GEARMOTOR FOR VEHICLE BRAKE, INCLUDING A POWER MODULE WITH MORE THAN THREE SWITCHING CELLS

Abstract

The invention relates to a geared motor for an electromechanical vehicle wheel brake. The adapter comprises an electric motor (2) and a power switching and control unit (9). The power switching and control unit (9) includes a power module (91) which has power inverter switches arranged in switching cells. The switching cells are configured to be connected to phases of the electric motor (2). The power module (91) has at least as many switching cells as there are phases of the electric motor (2) and includes at least four switching cells. (See Figure 1 for abbreviations.)

Description

Title of the invention: REDUCED MOTOR FOR VEHICLE BRAKE, COMPRISING A POWER MODULE COMPRISING MORE THAN THREE SWITCHING CELLS Technical field

[0001] The invention relates to the general technical field of vehicle brakes. More specifically, the invention relates to a geared motor for an electromechanical vehicle wheel brake. STATE OF THE PRIOR ART

[0002] An electromechanical vehicle brake gear motor of known structure comprises an electric motor, a reducer and a switching and power control member. The electric motor is a three-phase motor which is powered with direct current by a battery of the vehicle. The switching and power control member comprises a power control module and a power module. The power module comprises a three-phase inverter which is configured to power the electric motor when it is controlled by the power control module.

[0003] There is a need to facilitate the manufacture of the geared motor. In particular, there is a need for greater standardization of the geared motor, while having a switching and power control member that is specifically adapted to the electric motor of the geared motor. Statement of the invention

[0004] In this regard, the invention relates to a geared motor for an electromechanical vehicle wheel brake, comprising an electric motor and a power switching and control member comprising a power module which comprises power inverter switches which are arranged in switching cells. The switching cells are configured to be connected to phases of the electric motor.

[0005] According to the invention, the power module comprises at least as many switching cells as the number of phases of the electric motor. The power module comprises at least four switching cells.

[0006] Thanks to the power module according to the invention, the power switching and control member is more reliable and easier to manufacture, while having a power switching and control member which is adapted to the func operation of the electric motor of the geared motor and in particular the number of phases of the electric motor.

[0007] In particular, the power module which comprises a high number of switching cells allows emergency operation, possibly degraded, in the event of failure of a switching cell of the power module and in particular of a power switch.

[0008] The power module can be further standardized, by having a similar or identical structure for electric motors of different structures and / or different powers, while being suitable for operating the electric motor. In particular, the power module has, for example, the same number of switching cells for motors having a different number of phases. The switching and power control member can be further standardized. The standardization of the geared motor then tends to increase.

[0009] The invention may optionally comprise one or more of the following features, combined with each other or not.

[0010] According to a particular embodiment, the power module comprises as many switching cells as the number of phases of the electric motor. Each switching cell is electrically connected to a respective phase of the electric motor during normal operation of the geared motor.

[0011] According to a particular embodiment, the geared motor comprises switching sub-assemblies which each include a portion of the switching cells of the power module. Each switching sub-assembly comprises as many switching cells as the number of phases of the electric motor, the switching cells of only one of the switching sub-assemblies being simultaneously connected to the phases of the electric motor.

[0012] According to a particular embodiment, the power module comprises two switching sub-assemblies, each of the switching sub-assemblies comprising half of the switching cells of the power module.

[0013] According to a particular embodiment, the power module comprises a switch which is configured to electrically connect a first switching subassembly among the switching subassemblies to the phases of the electric motor, when the switch is in a first switching position. The switch is configured to electrically connect a second switching subassembly among the switching subassemblies to the phases of the electric motor, when the switch is in a second switching position.

[0014] According to a particular embodiment, the power module comprises six switching cells, for electrically connecting a three-phase electric motor of the geared motor to a vehicle battery or for connecting a six-phase electric motor of the geared motor to a vehicle battery.

[0015] According to a particular embodiment, the electric motor comprises six redundant phases to be able to operate on three phases. The six phases of the electric motor are connected to the switching cells of the power module so that the electric motor is able to operate at half of its maximum power, in the event of failure of one of the switching cells.

[0016] According to a particular embodiment, the geared motor is configured to control the operation of the power module. In other words, the geared motor is configured to monitor and / or detect failures of the power module.

