Double Rotor Machine

Abstract

The present disclosure relates to a double rotor machine (DRM) for selective mechanical power transmission and / or electrical power generation in a vehicle driveline, typically comprising an input drive shaft, an input rotor, and an output rotor coupled to an output drive shaft. In a preferred variant, the double rotor machine comprises an input drive shaft for mechanically coupling the double rotor machine to an internal combustion engine, the input drive shaft extending axially into a housing of the double rotor machine. Typically, the input rotor is mechanically interconnected to the input drive shaft and is rotatably disposed inside the housing about a common axis of rotation. The output rotor is mechanically interconnected to an output drive shaft, rotatably disposed about a common axis of rotation, passing through the housing for mechanically coupling the double rotor machine to a consumer of mechanical power.

Description

[Technical field]

[0001] The present disclosure relates to a dual rotor machine for selective mechanical power transmission and / or electrical power generation, and a driveline for a vehicle including such a dual rotor machine. [Background technology]

[0002] Conventional vehicles powered by an internal combustion engine (ICE) rarely operate at the optimum efficiency of the ICE. Depending on the driver's input as well as the roadway demands, the engine speed and torque of the ICE are determined and transmitted to the wheels via a mechanical transmission. However, the ICE only operates at high efficiency in a limited range of engine speeds and torques. To operate the ICE at high efficiency at all times, the generated engine speed and torque should be controlled to minimize co2 emissions by staying in the high efficiency range mentioned above. A four-quadrant converter (4QT) system that achieves this typically comprises an ICE, a battery, and a four-quadrant converter disposed between the ICE and the wheels. Compared to conventional vehicles, the four-quadrant converter functions as a transmission while also operating as an electric motor and generator to compensate for the over- / under-supply of engine speed and torque by the ICE operating at high efficiency at all times.

[0003] Hereinafter, several four-quadrant converters known from the prior art are described. FR2630868A1 published in 1989 in the name of Jean Paul Sibeud relates to a device designed to be placed between a rotating motor shaft and a rotating drive shaft, i.e. on the transmission driveline of a motor vehicle, which comprises, on the one hand, an electric machine having two concentric rotors, coaxial with a stator arranged inside, one of which is integral with the motor shaft and the other with a receiver shaft, in combination with, on the other hand, two concentric rotors.

[0004] U.S. Patent Application No. 2014292131(A1), published in 2014 in the name of Caterpillar Inc., is directed to a dual rotor switched reluctance machine with a fixed stator and separate input and output rotors on either side of the fixed stator, which is used to transfer power between a power source, such as a gas engine, and a mechanical drive device, such as wheels or caterpillar tracks.

[0005] EP 3075587 A1 published in 2016 in the name of Marc Vetter relates to a drive arrangement for a motor vehicle comprising an internal combustion engine with at least one output shaft providing a rotational motion, at least one wheel driven by the internal combustion engine, in particular at least two wheels, the wheel or each of the wheels comprising a drive shaft to which the rotational motion is provided to drive the respective wheel. The drive arrangement further comprises at least one electromechanical machine arranged between the output shaft and at least one of the drive shafts, such that the respective drive shaft is engageable and disengageable with respect to the output shaft by the electromechanical machine, and when the electromechanical machine engages with the output shaft and the drive shaft, the rotational motion provided by the output shaft is input directly or indirectly to the electromechanical machine and output directly or indirectly to the drive shaft by the electromechanical machine. Summary of the Invention [Problem to be solved by the invention]

[0006] A typical and known four quadrant converter (4QT) driveline motor-generator solution is a dual rotor machine and stator combination, usually a radial flux permanent magnet synchronous machine (RFPMSM). Mechanical power from the ICE is transferred to the outer rotor of the RFPMSM, which is coupled to the drive shaft, or the mechanical power is converted to electrical power by windings on the inner rotor and stator of the RFPMSM. The engine speed and torque transferred to the outer rotor are controlled, resulting in an independent drive shaft speed from the ICE.

