Systems for the thermal management of a vehicle

Abstract

System, comprehensive: a shaft assembly comprising a shaft outlet flange, a shaft inlet flange and an insert arranged in an internal volume formed by the shaft outlet flange and the shaft inlet flange, wherein the shaft inlet flange has an internal volume with internal surfaces in flush contact with a lance, and the shaft inlet flange is radially supported by a bearing; and a vent located in the shaft inlet flange at a point upstream of the bearing and the internal volume with respect to a lubricant flow direction.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] The present application claims priority over preliminary US application No. 63 / 751,108 entitled “SYSTEMS FOR THERMAL MANAGEMENT OF A VEHICLE,” which was filed on January 29, 2025. The entire contents of the aforementioned application are hereby incorporated by reference for all purposes. TECHNICAL AREA

[0002] The present description refers generally to a thermal management system for a vehicle's engine shaft. BACKGROUND AND DETOUR

[0003] Vehicles can be equipped with electrical energy storage devices to reduce their contribution to global warming. An electric motor can be configured to operate using electrical energy supplied by the electrical energy storage device, driving one or more of the vehicle's wheels. Similar to an internal combustion engine, the electric motor also requires cooling under certain operating conditions to regulate the temperature of the motor and its components.

[0004] The efficiency of an electric motor can depend, at least in part, on the efficiency of the cooling of the electric motor and its components. The stator windings are one component where the cooling methods used so far may be insufficient. Other components that may require improved cooling include the rotor, the motor shaft, and the motor bearings.

[0005] In one example, the problems described above can be solved by a system that includes the following: A shaft assembly comprising a shaft outlet flange, a shaft inlet flange, and an insert arranged in an internal volume formed by the shaft outlet flange and the shaft inlet flange, wherein the shaft inlet flange has an internal volume with internal surfaces in flush contact with a lance, and the shaft inlet flange is radially supported by a bearing. A vent is arranged in the shaft inlet flange at a location upstream of the bearing and the internal volume with respect to the lubricant flow direction.

[0006] It should be noted that the foregoing summary serves to present, in simplified form, a selection of concepts that are further explained in the detailed description. It does not serve to identify essential features of the claimed subject matter, the scope of which is defined exclusively by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to implementations that eliminate the disadvantages mentioned above or in any part of this disclosure. BRIEF DESCRIPTION OF THE FIGURES

[0007] The above advantages, as well as further advantages of the present disclosure, will be readily apparent to those skilled in the art from the following detailed description when viewed in light of the accompanying drawings, which are as follows: Fig. Figure 1 is a schematic representation of an exemplary vehicle powertrain according to an embodiment of the present disclosure; Fig. Figure 2 shows a schematic representation of a cross-section of a shaft according to an embodiment of the present disclosure; Fig. Figure 3 shows a representation of a first side of an electric motor housing according to an embodiment of the present disclosure; Fig. Figure 4 shows a representation of a second side of the electric motor housing according to an embodiment of the present disclosure; Fig. Figure 5 shows a cross-sectional view of the motor shaft including the lubricant flow direction according to an embodiment of the present disclosure; Fig. 6A shows a first view of the shaft insert according to an embodiment of the present disclosure; Fig. 6B is a second view of the shaft insertion according to an embodiment of the present disclosure; Fig. Figure 6C shows a cross-section of the shaft insert according to an embodiment of the present disclosure; Fig. Figure 7A is a perspective view of the shaft inlet flange according to an embodiment of the present disclosure; and Fig. Figure 7B shows a cross-sectional view of the shaft inlet flange according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0008] The following description refers to cooling systems for a drive unit. In one example, the drive unit is an electric motor of a vehicle, as shown in Fig. 1 shown. Fig. Figure 2 shows a schematic representation of a cross-section of the shaft of the electric motor. Fig. Figure 3 shows a representation of the first side of an electric motor housing. Fig. Figure 4 shows a view of the second side of the electric motor housing. Fig. Figure 5 shows a cross-section of the motor shaft including the lubricant flow direction. Fig. Figure 6A shows a first view of the shaft insertion. Fig. Figure 6B shows a second view of the shaft insertion. Fig. Figure 6C shows a cross-section of the shaft insert. Fig. 7A is a perspective view of the shaft inlet flange. Fig. Figure 7B shows a cross-sectional view of the shaft inlet flange according to an embodiment of the present disclosure.

