Electromechanical device, transmission unit with electromechanical device, and vehicle with transmission unit

Abstract

The present disclosure relates to an electric machine (100), a transmission unit including an electric machine (100) for changing operating parameters, and a vehicle including the transmission unit, the electric machine (100) comprising a first rotating electric machine (110) having a first stator (112) and a first rotor (120), and a second stator (132) and a second rotor (132) having a smaller radial extension than the first rotating electric machine (110). and a second rotating electric machine (130) having a stator (140) arranged radially within the first rotating electric machine (110), thereby forming an interleaved region (176) of the electric machine device (100), the first stator (112) and the second stator (132) being ironless, and the first rotor (120) being a permanent magnet rotor or a rotor with windings for electrical excitation.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] The commonly assigned international patent application having International Application No. PCT / EP2021 / 057125, entitled "Rotating electromechanical apparatus and method of manufacture of stator winding", is incorporated herein by reference in its entirety. The commonly assigned international patent application having International Application No. PCT / EP2022 / 057160, entitled "Ring cylindrical casing and method for producing a ring cylindrical casing of a rotating electromechanical apparatus", is incorporated herein by reference in its entirety.

[0002] [Technical field] The present disclosure relates to an electric machine, a transmission unit including the electric machine, and a vehicle including the transmission unit. Specifically, the present disclosure relates to an electric machine including a first rotating electric machine and a second rotating electric machine arranged coaxially with respect to each other, the second rotating electric machine being arranged radially within the first rotating electric machine, thereby forming an interleaved region of the electric machine. Furthermore, the present disclosure relates to an electric machine transmission unit, specifically including the first and second rotating electric machines, and a vehicle including the transmission unit. [Background technology]

[0003] Rotating electric machines, such as electric motors and generators, are well known and used in many domestic, industrial, and automotive applications and are available in many sizes and types depending on their application. One example of such an electric machine is a three-phase AC motor. In such a motor, alternating current (AC) applied to the electrical windings of the stator generates a rotating electromagnetic field, which produces torque on the rotor. The rotor may have, for example, a set of permanent magnets that interact with the rotating electromagnetic field, a rotor coil or rotor winding, a rotor conductor in which induced currents generate an electromagnetic field, or a soft magnetic material in which non-permanent magnetic poles of the rotor are induced.

[0004] In the automotive industry, vehicles with internal combustion engines and conventional drivetrains with discrete gear ratios account for the majority of vehicle production. Because the rotational speed of the internal combustion engine is mechanically linked to the speed of the wheels via the drivetrain, the internal combustion engine often operates at a suboptimal working point. Clutches are required for starting the internal combustion engine and for shifting between different gears. Internal combustion engines are important because they produce CO2 from using fossil fuels. If internal combustion engines could operate at the best possible working point, fuel consumption and CO2 emissions could be significantly reduced. One possible solution, mechanical continuous gears, has not yet been widely adopted in the automotive industry due to friction and wear issues.

[0005] Vehicles with all-electric drivetrains are being widely introduced to the market by a variety of manufacturers, but their market adoption is limited by operating range, battery production, and charging station availability.

[0006] A hybrid vehicle includes an internal combustion engine and an electric engine. The internal combustion engine is coupled to the wheels, for example, by a mechanical transmission unit. Mechanical gears with discrete gear ratios may connect the internal combustion engine and the electric engine or the electric engine and the mechanical transmission unit. Other variations of hybrid vehicles are also possible.

[0007] A three-phase electric motor or generator typically has a stator having a stator core and stator windings disposed in the slots of the stator core, the stator windings comprising various forms of conductors, such as Litz wire wound inside the stator in the stator core slots, or single hairpin wire segments inserted into the stator core slots and then electrically joined, for example, using laser welding.

[0008] In conventional electromechanical devices, the stator core comprises a stack of metal laminations or sheets. Electrical insulation between the sheets reduces eddy currents. The stack of laminations or sheet stack traditionally contains slots in which the stator windings are located.

[0009] In a conventional electromechanical system with multiple electric motors or generators, the various electric motors or generators may be connected in series or parallel. For example, one generator is powered by an internal combustion engine to generate electric current. This electric current is sent to an electric motor to drive another shaft of the machinery. In this scenario, the generator and the electric engine are two different electric machines located in different locations within the machinery. Therefore, the generator and the electric engine require a lot of installation space within the machinery.

[0010] It has not been possible to date to develop a small, powerful, high power electric machine, especially one that combines the functionality of an electric engine and an electric generator. Summary of the Invention

[0011] An object of the present disclosure is to provide an electromechanical device, a transmission unit including the electromechanical device, and a vehicle including the transmission unit, and in particular, an object of the present disclosure is to provide an electromechanical device, a transmission unit including the electromechanical device, and a vehicle including the transmission unit that do not have at least some of the drawbacks of the prior art.

[0012] According to the present disclosure, these objects are addressed by the features of the independent claims. In addition, further advantageous embodiments become apparent from the dependent claims, the combination of claims, and the detailed description and drawings.

[0013] According to the present disclosure, an electric machine for varying operating parameters is described in detail. The electric machine typically includes a first rotating electric machine having a first stator and a first rotor configured to rotate about a common rotational axis. The electric machine further includes a second rotating electric machine having a smaller radial extension than the first rotating electric machine and having a second stator and a second rotor configured to rotate about the common rotational axis. In one embodiment, the first rotating electric machine is an electric motor or a generator, and / or the second rotating electric machine is an electric motor or a generator. In a further embodiment, the electric machine includes a combination of an electric motor and a generator, where the first rotating electric machine is an electric motor and the second rotating electric machine is a generator, or vice versa.