[0007] A solution for implementing such a 4QT is a switched reluctance motor (SRM) in a radial flux (RF) configuration with simple manufacturing, robustness, easy maintenance, high efficiency, operation in extreme conditions, low cost, and fast acceleration. However, SRMs known from the prior art have several drawbacks, including high noise due to magnetic forces related to stator vibration, high torque ripple, and drive performance is highly dependent on the control strategy. One objective of the present disclosure is to address at least one of the problems of the prior art. [Means for solving the problem]

[0008] A double rotor machine (DRM) for selective mechanical power transmission and / or power generation in a vehicle driveline according to the present disclosure can be mechanically interconnected to an electric machine of the driveline to form an advanced four-quadrant converter. The omission of the stator of known approaches can make it possible to build a system that provides both high torque density and high power density. Typically, the double rotor machine comprises an input drive shaft, an input rotor, and an output rotor coupled to an output drive shaft. In a preferred variant, the double rotor machine comprises an input drive shaft for mechanically coupling the double rotor machine to an engine, in particular an internal combustion engine, an electric engine, a turbine, or any other type of engine, the input drive shaft extending axially into the housing of the double rotor machine. Typically, the input rotor is mechanically interconnected to the input drive shaft and is rotatably arranged inside the housing about a common axis of rotation. The output rotor is mechanically interconnected to an output drive shaft for mechanically coupling the double rotor machine to a consumer of mechanical power, the output rotor being rotatably arranged about a common axis of rotation and passing through the housing. The consumer of mechanical power may comprise at least one of the following: a drive shaft for driving wheels, or a hydraulic or pneumatic system, etc.

[0009] Depending on the design, the input rotor or the output rotor comprises a disk-shaped first array with ferromagnetic bodies and / or ferromagnetic material elements and a disk-shaped second array with ferromagnetic bodies and / or ferromagnetic material elements arranged next to the first array, preferably axially next to it or concentric therewith and spaced axially from it by a certain distance, with at least one spacer extending axially to rigidly interconnect the first and second arrays of ferromagnetic bodies and / or ferromagnetic material elements. Typically, the output rotor or the input rotor, respectively, is arranged rotatably around a common axis of rotation between the first and second disk-shaped arrays of ferromagnetic bodies. The ferromagnetic bodies and / or ferromagnetic material elements are, for example, at least partially made of iron or iron alloys (steel), in particular thin sheets of iron or steel. The ferromagnetic bodies and / or ferromagnetic material elements provide, for example, a permanent magnetic field. In other words, the ferromagnetic bodies and / or ferromagnetic material elements are, for example, permanent magnets.

[0010] To transmit mechanical power and / or generate electrical power, the input or output rotor typically includes a disk-shaped array of electromagnets positioned adjacent, preferably axially adjacent or concentric with, first and second arrays of ferromagnetic material and / or ferromagnetic material elements to generate electrical power when rotating at a smaller angular velocity than the input rotor.

[0011] Either the input rotor includes a first and second array of disk shapes and the output rotor includes a disk-shaped array with electromagnets, or the output rotor includes a first and second array of disk shapes and the input rotor includes a disk-shaped array with electromagnets.

[0012] The dual rotor machine preferably has an axial flux (AF) configuration. In other words, the magnetic flux between the electromagnets of the output rotor and the ferromagnetics of the input rotor is generally oriented parallel to the common axis of rotation. This allows for a compact construction of the dual rotor machine and improves the flexibility of the system. Furthermore, the AF topology allows for an increase in the number of magnetic poles and therefore the power density compared to the prior art, resulting in a DRM with higher performance. However, a radial flux configuration is also possible. A further benefit of the DRM according to the present disclosure is that no permanent magnets are required.

[0013] During operation, when power is supplied to the output rotor, the output rotor can preferably be driven at a higher angular speed than the input rotor. Alternatively or in addition, the output rotor can be driven at a lower angular speed than the input rotor to generate power. This allows the ICE to always be operated in a high efficiency region, resulting in a 15% to 40% reduction in fuel consumption compared to conventional vehicles. Reduced fuel consumption at similar performance results in reduced CO2 emissions.

[0014] Good results can be achieved if at least one ferromagnetic body of the first array and / or the second array has a substantially U- or V-shaped cross section. It is preferred that all ferromagnetic bodies of the first array and / or the second array have a substantially U- or V-shaped cross section.

[0015] In a preferred variant, the input rotor is of multi-part design. Depending on the design, the input rotor comprises a disk-shaped first base, which in the assembled state has a first arrangement of ferromagnetic bodies separably arranged thereon, and a disk-shaped second base, which in the assembled state has a second arrangement of ferromagnetic bodies separably arranged thereon. This makes it possible to reduce the complexity in manufacturing the input rotor, since the parts of the input rotor can be produced separately in an efficient manner. The first and / or second base are preferably made at least partially from a lightweight material, in particular a non-magnetic material, such as a metal or a metal compound, such as aluminum. However, other materials are also possible, such as composite materials, such as fiber-reinforced plastics.

[0016] Where appropriate, the ferromagnetic bodies of the first and / or second arrays are in a fixed position at the base of the first and / or second disk-shaped bodies, respectively, by a support element, in particular the support element being arranged at least partially inside the U- or V-shape of the respective ferromagnetic body in cross-sectional view. It is preferred that the first and second disk-shaped arrays have substantially the same diameter, in particular that the first disk-shaped array comprises the same number of ferromagnetic bodies as the second disk-shaped array.

