Rotor assembly and hybrid module

Abstract

This invention relates to a rotor assembly for an electric motor and a hybrid power module. The rotor assembly (2) includes: a lamination group (3) comprising a plurality of laminations arranged axially; a first balance plate (4) and a second balance plate (5), which are respectively constructed as annular plates and located on opposite sides of the lamination group (3); a rotor support (7); a first connecting member (6) passing through and fixingly connecting the first balance plate (4), the lamination group (3), and the second balance plate (5) axially; and a second connecting member (8) passing through and fixingly connecting the first balance plate (4) and the rotor support (7). The hybrid power module includes a clutch (9), a stator assembly (1), and the rotor assembly (2) as described above.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology. Specifically, it relates to a rotor assembly, a motor, and a hybrid power module. Background Technology

[0002] In the current hybrid power module motor, the rotor assembly includes permanent magnets and laminations made of silicon steel sheets. A large number of laminations arranged along the axial direction are combined to form a lamination group, and the magnets are fixed to the lamination group by adhesive material.

[0003] The laminations are typically press-fitted onto the axially extending section of the rotor support using an interference fit. For this purpose, a heat-shrink fitting process is usually employed to assemble the laminations to the rotor support. This process requires heating the rotor laminations and cooling the rotor support, followed by a heating process to dry any moisture after assembly. As motor torque increases, a large radial overlap is required between the rotor laminations and the rotor support to achieve reliable torque transmission, further increasing the difficulty of the heat-shrink fitting assembly process.

[0004] Furthermore, to meet the demands of mass production of rotors, especially in terms of production efficiency, the individual laminations in the rotor lamination assembly are first manufactured using a stamping process and then welded together to form the lamination assembly. Due to the high power requirements of the motor in the hybrid power module and the need to arrange other components in its radially inner space, the laminations in the rotor lamination assembly have a large outer diameter and a very small annular width. After stamping out the annular laminations, the material within the inner diameter of the laminations is discarded, resulting in low material utilization and high costs for the motor and even the hybrid power module. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide a rotor assembly for an electric motor and, preferably, a hybrid power module for a vehicle including the rotor assembly, wherein the rotor assembly or hybrid power module preferably has high assembly efficiency and reduced cost, and is particularly suitable for mass production.

[0006] According to one aspect of the invention, the above objective can be achieved by a rotor assembly. The rotor assembly includes: a lamination group comprising a plurality of laminations arranged axially; a first balance plate and a second balance plate, each configured as an annular plate and located on opposite axial sides of the lamination group; a rotor support; a first connecting member passing axially through and fixingly connecting the first balance plate, the lamination group, and the second balance plate; and a second connecting member passing axially through and fixingly connecting the first balance plate and the rotor support.

[0007] Here, the motor is particularly suitable for use in a hybrid powertrain module of a vehicle. Preferably, the motor is constructed as an internal rotor radial motor. Preferably, the motor is constructed as a permanent magnet synchronous motor. In addition to the rotor assembly mentioned herein, the motor also includes other necessary components such as a stator assembly. Within the scope of this document, unless otherwise stated, the terms "axial," "radial," and "circumferential" are defined based on the axis of rotation of the motor, i.e., the axis of rotation of the rotor assembly.

[0008] Preferably, the rotor assembly includes a lamination group that forms the rotor core. Preferably, the laminations of the lamination group are made of silicon steel sheets. Those skilled in the art will understand that the rotor assembly also includes other necessary components. For example, in the case of a permanent magnet synchronous motor, the rotor assembly also includes permanent magnets. As another example, in the case of an asynchronous motor, the rotor assembly also includes rotor windings. Optionally, the rotor assembly can be configured with a staggered or skewed pole structure as needed.

[0009] Preferably, the first and second balance plates are each constructed as annular plates. Preferably, the first and second balance plates are respectively arranged at both axial ends of the lamination assembly. In some embodiments, an electric motor or hybrid power module is arranged between the internal combustion engine and the transmission, with the first balance plate axially arranged on the internal combustion engine side and the second balance plate axially arranged on the transmission side. The first and second balance plates here ensure the dynamic balance of the rotor assembly during operation, for example by removing material or alternatively by adding material. Furthermore, the first and second balance plates also serve as connectors to link the individual laminations in the lamination assembly together and simultaneously connect the lamination assembly to the rotor support.