[0017] According to a particular embodiment, the switch is configured to switch from the first position to the second position, when a failure of the first switching subassembly is detected.

[0018] According to a particular embodiment, the electric motor is a permanent magnet synchronous motor.

[0019] The invention finally relates to a method for manufacturing a geared motor as defined above. The manufacturing method comprises a step of electrically connecting the power module to the electric motor, by electrically connecting each of the phases of the electric motor to one of the switching cells of the power module. The power module comprises at least four switching cells.

[0020] According to a particular embodiment, the manufacturing method comprises a step of selecting a first power module suitable for electrically supplying the first electric motor of the geared motor, from a set of power modules for geared motors which are of different structures.

[0021] The control module of the geared motor comprises a programmable computer which is programmable by being able to control each of the power modules of the set of power modules. The manufacturing method comprises programming the computer of the control module to control the first power module.

[0022] According to a particular embodiment, the manufacturing method comprises a prior step of selecting a first electric geared motor suitable for the vehicle from a set of electric geared motors which are of different structures. Brief description of the drawings

[0023] The present invention will be better understood on reading the description of exemplary embodiments, with reference to the appended drawings in which: [Fig.l] is a partial schematic representation in isometry and exploded of a mo- toreducer according to the invention; [Fig.2] is a partial schematic representation of a six-phase electric motor electrically connected to a power module of the geared motor according to a first embodiment of the invention; [Fig.3] is a partial schematic representation of a three-phase electric motor electrically connected to a power module of the geared motor according to a second embodiment of the invention; [Fig.4] illustrates a method of manufacturing the geared motor according to the first embodiment or according to the second embodiment.

[0024] DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

[0025] Identical, similar or equivalent parts of the different figures bear the same numerical references so as to facilitate the transition from one figure to another.

[0026] [Fig.l] represents a geared motor 1 for an electromechanical vehicle wheel brake. The geared motor 1 can be implemented in a motorized vehicle which comprises at least two wheels, three wheels and preferably four wheels. The motorized vehicle is for example a motorcycle. The motorized vehicle is for example a motor vehicle.

[0027] In the embodiment shown, the geared motor 1 is a disc brake geared motor, for example with a floating caliper.

[0028] The electromechanical brake is for example a front wheel and / or rear wheel brake. The electromechanical brake is for example a drive wheel brake.

[0029] The electromechanical brake is used, for example, to provide service braking for the motor vehicle. Alternatively or additionally, the electromechanical brake is used to provide parking braking and / or emergency braking for the motor vehicle.

[0030] The geared motor 1 comprises an electric motor 2, a transmission device 4, a geared motor housing 6, a connection module 7 and a switching and power control member 9. The geared motor 1 is used for service braking, emergency braking and / or parking braking of the vehicle.

[0031] The electric motor 2 is for example an alternating current motor such as a permanent magnet synchronous motor, also referred to as a brushless motor. The electric motor 2 is in particular a single-phase, three-phase or an electric motor with more than three phases, for example an electric motor 2 comprising six phases.

[0032] The transmission device 4 is for example configured to be connected to a piston of an electromechanical brake. It comprises a plurality of movement transmission elements such as toothed wheels. In the embodiment shown, the transmission device comprises for example an epicyclic reducer. The transmission device 4 is in particular configured to move in translation of a piston, when driven by the electric motor 2.

[0033] The housing 6 of the geared motor 1 comprises a housing body 60 and a cover 61 which is fixed in a sealed manner to the housing body 60. The housing body 60 is configured to receive the electric motor 2, the transmission device 4, the connection module 7 and the switching and power control member 9. The housing body 60 comprises a housing for the electric motor 62, a housing for the transmission device 63. The electric motor 2, the connection module 7 and the switching and power control member 9 are configured to be housed at least partially in the housing for the electric motor 62.

[0034] The power switching and control member 9 comprises a power module 91 and a control module 92 of the power module. The power module 91 comprises a power inverter.

[0035] The input of the power module 91 is configured to be electrically connected to an electrical power source of a vehicle such as an electric battery delivering continuous electrical energy. The output of the power module 91 is configured to be electrically connected to the phases of the electric motor 2. The power module 91 is configured to power the electric motor 2 from the electrical energy delivered by the electrical power source when it is controlled by the control module 92 of the power module.