[0009] Fig. Figures 1-7B show example configurations with the relative positioning of the various components of the present disclosure. If these elements are in direct contact with each other or are directly coupled, they can be described as being in direct contact or directly coupled, at least in one example. Similarly, elements shown side by side or adjacent to each other can be described as being adjacent to each other or adjacent to each other, at least in one example. For instance, components that are in planar contact with each other can be described as being in planar contact. As a further example, in at least one case, elements that are separated from each other with only a gap between them and that have no other components can be described as such.In yet another example, elements that are displayed above / below each other, on opposite sides, or to the left / right of each other can be described as such, relative to one another. Furthermore, in at least one example, as shown in the figures, a topmost element or the highest point of an element can be referred to as the "top" of the component, and a bottommost element or the lowest point of the element can be referred to as the "bottom" of the component. The terms top / bottom, upper / lower, and above / below used here can refer to a vertical axis of the figures and be used to describe the positioning of elements within the figures relative to each other. Thus, in one example, elements displayed above other elements are arranged vertically above the other elements.As a further example, the shapes of the elements depicted in the figures can be described as such (e.g., circular, straight, flat, curved, rounded, chamfered, angled, etc.). Furthermore, the depicted elements that intersect each other can be described as intersecting elements or as mutually intersecting elements in at least one example. Additionally, an element shown within another element or shown outside another element can be described as such in one example. It is understood that one or more components described as "substantially similar and / or identical" may differ from each other according to manufacturing tolerances (e.g., within a deviation of 1-5%). Fig. Figures 2-7B are shown approximately to scale, but other dimensions can be used if desired.

[0010] In Fig. Figure 1 shows a vehicle 100 comprising a drivetrain 101 and a transmission 103. The drivetrain includes a drive motor 106 and a transmission 108. The drive motor 106 can be, for example, an internal combustion engine or an electric motor and is operated to supply the transmission 108 with rotational power. The transmission 108 can be any type of transmission, such as a manual transmission, an automatic transmission, or a continuously variable transmission (CVT). The transmission 108 receives the rotational power produced by the drive motor 106 as input and outputs rotational power to the drivetrain 103 according to a selected gear or setting.

[0011] The drive motor 106 can be powered by energy from an energy storage device 105. In one example, the energy storage device 105 is a battery configured to store electrical energy. An inverter 107 can be placed between the energy storage device 105 and the drive motor 106 and configured to convert direct current (DC) to alternating current (AC). The drive motor 106 can contain a variety of components and circuits whose thermal requirements affect the efficiency of the motor. As described below, the drive motor 106 can include a cooling arrangement designed to meet the thermal requirements of the drive motor 106's components while simultaneously reducing its size. The cooling arrangement of the drive motor 106 is described in the Fig. 2-7B described in more detail.

[0012] Vehicle 100 can be a commercial vehicle, a light, medium, or heavy commercial vehicle, a passenger vehicle, a vehicle not intended for road use, or an off-road vehicle. Additionally or alternatively, Vehicle 100 and / or one or more of its components can be used in industry, locomotives, the military, agriculture, and aerospace. In one example, Vehicle 100 is an electric vehicle and the drive unit 106 is an electric motor.

[0013] In some examples, such as in Fig. As shown in Figure 1, the transmission 103 includes a first axle assembly 102 and a second axle assembly 112. The first axle assembly 102 can be configured to drive a first set of wheels 104, and the second axle assembly 112 can be configured to drive a second set of wheels 114. In one example, the first axle assembly 102 is located near the front of the vehicle 100 and therefore comprises a front axle, and the second axle assembly 112 is located near the rear of the vehicle 100 and therefore comprises a rear axle. The transmission 103 is shown in a four-wheel-drive configuration, although other configurations are possible. For example, the transmission 103 can have front-wheel drive, rear-wheel drive, or four-wheel drive. Furthermore, the transmission 103 can include one or more tandem axle assemblies.Thus, the transmission train 103 can also have other configurations without deviating from the scope of this disclosure, and those in . Fig. The configuration shown is for illustrative purposes only and does not represent a limitation. The vehicle can also include 100 additional wheels that are not coupled to the transmission 103.