[0010] Preferably, the rotor assembly includes at least two first connecting members distributed along the circumferential direction.

[0011] Preferably, the rotor assembly includes at least two second connecting members distributed along the circumferential direction.

[0012] The rotor assembly structure provided herein eliminates the need for welding tools during lamination assembly and avoids the use of heat-shrink assembly processes, thus eliminating the need for additional heating and cooling equipment. In particular, the first and second connecting members simplify the assembly of the lamination assembly itself and the assembly of the lamination assembly and rotor support. This improves assembly efficiency and reduces component costs.

[0013] In some preferred embodiments, the first connecting member is a bolt, a resilient cotter pin, or a rivet, and the second connecting member is also a bolt or rivet. This allows the same or similar processes to be used during the assembly of the lamination assembly and the assembly of the lamination assembly with the rotor support, thereby simplifying the assembly process and reducing component costs.

[0014] In some preferred embodiments, the laminations consist of at least two circumferentially distributed arc segments, with a first connecting member distributed circumferentially and extending through each arc segment. Here, the laminations are manufactured primarily by stamping the lamination arc segments from a material such as strip steel, and then assembling the arc segments into a complete annular lamination. The first connecting member connects the individual lamination arc segments to a first balance plate and a second balance plate, thereby assembling the first balance plate, the lamination assembly, and the second balance plate. In particular, compared to stamping the entire annular lamination and discarding material up to the inner diameter, the rotor assembly according to this embodiment can improve material utilization by rationally arranging the lamination arc segments on the material to be stamped, such as strip steel, thereby greatly saving lamination material and correspondingly reducing the cost of the rotor assembly and even the hybrid power module.

[0015] Preferably, the laminations consist of three or four arc segments distributed along the circumferential direction. This maximizes the utilization of the stamping material, such as strip steel, used to manufacture the laminations.

[0016] Preferably, adjacent arc segments in the same stack are abutted by adjacent portions having complementary shapes. In some embodiments, the complementary shapes are, for example, a semi-circular protrusion and a semi-circular groove. By means of adjacent portions with complementary shapes, adjacent arc segments can be connected to each other to simplify assembly.

[0017] In some preferred embodiments, the radially outer end of the rotor support is arranged radially inner to the lamination assembly, and the sub-assembly consisting of the first balance plate, the lamination assembly, and the second balance plate is centered at the axial end where the first balance plate is located via the radially outer end of the rotor support. Here, it is possible that the radially inner end of the lamination assembly and the radially outer end of the rotor support are configured for a transition fit. For example, the distance between the radially inner end of the lamination assembly and the radially outer end of the rotor support is within ±0.2 mm. The sub-assembly consisting of the first balance plate, the lamination assembly, and the second balance plate can thus be easily centered or aligned on an axial end side, such as the internal combustion engine side, while the rotor assembly as a whole can have a compact axial structure.

[0018] Preferably, the radially outer end of the rotor support is constructed in the shape of an annular disk. The rotor support here has a simple structure.

[0019] According to another aspect of the invention, the above-mentioned objective can be achieved by a hybrid power module. The hybrid power module includes a clutch, a stator assembly, and a rotor assembly according to the above embodiment.

[0020] Here, the hybrid power module can include an electric motor and a clutch. The electric motor includes a stator assembly and a rotor assembly. Those skilled in the art will understand that the electric motor can also include other necessary components. Preferably, the clutch is a wet clutch.

[0021] In some preferred embodiments, the clutch includes a clutch plate support, and the hybrid power module further includes a third connecting member that extends axially through and securely connects the rotor support and the clutch plate support. Preferably, the clutch plate support is the outer clutch plate support of the clutch. Preferably, the third connecting member is a bolt or rivet. Thus, the first, second, and third connecting members can be assembled using the same or similar processes, simplifying the assembly process of the hybrid power unit. This shortens the production cycle of the hybrid power module, making it suitable for mass production while maintaining lower costs.