[0017] For high magnetic flux density, the output rotor comprises several ferromagnetic cores, each having a first end section facing the first arrangement of ferromagnetic bodies in the axial direction and a second end section facing the second arrangement of ferromagnetic bodies. The first and / or second end section of each ferromagnetic core is preferably at least partially surrounded by a set of windings. To stabilize the arrangement of electromagnets, a spacer is preferably arranged between two adjacent cores, respectively. This allows a sectioned structure / multi-part design of the output rotor as well as the first and second arrangements of ferromagnetic bodies. Where appropriate, the spacer may have a substantially rectangular cross section perpendicular to the axial direction and the cores may have a corresponding substantially isosceles trapezoidal cross section. The ferromagnetic cores are, for example, made of the same material as the ferromagnetic bodies or ferromagnetic material elements.

[0018] Typically, the number of ferromagnets or ferromagnetic material elements and the number of electromagnets have a ratio of 1.1 to 1.5, in particular 1.2. Preferred pairs of numbers of electromagnets and ferromagnets are 12 / 18 or 10 / 12 or 20 / 24, most preferably 15 / 18 (electromagnets in the output rotor) / (ferromagnets in the input rotor, each array having 18 ferromagnets). However, the numbers may vary to take into account the spatial dimensions of the input and output rotors, depending on the field of application.

[0019] When present, the disk-shaped array of electromagnets typically includes at least one set of windings electrically interconnectable to the battery for receiving and / or providing electrical energy to the battery. In a preferred variant, the array of electromagnets includes three or more sets of windings. Good routing of the electrical interconnects is possible when the output shaft includes an axially extending central opening concentric with the common axis of rotation for passing the electrical interconnects of the at least one set of windings.

[0020] The input drive shaft and / or the output shaft are, for example, made of steel, in particular high strength steel, and at least some parts of the input rotor or the output rotor are made of aluminum, in particular aerospace aluminum.

[0021] The ferromagnetic bodies or ferromagnetic material elements of the first array are preferably arranged in a substantially mirror symmetrical manner with respect to the ferromagnetic bodies or ferromagnetic material elements of the second array, which results in a higher efficiency compared to an arrangement in which the first array is circumferentially offset with respect to the ferromagnetic bodies or ferromagnetic material elements of the second array.

[0022] For good performance, the axial distance (parallel to the common axis of rotation) between the output rotor and the input rotor is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1.5 mm, in particular about 1 mm.

[0023] Due to the high power density of the DRM according to the present disclosure, the cooling means can be arranged outside the housing, said cooling means being fluidly interconnected to the inside of the housing to provide good thermal control of the components arranged therein. The cooling means is preferably formed as an oil injection cooling section having at least one nozzle interconnected to an oil sink, in particular one or two devices of two or three nozzles each.

[0024] Another aspect of the disclosure is directed to a driveline for a vehicle, in particular an automobile, comprising the above-mentioned dual rotor machine, with an electric machine mechanically coupled to an output shaft of the dual rotor machine, for example for transmitting torque therebetween. The electric machine is typically implemented as an electric motor / generator. In the above driveline, the dual rotor machine forms a four-quadrant converter to which the electric machine is mechanically coupled, which can be used to control the engine speed and to control the torque provided to the wheels. The electric machine can be a stator of the dual rotor machine, e.g., a part of the dual rotor machine.

[0025] Vehicles of the present disclosure may include automobiles, heavy equipment, such as portable and / or stationary, configured for on-highway or off-highway use, although other vehicles are also contemplated.

[0026] If present, the electric machine is typically electrically interconnected to a battery, particularly the same battery as the dual rotor machine. In some variations, the electrical interconnection between the battery and the dual rotor machine and / or the electric machine comprises a current collector ring and / or power electronics between the dual rotor machine and the battery. The current collector rings for each electrical interconnection between the dual rotor machine and / or the electric machine are preferably arranged in a common current collector ring housing. For compact construction, the output drive shaft extends axially into the current collector ring housing to allow short wiring distances from the electromagnets to the current collector rings.

[0027] In a preferred variant, a controller is interconnected to at least one set of windings of the output rotor of the dual rotor machine and is configured to receive an operator input and to control the transmission of rotational speed from the input rotor to the output rotor based on the operator input. Where appropriate, the controller may be interconnected to an electric machine and is configured to control the electric machine to determine the torque transmitted between the output drive shaft and the electric machine. This allows control of both the torque provided to consumers of mechanical power, such as the wheels of a motor vehicle, and the engine speed.