[0014] In some configurations with all-wheel drive, such as in Fig. As shown in Figure 1, the transmission 103 includes a transfer case 110 configured to receive the rotational power supplied by the transmission 108. A first drive shaft 113 is driven by a first output 111 of the transfer case 110, while a second drive shaft 122 is driven by a second output 121 of the transfer case 110. The first drive shaft 113 (e.g., a front drive shaft) transmits the rotational power from the transfer case 110 to a first differential 116 of the first axle assembly 102 to drive the first set of wheels 104, while the second drive shaft 122 (e.g., a rear drive shaft) transmits the rotational power from the transfer case 110 to a second differential 126 of the second axle assembly 112 to drive the second set of wheels 114.For example, the first differential 116 is driven by a first set of axle shafts 118, which are coupled to the first set of wheels 104, and the second differential 126 is driven by a second set of axle shafts 128, which are coupled to the second set of wheels 114. It is understood that the first set of axle shafts 118 and the second set of axle shafts 128 can be arranged in a housing.

[0015] In some examples, the vehicle 100 can additionally or alternatively be a hybrid vehicle that includes both a motor and an electric machine, each configured to supply energy to one or more of the first axle assembly 102 and the second axle assembly 112. For example, one or both of the first axle assembly 102 and the second axle assembly 112 can be driven by the power from the electric machine in a first operating mode in which the electric machine is not operated to supply power (e.g., a pure motor mode), by the power from the electric machine in a second operating mode in which the motor is not operated to supply power (e.g., a pure electric mode), and by the power from both the motor and the electric machine in a third operating mode (e.g., an electric auxiliary mode).In another example, one or both of the first axis arrangement 102 and the second axis arrangement 112 can be an electric axis arrangement configured to be driven by an integrated electric machine.

[0016] In the Fig. 2 and Fig. Figure 5 shows an embodiment of a motor arrangement 200. The motor arrangement 200 can include a stator 260 and a rotor 270. In one example, the motor arrangement 200 is an electric motor arrangement 200. The stator 260 can include end windings 262 arranged at opposite ends. The rotor 270 can include rotor end caps 272 that interface with a section of a rotor shaft arrangement 202. The rotor 270 can be arranged radially outside the rotor shaft arrangement 202.

[0017] An axis system 290 is shown, which includes an x-axis parallel to an axial direction and a y-axis parallel to a vertical direction. A radial direction runs parallel to a plane containing the y-axis and a third axis that is perpendicular (e.g., one in the Fig. The motor assembly 200 (shown in Figures 3-4 and 6A-6B, z-axis) is oriented relative to the x- and y-axes. The motor assembly 200 can include a first side 292 and a second side 294. The second side 294 can be opposite the first side 292. In one example, the first side 292 is an inlet side and the second side 294 is an outlet side of the motor assembly 200, with power being transferred from the motor assembly 200 to a gearbox, gear set, or other device on the second side 294.

[0018] The rotor shaft assembly 202 can include three main parts, a shaft outlet flange 210, a shaft inlet flange 220, and a flow insert 230. In one example, the shaft outlet flange 210 and the flow insert 230 can define a main shaft body. The main shaft body can rotate about an axis of rotation parallel to the x-axis when the rotor 270 is in operation. In one example, the main shaft body rotates about its central axis, which is parallel to the x-axis. The flow insert 230 can be arranged in a cavity within the shaft outlet flange 210, the cavity being sealed via the shaft inlet flange 220. Fig. Figure 2 shows a more detailed view of the engine arrangement 200 compared to the one in Fig. 5 shown view.

[0019] The shaft outlet flange 210 is a movable component. The flow insert 230, which is also referred to as insert 230 in the following, can be held in the cavity of the shaft outlet flange 210. The shaft outlet flange 210, the shaft inlet flange 220, the insert 230, and the rotor 270 can act as rotating parts of the components in the Fig. 5 and Fig. The embodiment shown in Figure 2. In one example, the shaft inlet flange 220 and the shaft outlet flange 210 accommodate the insert 230. The insert 230 is in Fig. 6A, Fig. 6B, and Fig. 6C. is shown in further detail.