[0022] Preferably, the clutch includes an actuator housing, and a sub-assembly consisting of a first balance plate, a lamination group, and a second balance plate is centered at the axial end of the second balance plate via the radially outer end of the actuator housing. The clutch actuator engages the clutch discs and can be configured as a hydraulic, electric, or electromagnetic actuator as needed. In some embodiments, the actuator housing is the housing of a hydraulic actuator forming a hydraulic chamber. In some embodiments, the actuator housing is the housing of an electric actuator housing an electric motor. Here, the sub-assembly consisting of the first balance plate, the lamination group, and the second balance plate can thus be easily centered or aligned on an axial end side, such as the transmission side, while the hybrid power module as a whole can have a compact axial structure. Attached Figure Description

[0023] The features, advantages and technical effects of exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.

[0024] Figure 1 This is an axial sectional view of a hybrid power module according to an embodiment of the present invention;

[0025] Figure 2 yes Figure 1 An axial sectional view of the rotor assembly in the hybrid power module shown.

[0026] Figure 3 yes Figure 1 A perspective view of the rotor assembly in the hybrid power module shown; and

[0027] Figure 4 yes Figure 3 A perspective view of the laminated assemblies in the rotor assembly of the hybrid power module. Detailed Implementation

[0028] Figure 1 This is an axial sectional view of a hybrid power module according to an embodiment of the present invention. The hybrid power module is used in a hybrid vehicle. Here, as... Figure 1As shown, the hybrid power module is located in the vehicle between the internal combustion engine side A and the transmission side B.

[0029] like Figure 1 As shown, the hybrid power module includes an electric motor and a clutch 9 generally arranged radially inside the electric motor. Additionally, the hybrid power module also includes a module housing.

[0030] Here, the motor is constructed as an internal rotor radial motor. In this embodiment, the motor is constructed as a permanent magnet synchronous motor.

[0031] like Figure 1 As shown, the motor includes a stator assembly 1 and a rotor assembly 2. The stator assembly 1 is mounted on the module housing. The rotor assembly 2 is rotatably arranged within the radially inner space of the stator assembly 1.

[0032] Figure 2 yes Figure 1 An axial cross-sectional view of the rotor assembly 2 in the hybrid power module of the illustrated embodiment. Figure 3 yes Figure 1 A perspective view of rotor assembly 2 in the hybrid power module of the illustrated embodiment. Figure 1 and Figure 2 As shown, the rotor assembly 2 includes a first balance plate 4, a lamination group 3, and a second balance plate 5 arranged sequentially along the axial direction from the internal combustion engine side A to the transmission side B. The rotor assembly 2 also includes permanent magnets.

[0033] Figure 4 This is a perspective view of the lamination group 3 in the rotor assembly 2 of this embodiment. Figures 2 to 4 As shown, the lamination group 3 constitutes the rotor core. The lamination group 3 includes a plurality of laminations arranged axially. In this embodiment, each lamination is annular and made of silicon steel sheets segmented along the circumferential direction. Specifically, the lamination consists of at least two arc segments distributed along the circumferential direction. In this embodiment, the lamination consists of three arc segments. Adjacent arc segments in the same lamination are abutted by adjacent portions 14 having complementary shapes. In this embodiment, especially as shown... Figure 4 As shown, the complementary shapes of the adjacent portions 14 are, for example, a semi-circular protrusion and a semi-circular groove. Here, the laminations are manufactured primarily by stamping lamination arc segments from a material such as strip steel, and then assembling these arc segments into a complete annular lamination. Especially compared to a method that stamps the entire annular lamination and discards material up to the inner diameter, in the rotor assembly according to this embodiment, material utilization can be improved by rationally arranging the lamination arc segments on the material to be stamped, such as strip steel, thereby greatly saving lamination material. With the help of adjacent portions having complementary shapes, adjacent arc segments can be connected to each other to simplify assembly. The cost of the rotor assembly 2, and even the hybrid power module, can be reduced accordingly.

