Hub drive arrangement for a motor vehicle and motor vehicle

Abstract

The invention relates to a wheel hub drive (10) for a motor vehicle, comprising a wheel carrier (18), a wheel bearing arrangement (20) with at least one first wheel bearing (RL1), a wheel disk (14) which is rotatably supported on the wheel carrier (18) by means of the wheel bearing (20), an electric machine (24) with a stator (28) and a rotor (26), and a stator carrier (36) by means of which the stator (28) is held against rotation on the wheel carrier (18), wherein the stator carrier (36) has a first cylindrical section (Z1) which is arranged axially overlapping the stator (28) and a second cylindrical section (Z2) which is arranged radially within the first cylindrical section (Z1) and axially offset from the stator (28), wherein the second cylindrical section (Z2) has a radially inner first sleeve (H1) which is composed of a first material and a radially outer second sleeve (H2) which is composed of a second material which is different from the first material, the first material being a metallic material.

Description

Technical Field

[0001] This invention relates to a hub drive system for a motor vehicle, particularly an automobile, according to the preamble of claim 1. Furthermore, this invention relates to a motor vehicle having at least one such hub drive system. Background Technology

[0002] A wheel system for a vehicle is known from WO 2022 / 096504 A1, which has a stator, a rotor and a rotating bearing.

[0003] WO 96 / 22 895 A1 discloses a hub drive with an electric motor, wherein the stator frame of the motor has two cylindrical sections offset from each other in the axial direction. DE 10 2014 209 176 A1 and US 2020 / 0 238 817 A1 disclose a hub drive in which each stator frame is partially made of plastic or electrically insulating material. The stator frame of the hub drive disclosed in DE 102009 035 176 A1 has a tapered section. CN 1 02 390 253 A discloses an arrangement of a busbar on and within the stator frame of a hub drive. Summary of the Invention

[0004] The objective of this invention is to provide a hub drive system for a motor vehicle and a motor vehicle having at least one such hub drive system, thereby enabling a structure that is particularly advantageous in terms of the weight and installation space of the hub drive system.

[0005] This task is accomplished by a hub drive system having the features of claim 1 and a motor vehicle having the features of claim 5. The other claims provide advantageous designs with appropriate inventive improvements.

[0006] The first aspect of this invention relates to a hub drive device (also called a hub actuator or hub drive mechanism) for a motor vehicle (also simply a vehicle, preferably designed as an automobile, especially a passenger car). This means that the motor vehicle, in its fully manufactured state, has a hub drive device and can be driven by the hub drive device, especially in a purely electric manner. The hub drive device is preferably an electric hub drive device, by which the motor vehicle can be driven, especially in a purely electric manner. For example, the motor vehicle, in its fully manufactured state, has at least or exactly two axles, also simply referred to as axles, arranged sequentially and thus in the longitudinal direction of the motor vehicle. Each axle of the motor vehicle has at least or exactly two wheels, also simply referred to as wheels, wherein the corresponding wheels of each axle are arranged on opposite sides of the motor vehicle in its transverse direction. The wheels of the motor vehicle are ground contact elements by which the motor vehicle can be supported or is supported on the ground in its height direction. If a motor vehicle (also referred to as the interior space of the passenger compartment or cabin, for example, constituted by a vehicle body, particularly designed as a self-supporting body) travels along the ground, and the motor vehicle is supported downward on the ground in the vehicle height direction by means of the ground contact member, then the ground contact member rolls directly on the ground. The hub drive is also referred to as a first hub drive. For the purposes of this context, "hub drive" refers to the first hub drive unless otherwise stated. For example, the hub drive has exactly one first wheel on one of the axles. For the purposes of this context, "wheel" refers to the first wheel unless otherwise stated. Therefore, the first wheel can be driven, particularly electrically, by the first hub drive. For example, a motor vehicle in its fully manufactured state has a second hub drive in addition to the first hub drive, by which exactly one second wheel of the motor vehicle can be driven, particularly electrically, wherein the second hub drive includes the second wheel. Preferably, the first wheel and the second wheel are wheels on the same axle. For the purposes of this context, "wheel" refers to the first wheel unless otherwise stated. The contextual descriptions of the first hub drive and the first wheel can be directly applied to the second hub drive and the second wheel, and vice versa.

[0007] The hub drive system has a wheel carrier and a wheel bearing assembly, wherein the wheel bearing assembly has at least one first wheel bearing. Therefore, the first wheel bearing is, for example, a first sub-bearing of the wheel bearing assembly. Preferably, the first wheel bearing, and especially the entire wheel bearing assembly, is designed as a rolling bearing. The wheel disc is rotatably supported on the wheel carrier by means of and via the wheel bearing assembly. Here, the wheel disc is, for example, a component of the first wheel, wherein the hub drive system includes the wheel disc. For example, at least the wheels of a motor vehicle are rotatably supported on the wheel carrier by means of and via the wheel bearing assembly. In particular, the wheel disc, and thus the first wheel, is rotatably supported relative to the wheel carrier about the wheel's axis of rotation by the wheel bearing assembly. The vehicle, for example, has a wheel disc and a rim, which is permanently and anti-rotationally connected to the wheel disc. Therefore, the rim and the wheel disc can be components of the first wheel. In principle, it is conceivable that the rim and the wheel disc are constructed separately from each other and are permanently and anti-rotationally connected to each other, or that the wheel disc and the rim are integrally constructed, i.e., made of a single piece, and therefore permanently and anti-rotationally connected to each other. In particular, a wheel unit is formed by, for example, a rim and a disc, which may be, for example, the first wheel, or the wheel unit is a component of the first wheel. For example, a tire, especially made of rubber, is fixed to the rim, especially the tire of the first wheel, so the tire can be said to be fitted onto the rim. In particular, when the wheel rolls on the ground, the tire rolls directly on the ground.

