Electric machine for motor vehicle

Abstract

Electric machine for motor vehicle The invention relates to an electric machine for motor vehicle (1, 40) comprising at least one housing (2), a transmission shaft (3) disposed at least in part within the housing (2) and a small radial rotor / stator assembly (4, 5) or a large radial rotor / stator assembly (21, 22), the rotor / stator assembly used being housed in the housing (2), its rotor (4, 21) being integral with the transmission shaft (3) and its stator (5, 22) being fixed to the housing (2) via a fastening assembly characterized in that the electric machine (1, 40) comprises at least a first fastening assembly (12) and a second fastening assembly (13), the first fastening assembly (12) comprising first fastening means (14) integral with the housing (2) for fixing the small rotor / stator assembly (4, 5) in the housing (2),and the second fastening assembly (13) comprising second fastening means (15) integral with the housing (2) for fixing the large rotor / stator assembly (21, 22) in the housing (2), the first fastening means (14) being distinct from the second fastening means (15). (Figure 1),

Description

Title of the invention: Electric machine for motor vehicle

[0001] The present invention relates to the field of motor vehicles, and more particularly to the electrical machines equipping these motor vehicles.

[0002] Electric or hybrid motor vehicles use electric machines, in particular electric machines with at least one stator and one rotor, which are often radial flux machines. In such machines, the rotor and stator are coaxial and arranged around each other, such that windings on the stator, respectively the rotor, and magnetic elements present on the rotor, respectively the stator, generate a magnetic flux in a radial direction with respect to an axis of rotation of the electric machine.

[0003] Radial flux electric machines are available in various power ratings. They are designed for integration into different types of vehicles according to the specific power requirements of those vehicles. The power of an electric machine is notably influenced by the radial dimensioning of its two main components: the stator and the rotor.

[0004] Thus, to increase the power of an electrical machine, the radial dimensions of the stator and rotor can be increased. Conversely, to create a machine with lower power, their radial dimensions are reduced.

[0005] Currently, the manufacture of electrical machines of varying power ratings requires separate production lines. This is because the size of each component of the electrical machine must be adapted to the radial dimensions of the rotor and stator. Elements such as the housing, the drive shaft, the mounting means for the rotor / stator assembly, and other components are designed according to these dimensions. Consequently, a high-power electrical machine must be assembled on a different production line than a low-power electrical machine, since the component parts of these machines are not interchangeable.

[0006] This separation of production lines results in a loss of time and energy, as it is necessary to maintain and operate several separate production lines. Furthermore, the differences between the parts require the manufacture of unique components for each type of machine before assembly, which increases production costs and complexity.

[0007] The objective of the invention described in this document is therefore to overcome the disadvantages of the prior art by limiting the number of separate parts needed to make two electrical machines of different powers.

[0008] The main object of the present invention is thus an electric machine for a motor vehicle comprising at least one casing, a transmission shaft disposed at least partly within the casing and a small radial rotor / stator assembly or a large radial rotor / stator assembly, the rotor / stator assembly used being housed in the casing, its rotor being integral with the transmission shaft and its stator being fixed to the casing via a fastening assembly, the electric machine being characterized in that it comprises at least a first fastening assembly and a second fastening assembly, the first fastening assembly having first fastening means integral with the casing for fixing the small rotor / stator assembly in the casing, and the second fastening assembly having second fastening means integral with the casing for fixing the large rotor / stator assembly in the casing,The first means of fastening being distinct from the second means of fastening.

[0009] The electric machine here is a radial flux electric machine, in which the rotor and stator are cylindrical elements mounted around a common axis formed by the axis of rotation of the transmission shaft. More particularly, this is an internal rotor electric machine, with the stator surrounding the rotor.

[0010] The electrical machine according to the invention can be either a so-called low-power electrical machine or a so-called high-power electrical machine. The terms low power and high power should be understood to mean that a high-power electrical machine has a higher power output than a low-power machine.

[0011] The power of the electric machine is determined here by the radial dimensioning of the rotor / stator assembly. A rotor / stator assembly with a large radial dimension is capable of producing more power than a rotor / stator assembly with a small radial dimension. The terms "small radial dimension" and "large radial dimension" refer to a rotor / stator assembly with a large radial dimension that has a larger radial dimension than a rotor / stator assembly with a small radial dimension. Thus, the rotor and stator of the rotor / stator assembly with a large radial dimension have a larger radial dimension than the rotor and stator of the rotor / stator assembly with a small radial dimension.

[0012] It is therefore understood that an electrical machine comprising a large radial rotor / stator assembly is a high-power electrical machine, while an electrical machine comprising a small radial rotor / stator assembly is a low-power electrical machine.

[0013] The first and second fixing assemblies allow the stator and rotor to be fixed within the housing, regardless of whether it is a rotor and stator of a small radial rotor / stator assembly or a rotor and stator of a large radial rotor / stator assembly.

[0014] For this reason, the first fastening means of the first fastening assembly and the second fastening means of the second fastening assembly are distinct. In other words, the first fastening means and the second fastening means do not coincide and are therefore different structural elements.

[0015] It should be noted that when the electric machine is assembled by fixing a rotor / stator assembly, whether of small radial size or large radial size, one of the two fixing assemblies is operational for fixing said rotor / stator assembly, while the other of the two fixing assemblies is not operational.