[0020] A shaft passage 512 can extend from the second side 294 to the first side 292. Fluid can flow from a lance 504 through the shaft inlet flange 220, radially around the insert 230, and / or directly through the insert 230 and into the shaft passage 512. The shaft channel 512 can run parallel to and be aligned with the central axis of the main shaft body. In one example, the lance 504 is stationary and immobile.

[0021] The lance 504 can be inserted into the housing 252 of the electric motor 250 and into the shaft inlet flange 220. A seal 508 can be arranged at the interface between the lance 504 and the shaft inlet flange 220. The seal 508 can have a square cross-sectional shape. The seal 508 can be designed such that a certain minimum quantity of lubricant can flow to a first bearing 524 via a vent 526 arranged in the shaft inlet flange 220. In one example, the vent has no valve or other flow control device, so that when the lubricant flows past the seal 508 into a chamber 528, it can flow unhindered through the vent 526 toward the first bearing 524. In another example, the first bearing 524 is arranged to support the shaft inlet flange 220.

[0022] In one example, the lance 504 and the shaft inlet flange 220 are concentric, with the lance 504 located inside (e.g., radially inside) the shaft inlet flange 220. Together, the lance 504, the shaft inlet flange 220, and the insert 230 can ensure a desired flow of lubricant and air through the shaft assembly 202.

[0023] The arrows indicate the lubricant flow, the airflow, and combinations thereof through the shaft arrangement 202. A solid line and black arrows at the beginning indicate a lubricant flow mixed with air particles. Black arrows with dashed lines indicate a lubricant flow without air particles. White arrows with dashed lines indicate an airflow without lubricant. A solid line and white arrows at the beginning indicate an airflow containing lubricant particles. A lubricant flow mixed with air particles can have a higher lubricant-to-air ratio compared to an airflow mixed with lubricant particles. In this way, the shaft arrangement 202 provides four different flow modes.In other words, the stream of lubricant and air particles can be characterized by the fact that the majority of the stream contains lubricant (i.e., more lubricant than air). The air stream containing lubricant particles can be characterized by the fact that the stream contains mostly air (e.g., more air than lubricant).

[0024] As shown, the lance 504 and the shaft inlet flange 220 can be shaped to reduce the airflow through the outer radial passages 510 of the insert 230. In one example, the lubricant flow mixed with air enters an axial channel 505 of the lance 504. Due to radial forces, oil can accumulate on the outer surface of the radial grooves of the insert 230, while air can accumulate on the inner surfaces of the radial grooves of the insert 230. The grooves of the insert 230 are located in the Fig. 6A, Fig. 6B and Fig. Figure 6C shows that some of the air can escape through the vent 526 of the shaft inlet flange 220. The vent 526 can be located at a pivot point on the inner surface of the grooves, where the air collects. A certain amount of lubricant may leak through the seal and, along with the air, reach the bearing 524 via the vent 526. Another portion of the air, trapped in the radial passages of the insert 230, can be released through the axial channel 606. A further portion of the air can flow back from the chamber 528 towards a housing cover 402.

[0025] The lance 504 can draw lubricant from the rear of the motor housing 252 and direct the lubricant to the shaft inlet flange 220. The axial passage 505 can extend through the lance 504 and the shaft inlet flange 220 to direct lubricant to the insert 230. The lubricant can flow into the multiple radial passages between the insert 230 and the shaft outlet flange 210, which can direct the lubricant to the multiple outer passages, thereby cooling a first section of the shaft. The lubricant can exit from the multiple outer passages and enter a multiple of second radial passages at a second conical end of the insert 230, from where it can flow to the shaft passage 512 of the first section, which is aligned along a shaft axis with the central channel of the static lance and the rotating insert.In one example, the axial passage 505 borders the axial channel 606 and the shaft passage 512.

[0026] The shaft outlet flange 210 can be supported by the rotor 270 and second bearings 534. The second bearings 534 can be in surface contact with a section of the shaft outlet flange 210 that is located downstream of the insert 230 relative to the lubricant flow direction through the shaft outlet flange 210.