[0008] The hub drive also includes a motor having a stator and a rotor. The rotor can be driven by the stator and thus can rotate relative to the stator about the motor's rotation axis. Preferably, the rotor is arranged coaxially with the wheel bearing assembly, so that the motor's rotation axis preferably coincides with the wheel's rotation axis. The wheel's rotation axis is also called the main rotation axis of the hub drive. In particular, by driving the rotor, the wheel disc can be driven, especially electrically, and thus the wheel can be driven, especially via the wheel disc. The hub drive also includes a stator frame by which the stator is held anti-rotationally on the wheel frame. It is particularly specified that the stator and stator frame are constructed separately and are permanently anti-rotationally connected to the stator frame. For example, the stator frame is permanently anti-rotationally connected to the wheel frame. It can be specified that the stator frame and wheel frame are constructed separately and are permanently anti-rotationally connected to the wheel frame. In particular, the stator is, for example, a lamination assembly or includes a lamination assembly. Alternatively or additionally, the stator may include at least one or more magnets, especially permanent magnets, which are held, for example, on the lamination assembly and thus carried by the lamination assembly. Alternatively or additionally, the stator may have at least one winding, also known as a stator winding, which is held on and thus carried by the laminations. More particularly, the stator is a magnetic element (which is particularly distinct from the stator frame) by means of which magnetic flux can be guided, for example, by the motor, to drive a wheel or vehicle.

[0009] Preferably, the motor is a high-voltage component, and its voltage, especially the operating voltage or rated voltage, is preferably greater than 50 volts, particularly greater than 60 volts, and more preferably several hundred volts.

[0010] The stator frame has a first cylindrical section that overlaps with the stator axially, and a second cylindrical section that is radially arranged within the first cylindrical section and axially offset from the stator. Preferably, each cylindrical section is cylindrical at least on its outer circumferential side and preferably also on its inner circumferential side, thus having a shape that is particularly straight cylindrical. For example, it is at least specified that each cylindrical section has an outer circumferential surface facing outward in the radial direction of the hub drive, which is cylindrical and thus has a shape that is particularly straight cylindrical. It is also conceivable that each cylindrical section has an inner circumferential surface facing inward in the radial direction of the hub drive, which is preferably cylindrical and thus has a shape that is particularly straight cylindrical. The radial direction of the hub drive extends perpendicular to the axial direction of the hub drive, and its axial direction coincides with the main rotation axis (wheel rotation axis).

[0011] To achieve a particularly advantageous structure in terms of installation space and weight for the hub drive system, it is specified, in a manner known per se, that the second cylindrical section has a first sleeve radially inwardly made of a first material (i.e., a metallic material) and a second sleeve radially outwardly made of a second material different from the first material. Preferably, the first sleeve is arranged at least partially within the second sleeve in both the radial and axial directions, thus preferably, the first sleeve at least partially overlaps the second sleeve in both the axial and radial directions. This allows for a particularly advantageous and compact structure for the hub drive system.

[0012] To achieve a particularly advantageous structure in terms of weight and installation space for the hub drive unit, the present invention specifies that the stator frame has a tapered section that overlaps with the first wheel bearing in the axial direction. A second cylindrical section is arranged at least partially, particularly at least primarily, and therefore at least more than half, or even completely, between the tapered section and the wheel carrier in the axial direction, i.e., in the axial direction of the hub drive unit. In particular, the tapered section is a region, part, or segment of the stator frame that extends taperedly at least on its outer circumference and preferably also on its inner circumference, having a conical or truncated cone shape. Preferably, the tapered section is arranged adjacent to, i.e., directly connected to, the first and second cylindrical sections, particularly in the axial direction of the hub drive unit, in such a way that the tapered section is arranged axially between the first and second cylindrical sections. This means that no other region, part, or segment of the stator frame is arranged between the cylindrical sections and the tapered section in the axial direction of the hub drive unit. For example, the tapered segment extends radially inward toward the wheel bearing assembly and thus toward the wheel axis of rotation from the first cylindrical segment (i.e., from the first cylindrical segment), and axially toward the wheel carrier. In other words, viewed in an extension direction that coincides with or is parallel to the axial direction of the wheel hub drive unit and extends from the first cylindrical segment toward the wheel carrier, the tapered segment extends radially inward toward the wheel bearing assembly and thus toward the wheel axis of rotation from the first cylindrical segment. Therefore, the tapered segment gradually narrows from the first cylindrical segment toward the wheel carrier. Conversely, the tapered segment gradually widens from the wheel carrier toward the first cylindrical segment. This allows for a particularly compact structure.

[0013] Since the second cylindrical section is arranged radially, i.e., in the radial direction of the hub drive unit, within the first cylindrical section, the first cylindrical section is the outermost first cylindrical section radially, i.e., in the radial direction of the hub drive unit. The second cylindrical section is the innermost second cylindrical section of the stator frame radially, i.e., in the radial direction of the hub drive unit. The radial direction of the hub drive unit extends perpendicular to its axial direction, and its axial direction coincides with the wheel rotation axis (main rotation axis).

[0014] Within the scope of this disclosure, the feature "overlapping radially" means that when two elements, especially at least substantially rotationally symmetric elements, are each arranged at least partially in regions having the same radial coordinates, and especially the same angular coordinates, they are arranged to overlap radially with each other, particularly with respect to a common axis, such as an axis extending in the radial direction of the hub drive, and / or particularly in the radial direction of the hub drive. The term "radial" refers to the radial direction of the hub drive. In other words, the term "radial" refers to the radial direction of the hub drive. For the purposes of this context, "radial direction" refers to the radial direction of the hub drive, unless otherwise stated.

[0015] The feature "overlapping in the axial direction" means that when two elements (e.g., the stator and the first cylindrical section) are each at least partially arranged in regions having the same axial coordinates, they are arranged to overlap each other axially about a common axis, particularly an axis extending in the axial direction of the hub drive and / or particularly in the axial direction of the hub drive. Within the scope of this disclosure, the term "axial" refers to the axial direction of the hub drive. In other words, the term "axial" is the axial direction of the hub drive. Furthermore, "axial" refers to the axial direction of the hub drive, and "radial" refers to the radial direction of the hub drive. For the axial direction described in the context, unless otherwise stated, it refers to the axial direction of the hub drive.