[0036] The inverter comprises switching sub-assemblies 96 which each include switching cells 95. The inverter of the power module 91 is adapted to generate alternating voltages and currents from the direct electrical energy delivered by the direct electrical power source.

[0037] The switching cells 95 each comprise power switches 94. Each switching cell 95 comprises two power switches 94, in each of the two embodiments shown. Each phase of the electric motor 2 is electrically connected to one of the switching cells 95, for example by the connection module 7 or by conductive wires 80 as illustrated in [Fig.2],

[0038] The power switches 94 are for example IGBTs (IGBT meaning insulated gate bipolar transistor) in each of the embodiments shown.

[0039] The control module 92 of the power module comprises a computer which includes control software for controlling the power module 91. The control module 92 of the power module is configured to control the opening and / or closing of the switches 94 of the power module 91. The computer of the control module 92 of the power module is for example a microcontroller.

[0040] The control modules 92 of the power module of the geared motors 1 of each of the embodiments shown are, for example, structurally identical. In particular, the control software can be programmed both to control the power module 91 of the geared motor 1 according to the first embodiment and the power module 91 of the geared motor according to the second embodiment. Alternatively, the control modules 92 of the power module of the geared motors 1 of each of the embodiments shown differ only in their control software, i.e. in their programming.

[0041] The geared motor 1 is configured to control the operation of the power module 91, in particular to monitor and detect a failure of the power module 91. The control of the operation of the power module 91 can be operated from the control module 92 of the power module, or from a brake control unit. The brake control unit is for example a local control unit which is part of the electromechanical brake. This local control unit is configured to control the control module 92 of the power module so that it orders the power module 91 to power the electric motor 2 of the geared motor to brake or release the brakes of the corresponding wheel of the vehicle.

[0042] The connection module 7 is configured to electrically connect the power module 91 and the control module 92 of the power module to the electric motor 2. In the embodiment shown, the power module 91 and the control module 92 of the power module are respectively on separate supports 98 and 99. The control module 92 of the power module controls the operation of the power module 91, in particular via the connection module 7.

[0043] [Fig.2] more specifically represents the electric motor 2 and the power module 91 of the geared motor 1, according to the first embodiment of the invention.

[0044] In this embodiment, the electric motor 2 is a six-phase electric motor. The six phases of the electric motor are preferably redundant. In particular, the electric motor 2 can operate as a three-phase electric motor. The electric motor 2 is notably capable of operating at half its maximum power in the event of failure of a switching cell 95 of the power module 91, then operating on three phases.

[0045] The power module 91 here comprises six switching cells 95 for electrically connecting each of the phases of the electric motor 2 to the electrical power source of the vehicle. More generally, the power module 91 of the geared motor 1 according to the first embodiment comprises as many switching cells 95 as the number of phases of the electric motor 2. Each switching cell mutation 95 is electrically connected to one of the respective phases of the electric motor 2 during normal operation of the geared motor 1.

[0046] A portion of the switching cells 95 is included in the switching subassemblies 96 of the power module 91. In particular, the power module 91 comprises two switching subassemblies 96 each comprising half of the switching cells 95 of the power module 91, i.e. three switching cells. The switching cells 95 can operate independently of each other in the sense that in the event of failure of a switch 94 and / or a switching cell 95 of a switching subassembly 96, the other switching subassembly 96 continues to operate normally and independently of the faulty switching subassembly.

[0047] In this respect, the electric motor 2 is powered by only one of the switching sub-assemblies 96, when the other of the switching sub-assemblies 96 is faulty. This has the effect of reducing by half the electrical energy supplied by the power module 91 to the electric motor 2. The power module 91 ensures continuity of operation of the electric motor 2 in the event of failure of a switch 94 and / or a switching cell 95. The power module 91 thus avoids a total failure of the geared motor.

[0048] [Fig. 3] shows the electric motor and the power module of the geared motor 1, according to the second embodiment of the invention. The geared motor 1 according to the second embodiment is mainly distinguished from that according to the first embodiment by the structure of the electric motor 2 and by the structure of the power module 91. The control modules 92 of the power module are preferably similar in these two embodiments shown, at least structurally.