[0027] In an alternative embodiment, the shaft outlet flange 210 can have a radial passage 536. The radial passage 536 can be configured to divert lubricant from the shaft channel 512 to the second bearings 534. Additionally or alternatively, the radial passage 536 can be configured to divert lubricant from the multiple outer passages of the insert 230 to the second bearing 534.

[0028] In the Fig. 3 and Fig. Figure 4 shows a first view 300 and a second view 400 of the housing 252. The first view 300 shows the second side 294 of the housing 252, and the second view 400 shows the first side 292 of the housing 252. In the first view 300, an oil passage 302 is supplied with lubricant by an oil pump 304, which is fluidically coupled to an oil sump 306. In one example, the oil sump 306 is additionally or alternatively a gearbox. The first view 300 also shows the second bearings 534 upstream of the keyways 350 of the shaft outlet flange 210. The keyways 350 can engage with a gear or other toothed element of the drive train. The shaft passage 512 can direct the lubricant contained therein into an oil sump or a gearbox. The second view 400 shows a housing cover 402.The housing cover 402 may have structures on its inner surface that allow lubricants from the inner passages of the housing 252 to reach the lance (e.g. lance 504 in . Fig. 5) manage.

[0029] The Fig. 6A, Fig. 6B, and Fig. Figure 6C shows different views of the deployment of the 230. Fig. Figure 600 shows a perspective view of one end of the insertion 230, that of the first page (e.g., the first page 292 in the Fig. 2 and Fig. 5) facing the motor assembly. The insert 230 can have a plurality of radial passages 602. The plurality of radial passages 602 can be arranged at a first conical end 692 of the conical ends of the insert 230. The plurality of radial passages 602 can direct lubricant to several outer axial passages 612. Each of the plurality of outer axial passages 612 can have a width greater than the width of each of the plurality of radial passages 602. This can reduce the turbulence of the lubricant as it flows axially between the insert 230 and the shaft outlet flange. Adjacent axial passages of the plurality of outer axial passages 612 can be separated from one another by a plurality of axial projections 614. This means that lubricant in one of the multiple external axial passages 612 must not flow into any of the other external axial passages.The multitude of axial projections 614 and the multitude of external axial passages 612 can extend over the entire axial length of the insert 230.

[0030] The insert 230 can also have a collection opening 604, as shown in the third view 650 in Fig. Figure 6C illustrates this. The collecting opening 604 can be configured to distribute lubricant to the plurality of radial passages 602 and to an inner axial channel 606. More precisely, the plurality of first radial projections 608 form each of the plurality of radial passages 602 and the collecting opening 604. The plurality of radial passages 602 can widen radially outward, away from the collecting opening 604. An inner axial opening 616 can fluidically connect the collecting opening 604 to the inner axial channel 606. The inner axial opening 616 can have a diameter smaller than the diameter of the inner axial channel 606. The shape of the first conical end 692 can be designed to promote the lubricant flow to the plurality of outer axial passages 612, while simultaneously allowing lubricants mixed with air to flow to the inner axial channel 606.In this way, losses due to air turbulence can be avoided and more efficient lubrication and cooling of the shaft can be achieved.

[0031] In one example, the inner axial opening 616 is dimensioned such that there is a constriction at the collection opening 604. The constriction can help lubricant flow into the plurality of radial passages 602, while at the same time air and lubricant enter the inner axial channel 606.

[0032] Fig. Figure 6B shows a second view 625, which depicts a second conical end 694 of the conical ends of the insert 230, having a plurality of radial passages 622 and an inner axial channel outlet 632. The plurality of radial passages 622 can be formed by a plurality of second radial projections 624. The plurality of second radial projections 624 can terminate in a central projection 626, on which the inner axial channel outlet 632 is located. In one example, the slope of the plurality of radial passages 622 can differ from the slope of the plurality of radial passages 602. Each of the plurality of radial passages 622 and each of the plurality of radial passages 602 can be coupled to only one of the plurality of outer axial passages 612.