[0016] Within the scope of this disclosure, the feature "the first member is arranged radially within the second member" means that the first member is arranged in an area smaller than the radius of the second member, particularly with respect to the wheel rotation axis (main rotation axis). Furthermore, the feature "the first member is arranged axially within the second member" means that, in the mounting position of the hub drive (the hub drive is in its mounting position in the complete manufacturing state of the motor vehicle having the hub drive), and especially with regard to the straight-line travel of the motor vehicle, i.e., particularly when the vehicle steering system is configured to achieve straight-line travel, the first member arranged axially within the second member is arranged on the side of the second member facing the vehicle center, also known as the vehicle center. Therefore, the first member is arranged on the side of the second member facing the vehicle center, and thus, particularly in the transverse direction of the motor vehicle, the first member is arranged closer to the inside than the second member, i.e., closer to the vehicle center.

[0017] Within the scope of this disclosure, the feature "two components are anti-rotationally connected" means that the anti-rotationally connected components are arranged coaxially with each other, and especially when the components are driven, they rotate together or simultaneously about a common axis of rotation (e.g., a main axis of rotation) of the components, at the same angular velocity, especially relative to a reference element (e.g., a wheel carrier). In other words, two elements are anti-rotationally connected when they are arranged coaxially with each other, especially about their axis of rotation or about their axis of rotational symmetry, and when they are connected to each other in a manner that always rotates at the same angular velocity. When a component cannot rotate relative to, i.e., about the housing, that component is anti-rotationally connected to the housing. Therefore, when a component cannot rotate relative to, i.e., about the wheel carrier, that component is anti-rotationally connected to the wheel carrier.

[0018] The feature "two components are connected or engaged to each other in a manner that transmits torque" means that the components are engaged or connected to each other in a manner that allows torque to be transmitted between them. Specifically, when the components are connected or engaged to each other in a manner that resists rotation, they are also connected or engaged to each other in a manner that transmits torque. Therefore, two components connected to each other in a manner that transmits torque can be connected in a manner that resists rotation. It is also conceivable that two components connected to each other in a manner that transmits torque are connected to each other through an intermediate transmission unit, thereby enabling torque to be transmitted between the components via the transmission unit, while the components are connected to each other in a manner that transmits torque, wherein the components can still rotate relative to each other.

[0019] The feature "two components are permanently connected or engaged to each other in a torque-transmitting manner" means that, without providing, for example, a switching element that can switch between an engaged state in which the components are connected or engaged to each other in a torque-transmitting manner and a disengaged state in which torque cannot be transmitted between the components by the switching element; rather, the components are always, and therefore permanently connected or engaged to each other in a torque-transmitting manner, that is, in a manner in which torque can be transmitted between the components. Thus, for example, one component can be driven by the corresponding other component, and vice versa.

[0020] In particular, the feature “two components are permanently and non-rotatably connected or engaged” means that, for example, a switching element is not provided, which can switch between an engaged state in which the components are permanently and non-rotatably connected or engaged and a disengaged state in which the components are separated from each other and rotatable relative to each other, so that torque cannot be transmitted between the components by the switching element; rather, the components are always or consistently and therefore permanently and non-rotatably connected or engaged.

[0021] Furthermore, the feature "two components can be connected or engaged with each other in a rotationally resistant manner" means that each component is equipped with a switching element, wherein the switching element can switch between at least one engaged state and at least one disengaged state. In the engaged state, the components are connected or engaged with each other in a rotationally resistant manner via the switching element. In the disengaged state, the components are separated from each other, so that each component can rotate relative to each other about its axis of rotation. This also applies to the feature "two components can be connected or engaged with each other in a torque-transmitting manner." Therefore, for example, the feature "two components can be connected or engaged with each other in a torque-transmitting manner" means that each component is equipped with a switching element, wherein the switching element can switch between at least one connected state and at least one released state. In the connected state, the components are engaged or connected with each other in a torque-transmitting manner via the switching element, so that torque can be transmitted between the components, especially via the switching element. In the released state, the components are separated from each other, so that torque cannot be transmitted between the components via the switching element in the released state.

[0022] In particular, each cylindrical segment is a region, section or part of the stator frame, which is cylindrical on the outer circumference and, for example, also on the inner circumference, and thus has a shape that is particularly straight cylindrical.

[0023] In order to keep the installation space requirements of the hub drive unit to a very low level, the present invention also specifies that the tapered section is made of a second material and is integrally formed with a second sleeve, also known as the outer sleeve.

[0024] The present invention further specifies that the second material is an electrically insulating plastic. Therefore, this plastic is preferably characterized by an electrical conductivity of less than 10. -8 S*cm -1 Electrical insulator.

[0025] To achieve a particularly compact design for the hub drive system, it is especially advantageous that the busbar (by which electrical energy can be supplied to and / or provided by the motor) is constructed separately from the stator frame, rotor frame, rotor, stator, wheel disc, wheel frame, and wheel bearing assembly, at least partially, and especially completely, embedded in a second material, particularly insulating plastic, and thus, for example, embedded in a second sleeve. By supplying electrical energy to the motor, the motor operates, for example, in motor mode and thus can operate as an electric motor. The wheel disc can be driven, especially in a purely electric manner, and thus the wheels can be driven. It is also conceivable, for example, that the motor can operate in generator mode and thus as a generator, by which the kinetic energy of the vehicle can be converted into electrical energy that can be supplied by a generator. For example, the electrical energy supplied or provided by the motor in generator mode can be output from the motor through at least one of the busbars. The electrical energy that can be supplied to the motor can, for example, be provided by the vehicle's battery. Furthermore, the electrical energy supplied or provided by the generator can, for example, be transmitted to the battery via at least one busbar and thus stored in the battery. Preferably, the energy storage device is a high-voltage component, and its voltage, especially the operating voltage or rated voltage, is preferably greater than 50 volts, particularly greater than 60 volts, and more preferably several hundred volts.