[0016] Having both mounting assemblies permanently attached to the housing, and enabling operation of either one depending on the size of the rotor / stator assembly, allows for the use of only one housing size for assembling either of the two assemblies, provided the housing is large enough to accommodate the larger rotor / stator assembly. This allows for the standardization of parts other than the rotor / stator assembly. It should therefore be understood that the housing, the drive shaft, and all the parts of the electric machine, other than the rotor / stator assembly, are common to both small and large electric machines. Thus, during assembly on a production line, only the rotor / stator assembly needs to be changed to obtain either a small or a large electric machine.

[0017] According to an optional feature of the invention, the second fastening means are arranged radially around the first fastening means.

[0018] It is therefore appropriate to understand that the first fastening means are arranged radially around the axis of rotation of the transmission shaft, and the second fastening means are arranged radially around the first fastening means.

[0019] The radial arrangement refers to the arrangement where the first fixing means and the second fixing means are arranged in directions perpendicular to the axis of rotation.

[0020] The term "around" indicates that the second fastening means are arranged radially further away from the axis of rotation than the first fastening means.

[0021] It should be noted that when the electrical machine is a high-power electrical machine, equipped with a large radial rotor / stator assembly, it is the second mounting assembly that is operational and the first mounting assembly that is not. When the electrical machine is a low-power electrical machine, equipped with a small radial rotor / stator assembly, it is the first fastening system which is operational and second fastening system which is not operational.

[0022] According to an optional feature of the invention, at least one of the first fastening means and at least one of the second fastening means are arranged in the same radial direction perpendicular to an axis of rotation of the transmission shaft.

[0023] It is therefore understood that the second fastening means, the first fastening means, and the axis of rotation of the transmission shaft are arranged so as to be aligned on the same straight line. This straight line corresponds to the radial direction along which the second fastening means and the first fastening means are positioned.

[0024] The alignment of the second and first fixing means is determined by considering a straight line passing through the center or central axis of these fixing means.

[0025] Preferably, each of the first fastening means is arranged in a radial direction where one of the second fastening means is also arranged.

[0026] According to an optional feature of the invention, the first fastening means and the second fastening means are configured to cooperate with common fastening members, which can indifferently cooperate with the first fastening means to fix the small rotor / stator assembly or with the second fastening means to fix the large rotor / stator assembly.

[0027] The fasteners can, for example, be screws. The term "common" makes explicit the fact that a fastener can be used both to fix a small radial rotor / stator assembly when it is assembled in the housing and the first fastener assembly is operational, and also to fix a large radial rotor / stator assembly when it is assembled in the housing and the second fastener assembly is operational.

[0028] It is therefore understood that one or the other of the two fastening assemblies is considered operational when it cooperates with a fastening member in order to fix a rotor / stator assembly.

[0029] In this way, the number of different parts between a low-power machine and a high-power machine is reduced, since the fastening element can be used for either a high-power or a low-power machine. This therefore facilitates the assembly of these machines in a production line where they are manufactured.

[0030] According to an optional feature of the invention, the first fastening means and the second fastening means are threaded barrels formed in a wall of the housing.

[0031] It is therefore understood that the threaded barrels of the first fixing assembly are the first fixing means and that the threaded barrels of the second fixing assembly are the second fixing means.

[0032] Since the first and second fixing means are threaded barrels, they are thus designed to cooperate effectively with the fixing members in order to fix either the small radial rotor / stator assembly, when it is a threaded barrel corresponding to a first fixing means, or the large rotor / stator assembly, when it is a threaded barrel corresponding to a second fixing means.

[0033] It is understood that in order for the barrels of the two separate fixing assemblies to cooperate with the same fixing member, these barrels must have the same thread diameter.

[0034] It should be understood that when the first or second fastening assembly is operational, respectively, the first or second fastening means cooperate with the fastening members thanks to their threaded barrel shape. Conversely, when the first or second fastening assembly is not operational, respectively, the first or second fastening means do not cooperate with the fastening members.

[0035] For example, when a large rotor / stator assembly is installed in the housing to form a high-power electrical machine, each of the threaded shafts of the second fastening assembly, i.e., each of the second fastening means, cooperates with a fastening member and makes the second fastening assembly operational. In this context, the first fastening assembly is not operational, and the threaded shafts of the first fastening assembly, i.e., the first fastening means, do not cooperate with a fastening member.

[0036] It should be noted that when mounting a high-power electrical machine, the large rotor / stator assembly has openings opposite the second fastening means, and the fastening elements are inserted into the second fastening means and the openings to secure the large radial rotor / stator assembly. When mounting a low-power electrical machine, the small rotor / stator assembly has openings opposite the first fastening means, and the fastening elements are inserted into the first fastening means and the openings to secure the small radial rotor / stator assembly.

[0037] According to an optional feature of the invention, the first fastening means and the second fastening means are formed in the same wall of the housing.

[0038] The electric machine, whether low power or high power, may include an electronic control unit and a motor output unit arranged on either side of the housing. The electronic control unit is configured to supply an electric current to the rotor / stator assembly, in a mode power supply, and to recover an electrical current generated by the rotation of the rotor / stator assembly, in an energy recovery mode, while the motor output part uses or generates, depending on the mode implemented, the mechanical energy of the rotation of the transmission shaft.