[0033] As in Fig. As shown in Figure 6C, the first conical end 692 has a first bevel, and the second conical end 694 has a second bevel. The first bevel differs from the second bevel.

[0034] In Fig. Figure 7A shows a perspective view 700 of the shaft inlet flange 220. The shaft inlet flange 220 can comprise a first body 712, a second body 714, a third body 716, and a fourth body 718. In one example, the shaft inlet flange 220 is a single piece. The first body 712 can have a cylindrical shape with a first diameter. The second body 714 can have a cylindrical shape with a second diameter, the second diameter being larger than the first diameter. The vent 526 can be arranged in the second body 714. In one example, the vent 526 is located at the point where the second body 714 transitions into the third body 716. The third body 716 can have a cylindrical shape with a third diameter, the third diameter being larger than both the first and second diameters.The fourth body 718 can have a disk shape with a fourth diameter, the fourth diameter being larger than the third, second, and first diameters. In one example, the fourth body 718 can be connected to the rotor end cap 272. In another example, the rotor end cap 272 can hold the shaft inlet flange 220 in a desired position by exerting forces on the fourth body 718.

[0035] Fig. Figure 7B shows a cross-sectional view 750 of the shaft inlet flange 220. The cross-sectional view 750 shows a first internal volume 752, a second internal volume 754, a third internal volume 756, and a fourth internal volume 758. The first internal volume 752 may have a first diameter formed by the first body 712. The cross-sectional view 750 shows a stepped transition 753 from the first body 712 to the second body 714. The stepped transition 753 may have a 90-degree angle and extends from the first body 712 to the second body 714. The second internal volume 754 may have an opening formed by the second body 714 with a second diameter, the second diameter of the second internal volume being larger than the first diameter of the first internal volume 752.The third internal volume 756 can have a third diameter formed by the third body 716, wherein the third diameter of the third internal volume 756 is smaller than both the first diameter of the first internal volume 752 and the second diameter of the second internal volume 754. The vent 526 is located on an inner surface of the second body 714 at a position corresponding to the pivot point of the shaft inlet flange 220. In one example, the third internal volume 756 is dimensioned to accommodate the lance (e.g., the lance 504). Fig. 5) can accommodate the lance so that it rests against the inner surfaces of the third inner volume 756. In this way, the seal (e.g., seal 508) can be compressed between the inner surfaces of the third inner volume 756 and the outer surfaces of the lance. The first body 712 and the second body 714 can be dimensioned to have a distance from the outer surface of the lance, while the lance extends through the first inner volume 752 and the second inner volume 754 toward the third inner volume 756. In one example, the chamber (e.g., the chamber 528 from Fig. 5) be arranged between the lance and the second body 714.

[0036] A barrier 704 is arranged between the third internal volume 756 and the fourth internal volume 758. The barrier 704 can have a plurality of perforations 702 that are offset from the central axis 792 of the shaft inlet flange 220. In one example, the plurality of perforations 702 is not aligned with the central axis of the shaft (e.g., the rotor shaft assembly 202). The plurality of perforations 702 can direct the lubricant toward the collecting opening 604 according to Fig. 6C. The axial channel can release the air trapped in the numerous radial inlet channels. This allows air to accumulate on the surfaces of the shaft inlet flange 220, thereby allowing more air to reach the bearing (e.g., the first bearing 524 in Fig. 5) and less to the shaft outlet flange (e.g. to the shaft outlet flange 210 in Fig. 5) is reached.

[0037] The fourth internal volume 758 can have a non-uniform diameter that increases from the barrier 704 to the shaft outlet flange. In one example, the fourth internal volume 758 can have a conical shape formed by a fifth body 762, which connects to the first conical end 692 of the insert 230. Fig. 6A is aligned. The first conical end 692 and the fifth body 762 can form the multitude of radial inlet channels 602. Fig.6A. In one example, the fourth internal volume 758 has a variable diameter, the smallest diameter of which corresponds to the third diameter of the third internal volume 756, and the largest diameter of which is larger than the second diameter of the second internal volume 754. The fifth body 762 may have openings 764 designed to receive a connecting element, such as a locking pin, bolt, or screw. The openings 764 may be arranged between the barrier 704 and an outer surface of the fifth body 762.