[0026] Since the second material is preferably an electrical insulator, and the busbar is preferably at least partially embedded in the second material, the second material serves as the electrical insulation of the busbar, and the busbar achieves electrical insulation through the second material.

[0027] Finally, the present invention specifies that the busbar extends at least partially within the tapered section, such that, for example, the busbar is at least partially cast within the tapered section. This maintains very low installation space requirements.

[0028] In order to keep the installation space requirement of the hub drive device within a very low range, another design of the present invention specifies that the first cylindrical section is made of a second material and is integrally formed with a radially outward second sleeve.

[0029] Another embodiment is characterized in that the conical section is integrally formed with the first cylindrical section, thereby keeping the number of components and, consequently, the installation space requirements very low.

[0030] The feature “two elements (e.g., the conical segment and the second sleeve) are integrally formed” means that the elements are not constructed separately and connected to each other, but are composed of individual pieces and thus integrally formed, that is, a one-piece design, so that the elements are constructed as a whole, that is, composed of individual pieces and thus manufactured as a whole, and constituted as a single piece.

[0031] For example, a rotor frame is provided, which carries the rotor. It is particularly specified that the rotor is constructed separately from the rotor frame and is permanently and rotationally resistantly connected to the rotor frame. In particular, for example, the rotor is or comprises a lamination assembly also known as a rotor lamination assembly. Alternatively or additionally, the rotor may include at least one or more magnets, especially permanent magnets, which are held on and thus carried by the rotor lamination assembly. Alternatively or additionally, for example, the rotor may have at least one winding, also known as a rotor winding, which is held on and thus carried by the rotor lamination assembly. In particular, the rotor is a magnetic element (this is particularly distinct from the rotor frame), by means of which, for example, guides or is able to guide the aforementioned magnetic flux, which can be generated by the motor during operation, particularly for driving discs or wheels.

[0032] In order to keep the installation space requirement very low, another design of the present invention specifies that the busbar is cast in a second material, in particular an electrically insulating plastic.

[0033] To achieve a particularly advantageous and compact support for the wheel disc on the wheel carrier, another design of the invention specifies that the wheel bearing assembly has a second wheel bearing, which is arranged to overlap with the wheel carrier in both the radial and axial directions, and thus is arranged particularly within the wheel carrier in the radial direction, such that the wheel carrier is arranged to radially surround the second wheel bearing. Preferably, the second wheel bearing is designed as a second rolling bearing.

[0034] The second aspect of the invention relates to a motor vehicle, also simply referred to as a vehicle and preferably designed as an automobile, particularly a passenger car, having at least one hub drive device according to the first aspect of the invention. The advantages and advantageous designs of the first aspect of the invention should be considered as advantages and advantageous designs of the second aspect of the invention, and vice versa.

[0035] Preferably, at least a portion of the first cylindrical section, the conical section, and the second cylindrical section are integrally formed, i.e., they are composed of a single piece.

[0036] In this example, it is specified that the aforementioned second sleeve is the aforementioned part of the second cylindrical section, and thus the second sleeve, the conical section, and the first cylindrical section are preferably integrally formed. Therefore, for example, the first cylindrical section, the conical section, and the second sleeve are made of a second material, especially plastic.

[0037] Specifically, the first wheel bearing is arranged radially within the wheel carrier and axially overlaps with the wheel carrier. This allows for a particularly advantageous split support in a space-saving manner, thereby providing a highly advantageous support for the disc and, consequently, the wheel in terms of both installation space and weight.

[0038] A hub drive mechanism, for example, has a hub, in which it is conceivable that the disc and thus the wheel can be detachably connected to the hub without damage, such that the disc and, in particular, the wheel, are connected to the hub in a rotationally resistant manner. Specifically, the hub is rotatably supported on the wheel carrier about the wheel's axis of rotation via a wheel bearing assembly. The second wheel bearing is, for example, a second sub-bearing of the wheel bearing assembly, thereby achieving a particularly advantageous split support. Here, the second sub-bearing is axially arranged within the first sub-bearing. In other words, the second wheel bearing is axially arranged within the first wheel bearing.

[0039] To achieve a particularly advantageous support in terms of installation space and weight, it is preferably specified that the first wheel bearing has a first roller and a first raceway assembly, the first raceway assembly having a first raceway for the first roller and a second raceway arranged radially within the first raceway. The second wheel bearing has a second roller, which is in particular contact with the first roller in the axial direction of the hub drive device in such a way that the first roller is spaced apart from the second roller in the axial direction, and vice versa. Furthermore, the second wheel bearing has a second raceway assembly that is in contact with the first raceway assembly in the axial direction, the second raceway assembly preferably being spaced apart from the first raceway assembly in the axial direction. The second raceway assembly has a third raceway for the second roller and a fourth raceway arranged radially within the third raceway. When the wheel disc and, for example, the hub rotate about the wheel's axis of rotation relative to the wheel frame, the first roller rolls particularly directly on the first and second raceways, and the second roller rolls particularly directly on the third and fourth raceways.

[0040] Preferably, the motor is designed as an external rotor type, i.e., designed as an external rotor motor, also known as an external rotor electric motor. This specifically means that the stator is connected to the wheel carrier on its radially inner side. For example, it is also specified that at least one section of the rotor carrier is arranged radially outside the stator, wherein this rotor carrier section is preferably a cylindrical section, i.e., a rotor carrier section that is cylindrical at least on the outer circumference and preferably also on the inner circumference. In particular, for example, the rotor is permanently and rotationally resistantly connected to the rotor carrier and is therefore carried by the rotor carrier. More preferably, the motor is designed as an axial flux motor (AFM), also known as an axial flux motor. Attached Figure Description

[0041] Other advantages, features, and details of the invention arise from the following description of preferred embodiments of the invention with reference to the accompanying drawings. The features and combinations of features mentioned above in the specification, as well as those mentioned below in the description of the drawings and / or shown only in the drawings, may be used not only in the correspondingly specified combinations, but also in other combinations or alone, without departing from the scope of the invention. Wherein:

[0042] Figure 1 A partial longitudinal sectional view of a hub drive system for a motor vehicle is shown.