[0028] In one variant, the double rotor machine further comprises at least one inverter electrically connected to the disk-shaped arrangement of electromagnets and preferably to a battery, the inverter being configured to convert the received current. The power source of the double rotor machine is, for example, a battery generating a DC voltage, and the double rotor machine itself is, for example, a three-phase AC electric machine. The inverter of the double rotor machine connects both components by converting the DC side of the battery to a three-phase AC voltage used by the double rotor machine. In AC, electricity flows in both directions in the circuit, since the voltage changes from positive to negative. The inverter regulates the flow of power, allowing the double rotor machine to operate in motor and generator modes. The inverter of the double rotor machine is a three-phase inverter, with one winding / coil connected to two legs forming a half bridge. An additional seventh leg of the inverter exists for braking.

[0029] The dual rotor machine structure is preferably based on a switched reluctance machine because when the windings of the outer rotor connected to the traction side are powered, the magnetic reluctance of the outer rotor creates a force that aligns the inner rotor poles connected to the internal combustion engine with the nearest outer rotor poles. To maintain rotation, an electrical control system switches the windings of successive stator poles in sequence so that the stator magnetic field "leads" the rotor poles and pulls them forward. The inverter enables this switching sequence by appropriately turning on and off transistors in its phase legs. As a result, the desired output waveform is delivered to the dual rotor machine.

[0030] An advantageous assembly is possible when at least one of the input rotor or the output rotor includes a sectioned rotor structure, whereby it is formed from a plurality of rotor sections.

[0031] For example, advantageous control of rotational speed increase can be achieved when a double rotor machine comprises a first array of a plurality of disks, a second array of a plurality of disks, and a disk-shaped array of a plurality of electromagnets, arranged next to each other, preferably axially next to each other or concentric with each other, and rotatable around a common axis of rotation.

[0032] A favorable mechanical connection of the rotating parts can be achieved if at least some of the rotating parts are connected to one another via at least one conical element that is preloaded and configured to relieve stress during operation, for example the preloaded conical element being arranged between the ferromagnetic / ferromagnetic material element and the support element of the rotor.

[0033] An improved mechanical connection is possible if at least one bearing, preferably all bearings, of the input drive shaft are shrink fitted onto the input drive shaft and / or at least one bearing, preferably all bearings, of the output drive shaft are shrink fitted onto the output drive shaft, the bearings being configured to journal the respective shafts within the housing of the double rotor machine.

[0034] The first array of disk shapes together with the second array of disk shapes may have a number of magnetic poles in the range of 15 to 20, preferably 18, and / or the array of disk shapes includes electromagnets which may have a number of magnetic poles in the range of 10 to 20, preferably 15.

[0035] Advantageous stability is possible if the input drive shaft and / or the output shaft are made of an iron alloy, preferably steel, especially high strength steel. Furthermore, an advantageous reduction in rotating mass is possible if the input rotor and / or the output rotor are at least partially made of aluminum, in particular aerospace aluminum, e.g., the support element, the first base and / or the second base are made of aluminum.

[0036] The nominal DC link voltage of the dual rotor machine is in the range of 250V to 400V, preferably 375V. It is preferred that the nominal speed of the input rotor is in the range of 2400 rpm to 3200 rpm, preferably 2700 rpm, and / or the nominal speed of the output rotor is in the range of 3600 rpm to 4500 rpm, preferably 4200 rpm.

[0037] It is to be understood that both the foregoing general description and the following detailed description are intended to present embodiments and provide an overview or framework for understanding the nature or features of the present disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operation of the disclosed concepts.

[0038] The disclosure described herein will be more fully understood from the detailed description and accompanying drawings given herein below, which should not be construed as limiting the disclosure as set forth in the appended claims. [Brief description of the drawings]

[0039] [Figure 1] FIG. 2 is an exploded view of a first variant of a double rotor machine according to the present disclosure; [Diagram 2] FIG. 2 is a partial cross-sectional view of a first variant of a double rotor machine. [Diagram 3] FIG. 3 is a detailed view of the double rotor machine of FIG. 2 indicated at circle O. [Figure 4] FIG. 3 is a cross-sectional view of a first variant of the double rotor machine of FIG. 2, indicated by the section line MM. [Diagram 5] FIG. 1 is a schematic diagram of a first variation of a drive train according to the present disclosure. [Figure 6] FIG. 13 is a schematic diagram of a second variation of the drive train according to the present disclosure. [Figure 7] FIG. 13 is a cross-sectional view of a second variant of a double rotor machine. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all, of the features are shown. Indeed, the embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Wherever possible, like reference numbers will be used to refer to like components or parts.