[0039] The housing wall in which the first and second fastening means are formed constitutes a closing wall located on the side of the motor output portion. The stator / rotor assembly is mounted in the housing through an opening arranged opposite the closing wall, until the stator comes to rest against the first and / or second fastening means.

[0040] According to an optional feature of the invention, the fastening members comprise at least a head and a rod having a threaded end capable of cooperating with one of the first fastening means or with one of the second fastening means.

[0041] The heads of the fastening elements are located on the side of the electronic control unit. During assembly, the fastening element is therefore inserted on the side of the opening opposite the closing wall and then, when the first and / or second fastening means are threaded bushings, tightened by screwing the threaded portion into the corresponding threaded bushing. The electronic control unit can then be attached to the housing to be positioned close to the stator.

[0042] The threaded barrels corresponding to the first fastening means and / or the second fastening means are arranged in such a way that, when the threaded end cooperates with the threaded barrel, the rod of the fastening member extends in a direction parallel to the axis of rotation of the transmission shaft.

[0043] It should therefore be understood that, in this direction parallel to the axis of rotation of the transmission shaft extending from the head of the fastening member to its threaded end, the rod of the fastening member passes through the stator. The fastening member is dimensioned such that, when the head of the fastening member is bearing against the face of the stator that is opposite the electronic control part of the electric machine, the threaded end protrudes from the opposite face of the stator in order to cooperate with the threaded shaft corresponding to one of the first fastening means or one of the second fastening means.

[0044] According to an optional feature of the invention, the stator comprises at least one radial boss provided with an orifice, the rod of the fastening member being housed in said orifice.

[0045] It should be understood that the radial boss locally and radially increases the stator's dimensions, that is, in a radial direction perpendicular to the axis of rotation of the transmission shaft. This increase in thickness allows the fastening elements to be placed around the periphery of the stator without compromising the quantity of material of the stator participating in the formation of the electromagnetic field. The radial boss extends from one axial end of the stator to the other, so as to be in contact on one side with the head of the fixing member and on the other side in contact with the threaded barrel corresponding to one of the first fixing means or one of the second fixing means.

[0046] The orifice is an opening passing through the stator in a direction parallel to the axis of rotation of the transmission shaft. This orifice allows the rod of the fastening member to pass through the radial boss of the stator in order to hold the stator, and therefore the rotor / stator assembly, in place within the housing.

[0047] The stator may include a plurality of radial bosses, since the electrical machine includes a fastening element for each of the first or second fastening means. In this case, there may be one radial boss for each fastening element, such that the rod of the fastening element passes through the opening of each radial boss, thus securely holding the stator in the housing. When there are a plurality of radial bosses, they may, for example, be arranged at equal distances from each other and be angled regularly so as to surround the stator. In this way, when their openings are traversed by the fastening elements, the stator is securely fastened to the housing.

[0048] According to an optional feature of the invention, the stator is in contact with the first fastening means and / or with the second fastening means.

[0049] More specifically, when there is a radial boss, the radial boss of the stator is in contact with one of the first or second fastening means. It should be noted that when the rotor / stator assembly is large, the stator may be in contact with each of the first fastening means, while the radial boss and the through-hole are located at one of the second fastening means.

[0050] Thanks to this, the fastening element is entirely housed within the stator and within the threaded barrel corresponding to one of the first or second fastening means, without any part, except for its head, being exposed in the event of an impact. This arrangement thus reduces the risk of bending or breaking the fastening element.

[0051] The invention also relates to an assembly method enabling, in particular, the manufacture of high-power or low-power electrical machines as previously mentioned. More specifically, according to the invention, an assembly method for an electrical machine may comprise at least the following steps:

[0052] 1) identification of a reference of a first type of electrical machine or of a reference to a second type of electrical machine,

[0053] 2) assembly of an electrical machine according to the reference indicated:

[0054] - if the reference corresponds to the first type of electrical machine, assembly of a electric machine comprising a small radial rotor / stator assembly as previously mentioned,

[0055] - if the reference corresponds to the second type of electrical machine, assembly of an electrical machine comprising a large radial rotor / stator assembly as previously mentioned.

[0056] The process thus makes it possible to produce two types of machines on the same production line. Indeed, all the parts, with the exception of the rotor / stator assembly, are similar in both small and large power electrical machines. In this way, the assembly of the electrical machine is essentially the same. The only different step is the positioning of the rotor / stator assembly, which varies depending on whether it is a small or large power electrical machine.

[0057] Thus, for a low-power electrical machine, a small radial rotor / stator assembly, as described in the description, is installed. For a high-power machine, a large radial rotor / stator assembly is installed. To do this, it is sufficient to insert the rotor / stator assembly corresponding to the desired electrical machine by pushing the rotor / stator assembly against the wall of the housing equipped with the first and second fastening means, and then to secure it either with the first or second fastening set, both of which are present in the machine, regardless of its type.