[0049] The power module 91 of the second embodiment differs from the power module 91 of the first embodiment in that it comprises a switch 97. To simplify the description, the same numerical references have therefore been used except for the electric motor for which a similar reference but with the addition of the number 100 has been used.

[0050] In this geared motor 1, the electric motor 102 is a three-phase electric motor. In this respect, each switching subassembly 96 comprises as many switching cells 95 as the number of phases of the electric motor 102. The phases of the electric motor 102 are connected simultaneously to each switching cell 95 of one of the switching subassemblies 96 of the power module 91. In other words, the phases of the electric motor 2 are connected either to each switching cell 95 of a first switching subassembly 96, or to each switching cell 95 of the other switching subassembly 96.

[0051] The switch 97 is configured to electrically connect one of the switching subassemblies 96 to the phases of the electric motor 102, when it is in a first switching position, and to electrically connect the other of the switching subassemblies 96 to the phases of the electric motor 102, when it is in a second switching position.

[0052] In the first switching position, the switch 97 electrically connects the phases Ub Vi, Wb coming from the switching cells 95 of one of the switching sub-assemblies 96 to the phases of the electric motor 102, while in the second switching position, the switch 97 electrically connects the phases U2, V2, W2, coming from the switching cells 95 of the other of the switching sub-assemblies 96 to the same phases of the electric motor 102.

[0053] The switch 97 is electrically connected at the input to the switching cells 95 of each subassembly 96 of the power module 91, for example via the connection module 7 or conductive wires 81 as illustrated. The switch 97 is electrically connected at the output to the phases of the electric motor 102, for example via the connection module 7 or conductive wires 82 as illustrated.

[0054] The switch 97 switches from the first position to the second position, in particular when a failure of the switching subassembly 96 which is electrically connected to the phases of the electric motor 102 is detected. This makes it possible to provide redundancy which ensures the continuity of operation of the electric motor 102 in the event of failure of a switch 94 and / or a switching cell 95. The reliability of the geared motor 1 is improved.

[0055] The switch 97 is manually or alternatively automatically controlled to switch from one switching position to another. The switch 97 is in particular manually controlled to switch from one switching position to another to test the operation of each subassembly 96.

[0056] [Fig.4] represents a manufacturing method 200 of the geared motor 1 according to the first embodiment or according to the second embodiment.

[0057] The manufacturing method 200 comprises a manufacturing step 201 of the electric motor 2, the transmission device 4, the housing 6, the connection module 7 and the switching and power control member 9 which comprises the power module 91 and the control module 92 of the power module. The housing 6 is standard, being adapted to house the electric motor 2, the transmission device 4, the connection module 7 as well as the switching and power control member 9.

[0058] Generally, the electric motor 2 is manufactured by being adapted to the motorized vehicle and to the geared motor 1. The electric motor 2 is for example selected among a set of electric motors of different structures.

[0059] The power module 91 is manufactured by being adapted to the electric motor 2 of the geared motor 1. The power module 91 is for example selected from a set of power modules of different structures, being capable of electrically supplying the electric motor 2 of the geared motor 1.

[0060] The control module 92 of the power module is for example manufactured with a standard structure and programming which is specific to the power module 91. The control module 92 of the power module notably comprises a programmable computer such as a microcontroller, the control module 92 of the power module being programmed to control the power module 91 of the geared motor 1.

[0061] Referring again to [Fig. 4], the manufacturing method 200 then comprises a step 202 of electrical and mechanical connection of the power module 91 to the connection module 7, a step 203 of electrical and mechanical connection of the control module 92 of the power module to the connection module 7 and a step 204 of electrical and mechanical connection of the electric motor 2 to the connection module 7.

[0062] The step 202 of electrical and mechanical connection of the power module 91 to the connection module 7 and step 203 of electrical and mechanical connection of the control module 92 of the power module can take place interchangeably one before the other or substantially simultaneously.

[0063] The step 204 of connecting the electric motor 2 to the connection module 7 can be implemented by inserting the connection module 7 into the housing of the electric motor 62 until the bottom wall 74 closes the housing 62 of the electric motor. The control module 92 of the power module and the power module 91 are housed inside the housing of the electric motor 62 of the geared motor housing 6.