[0043] Figure 2 A partial front sectional view of the stator frame of the hub drive unit is shown.

[0044] Figure 3 Another longitudinal sectional view showing a portion of the hub drive unit; and

[0045] Figure 4 Another front sectional view showing a portion of the stator frame; and

[0046] Figure 5 This is another front sectional view of a portion of the stator frame.

[0047] In the accompanying drawings, identical or functionally identical parts are marked with the same reference numerals. Detailed Implementation

[0048] Figure 1 Along Figure 2The longitudinal sectional view shown in section BB partially illustrates a hub drive system 10 for a motor vehicle, also simply referred to as a vehicle, preferably designed as an automobile, and especially as a passenger car. The hub drive system is also referred to as a hub actuator or hub drive mechanism. The hub drive system 10 can drive the wheels 12 of the motor vehicle, particularly electrically, as detailed below. The wheel 12 has a disc 14 and a rim 16. At least the disc 14 can be a component of the hub drive system 10, and therefore the hub drive system may include at least the disc 14. For example, the wheel 12 is a component of the hub drive system 10. A tire, not shown in the figures and made of, for example, rubber, can be fixed to the rim 16; therefore, the tire can be said to be fitted onto the rim 16. Figure 1 In the illustrated embodiment, the rim 16 and the disc 14 are constructed separately from each other and are connected to each other in a particularly permanent, anti-rotational manner.

[0049] The hub drive unit 10 has a wheel carrier 18 and a wheel bearing assembly 20, also referred to as a wheel bearing mechanism. The wheel disc 14 is rotatably supported on the wheel carrier 18 about the wheel rotation axis 22 (also referred to as the main rotation axis or rotation axis) via the wheel bearing assembly 20. Figure 1 In the embodiment shown, the wheel 12 is rotatably supported on the wheel frame 18 by means of the wheel bearing assembly 20 and via the wheel bearing assembly 20 about the wheel rotation axis 22.

[0050] The hub drive unit 10 has exactly one motor 24, which in this example is designed as an axial flux motor. The motor 24 has a rotor 26 and a stator 28, the rotor 26 being driven by the stator 28 and thus rotatable about the wheel rotation axis 22 relative to the wheel carrier 18 and relative to the stator 28. For example, the rotor 26 includes a disc 14, such that by driving the rotor 26, the disc 14 and thus the wheel 12 can be driven and thus rotatable about the wheel rotation axis 22 relative to the wheel carrier 18. Alternatively, in this example, the hub drive unit 10 is provided with a rotor carrier 27. More specifically, the rotor 26 is constructed separately from the rotor carrier 27 and is permanently and rotationally resistantly connected to the rotor carrier 27. Here, the rotor carrier 27 has, for example, the disc 14. In other words, the disc 14 is preferably a component of the rotor carrier 27. The entire motor vehicle can be driven, for example, by driving the wheel 12. The rotor 26 includes two rotor elements 30 and 32. More specifically, the disk 14 and thus the rotor frame 27 are constructed separately from the rotor 26, and also separately from the rotor elements 30 and 32. The rotor elements 30 and 32, constructed separately from the rotor frame 27 and therefore separately from the disk 14, are permanently and anti-rotationally connected to the rotor frame 27 and thus to the disk 14. For example, each rotor element 30, 32 is at least substantially disk-shaped. Figure 1It can be seen that rotor elements 30 and 32 are spaced apart from each other in the axial direction of the hub drive unit 10, and the radial direction of the hub drive unit 10 extends perpendicular to its axial direction. The axial direction of the hub drive unit 10 coincides with the wheel rotation axis 22, also known as the main rotation axis, and the radial direction of the hub drive unit 10 extends perpendicular to the axial direction of the hub drive unit 10 and therefore perpendicular to the wheel rotation axis 22. Figure 1 The image is shown by arrow 34. The stator 28 is arranged between rotor elements 30 and 32 in the axial direction of the hub drive unit 10 such that rotor element 30 at least partially overlaps with, is covered by, the stator 28 in a first direction, and rotor element 32 at least partially overlaps with, is covered by, the stator in a second direction. The first direction coincides with or extends parallel to the axial direction of the hub drive unit 10 and points from rotor element 30 to rotor element 32. The second direction is opposite to the first direction, extends parallel to or coincides with the axial direction of the hub drive unit 10, and extends from rotor element 32 toward rotor element 30. For the purposes of this context, radial directions refer to the radial direction of the hub drive unit 10 unless otherwise stated. For the purposes of this context, axial directions refer to the axial direction of the hub drive unit 10 unless otherwise stated.

[0051] The hub drive unit 10 has a stator frame 36, and the stator 28 is held on the wheel carrier 18 by means of and via the stator frame in a particularly permanent, anti-rotational manner. In the embodiment shown in the figures, the stator 28 is constructed separately from the stator frame 36 and is connected to the stator frame 36 in a particularly permanent, anti-rotational manner. In this example, it is also specified that the stator frame 36 is constructed separately from the wheel carrier 18 and is connected to the wheel carrier 18 in a particularly permanent, anti-rotational manner.

[0052] Figure 2 The stator frame 36 is partially shown in the previous schematic diagram, wherein, Figure 2 The stator frame 36 is shown in particular in a cross-sectional view, wherein the cross-section extends perpendicular to the axial direction. From Figure 2As can be seen, the stator frame 36 has first channels 38 extending inside the stator frame 36. Each first channel 38 accommodates exactly one high-voltage line (cable) 40, which thus extends within each channel 38 and therefore within the stator frame 36. Specifically, the high-voltage line 40 is electrically connected to the stator 28. The high-voltage line 40 is designed to transmit electrical energy, preferably at a voltage greater than 50 volts, particularly greater than 60 volts, and especially preferably several hundred volts. The stator frame 36 also has second channels 42 extending inside the stator frame 36. The second channels 42 are cooling channels, through which a liquid coolant preferably flows, i.e., the coolant directly contacts the stator frame 36 in its path through each channel 42, i.e., directly contacts the corresponding inner circumferential surface of the stator frame 36 that directly defines each channel 42. It is also conceivable that each channel 42 accommodates exactly one cooling conduit, which is separately constructed from the stator frame 36 and through which the coolant flows. Therefore, each channel 42 can be traversed by coolant, wherein, for example, coolant can be directed to the stator 28 through at least one of the channels 42. It is also conceivable that coolant can be discharged from the stator 28 through at least another channel 42. The stator 28 can be cooled by the coolant. Preferably, the coolant is oil. The channels 42 are arranged, for example, in a coolant circuit through which the coolant can flow. It is also conceivable that each high-voltage line 40 is constructed separately from the stator frame 36.