[0034] like Figure 2 and Figure 4 As shown, in this embodiment, the permanent magnets are arranged internally within the lamination group 3, or the rotor core. Furthermore, the rotor assembly 2 is configured with two misaligned poles.

[0035] The first balance plate 4 is made of insulating material. The first balance plate 4 is made, for example, of stainless steel or aluminum alloy. The first balance plate 4 is constructed as a ring-shaped plate. The first balance plate 4 is arranged axially on the internal combustion engine side A of the laminated assembly 3. The first balance plate 4 here ensures the dynamic balance of the rotor assembly 2 during operation, for example by removing material or alternatively by adding material.

[0036] The second balance plate 5 is made of insulating material. The second balance plate 5 is made, for example, of stainless steel or aluminum alloy. The second balance plate 5 is constructed as a ring-shaped plate. The second balance plate 5 is arranged axially on the gearbox side B of the lamination assembly 3. The second balance plate 5 ensures the dynamic balance of the rotor assembly 2 during operation, for example, by removing material or alternatively by adding material.

[0037] like Figures 1 to 3 As shown, the rotor assembly 2 also includes first connecting members 6. The first connecting members 6 are distributed circumferentially. The first connecting members 6 are, for example, bolts, resilient cotter pins, or rivets. The first connecting members 6 pass axially through and securely connect the first balance plate 4, the lamination group 3, and the second balance plate 5, respectively. The first connecting members 6 connect the individual lamination segments to the first balance plate 4 and the second balance plate 5, thereby assembling the first balance plate 4, the lamination group 3, and the second balance plate 5. For example, in this embodiment, the rotor assembly 2 is provided with twelve first connecting members 6, where each lamination segment is connected to the first balance plate 4 and the second balance plate 5 via four first connecting members 6 distributed circumferentially.

[0038] With the structure of the rotor assembly 2 provided herein, no welding tools are required when assembling the lamination group 3, and the heat-shrink assembly process is avoided when assembling the rotor assembly 2, eliminating the need for additional heating and cooling equipment. In particular, the assembly of the lamination group 3 itself can be simplified through the first connecting member 6. Assembly efficiency is thus improved, and the cost of the rotor assembly 2 is reduced.

[0039] like Figures 1 to 3 As shown, the rotor assembly 2 also includes a rotor support 7 and a second connecting member 8.

[0040] In this embodiment, the rotor support 7 is generally annular disc-shaped. The radially outer end of the rotor support 7 is constructed as annular disc. The radially outer end of the rotor support 7 is arranged radially inner to the lamination assembly 3 and on the transmission side B of the first balance plate 4. The second connecting member 8 passes through axially and fixes the first balance plate 4 to the rotor support 7. The rotor assembly 2 includes at least two second connecting members 8 distributed circumferentially. The second connecting members 8 are, for example, bolts or rivets. The radially inner end of the rotor support 7 is anti-rotationally connected to the shaft 14 for connection to the internal combustion engine, for example, by a spline connection.

[0041] like Figure 1 As shown, the clutch in this embodiment is constructed as a wet clutch. Here, the clutch includes outer clutch plates and supports connecting each outer clutch plate radially outward, i.e., outer clutch plate supports 10; the clutch also includes inner clutch plates and supports connecting each inner clutch plate radially inward, i.e., inner clutch plate supports. The clutch includes an actuator to engage or disengage the axially alternating inner and outer clutch plates. In this embodiment, the actuator is constructed as a hydraulic actuator and includes an actuator housing 12 for forming a hydraulic chamber.

[0042] The hybrid power module also includes a third connecting member 11. The third connecting member 11 is a bolt or rivet. The third connecting member 11 extends axially through and securely connects the rotor support 7 and the clutch plate support 10. Here, the first connecting member 6, the second connecting member 8, and the third connecting member 11 can be assembled using the same or similar processes, simplifying the assembly process of the hybrid power unit. This shortens the production cycle of the hybrid power module, making it suitable for mass production while maintaining lower costs.