[0041] Figure 1 shows an exploded view of a first variant of a double rotor machine 1 according to the present disclosure. Figure 2 shows a partial cross-sectional view of the first variant of the double rotor machine 1 and Figure 3 displays a detailed view of the double rotor machine 1 of Figure 2 indicated by the circle O. Figure 4 shows a cross-sectional view of the first variant of the double rotor machine 1 of Figure 2 indicated by the section line MM and Figure 5 shows in a schematic diagram a first variant of the drive train 2 according to the present disclosure. Figure 6 shows a cross-sectional view of a second variant of the double rotor machine 1 according to the present disclosure.

[0042] A first variant of a double rotor machine 1 shown in Figures 1 to 4 typically comprises an input drive shaft 3, an input rotor 6 and an output rotor 11 coupled to an output drive shaft 12 for selective mechanical power transmission and / or electrical power generation in a driveline 2 (not shown) of a motor vehicle. The input drive shaft 3 is mechanically interconnectable to the ICE 4, whereas the output drive shaft 12 is mechanically interconnectable to respective motor vehicle wheels 29. As best seen in Figure 2, the input drive shaft 3 extends in an axial direction z into a housing 5 of the double rotor machine 1. When attached to the input drive shaft 3, the input rotor 6 is rotatably arranged inside the housing 5 about a common axis of rotation R. The output rotor 11 is rotatably arranged about the same common axis of rotation R and is mechanically interconnected to an output drive shaft 12 passing through the housing 5 on the opposite side to the input drive shaft 3.

[0043] As seen in FIG. 1, the input rotor 3 comprises a disk-shaped first array 8 of ferromagnetic materials 7 and a disk-shaped second array 9 of ferromagnetic materials 7 arranged concentrically with the first array 8 of ferromagnetic materials 7 and spaced a distance D1 therefrom in the axial direction z (they both rotate around the same common axis of rotation R during operation). Several spacers 10 extend in the axial direction z to rigidly interconnect the first and second arrays 8, 9 of ferromagnetic materials 7. The first and second arrays 8, 9 of ferromagnetic materials 7 form a cage-like structure for accommodating an output rotor 11 therein. Said output rotor 11 is arranged rotatably around the same common axis of rotation R between the first and second arrays 8, 9 of ferromagnetic materials 7. The output rotor 11 typically comprises a disk-shaped array 14 of electromagnets 13 arranged concentrically with the first and second arrays 8, 9 of ferromagnetic materials 7 to generate power when rotating at a smaller angular velocity than the input rotor 3.

[0044] Regarding the design of the input rotor 3 and the output rotor 11, as shown in FIG. 1, both have a segmented / multipart structure compared to known rotors. The first and second arrays 8 and 9 of ferromagnetic bodies 7 have a substantially U- or V-shaped cross section in a plane parallel to the axial direction z. These ferromagnetic bodies 7 are separably arranged on a first or second base 15 or 16, respectively, and are fixed thereto by support elements 17. The support elements 17 extend along the indentations of the ferromagnetic bodies 7 formed by the U- or V-shaped cross section of the ferromagnetic bodies 7. The support elements 17 are attached to the respective bases 15, 16 by means of screws. Both arrays 8, 9 of ferromagnetic bodies of the first variant each have eighteen (18) ferromagnetic bodies.

[0045] The output rotor 11 comprises fifteen (15) electromagnets 13. Each electromagnet comprises a first end section 21 facing the first array 8 of ferromagnetic bodies 7 and a second end section 22 facing the second array 9 of ferromagnetic bodies 7. The distance D1 between the first end section 21 and the first array 8 of ferromagnetic bodies 7 is approximately 1 mm in the illustrated variant. Similarly, the distance D1 between the second end section 22 and the second array 9 of ferromagnetic bodies 7 is approximately 1 mm in the illustrated variant.

[0046] As can be seen in Fig. 1, each core 20 of the end sections 21, 22 is wound with a winding 18. The windings 18 around each core 20 of the end sections 21, 22 respectively belong to a common winding 18. The illustrated variant comprises three separate sets of windings 18, which allow the output rotor 11 to be operated in three phases. To electrically interconnect the windings 18 to the battery 19 for receiving and / or providing electrical energy thereto, the output drive shaft 12 comprises a central opening 23 extending in the axial direction z concentric with the common axis of rotation R for passing the electrical interconnections of the windings 18. Alternatively or additionally, the input drive shaft 3 may comprise a corresponding central opening for passing the electrical interconnections of the windings 18.