[0058] This process therefore allows for a significant saving in time and energy, since the parts, with the exception of the rotor / stator assembly, remain the same between the two types of electrical machines. Thus, it is possible to produce more electrical machines more quickly, and to easily change production by switching from a high-power electrical machine to a low-power electrical machine.

[0059] Other features, details and advantages of the invention will become clearer upon reading the following description on the one hand, and the illustrative and non-limiting examples of embodiments given with reference to the accompanying drawings on the other hand, in which:

[0060] [Fig.l] is a cross-section in an axial plane of a small power electrical machine showing a housing containing a small radial rotor / stator assembly, a transmission shaft, an electronic control part and a motor output part;

[0061] [Fig.2] is a cross-section in an axial plane of a large electrical machine power making the crankcase, transmission shaft, and control section visible electronics and motor output part visible in [Fig.1], the casing here housing a large radial rotor / stator assembly;

[0062] [Fig.3] is a radial plane cross-section of the housing of the electric machine of the [Fig.1] or [Fig.2] in which a rotor / stator assembly is not shown;

[0063] [Fig.4] is a section in the same radial plane as that of [Fig.3] of the machine small power electric of the [Fig.l];

[0064] [Fig.5] is a section in the same radial plane as that of [Fig.3] of the machine high power electric of the [Fig.2].

[0065] The features and variants of the invention can be combined in various ways, provided they are not incompatible or mutually exclusive. In particular, variants of the invention may be conceived comprising only a selection of the features described below, isolated from the other described features, if this selection of features is sufficient to confer a technical advantage and / or to differentiate the invention from the prior art.

[0066] In the figures, the elements common to several figures retain the same reference.

[0067] In the following figures, [Fig. 1] represents a small power machine and [Fig. 2] a large power machine. It should be noted that the choice of radial dimensioning for the rotor / stator assembly of these electrical machines depends on the desired power output of the electrical machine. Thus, for a high power electrical machine, a rotor / stator assembly with a large radial dimension is used, while for a small power electrical machine, a rotor / stator assembly with a small radial dimension is preferred.

[0068] It is therefore understood that the small power electric machine and the large power electric machine have common parts and differ from each other only by the radial size of the rotor / stator assembly and by distinct fastening assemblies which may be operational or non-operational depending on the electric machine which is assembled.

[0069] Fig. 1 is a cross-section in an axial plane of the small power electric machine 1. The small power electric machine 1 includes, in particular, a housing 2 designed to accommodate either a small radial rotor / stator assembly or a large radial rotor / stator assembly, a drive shaft 3 that can cooperate with either a small radial rotor / stator assembly or a small radial rotor / stator assembly, and it includes a small radial rotor / stator assembly 4, 5. In addition, the electric machine 1 includes an electronic control part 6 and a motor output part 7.

[0070] More specifically, the housing 2 is an enclosure that surrounds certain components of the small power electric machine 1. The small radial rotor / stator assembly 4,5 is thus housed in this housing 2, and a portion of the transmission shaft 3 is also located in the housing 2. The housing 2 includes a closing wall 60 that extends perpendicularly to an axis of rotation A of the transmission shaft 3, and opposite the motor output portion 7. This closing wall 60 is traversed by the transmission shaft 3.

[0071] The small radial rotor / stator assembly 4, 5 comprises a small radial rotor 4 and a small radial stator 5. These elements are referred to as small radial in size as opposed to a large radial rotor / stator assembly, which has a larger radial dimension of its stator than the small radial stator 5, and a larger radial dimension of its rotor than the small radial rotor 4. For example, and without limitation, the diameter of the small radial rotor 4 may be 121.8 mm, while that of the large radial rotor is 152.3 mm. Similarly, the diameter of the small radial stator 5 may be 122.8 mm, while that of the large radial stator is 153.3 mm.

[0072] The small radial stator 5 is a stationary part of the small power electric machine 1. It may include conductive elements which, when supplied with electricity, generate a magnetic field, or which, conversely, when subjected to a magnetic field, generate an electric current at the machine's output. These conductive elements may, in particular, be arranged axially in slots formed within the stator, and the winding formed by all these interconnected conductive elements presents coils at the axial ends of the stator, which are not shown in the figures.

[0073] The electronic control unit 6 is configured, in particular, to supply electric current to the conductive elements of the small radial stator 5, and / or to recover electric current and / or to excite the small radial rotor 4. The electronic control unit 6 comprises a plurality of electronic components for controlling the electrical connection with the conductive elements. Because of this electrical connection, it is necessary to ensure that the position of the electronic control unit 6 relative to the small radial stator 5 and the small radial rotor 4 conforms to the desired theoretical position, particularly axially.

[0074] The small radial rotor 4 is a component of the electric machine rotating about the axis of rotation A. It can, for example, be formed from a set of stacked laminations and include coils wound on poles reacting to the magnetic field produced within the small radial stator 5, which has the effect, by driving a rotating magnetic field, to generate a rotational movement around this axis of rotation A.

[0075] The transmission shaft 3 is connected to the small radial rotor 4; thus, when this rotor 4 rotates, the transmission shaft 3 also rotates around the axis of rotation A. It is thus understood that the small radial stator 5, the small radial rotor 4 and the transmission shaft 3 share a common axis of rotation, which is the axis of rotation A. The transmission shaft 3 then transmits the mechanical energy of the rotational motion to the motor output part 7.