[0053] In the embodiment shown in the accompanying drawings, the stator frame 36 also has at least one or exactly one third channel 44 for the sensor line (cable) 46. In this example, the sensor line 46 is constructed separately from the stator frame 36 and passes through the third channel 44 and thus extends inside the stator frame 36. The sensor line 46 is designed to transmit signals, in particular electrical signals, characterizing, for example, measured values. The hub drive unit 10, for example, has at least one sensor (not shown) by means of which measured values ​​can be acquired or will be acquired. The sensor can provide a signal, also known as a sensor signal, which can be output from the sensor, for example, via the sensor line 46. The sensor line 46 is also referred to, for example, as a cable or signal cable.

[0054] Figure 1 One of the channels, 38, is shown. Figure 3Arrow 48 indicates the high-voltage line 40 housed in this channel 38. Specifically, arrow 48 shows that, for example, at least through the high-voltage line 40 housed in this channel 38, the aforementioned electrical energy can be supplied to the stator 28, which may be provided by or will be provided by the vehicle's battery. Generally, channels 38, 42, and 44 are used to guide the high-voltage line 40, coolant, and sensor line 46, also known as a signal line. Therefore, the guiding structure (also known as the line guiding structure) for the high-voltage line 40, coolant, and sensor line 46 is integrated into the stator frame 36, thereby achieving a structure that is particularly advantageous in terms of installation space and weight for the hub drive unit 10.

[0055] from Figure 1 and Figure 3 As can be seen, the stator frame 36 has a first cylindrical section Z1 located radially outward, i.e., on the outer side in the radial direction, which is cylindrical at least on the outer circumference and preferably also on the inner circumference. Here, the stator 28 is arranged to overlap the first cylindrical section Z1 axially and surround it radially, wherein, in this example, the stator 28 is arranged directly on the first cylindrical section Z1. In particular, the stator 28 is, for example, permanently and anti-rotationally connected to the first cylindrical section Z1. Figure 1 The outer circumferential surface of the first cylindrical section Z1 is designated by the symbol 50. The outer circumferential surface 50 points outward in the radial direction of the hub drive device 10 and is cylindrical, thus having the shape of a straight cylinder. In particular, the stator 28 is arranged directly on the outer circumferential surface 50.

[0056] The stator frame 36 also has a tapered section K directly connected to the first cylindrical section Z1, which extends radially from the first cylindrical section Z1 inward toward the wheel bearing assembly 20 and thus toward the wheel rotation axis 22, and axially in the direction of the wheel carrier 18. Here, the stator frame 36 has a second cylindrical section Z2 directly connected to the tapered section K. The second cylindrical section Z2 is arranged axially between the wheel carrier 18 and the tapered section K, in the axial direction of the wheel drive device 10. The second cylindrical section Z2 is radially inward because it is radially arranged inside the cylindrical section Z1, and therefore closer to the inner side radially than the cylindrical section Z1. However, in this example, it is specified that the cylindrical section Z2 is arranged without axial overlap with the cylindrical section Z1, and vice versa. Figure 1 and Figure 3 It can also be seen that the cylindrical section Z1 is arranged to overlap with the stator 28 axially, and the second cylindrical section Z2 is arranged to be located within the first cylindrical section in the radial direction and offset from the stator 28 in the axial direction.

[0057] from Figure 2As can be seen, the stator frame 36 has at least one, or in this example multiple, openings 52, also referred to as threaded openings. In each opening 52, a fastening element is arranged, in particular exactly one. By means of the respective fastening elements, the stator frame 36 is fixed to the wheel carrier 18, thereby being permanently and rotationally resistantly connected to the wheel carrier 18. The respective fastening elements are, for example, corresponding threaded connections, especially bolts, such that, for example, the stator frame 36 is threadedly connected to the wheel carrier 18 by the corresponding threaded connections, thereby being permanently and rotationally resistantly connected to the wheel carrier 18. The channels 38, 42, and 44, and preferably the openings 52, are also at least inside the stator frame 36, especially in pairs, spaced apart from each other, especially fluid-isolated from each other, and extend respectively within the stator frame 36. Figure 1 One of the fastening elements is shown, labeled 53.

[0058] by Figure 3 Taking channel 38 as an example, from Figure 3 It can be seen that each of the channels 38, 42, and 44 corresponds, for example, to another channel 54 that extends within the wheel frame 18. Figure 1 The channel 38 shown corresponds to the other channel extending within the wheel carrier 18. Figure 3 The symbol is marked 54. Here, for example, each high-voltage line 40 or sensor line 46 is arranged in another channel extending within the wheel frame 18 corresponding to each channel 38 or 44. Furthermore, the other channel extending within the wheel frame 18 corresponding to each channel 42 can be through which coolant flows or can flow through the corresponding channel 42. Therefore, the high-voltage line 40, sensor line 46, and coolant can originate from the wheel frame 18, and thus pass from the wheel frame 18 into the corresponding channels 38, 42, and 44 and are delivered to the given element 28 via these channels, and / or delivered in reverse.