[0047] To provide cooling, in particular to the electromagnets 13 of the output rotor 11, cooling means 24 are arranged outside the housing 5. In the illustrated variant, the cooling means 24 are formed as an oil injection cooler 24 fluidly interconnected inside the housing 5. The oil injection cooler 24 comprises several nozzles fed by an oil sink to inject oil onto the rotors 3, 11.

[0048] 5 shows a first variant of a drivetrain 2, said drivetrain 2 typically comprising an ICE 4 or any other engine mechanically interconnected to a DRM 1 via an input drive shaft 3. The DRM 1 is mechanically interconnected on the other side to an electric machine 25 via a transmission 30 mechanically linked to the output drive shaft 12. The electric machine 25 is typically electrically interconnected to a battery 19, in particular the same battery 19 as the double rotor machine 1.

[0049] The solid lines in FIG. 5 indicate interconnections for the transfer of energy, either mechanical or electrical. The dashed lines indicate signal paths. In the illustrated variant, a controller 26 is interconnected to at least one set of windings 18 of the output rotor 11 of the double rotor machine 1. The controller 26 is configured to receive an operator input and to control the transfer of the rotational speed from the input rotor 3 to the output rotor 11 based on the operator input. Furthermore, the controller 26 is typically interconnected to an electric machine 25 and is configured to determine the torque transferred between the output drive shaft 12 and the electric machine 25 by controlling the electric machine 25. The output drive shaft 12 can further be mechanically interconnected to the wheels 29 of the respective vehicle, directly or indirectly by known means.

[0050] In the illustrated variant, the electrical interconnections between the battery 19 and the double rotor machine 1 and / or the electric machine 25 each comprise a current collector ring 27. As best seen in Figures 2 and 4, the current collector rings 27 for each electrical interconnection with the double rotor machine 1 and / or the electric machine 25 are arranged in a common current collector ring housing 28. The output drive shaft 12 preferably extends in the axial direction z into the current collector ring housing 28 to allow short wiring distances from the electromagnets 13 to the current collector rings 27. The double rotor machine 1 may further comprise at least one inverter configured to transform the current received either from the electrical windings 18 or from the battery 19 depending on the use case.

[0051] In Fig. 6 a second variant of the drivetrain 2 is shown, said drivetrain 2 typically comprising an ICE 4 or any other engine mechanically interconnected to the DRM 1 via an input drive shaft 3. The DRM 1 is mechanically interconnected on the other side to an electric machine 25 via a transmission 30 mechanically linked to the output drive shaft 12. The electric machine 25 is usually electrically interconnected to a battery 19, in particular to the same battery 19 as the double rotor machine 1. Fig. 6 further shows in a schematic manner a control device 26, which is configured to control different parts of the drivetrain 2. Fig. 6 further shows two inverters, a first one arranged between the battery 19 and the electric machine 25 and a second one arranged between the battery 19 and the double rotor machine 1. The inverters are configured to convert a direct current received from the battery 19 into an alternating current for the double rotor machine 1 or the electric machine 25, or vice versa. 6 further shows that the electric machine 25 is mechanically coupled to the double rotor machine 1 (thereby forming, for example, part of the double rotor machine 1) via a transmission 30. Furthermore, the double rotor machine 1 and the electric machine 25 are coupled to wheels 29 via the transmission 30.

[0052] FIG. 7 shows a second variant of the double rotor machine 1 in a longitudinal section. This variant differs from the variant shown in FIG. 4 mainly in the bearing concept. The input drive shaft 3 is supported by two bearings arranged between the input drive shaft 3 and the housing 5. The bearings are, for example, shrink-shrunk on the input drive shaft 3. The bearing arranged near the input end of the input drive shaft 3 is, for example, a double row roller bearing in O configuration, and the bearing arranged near the output drive shaft 12 is, for example, a double row roller bearing in X configuration. Having such a bearing configuration has the advantage of increasing the rotational stability of the input drive shaft 3 and the input rotor 3. According to the variant shown in FIG. 4 and the variant shown in FIG. 6, the output drive shaft 12 is supported by two bearings. The bearing arranged near the input drive shaft 3 is arranged between the housing 5 of the DRM 1 and the output drive shaft 12. This bearing is, for example, a double row roller bearing in X configuration. The bearing arranged further from the interior of the DRM 1 is arranged between the collector ring housing 27 and the output drive shaft 12. The bearing is, for example, a single row roller bearing in an X configuration. Both bearings are, for example, shrunk onto the output drive shaft 12. Figure 7 further differs from Figure 4 in that a different embodiment of the output rotor 12 is made up of multiple rotationally symmetrical parts connected by screws, as compared to the single output rotor 12 of Figure 4.