[0076] The small radial stator 5 and the small radial rotor 4 both have a cylindrical shape surrounding the axis of rotation A. In the illustrated example of a radial flux motor with an internal rotor, the small radial stator 5 surrounds the small radial rotor 4, which itself surrounds the transmission shaft 3. The magnetic field within the small radial stator 5 passes radially between this stator 5 and the small radial rotor 4.

[0077] The small radial stator 5 is composed of a first axial end 8 and a second axial end 9, corresponding respectively to the ends of the cylinder in an axial direction parallel to the axis of rotation A.

[0078] The small radial rotor 4 has a first axial termination 10 and a second axial termination 11. The small radial rotor 4 is axially centered with respect to the small radial stator 5, so that its terminations coincide axially with the ends of the small radial stator 5. In other words, the first axial termination 10 of the small radial rotor 4 is positioned at the same axial level as the first axial end 8 of the small radial stator 5, and the second axial termination 11 of the small radial rotor 4 is positioned at the same axial level as the second axial end 9 of the small radial stator 5.

[0079] The small power electric machine 1 also includes a first set of fixings 12 and a second set of fixings 13.

[0080] The first mounting assembly 12 allows the small radial rotor / stator assembly 4.5 to be fixed in the housing 2, and in this case the first mounting assembly 12 is operational while the second mounting assembly 13 is not. Conversely, the second mounting assembly 13 allows a large radial rotor / stator assembly to be fixed in the housing 2, and in this case the second mounting assembly 13 is operational while the first mounting assembly 12 is not operational.

[0081] In this case, since it is a small power electrical machine 1, said machine 1 comprises the small radial rotor / stator assembly 4, 5. Therefore, as illustrated, the first fastening assembly 12 is operational and will to be described later, the second fixing set 13 having no particular function here.

[0082] The first fastening assembly 12 comprises first fastening means 14, of which there are four in this embodiment, as can be seen in [Fig. 3]. The second fastening assembly 13 comprises second fastening means.

[0083] The first fastening means 14 are here threaded barrels formed in a wall of the housing 2 and since they are operational, each of the first fastening means 14 cooperates with a fastening member 17. The first fastening means 14 are here made in the closing wall 60, although it is possible that they are made in other walls.

[0084] The fastening member 17 is designed to cooperate with the threaded barrel, corresponding to one of the first fastening means 14, in order to hold in place the small radial size rotor / stator assembly 4,5. More specifically, when the small radial size stator 5 is disposed in the housing 2, the fastening member 17 is configured to press the second axial end 9 of the small radial size stator 5 against the first fastening means 14.

[0085] It is therefore understood that, when assembling a small radial rotor / stator assembly 4.5 to obtain a low-power electric machine, the first fastening means 14, by cooperating with the fastening member 17, make the first fastening assembly 12 operational. Conversely, the second fastening assembly 13, being non-operational, does not include fastening members cooperating with one of the second fastening means.

[0086] The fastening member 17 comprises a rod 18 and a head 19, the rod 18 having a threaded end 20. This threaded end 20 is designed to cooperate with the tapped barrel corresponding to one of the first fastening means 14, while the rod 18 passes through the small radial stator 5. The latter has an orifice intended to be passed through by the rod 18. Thus, the rod 18 passes through the small radial stator 5 from its first axial end 8 to its second axial end 9 in a direction perpendicular to the axis of rotation A.

[0087] It should be noted that in this embodiment, the small radial stator 5 includes several orifices, each intended to be traversed by a fastening member 17 in order to fix the small radial rotor / stator assembly 4,5 to the housing 2. Indeed, given that the small power electric machine includes four first fastening means 14, it therefore includes four fastening members 17 and thus four orifices.

[0088] When the small radial stator 5 is housed within the casing 2, it is inserted through an opening located opposite the closing wall 60 carrying the first fastening means 14, until the second axial end 9 of the stator of The small radial size 5 is in contact with a stop face of the first fastening means 14. In this position, the holes formed in the stator 5 are aligned with the first fastening means 14. The fastening members 17 are then inserted into the corresponding holes, so that the stem 18 of the fastening member 17 passes through the small radial size stator 5, allowing its threaded end 20 to cooperate with the tapped hole in the threaded barrel corresponding to the first fastening means 14. The head 19 of the fastening member 17 is then positioned in contact with the first axial end 8 of the small radial size stator 5, thus contributing to the clamping of this stator 5 against the first fastening means 14.

[0089] The buttress faces of the first fixing means 14, on which the small radial stator 5 rests, form a reference positioning surface 45 ensuring that the stator is firmly pressed against these first fixing means 14 and thus ensuring its correct positioning in the housing 2, in particular with respect to the electronic control part 6.

[0090] Thanks to the first fixing means 14, the small radial rotor / stator assembly 4.5 can thus be correctly positioned in a housing 2 designed to accommodate a small radial rotor / stator assembly 4.5 or a large radial rotor / stator assembly.

[0091] It should be noted that, since the housing 2 is designed to accommodate either a high-power or low-power rotor / stator assembly, when the small radial rotor / stator assembly 4,5 is assembled in the housing, this assembly 4,5 is positioned radially away from the housing. This implies that there is a radial clearance JRI between the small radial rotor / stator assembly 4,5 and the housing 2.