[0059] For example, in the hub drive unit 10, each first channel 38 has a corresponding first channel segment, and each second channel 42 has a corresponding second channel segment. The first channel segment and the second channel segment extend, for example, in the wall W of the second cylindrical segment Z2 in the axial direction of the hub drive unit 10. Figure 1 Will Figure 3 The first channel segment of the channel 38 shown is marked KA1. As will be detailed below, at least a portion of the second cylindrical segment Z2, the cylindrical segment Z1, and the conical segment K are integrally formed, i.e., constituted as a single piece; therefore, at least a portion of the cylindrical segment Z1, the conical segment K, and the second cylindrical segment Z2 are constituted by the body KR, which is integrally formed, i.e., a one-piece design, and is therefore constituted as a single piece. In other words, the body KR is constructed as a single block. More specifically, the body KR is cast (pouring), and is therefore designed as a cast component, also known as a casting.

[0060] For example, the stator frame 36 has a third cylindrical section Z3, which is arranged, for example, axially, between the second cylindrical section Z2 and the wheel disk 14, i.e., in the axial direction of the hub drive 10. In the embodiment shown in the figures, the third cylindrical section Z3 is axially adjacent to, and directly connected to, the cylindrical section Z2 towards the wheel disk 14, so that no other area or segment of the stator frame 36 is arranged axially between the cylindrical sections Z2 and Z3. For example, the cylindrical section Z3 is formed by the body KR, such that the cylindrical section Z3, at least a portion of the cylindrical section Z2, the tapered section K, and the first cylindrical section Z1 are preferably integrally formed and thus permanently and rotationally resistantly connected to each other. Each high-voltage line 40 is, for example, a busbar, or also referred to as a bus.

[0061] The rotor frame 27 and the hub drive 10 therefrom have a rotor cover 56, which in this example is separately constructed from the wheel 14 and is permanently and rotationally resistantly connected to the wheel 14. Here, the rotor element 30 is permanently and rotationally resistantly connected to the rotor cover 56. The wheel 14 can be another component of the rotor frame 27, since, for example, the rotor element 32 is permanently and rotationally resistantly connected to the wheel 14. Here, the rotor frame 27 has a rotor frame section 58 that is cylindrical at least on the outer circumferential side and, in this example, also on the inner circumferential side. In particular, the rotor frame section 58 and the wheel 14 are integrally formed, i.e., constituted as a single piece.

[0062] In order to achieve a particularly compact structure, the hub drive unit 10 has a seal 60, also called a sealing element and made of rubber, for sealing the rotor cover 56 and thus the rotor frame 27 relative to the cylindrical section Z2 and therefore relative to the stator frame 36. For this purpose, the seal 60 seals the annular gap R arranged radially, i.e., in the radial direction of the hub drive unit 10, between the rotor cover 56 and the second cylindrical section Z2, which is directly defined radially outward by the rotor cover 56 (especially the inner circumferential surface M1 of the rotor cover 56) and radially inward by the cylindrical section Z2 (especially the outer circumferential surface M2 of the cylindrical section Z2). Here, for example, the circumferential surfaces M1 and / or M2 are cylindrical. The seal 60, for example, directly abuts the circumferential surface M1 on one side and the circumferential surface M2 on the other side, such that the annular gap R is completely filled and thus sealed by the seal 60. For example, the seal 60 can rotate with the rotor frame 27 about the wheel rotation axis 22 relative to the wheel frame 18 and relative to the cylindrical section Z2, thus, for example, the seal 60 is permanently and irreversibly connected to the rotor frame 27. Alternatively, it is conceivable that the seal 60 is permanently and irreversibly connected to the cylindrical section Z2 and thereby to the stator frame 36, so that the rotor frame 27 and thus the rotor cover 56 can rotate about the wheel rotation axis 22 relative to the seal 60.

[0063] For example, the body KR is made of aluminum, that is, it is made of aluminum alloy.

[0064] A split-type support structure is achieved by means of a wheel bearing assembly 20. For this purpose, the wheel bearing assembly 20 has a first wheel bearing RL1, also referred to as a first bearing, and a second wheel bearing RL2, also referred to as a second bearing. The second wheel bearing RL2 is arranged on the side S1 of the first wheel bearing RL1 that faces the wheel frame 18 in the axial direction and is away from the wheel disc 14. The first wheel bearing RL1 has a first roller 62 and a first raceway assembly having a first raceway 64 for the roller 62 and a second raceway 66 arranged radially within the first raceway 64. The second wheel bearing RL2 has a second roller 68 and a second raceway assembly having a third raceway 70 and a fourth raceway 72 for the second roller 68. When the wheel disc 14 and thus the wheel 12 rotate relative to the wheel frame 18 about the wheel rotation axis 22, the roller 62 rolls directly along raceways 64 and 66, and the roller 68 rolls directly along raceways 70 and 72.

[0065] It can be seen that the seal 60 is arranged to overlap the second cylindrical section Z2 axially and surround it radially. Furthermore, the seal 60 is axially arranged between the first wheel bearing RL1 and the wheel carrier 18, particularly between wheel bearing RL1 and wheel bearing RL2. The tapered section K is axially overlapped with the first wheel bearing RL1, wherein the second cylindrical section Z2 is axially arranged between the tapered section K and the wheel carrier 18.

[0066] from Figures 1 to 4 It can be seen that the second cylindrical section Z2 has a first sleeve H1 located radially inward and a second sleeve H2 located radially outward. Sleeve H1 is also called the inner sleeve, and the second sleeve H2 is also called the outer sleeve. Sleeves H1 and H2 are located in... Figure 1 , 3 As can be clearly seen in 5, Figure 2 and 4 Not shown separately. The first sleeve H1 is made of a first material, which is a metal. The sleeve H2 is made of a second material different from the first material, which in the embodiment shown in the drawings is plastic or contains plastic. Here, the plastic is preferably an electrically insulating plastic, and thus the plastic is preferably a plastic with a conductivity of less than 10. -8 S*cm -1The insulator. In the embodiment shown in the figures, sleeve H2 is the aforementioned portion of the second cylindrical segment Z2. Therefore, for the embodiment shown in the figures, sleeve H2, tapered segment K, and first cylindrical segment Z1 are integrally formed and made of a second material (i.e., plastic in this example). This also means that body KR constitutes the second sleeve H2, tapered segment K, and first cylindrical segment Z1, wherein body KR is made of a second material and therefore, in this example, of plastic. In this example, raceways 64 and 70 are formed by the first sleeve H1 and are therefore made of a first material, i.e., a metallic material.