[0053] It will be understood that the words used in this specification are words of description rather than of limitation, and various changes may be made without departing from the scope of the disclosure. [Explanation of symbols]

[0054] 1. Double Rotor Machine (DRM) 2. Drive system 3 Input Rotor 4. Internal Combustion Engine (ICE) 5 Housing (Dual rotor machine) 6 Input Rotor 7 Ferromagnetic material 8 First arrangement of ferromagnetic materials 9 Second arrangement of ferromagnetic materials 10 Spacer 11 Output rotor 12 Output drive shaft 13 Electromagnet 14 Electromagnet arrangement (output rotor) 15 First base (input rotor) 16 Second base (input rotor) 17 Support element (input rotor) 18 Windings 19 Battery 20 core (ferromagnetic, output rotor) 21 First End Section 22 Second End Section 23 Center opening (output drive shaft) 24 Cooling means 25 Electrical Machinery 26 Control device 27 Current collector ring 28 Current collector housing 29 wheels 30 Transmission R common axis of rotation D1 Distance (between the first and second arrays of ferromagnetic materials) D2 Distance (between input rotor and output rotor)

Claims

1. A double rotor machine (1) for selective mechanical power transmission and / or electrical power generation in a vehicle driveline (2), comprising: an input drive shaft (3) for mechanically connecting the double rotor machine (1) to an engine (4), the input drive shaft (3) extending axially into a housing (5); an input rotor (6) mechanically interconnected with said input drive shaft (3) and rotatably disposed inside said housing (5) about a common axis of rotation (R); an output rotor (11) rotatably arranged about said common axis of rotation (R) and mechanically interconnected to an output drive shaft (12) passing through said housing (5) for mechanically connecting said double rotor machine (1) to a consumer of mechanical power; Equipped with The input rotor (6) or the output rotor (11) a ferromagnetic body (7) and / or a disk-shaped first array (8) having ferromagnetic material elements; a second array (9) of ferromagnetic bodies (7) and / or ferromagnetic material elements in the shape of a disk, arranged adjacent to the first array (8) and spaced a certain distance (D1) therefrom in the axial direction (R, z); Including, at least one spacer (10) extending in said axial direction to rigidly interconnect said first and second arrays (8, 9); The input rotor (6) or the output rotor (11) a disk-shaped arrangement (14) having a ferromagnetic body (7) and / or electromagnets (13) arranged next to the first and second arrangements (8, 9) of ferromagnetic material elements so as to be rotatable about a common axis of rotation (R); a disk-shaped array (14) of electromagnets (13) is disposed between the first and second arrays (8, 9) of the input rotor (6) or the output rotor (11), respectively; Double rotor machine (1).

2. When power is supplied to the output rotor (11), the output rotor (11) can be driven at a higher angular velocity than the input rotor (6); and / or When power is removed from the output rotor (11), the output rotor (11) can be driven at a lower angular velocity than the input rotor (6). A double rotor machine (1) according to claim 1.

3. at least one ferromagnetic body (7) and / or at least one ferromagnetic material element of said first array (8) and / or said second array (9) has a substantially U- or V-shaped cross section, In particular, all ferromagnetic bodies (7) and / or all ferromagnetic material elements of said first array (8) and / or said second array (9) have a substantially U- or V-shaped cross section, A double rotor machine (1) according to claim 1.

4. the disk-shaped first array (8) comprises a disk-shaped first base (15) having, in an assembled state, the ferromagnetic bodies (7) and / or the ferromagnetic material elements of the first array (8) separably arranged thereon, the disk-shaped second array (9) comprises, in an assembled state, a disk-shaped second base (16) having the ferromagnetic bodies (7) and / or the ferromagnetic material elements of the second array (9) separably arranged thereon; A double rotor machine (1) according to claim 1.

5. the ferromagnetic bodies (7) and / or the ferromagnetic material elements of the first and / or second arrays (8, 9) are in a fixed position on the first and / or second bases (15, 16), respectively, by means of support elements (17); In particular, the support element (17) is arranged at least partially inside the U- or V-shaped cross section of the respective ferromagnetic body (7) and / or ferromagnetic material element in cross section. A double rotor machine (1) according to claim 4.

6. the disk-shaped array (14) of electromagnets (13) includes at least one set of windings (18) electrically interconnectable with a battery (19) for receiving and / or providing electrical energy from the battery (19); A double rotor machine (1) according to claim 1.