[0064] The manufacturing method 200 comprises a step 205 of electrically connecting the electric motor to a continuous electrical power source such as a vehicle battery. The step 205 of electrically connecting the connection module 7 can take place substantially simultaneously with the closing of the housing 6 and the electrical connection 204 of the connection module 7 to the electric motor 2.

[0065] With more specific reference to the geared motor according to the first embodiment, the step 202 of electrically connecting the power module 91 to the electric motor 2 is carried out by electrically connecting each of the phases of the electric motor 2 to one of the switching cells 95 of the power module 91 and by electrically connecting each of the switching cells 95 to one of the phases of the electric motor 2.

[0066] With reference to [Fig.4], the manufacturing method of the geared motor 1 according to the second embodiment is distinguished from that of the geared motor 1 according to the first embodiment, by the step of electrical connection 302 of the power module to the electric motor 102.

[0067] The step 302 of electrically connecting the power module 91 to the electric motor 102 is implemented by electrically connecting each of the switching cells 95 of the power module 91 to the switch 97, for example via the connection module 7 or conductive wires 81, instead of connecting the switching cells 95 directly to the electric motor. The step 302 of electrically connecting the power module 91 to the electric motor 102 is implemented by electrically connecting each of the phases of the electric motor 102 to the switch 97, for example via the connection module 7 or conductive wires 82, instead of connecting them directly to the switching cells 95. The switch 97 electrically connects only one of the switching subassemblies 96 at a time to the phases of the electric motor 102.

[0068] Thanks to the power module 91 according to the invention, the power switching and control member 9 is more reliable and easier to manufacture, while having a power switching and control member 9 which is adapted to the operation of the electric motor 2 of the geared motor 1 and in particular to the number of phases of the electric motor 2.

[0069] In particular, the power module 91 which comprises a high number of switching cells 95 allows emergency operation, possibly degraded, in the event of failure of a switching cell 95 of the power module 91 and in particular of a power switch 94.

[0070] The power module 91 can be further standardized, by having a similar or identical structure for electric motors 2 of different structures and / or different powers, while being adapted to operate the electric motor 2. In particular, the power module 91 has, for example, an identical number of switching cells 95 for electric motors 2 having a different number of phases.

[0071] The power module 91 may also be common to different control modules 92 of the power module which differ by their computer and / or their control software of the power module 91.

[0072] Additionally or alternatively, the control module 92 of the power module may be standard for different switching and power control members 9, in particular for different power modules 91, by having a computer and control software capable of controlling different power modules 91 and the power supply of different electric motors 2. Alternatively, power module control modules 92 may be structurally identical and differ only in their programming.

[0073] The switching and power control member 9 can be further standardized. The standardization of the geared motor 1 then tends to increase.

[0074] It is also possible to electrically connect 2 different electric motors to a power module 91 by adding only one switch 97 if necessary, depending on the type of electric motor 91.

[0075] Of course, various modifications can be made by those skilled in the art to the invention which has just been described without departing from the scope of the disclosure of the invention.

[0076] Alternatively, the geared motor 1 is a disc brake geared motor with fixed caliper. Alternatively, the geared motor 1 is a drum brake geared motor.

[0077] The structure of the electric motor 2 may vary. In particular, the electric motor 2 may be with or without brushes. More particularly, the electric motor may be asynchronous.

[0078] Alternatively, the electric motor 2, 102 may comprise four, five or more than six phases. The number of switching cells 95 remains a multiple of that of the number of phases of the electric motor 2, 102.

[0079] The structure of the transmission device 4 may vary and the transmission device 4 comprises, for example, a parallel gear train instead of an epicyclic reducer.

[0080] The structure of the power switching and control member 9 may vary. In particular, the power module 91 and the control module 92 of the power module may be on a single support. In this case, the connection module 7 may comprise a single connector.

[0081] The structure of the power module 91 may vary. The power switches 94 comprise, for example, power transistors or thyristors.

[0082] The power module 91 may comprise at least three switching sub-assemblies 96.

[0083] Alternatively, the control module 92 of the power module can control the inverter of the power module 61 via a data transmission network or a wireless link.

[0084] Alternatively, the computer and in particular the control software of the control module 92 of the power module may be specific and individual to each power module 91.