[0067] from Figure 5 It can be seen that each opening 52 is completely defined by and formed by the sleeve H1 in its respective circumference, so that each opening 52 is completely formed within the sleeve H1. Each channel 38 and 44 is respectively partially defined by the sleeve H1 and partially by the sleeve H2 in its respective circumference, that is, respectively partially defined by the first material and partially by the second material. Figure 5 It can be seen that each high-voltage line 40 and sensor line 46 is at least partially embedded in a second material (i.e., plastic in this example). Here, for example, each high-voltage line 40 or sensor line 46 is cast into the second material. In particular, the second material is cast and / or injection molded onto the sleeve H1.

[0068] In the embodiment shown in the accompanying drawings, the hub drive device 10 also includes a hub sleeve 80, which in this example is, for example, a component of the hub 82. It can be seen that the disc 14 is constructed separately from the hub 82 and is connected to the hub 82 in a rotationally resistant manner. In particular, the disc 14 is constructed separately from the hub 82 and is connected to the hub 82 in a particularly non-destructive manner, such that the disc 14 is connected to the hub 82 in a rotationally resistant manner. For this purpose, for example, the disc 14 is threaded to the hub 82 by bolts, thereby achieving a non-destructive and rotationally resistant connection to the hub 82. Figure 1 One of the bolts is shown, marked 84.

[0069] The hub sleeve 80 forms raceways 66 and 62, and in this example, is the radially inner first bearing sleeve of the wheel bearing assembly 20. The sleeve H1, in this example, is the radially outer second bearing sleeve of the wheel bearing assembly 20, wherein the second bearing sleeve is arranged to overlap the first bearing sleeve axially and to surround the first bearing sleeve radially. The hub 82 and thus the second bearing sleeve (i.e., the hub sleeve 80) are rotatable about the wheel rotation axis 22 relative to the sleeve H1 and thus relative to the second wheel bearing sleeve of the wheel bearing assembly 20.

[0070] In the manufacturing method of the hub drive unit 10, for example, a high-voltage line 40, particularly designed as a bus or also called a bus, is arranged on a pre-made sleeve H1. Then, with the high-voltage line 40 arranged on the sleeve H1, a second material, and thus the sleeve H2, is cast and / or injection molded onto the sleeve H1. Thus, the high-voltage line 40 is at least partially cast into the second material and thus into the sleeve H2.

[0071] List of reference numerals

[0072] 10. Hub drive system

[0073] 12 wheels

[0074] 14 Roulette

[0075] 16-inch rims

[0076] 18 Wheel frame

[0077] 20 Wheel bearings

[0078] 22 Wheel rotation axis

[0079] 24 motors

[0080] 26 rotors

[0081] 27 Rotor frame

[0082] 28 stators

[0083] 30 Rotor Components

[0084] 32 Rotor Components

[0085] 34 Double-headed arrow

[0086] 36 Stator frame

[0087] 38 First Channel

[0088] 40 High-voltage lines

[0089] 42 Second Channel

[0090] 44 Third Channel

[0091] 46 Sensor Circuit

[0092] 48 arrows

[0093] 50 outer perimeter

[0094] 52 Opening

[0095] 53 Fastening elements

[0096] 54 Another channel

[0097] 56 Rotor cover

[0098] 58 Rotor frame section

[0099] 60 Seals

[0100] 62 First Roller

[0101] 64 First Rolling Track

[0102] 66 Second Rolling Track

[0103] 68 Second Roller

[0104] 70 Third Rolling Track

[0105] 72 Fourth Rolling Track

[0106] M1 inner surface

[0107] M2 outer perimeter

[0108] K conical segment

[0109] KR ontology

[0110] H1 First Sleeve

[0111] H2 Second Sleeve

[0112] RL1 First Wheel Bearing

[0113] RL2 Second Wheel Bearing

[0114] S1 side

[0115] Z1 First Cylindrical Section

[0116] Z2 Second Cylindrical Section

[0117] Z3 Third Cylindrical Section

[0118] KA1 First Channel Section

Claims

1. A hub drive device (10) for a motor vehicle, comprising: Wheel frame (18); A wheel bearing assembly (20) having at least one first wheel bearing (RL1). The wheel (14) is rotatably supported on the wheel frame (18) by means of the wheel bearing (20); The motor (24) has a stator (28) and a rotor (26); and A stator frame (36) is used to hold the stator (28) anti-rotationally on the wheel frame (18), wherein, The stator frame (36) has a first cylindrical section (Z1) that overlaps with the stator (28) in the axial direction and a second cylindrical section (Z2) that is arranged radially within the first cylindrical section (Z1) and offset from the stator (28) in the axial direction. The second cylindrical section (Z2) has a first sleeve (H1) radially inward made of a first material and a second sleeve (H2) radially outward made of a second material different from the first material. The first material is a metallic material. Its features are, The stator frame (36) has a tapered section (K) that overlaps with the first wheel bearing (RL1) in the axial direction, wherein the second cylindrical section (Z2) is arranged in the axial direction between the tapered section (K) and the wheel frame (18). The tapered segment (K) is made of the second material and is integrally formed with the second sleeve (H2). The second material is an electrically insulating material. The second material contains an embedded busbar (40), which enables the supply of electrical energy to and / or the generation of electrical energy from the motor (24). The busbar (40) extends at least partially within the conical segment (K).

2. The hub drive device according to the preceding claim, characterized in that, The first cylindrical section (Z1) is made of the second material and is integrally formed with the radially outward second sleeve (H2).

3. The hub drive device according to claim 2, characterized in that, The conical segment (K) is integrally formed with the first cylindrical segment (Z1).

4. The hub drive device (10) according to any one of the preceding claims, characterized in that, The busbar (40) is cast into the second material.

5. A motor vehicle having at least one hub drive device (10) according to any one of the preceding claims.

Images