[0038] The disclosure further relates to a system comprising a shaft arrangement, including a shaft outlet flange, a shaft inlet flange and an insert arranged in an internal volume formed by the shaft outlet flange and the shaft inlet flange, wherein the shaft inlet flange has an internal volume with internal surfaces in flush contact with a lance and radially oriented towards a bearing, and a vent arranged in the shaft inlet flange at a location upstream of the bearing and the internal volume with respect to the lubricant flow direction.In a first embodiment of the system, the insert has conical ends comprising a plurality of radial passages, wherein the plurality of radial passages is fluidically coupled to a plurality of external axial passages arranged on the outer diameter of the insert between the conical ends, and wherein the center projects toward an inlet of the shaft assembly. In a second embodiment of the system, which optionally includes the first embodiment, a first conical end of the insert has a first chamfer and a second conical end has a second chamfer, the second chamfer being different from the first chamfer. In a third embodiment of the system, which optionally includes one or both of the first and second embodiments, the shaft assembly is an electric motor shaft assembly.In a fourth embodiment of the system, optionally comprising one or more of the first three examples or all of these examples, the insert has an axial passage extending through the entire internal volume of the insert. In a fifth embodiment of the system, optionally comprising one or more of the first four embodiments or all of them, the shaft inlet flange has a barrier downstream of the internal volume, the barrier having a plurality of perforations offset from the central axis of the shaft assembly. In a sixth embodiment of the system, optionally comprising one or more of the first five embodiments or all of them, the shaft inlet flange has a conical outlet configured to engage with the shaft outlet flange.In a seventh embodiment of the system, which optionally comprises one or more or all of the first to sixth embodiments, the insert has a plurality of projections which form a plurality of passages on the outer surfaces of the insert.

[0039] The disclosure further relates to a system with an electric motor comprising a housing, a stator arranged in the housing and surrounding a rotor, and a shaft arranged in the housing and at least partially surrounded by the rotor, wherein the shaft has a shaft inlet flange and a shaft outlet flange in which an insert is accommodated, wherein the shaft inlet flange has an internal volume that is radially oriented towards a bearing and has surfaces that receive a lance, wherein the shaft inlet flange further comprises a vent upstream of the internal volume with respect to the direction of lubricant flow through the shaft inlet flange, and a shaft end cap that is pressed against an outer flange of the shaft inlet flange. In a first embodiment of the system, the outer surfaces of the lance are pressed against the inner surfaces of the internal volume of the shaft inlet flange.In a second embodiment of the system, which optionally includes the first embodiment, the shaft inlet flange has a barrier downstream of the internal volume, the barrier having a plurality of perforations that are not aligned with the central axis of the shaft assembly. In a third embodiment of the system, which optionally includes the first and / or the second embodiment, an axial passage of the insert is aligned with the central axis of the shaft assembly and is designed to discharge air trapped in the radial channels of the insert. In a fourth embodiment of the system, which optionally includes one, more, or all of the first through third embodiments, the shaft inlet flange has an outer flange that is in contact with a rotor end cap.In a fifth embodiment of the system, which optionally comprises one, more, or all of the first to fourth embodiments, the insert has radial and axial projections. In a sixth embodiment of the system, which optionally comprises one, more, or all of the first to fifth embodiments, the vent runs parallel to a radial direction.

[0040] The disclosure further relates to an electric motor arrangement comprising a stator, a rotor, and a shaft arrangement having a shaft inlet flange and a shaft outlet flange, wherein the shaft arrangement is configured to rotate about a central axis, and an insert arranged in a cavity of the shaft outlet flange, the insert being in flush contact with the shaft inlet flange and the shaft outlet flange, and a shaft inserted into an internal volume of the shaft inlet flange, wherein an interface between the shaft inlet flange and the shaft inlet flange is configured such that air can flow through it to a vent arranged in the shaft inlet flange. In a first embodiment of the system, the distance between the vent and the insert is greater than the distance between the interface and the insert.In a second embodiment of the system, which optionally includes the first embodiment, the vent directs air to a bearing designed to support the shaft inlet flange. In a third embodiment of the system, which optionally includes the first and / or the second embodiment, the shaft inlet flange has a barrier with a plurality of perforations arranged between the insert and the lance.In a fourth embodiment of the system, which optionally comprises one or more of the first to third embodiments or all of them, the insert has a collecting opening coupled to a plurality of radial passages and an inner axial opening, wherein the inner axial opening is configured to direct air to an axial passage of the insert, and wherein the plurality of radial passages are configured to direct lubricant to several outer axial channels arranged between the insert and the shaft outlet flange.