[0043] On the internal combustion engine side A, i.e., at the axial end where the first balance plate 4 is located, the sub-assembly consisting of the first balance plate 4, the lamination group 3, and the second balance plate 5 is centered via the radially outer end of the rotor support 7. Here, the radially inner end of the lamination group 3 and the radially outer end of the rotor support 7 are configured for a transition fit. For example, the distance between the radially inner end of the lamination group 3 and the radially outer end of the rotor support 7 is within ±0.2 mm. On the transmission side B, i.e., at the axial end where the second balance plate 5 is located, the sub-assembly consisting of the first balance plate 4, the lamination group 3, and the second balance plate 5 is centered via the radially outer end of the actuator housing 12. Here, the sub-assembly consisting of the first balance plate 4, the lamination group 3, and the second balance plate 5 can thus be easily centered or aligned on both axial sides, while the hybrid power module as a whole can have a compact axial structure.

[0044] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention. In the description herein, it should be noted that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0045] List of reference numerals

[0046] 1. Stator assembly of the motor

[0047] 2. Rotor assembly of the motor

[0048] 3 stacked pieces

[0049] 4 First Balance Plate

[0050] 5. Second Balance Plate

[0051] 6 First connecting member

[0052] 7 Rotor support

[0053] 8 Second connecting member

[0054] 9. Clutch

[0055] 10 External Clutch Plate Support

[0056] 11 Third connecting member

[0057] 12 Actuator Housing

[0058] 13-axis component

[0059] 14 Adjacent parts

[0060] A. Internal combustion engine side

[0061] B. Transmission side

Claims

1. A rotor assembly (2) for an electric motor, comprising: The stacked assembly (3) comprises multiple stacked pieces arranged axially; The first balance plate (4) and the second balance plate (5) are respectively constructed as annular plates and are located on both sides of the axial direction of the stacked plate group (3); Rotor support (7); A first connecting member (6) passes through and fixes the first balancing plate (4), the stacked plate group (3), and the second balancing plate (5) axially; and The second connecting member (8) passes through and is fixedly connected to the first balance plate (4) and the rotor support (7) along the axial direction.

2. The rotor assembly (2) according to claim 1, wherein, The first connecting member (6) is a bolt, a resilient cotter pin or a rivet, and the second connecting member (8) is a bolt or a rivet.

3. The rotor assembly (2) according to claim 1, wherein, The stack consists of at least two arc segments distributed along the circumferential direction, and the first connecting member (6) is distributed along the circumferential direction and extends through the arc segments respectively.

4. The rotor assembly (2) according to claim 3, wherein, The stacked pieces consist of three or four arc segments distributed along the circumference.

5. The rotor assembly (2) according to claim 3, wherein, Adjacent arc segments in the same stack are adjacent to each other through adjacent portions (14) with complementary shapes.

6. The rotor assembly (2) according to claim 1, wherein, The radially outer end of the rotor support (7) is arranged on the radially inner side of the lamination group (3), and the sub-assembly composed of the first balance plate (4), the lamination group (3) and the second balance plate (5) is centered at the axial end of the first balance plate (4) through the radially outer end of the rotor support (7).

7. The rotor assembly (2) according to claim 6, wherein, The radially outer end of the rotor support (7) is constructed in the shape of an annular disk.

8. A hybrid power module, comprising a clutch (9), a stator assembly (1), and a rotor assembly (2) according to any one of claims 1 to 7.

9. The hybrid power module according to claim 8, wherein, The clutch (9) includes a clutch plate support (10), and the hybrid power module also includes a third connecting member (11) that extends axially through and securely connects the rotor support (7) and the clutch plate support (10).

10. The hybrid power module according to claim 9, wherein, The clutch (9) includes an actuator housing (12), and a sub-assembly consisting of the first balance plate (4), the stacked plate group (3) and the second balance plate (5) is centered at the axial end of the second balance plate (5) via the radially outer end of the actuator housing (12).

Images