[0092] The [Fig.2] is a cross-section in an axial plane of the high-power electrical machine 40.

[0093] Similar to what was previously described for the small power electric machine 1, the high power electric machine 1 comprises a housing 2 designed to accommodate either a small radial rotor / stator assembly or a large radial rotor / stator assembly, as well as a drive shaft 3 common to each of these assemblies. In addition, the high power electric machine 40 comprises an electronic control unit 6 and a motor output unit 7, as well as a first mounting assembly 12 and a second mounting assembly 13. The housing 2, the drive shaft 3, the electronic control unit 6, the motor output unit 7, the first mounting assembly 12, and the second mounting assembly 13 are therefore common parts of the electric machine of [Fig. 1] and of this high power electric machine 40. The description given in the description of [Fig. 1]l] in relation to these elements, therefore applying identically to the high-power electrical machine 40. .

[0094] One of the differences of this high-power machine 40 compared to the low-power machine 1 lies in the stator / rotor assembly housed in the casing 2, which here is a large radial rotor / stator assembly 21,22.

[0095] The axial dimensioning of the large radial stator 22 and the large radial rotor 21, as well as the presence of axial ends and axial terminations, are similar to the small radial rotor / stator assembly 4,5. Thus, when the large radial rotor / stator assembly 21,22 is supported by an axial end against the closing wall 60, it is at the same distance from the electronic control part 6 as is the small radial rotor / stator assembly when it is mounted in the housing 2.

[0096] The difference here lies in the radial dimensioning, that is to say in the diameter of the large radial stator 22, which is larger than that of the small radial stator 5, and in the diameter of the large radial rotor 21, which is larger than that of the small radial rotor 4.

[0097] In order to fix this large radial rotor / stator assembly 21,22 within the housing 2, the second fixing assembly 13 is operational, while the first fixing assembly 12 is not.

[0098] The second fastening assembly 13 thus includes second fastening means 15, of which there are four in this embodiment, as can be seen in [Fig.3].

[0099] It should be noted that since the second fastening assembly 13 is operational, the second fastening means 15 cooperate with fastening members 17. On the other hand, since the first fastening assembly 12 is not operational, the first fastening means 14 do not cooperate with fastening members 17.

[0100] In order to facilitate this cooperation, the second fastening means 15, similarly to the first fastening means 14, are threaded barrels formed in the closing wall 60 of the housing 2.

[0101] The fastening element 17 used in the second fastening means 15 is similar to that used in the first fastening means 14 of the small power electric machine 1 described above. Thus, these fastening elements are identical and can be used interchangeably in the assembly of either a small power machine or a large power machine. It is therefore understood that, in order to be able to assemble either a small radially sized or a large radially sized rotor / stator assembly in the housing 2, the dimensions of the threaded barrels corresponding to the first fastening means 14 and the dimensions of the threaded barrels corresponding to the second fastening means 15 are the same.

[0102] The fastening member 17 therefore comprises a rod 18 having a threaded end 20 and a head 19, said rod 18 passing through, in a direction perpendicular to the axis of rotation A, the large radial stator 22. For this purpose, the large radial stator 22 has orifices intended to be passed through by the fastening member 17, and more precisely four orifices since there are four fastening members 17 associated with the four second fastening means 15 in this embodiment.

[0103] The fastening member 17 is therefore designed to cooperate with one of the second fastening means 15 in order to hold in place the large radial rotor / stator assembly 21,22. Similar to the small power electric machine 1, when the large radial stator 22 is disposed in the housing 2, the fastening member 17 is configured to press one of the axial ends of the large radial stator 22 against one of the second fastening means 15.

[0104] The second fastening means 15 are arranged at a greater distance from the axis of rotation A compared to the first fastening means 14. In other words, they are arranged radially on the closing wall 60 at a greater distance than the distance separating the axis of rotation A from the first fastening means 14. This arrangement allows the second fastening means 15 to align with the large stator 22 openings intended to be traversed by the rod 18 of the fastening member 17. Thus, the fastening member 17 allows the large radial stator 22 and therefore the large radial rotor / stator assembly 21, 22 to be correctly fixed.

[0105] When mounting a large radial rotor / stator assembly 21 / 22 to obtain a high-power electric machine 40, the second fastening assembly 13 is operational since each of the second fastening means 15 cooperates with a fastening member 17. On the contrary, the first fastening assembly 12 is not operational since the first fastening means 14 do not cooperate with the fastening members 17.

[0106] It should be noted that, since the housing 2 is designed to accommodate either a high-power or low-power rotor / stator assembly, when the large radial rotor / stator assembly 21, 22 is assembled in the housing 2, this assembly 21, 22 is positioned at a radial distance from the housing 2, this distance being smaller than the radial distance separating the small radial rotor / stator assembly 4, 5 from the housing 2 in the low-power electric machine 1 of [Fig. 1]. It is thus understood that there is a radial clearance JR40 between the large radial rotor / stator assembly 21, 22 and the housing 2, which is smaller than the radial clearance JRI between the small radial rotor / stator assembly 4, 5 and the housing 2.