7. the disk-shaped array (14) of electromagnets (13) comprises several ferromagnetic cores (20) each having a first end section (21) facing the first array (8) and a second end section (22) facing the second array (9) in the axial direction; the first and / or second end sections (21, 22) of each ferromagnetic core (20) being at least partially surrounded by a common phase winding (18); A double rotor machine (1) according to claim 6.

8. the output drive shaft (12) includes a central opening (23) extending in the axial direction (R, z) concentric with the common axis of rotation (R); A double rotor machine (1) according to claim 2.

9. the first array (8) of disk-shaped elements comprises the same number of ferromagnetic bodies (7) and / or ferromagnetic material elements as the second array (9) of disk-shaped elements; A double rotor machine (1) according to claim 1.

10. the ferromagnetic bodies (7) and / or the ferromagnetic material elements of the first array (8) are arranged substantially mirror-symmetrically with respect to the ferromagnetic bodies (7) and / or the ferromagnetic material elements of the second array (9), A double rotor machine (1) according to claim 1.

11. the axial (R, z) distance (D2) between the output rotor (11) and the input rotor (6) is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1.5 mm, in particular 1 mm; A double rotor machine (1) according to claim 1.

12. A cooling means (24) Located outside the housing (5), fluidly interconnected to the inside of said housing (5), A double rotor machine (1) according to claim 1.

13. the cooling means (24) comprises a cooling oil jet with at least one nozzle interconnected to an oil sink, in particular one or two devices of two or three nozzles each, A double rotor machine (1) according to claim 12.

14. further comprising an inverter electrically connected to the disk-shaped array (14) of electromagnets (13) and preferably to the battery (19); the inverter is configured to convert the received current; A double rotor machine (1) according to claim 1.

15. at least one of the input rotor (6) or the output rotor (11) includes a segmented rotor structure, whereby it is formed from a plurality of rotor segments; A double rotor machine (1) according to claim 1.

16. a first array (8) of a plurality of said disk-shaped members arranged next to each other and rotatable about said common axis of rotation; a second array (9) of a plurality of said disk-shaped members; a disk-shaped array (14) of a plurality of said electromagnets (13); A double rotor machine (1) according to claim 1, comprising:

17. At least some of the rotating parts are connected to one another via at least one conical element that is preloaded and configured to release stress during operation. A double rotor machine (1) according to claim 1.

18. the ferromagnetic body (7) and / or the ferromagnetic material element are made of an iron alloy, in particular an iron alloy sheet; A double rotor machine (1) according to claim 1.

19. At least one bearing, preferably all bearings of the input drive shaft (3) are shrink fitted onto the input drive shaft (3); and / or At least one bearing, preferably all bearings of the output drive shaft (12) are shrink fitted onto the output drive shaft (12). A double rotor machine (1) according to claim 1.

20. said first array of discs (8) together with said second array of discs (9) have a number of magnetic poles ranging from 15 to 20, preferably 18; and / or a disk-shaped array (14) comprising said electromagnets (13) having a number of magnetic poles ranging from 10 to 20, preferably 15; A double rotor machine (1) according to claim 1.

21. the input drive shaft (3) and / or the output shaft (12) are made of steel, in particular high-strength steel, and / or the input rotor (6) and / or the output rotor (11) are at least partially made of aluminum, in particular aerospace aluminum; A double rotor machine (1) according to claim 1.

22. The nominal DC link voltage is in the range of 250V to 400V, preferably 375V; A double rotor machine (1) according to claim 1.

23. the nominal speed of the input rotor (6) is in the range of 2400 rpm to 3200 rpm, preferably 2700 rpm; and / or The nominal speed of the output rotor (11) is in the range of 3600 rpm to 4500 rpm, preferably 4200 rpm. A double rotor machine (1) according to claim 1.

24. A drivetrain (2) for a vehicle, comprising: A double rotor machine (1) according to claim 1, an electric machine (25) mechanically coupled to the output drive shaft (12) of the double rotor machine (1) for transmission of torque therebetween; Drive system (2).

25. A control device (26) interconnected to the at least one set of windings (18) of the output rotor (11) or the input rotor (6) of the double rotor machine (1); configured to receive an operator input and, based on the operator input, to control the transmission of rotational speed from the input rotor (6) to the output rotor (11) and vice versa. A drivetrain (2) according to claim 24.

26. The control device (26) interconnected to said electric machine (25); configured to determine the torque transmitted between the output drive shaft (12) and the electric machine (25) by controlling the electric machine (25). A drivetrain (2) according to claim 25.

27. the control device (26) is configured to control the double rotor machine (1) using a control algorithm to selectively transmit / generate mechanical power and / or selectively transmit / generate electrical power; A drivetrain (2) according to claim 25.

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