[0085] Alternatively, the geared motor 1 does not include a connection module 7. In this case, the power module 91 and / or the control module 92 of the power module are electrically connected directly to the electric motor 2. NOMENCLATURE IN REFERENCE TO FIGURES

[0086] 1: geared motor 2, 102: electric motor 4: transmission device 6: geared motor housing 7: Connection module 9: switching and power control organ 61: cover 62: electric motor housing 63: housing of the transmission device 65: housing connector 74: bottom surface 80: conductive wires 81: conductive wires 82: conductive wires 91: power module 92: Power module control module 94: Power inverter switch 95: switching cell 96: switching subassembly 97: switch 98: power module support 99: Power control module support 200: geared motor manufacturing process 201: supply of electric motor, transmission device, housing and power switching and control member 202, 302: connection of the power module to the electric motor 203: insertion of the electric motor, the transmission device and the switching and power control member into the housing 204: connection of the power module to the electrical connector of the box 205: connection of the electrical connector of the box to the electrical connector of the power supply

Claims

Claims

1. Geared motor for an electromechanical vehicle wheel brake, comprising an electric motor (2, 102) and a power switching and control member (9) comprising: a power module (91) which comprises power inverter switches (94) which are arranged in switching cells (95), the switching cells (95) being configured to be connected to phases of the electric motor (2, 102), the power module (91) comprising at least as many switching cells (95) as the number of phases of the electric motor (2, 102), the power module (91) comprising at least four switching cells (95), wherein the geared motor comprises switching subassemblies (96) which each include a portion of the switching cells (95) of the power module (91), each switching subassembly (96) comprising as many switching cells (95) as the number of phases of the electric motor (102),the switching cells (95) of only one of the switching sub-assemblies (96) being simultaneously connected to the phases of the electric motor (102), wherein the power module (91) comprises two switching sub-assemblies (96), each of the switching sub-assemblies (96) comprising half of the switching cells (95) of the power module (91), wherein the power module (91) comprises a switch (97) which is configured to electrically connect a first switching subassembly (96) among the switching subassemblies (96) to the phases of the electric motor (102), when the switch (97) is in a first switching position, the switch (97) being configured to electrically connect a second switching subassembly (96) among the switching subassemblies (96) to the phases of the electric motor (102), when the switch (97) is in a second switching position.

2. Geared motor according to the preceding claim, in which the power module (91) comprises as many switching cells (95) as the number of phases of the electric motor (2), each switching cell being electrically connected to a respective phase of the motor. electric (2, 102) in normal operation of the geared motor (1).

3. Geared motor according to any one of the preceding claims, in which the power module (91) comprises six switching cells (95), for electrically powering a three-phase electric motor (102) of the geared motor or for electrically powering a six-phase electric motor (2) of the geared motor (1), in particular by electrically connecting the electric motor to a vehicle battery.

4. Geared motor according to the preceding claim and according to claim 2, in which the electric motor (2) comprises six redundant phases to be able to operate on three phases, the six phases of the electric motor (2) being connected to the switching cells (95) of the power module (91) so that the electric motor (2) is able to operate at half of its maximum power, in the event of failure of one of the switching cells (95).

5. A geared motor according to any preceding claim, wherein the geared motor (1) is configured to control the operation of the power module (91).

6. Geared motor according to the preceding claim and according to claim 5, wherein the switch (97) is configured to switch from the first position to the second position, when a failure of the first switching subassembly (96) is detected.

7. A geared motor according to any preceding claim, wherein the electric motor (2, 102) is a permanent magnet synchronous motor.

8. A method of manufacturing (200) a geared motor (1) according to any one of claims 1 to 10, comprising: electrically connecting (202) the power module (91) to the electric motor (2), by electrically connecting each of the phases of the electric motor (2) to one of the switching cells (95) of the power module (91), the power module (91) comprising at least four switching cells (95).

9. Method of manufacturing (200) a geared motor (1) according to the preceding claim, the geared motor (1) comprising a first electric motor (2, 102), the method comprising: a step of selecting a first power module (91) suitable for electrically supplying the first electric motor (2, 102), from a set of power modules for geared motors which are of different structures, the control module (92) of the geared motor comprising a programmable calculator which is programmable by being able to control each of the power modules (91) of the set of power modules, the calculator of the control module (92) being programmed to control the first power module (91).

Images