[0107] Fig. 3 is a radial plane cross-section of the casing 2 of the electric machine according to Fig. 1 or Fig. 2, in which the rotor / stator assembly is not shown. in particular to be able to better observe how the first fixing set 12 and the second fixing set 13 are arranged.

[0108] It should therefore be understood that the casing 2, the first fixing assembly 12, the second fixing assembly 13, and the transmission shaft 3 shown in this figure are common elements of the two machines that have been illustrated in Figures 1 and 2, and are therefore used both in a high-power machine as described in [Fig.2] and in a low-power electrical machine as described in [Fig.1].

[0109] The first fastening assembly 12 radially surrounds the transmission shaft 3, and more particularly its axis of rotation A. This means that its first four fastening means 14 are arranged radially around the transmission shaft 3 and its axis of rotation A. In this figure, only the first fastening means 14 are shown and not the fastening elements 17, since no electrical machine is mounted in the housing 2 and therefore both the first fastening assembly 12 and the second fastening assembly 13 are not operational. It can thus be observed that each first fastening means 14 is located in the closing wall 60 at an equal radial distance from the axis of rotation A.

[0110] The second fastening assembly 13 radially surrounds the transmission shaft 3 and its axis of rotation A, but also the first fastening assembly 12. Thus, it should be understood that its second fastening means 15 are arranged radially around the axis of rotation A and also around the first fastening means 14. The second fastening means 15 are therefore arranged in the closing wall 60 at a greater distance from the axis of rotation A than the distance separating the first fastening means 14 from the axis of rotation A.

[0111] In this embodiment, each of the first fixing means 14 is arranged with a second fixing means 15 in a radial direction which is perpendicular to the axis of rotation A. Thus, in this radial direction, each first fixing means 14 is positioned between the axis of rotation A and a second fixing means 15.

[0112] Thanks to this alignment of a first fastening means 14 and a second fastening means 15, these two fastening means 14, 15 form a pair of fastening means. It should be noted that the reference positioning surface 45 is the same for each pair of fastening means, that is to say, for two radially aligned fastening means.

[0113] The [Fig.4] is a section in the same radial plane as that of the [Fig.3] of the small power electric machine 1 of the [Fig.1].

[0114] It should therefore be understood that this figure represents a housing 2 and its elements as shown in [Fig. 3], as well as a rotor / stator assembly of small radial size 4.5 which participates in forming the small power electric machine 1. For this purpose, the fixing members 17 were inserted into the holes provided for this purpose in the small radial size stator 5, so that their threaded ends 20 cooperate with the threaded barrels corresponding to the first fixing means 14.

[0115] This figure makes it easier to observe that the small radial rotor 4 and the small radial stator 5 are cylinders, and to better understand that the small radial stator 5 surrounds the small radial rotor 4, which in turn surrounds the axis of rotation A. This figure also makes it visible that the small radial stator 5 includes at least one radial boss 28.

[0116] The radial bosses 28 are local increases in the radial dimension of the small radial stator 5, the radial dimension being measured perpendicular to the axis of rotation A. They are configured so as to locally increase the radial dimension of the small radial stator 5 along its entire axial dimension. The radial bosses 28 extend parallel to the axis of rotation A continuously from one axial end to the other of the small radial stator 5.

[0117] In this small power machine 1, the small radial stator 5 comprises four radial bosses 28 arranged at regular intervals around its circumference. Each of the radial bosses 28 includes an orifice as described previously. Each of these orifices extends within one of the radial bosses 28, parallel to the axis of rotation A, in order to allow the insertion of the fastening members 17 and to facilitate the cooperation of their threaded end 20 with the first fastening means 14, thus enabling the fastening of the small radial rotor / stator assembly 4, 5.

[0118] This [Fig.4] also clearly shows that in the small power electric machine 1, the second fastening assembly 13 is not operational insofar as the small radial stator 5 does not cover the threaded barrels corresponding to the second fastening means 15 of the second fastening assembly 13. The radial clearance JRI between the small radial stator 5 and the housing 2 can also be observed. It is thus understood that the housing 2 is oversized in relation to the small radial rotor / stator assembly 4,5, but can therefore be common to both types of electric machine.

[0119] The [Fig.5] is a section in the same radial plane as that of the [Fig.3] of the high power electric machine 40 of the [Fig.2].

[0120] It is understood that this figure illustrates the housing 2 and its components in accordance with [Fig. 3] as well as a large radial rotor / stator assembly 21, 22 which contributes to the formation of the high-power electric machine 40 shown in [Fig. 2]. For this purpose, the fastening members 17 have been placed in the stator openings of large radial size 22, so that their threaded ends 20 cooperate with the second means of fastening 15.

[0121] Similar to the small radial stator 5, the large radial stator 22 comprises four radial bosses 28 which locally increase its radial dimension along its entire axial dimension. Each of these radial bosses 28 includes an orifice, as described previously, extending within one of the radial bosses 28, parallel to the axis of rotation A. This allows the insertion of the fastening members 17 and the cooperation of their threaded end 20 with the second fastening means 15, thus ensuring the fastening of the large radial rotor / stator assembly 21, 22.