[0041] Unless otherwise stated, the term "approximately" means plus or minus five percent of the range.

[0042] The following claims specifically indicate certain combinations and subcombinations that are considered novel and not obvious. These claims may refer to "one" element, "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements, with two or more such elements neither required nor excluded. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application. Such claims, whether they have a broader, narrower, the same, or different scope than the original claims, are also considered to be included in the subject matter of the present disclosure. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 751,108

[0001]

Claims

[1] System, encompassing: a shaft assembly comprising a shaft outlet flange, a shaft inlet flange and an insert arranged in an internal volume formed by the shaft outlet flange and the shaft inlet flange, wherein the shaft inlet flange has an internal volume with internal surfaces in flush contact with a lance, and the shaft inlet flange is radially supported by a bearing; and a vent located in the shaft inlet flange at a point upstream of the bearing and the internal volume with respect to a lubricant flow direction. [2] System according to claim 1, wherein the insert has conical ends comprising a plurality of radial passages, wherein the plurality of radial passages is fluidically coupled to a plurality of outer axial passages arranged on an outer diameter of the insert extending between the conical ends, and wherein the plurality of outer axial passages faces an inner surface of the shaft outlet flange. [3] System according to claim 2, wherein a first conical end of the conical ends has a first slope and a second conical end of the conical ends has a second slope, wherein the second slope differs from the first slope. [4] System according to one of the preceding claims, wherein the shaft arrangement is an electric motor shaft arrangement. [5] System according to any of the preceding claims, wherein the insert has an axial channel extending through the entire internal volume of the insert. [6] System according to one of the preceding claims, wherein the shaft inlet flange has a barrier downstream of the internal volume, the barrier comprising a plurality of perforations which are not aligned with the central axis of the shaft arrangement. [7] System according to one of the preceding claims, wherein the shaft inlet flange has a conical outlet which is arranged to engage with the shaft outlet flange. [8] System according to one of the preceding claims, wherein the insert has a plurality of projections forming a plurality of passages on outer surfaces of the insert, and wherein the plurality of projections fluidically separates adjacent passages of the plurality of passages from one another. [9] System, comprehensive: an electric motor that includes a housing; a stator that is arranged in the housing and surrounds a rotor; a shaft arranged in the housing and at least partially enclosed by the rotor, wherein the shaft has a shaft inlet flange and a shaft inlet flange in which an insert is received, wherein the shaft inlet flange has an internal volume that is radially aligned with a bearing and comprises surfaces that receive a lance in the internal volume, wherein the shaft inlet flange further comprises a vent, the vent being located further from the insert than an interface between the lance and the shaft inlet flange; and a rotor end cap that is pressed against an outer flange of the shaft inlet flange. [10] System according to claim 9, wherein the outer surfaces of the lance are pressed against the inner surfaces of the inner volume of the shaft inlet flange at the interface, further comprising a chamber arranged in the inner volume of the shaft inlet flange between the lance and the vent. [11] System according to claim 9 or 10, wherein the shaft inlet flange has a barrier downstream of the internal volume, the barrier comprising a plurality of perforations which are not aligned with the central axis of the shaft arrangement. [12] System according to one of claims 9 to 11, wherein an axial channel of the insert is aligned with the central axis of the shaft arrangement and is configured to discharge air trapped in the radial channels of the insert. [13] System according to one of claims 9 to 12, wherein a seal is arranged at the interface between the lance and the shaft inlet flange and wherein the seal is arranged to direct a greater quantity of air than lubricant towards the vent. [14] System according to any one of claims 9 to 13, wherein the insert has radial and axial projections. [15] System according to any one of claims 9 to 14, wherein the venting runs parallel to a radial direction.

Images