is provided with a plurality of mounting slots distributed circumferentially, and the rotor winding coils are embedded in the mounting slots.

10. A highly compact power drive system, characterized in that, The high-compact power drive system includes a gearbox, a clutch, and a high-compact power drive device as described in any one of claims 1-9; The gearbox has a first input section, a second input section, and an output section. The output section is used for transmission connection with a driven component. The first input section is transmissionally connected to the rotor of the first motor, and the second input section is transmissionally connected to the rotor of the second motor through the clutch to control the on / off of power transmission between the rotor of the second motor and the second input section.

11. The highly compact power drive system according to claim 10, characterized in that, The gearbox includes a sun gear, planet gears, a planet carrier, and a ring gear; a plurality of planet gears mesh with the sun gear and are arranged around the sun gear; the plurality of planet gears are all mounted on the planet carrier. The gear ring is sleeved on the outside of the plurality of planetary gears and meshes with all of the plurality of planetary gears; The sun gear forms the second input section, the gear ring forms the first input section, and the planet carrier forms the output section.

12. The highly compact power drive system according to claim 10, characterized in that, The high-compact power drive system also includes a housing, which includes a first housing portion, a second housing portion, and a third housing portion connected in sequence. The first housing portion forms a first space for accommodating the high-compact power drive device, the second housing portion forms a second space for accommodating the clutch, and the third housing portion forms a third space for accommodating the gearbox.

13. A power equipment, characterized in that, The power equipment includes an engine, an energy storage structure, and a high-compact power drive system as described in any one of claims 10-12. The engine is driven by a second motor rotor to drive the second motor rotor. The energy storage structure is electrically connected to the high-compact power drive device to supply power to the high-compact power drive device or store the electrical energy generated by the high-compact power drive device.

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