[0122] These two figures 4 and 5 thus clearly show that one goes from one machine to the other keeping the same casing 2 and the same fixing elements 17 and changing only the radial size of the rotor / stator assembly, and the position where the fixing elements 17 are placed.

[0123] We will now describe a method for assembling an electrical machine which offers the possibility of building either a small power machine 1, as described in Figures 1 and 4, or a large power machine 40, as described in Figures 2 and 5. With a large number of standard parts, this assembly method therefore allows, on the same production line, without it being necessary to interrupt production at each change of reference of machine to be assembled, the assembly of either a small power electrical machine 1 or a large power electrical machine 40.

[0124] The assembly process begins with an identification step, during which an operator or a machine locates on the production line a reference to determine whether it is a small power electrical machine 1 or a large power electrical machine 40 to be assembled.

[0125] Next, the assembly process continues with an assembly step. When the electrical machine to be assembled is identified as a small power machine 1, certain parts common to both small and large power machines are assembled first, for example the casing 2, then a small radial rotor / stator assembly 4,5 is installed using the first fastening assembly 12 and therefore the first fastening means 14. This involves inserting the fastening members 17 into the holes of the small radial stator 5, so that their threaded ends 20 cooperate with the first fastening means 14.

[0126] On the other hand, if the electrical machine to be assembled is identified as a high-power machine 40, the process also consists of first assembling certain parts common to both types of machines, then installing a large radial rotor / stator assembly 21, 22 using the second fixing assembly 13 and therefore the second fastening means 15. This involves inserting the fastening members 17 into the orifices of the large radial stator 22, so that their threaded ends 20 cooperate with the second fastening means 15.

[0127] As described above, the present invention achieves its intended purpose by providing an electric motor for vehicles comprising a housing, a drive shaft, a rotor / stator assembly, and a first and second mounting assembly for attaching a small radial rotor / stator assembly or a large radial rotor / stator assembly, respectively. This design allows the use of standardized components to manufacture electric motors of varying power ratings, thus simplifying and simplifying their production process.

[0128] The present invention is not limited to the means and configurations described and illustrated herein and extends also to any equivalent means and configuration as well as to any technically operative combination of such means.

Claims

Demands

1. Electric machine for motor vehicle (1, 40) comprising at least one housing (2), a transmission shaft (3) disposed at least in part within the housing (2) and a small radial rotor / stator assembly (4, 5) or a large radial rotor / stator assembly (21, 22), the rotor / stator assembly used being housed in the housing (2), its rotor (4, 21) being integral with the transmission shaft (3) and its stator (5, 22) being fixed to the housing (2) via a fastening assembly characterized in that the electric machine (1, 40) comprises at least a first fastening assembly (12) and a second fastening assembly (13), the first fastening assembly (12) having first fastening means (14) integral with the housing (2) for fixing the small rotor / stator assembly (4, 5) in the housing (2),and the second fastening assembly (13) comprising second fastening means (15) integral with the housing (2) for fixing the large rotor / stator assembly (21, 22) in the housing (2), the first fastening means (14) being distinct from the second fastening means (15).

2. Electric machine (1, 40) according to claim 1, wherein the second fastening means (15) are arranged radially around the first fastening means (14).

3. Electric machine (1, 40) according to any one of claims 1 or 2, wherein at least one of the first fastening means (14) and at least one of the second fastening means (15) are arranged in the same radial direction perpendicular to an axis of rotation (A) of the transmission shaft (3).

4. Electric machine (1, 40) according to any one of claims 1 to 3, wherein the first fastening means (14) and the second fastening means (15) are configured to cooperate with common fastening members (17), which can indifferently cooperate with the first fastening means (14) to fix the small rotor / stator assembly (4, 5) or with the second fastening means (15) to fix the large rotor / stator assembly (21, 22).

5. An electrical machine (1,40) according to any one of claims 1 to 4, wherein the first fastening means (14) and the second means of fixing (15) are threaded barrels formed in a wall of the housing (2).

6. Electric machine (1,40) according to claim 5, wherein the first fastening means (14) and the second fastening means (15) are formed in the same wall of the casing (2).

7. Electric machine (1,40) according to any one of claims 5 or 6 in combination with claim 4, wherein the fastening members (17) comprise at least one head (19) and one rod (18) having a threaded end (20) capable of cooperating with one of the first fastening means (14) or with one of the second fastening means (15).

8. Electric machine (1, 40) according to claim 7, wherein the stator (5, 22) comprises at least one radial boss (28) provided with an orifice, the rod (18) of the fastening member (17) being housed in said orifice.

9. Electric machine (1, 40) according to any one of claims 5 to 8, wherein the stator (5, 22) is in contact with the first fastening means (14) and / or with the second fastening means (15).

10. Method of assembling an electrical machine (1, 40) comprising at least the following steps: 1) identification of a reference of a first type of electrical machine (1) or of a reference of a second type of electrical machine (40), 2) assembly of an electrical machine according to the reference indicated: - if the reference corresponds to the first type of electrical machine (1), assembly of an electrical machine (1) comprising a small radial rotor / stator assembly (4,5) according to any one of claims 1 to 9, - if the reference corresponds to the second type of electrical machine (40), assembly of an electrical machine (40) comprising a large radial rotor / stator assembly (21, 22) according to any one of claims 1 to 9.

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