[0014] According to the present disclosure, the rotating electric machines are arranged so that their rotational axes are coaxial and both rotors rotate about a common rotational axis. According to the present disclosure, the second rotating electric machine is arranged radially within the first rotating electric machine, preferably completely within the first rotating electric machine, thereby forming an interleaved region of the electric machine system. In other words, the first rotating electric machine surrounds the second rotating electric machine. The interleaved region is an axially extending portion of the electric machine system including the first and second rotating electric machines. "Arranged radially within" means, for example, that the magnets of the rotor and the windings or coils of the stator of the second rotating electric machine are surrounded by the first rotating electric machine. Other components of the second rotating electric machine, such as input / output shafts, may be arranged externally or extend externally.

[0015] According to the present disclosure, the first stator and the second stator are ironless. An ironless rotating electric machine does not have a highly permeable material inside or extending into the area of ​​its coils / windings. An ironless rotating electric machine also preferably has stator iron to guide the magnetic flux. This stator iron is typically ring-shaped and is radially inside or outside the windings or coils, facing away from the rotor. That is, an ironless stator does not mean that the entire stator is ironless, but rather that the portion of the stator that has the coils or windings is ironless. Ironless electric machines are very radially compact, capable of providing high torque and high power output while having small radial dimensions.

[0016] For example, an ironless rotating electric machine does not have any highly magnetically permeable material extending within or in the coil / winding region of the stator of the electric machine, particularly the stator having coils and / or windings, i.e., ironless means that the portion of the stator having the coils and / or windings does not contain iron and / or ferromagnetic material and / or material with a magnetic permeability of, for example, 4 or more, preferably 40 or more, more preferably 300 or more.

[0017] The first stator portion of the electric machine comprising the coils and / or windings does not have a highly magnetically permeable material therein and / or does not contain iron, and the second stator portion of the electric machine comprising the coils and / or windings does not have a highly magnetically permeable material therein and / or does not contain iron.

[0018] In one embodiment, the material inside the first stator and / or the second stator or extending in the area of ​​the coils of the first stator and / or the second stator, respectively, has a magnetic permeability μ of less than 300, preferably less than 40, and more preferably less than 4. r The material within or extending through the region of the ironless stator coils may be, for example, a plastic, composite, resin, and / or metallic material having the magnetic permeability characteristics described above and providing at least partial support for the respective stator coils and / or windings.

[0019] According to the present disclosure, the first rotor is a permanent magnet rotor or a rotor with windings for electrical excitation, and the second rotor is a permanent magnet rotor or a rotor with windings for electrical excitation. Small radial dimensions of the rotor are also important to ensure the benefits of a compact stator are not compromised. A permanent magnet rotor allows for the design of a rotor with small radial dimensions. A rotor with rotor coils or windings for electrical excitation can also be designed with small radial dimensions. The radial dimensions of the rotor are preferably in the same range as the radial dimensions of the stator, more preferably smaller than the radial dimensions of the stator, and even more preferably smaller than half the radial dimensions of the stator.

[0020] The ironless stator, combined with a radially compact rotor, allows the design of electric machines with small radial dimensions, forming a "ring-motor." Ring motors can be stacked one on top of another. For example, such a motor cascade, comprising a first and a second rotating electric machine, has a maximum outer dimension comparable to that of the first rotating electric machine, surrounding the second rotating electric machine.

[0021] The extent of the active gap between the corresponding stator and rotor determines the torque and power of the corresponding rotating electric machine. For example, a relatively larger diameter allows more magnets to be placed on the outer periphery of the rotor, thereby increasing the torque or power of the rotating electric machine. By using a relatively small radial first rotating electric machine, a second electric machine located inside the first can still have a relatively large active diameter, allowing for high torque and power for the second electric machine as well.

[0022] The coaxial, interleaved arrangement of two rotating electric machines as disclosed herein provides a significant advantage to the electric machine. The overall installation space of the disclosed electric machine is significantly smaller than, for example, a conventional design in which two electric machines are arranged next to each other. In applications where installation space is at a premium, such as in automobiles, the disclosed electric machine reduces the installation space required compared to conventional designs.

[0023] In particular, electromechanical devices as disclosed herein can be constructed to be comparable to or even smaller and more compact than conventional mechanical gear units in vehicles such as automobiles or trucks, thereby enabling electromechanical devices as disclosed herein to replace mechanical gear units.

[0024] A further advantage of the present disclosure is that it provides a transmission unit for a vehicle that allows for complete mechanical decoupling of the internal combustion engine from the drivetrain, thereby allowing the internal combustion engine to operate at an optimized working point during operation. Furthermore, the transmission unit can be provided to upgrade a conventional vehicle to a hybrid vehicle. By equipping the transmission unit, it is possible to reduce fuel consumption, operate partially as a fully electric vehicle, and / or increase combustion power with additional battery power without any penalty in space requirements.

[0025] According to one embodiment, both the first and second rotating electric machines are designed as internal-rotor electric machines. An input shaft configured to be coupled to either the first rotor or the second rotor is arranged coaxially with an output shaft configured to be coupled to the other of the first rotor or the second rotor. Internal-rotor electric machines have rotors arranged radially inside a stator. This embodiment offers the advantage that the input and output shafts enter and / or exit the electric machine at a center of rotation about a common rotation axis and coaxially with said common rotation axis. The input and output shafts are also arranged coaxially with each other. According to this embodiment, both rotors are surrounded by a stator arranged on the outermost side of the respective rotating electric machine.

[0026] In another embodiment, the first rotating electric machine is designed as an internal-rotor electric machine, and the second rotating electric machine is designed as an external-rotor electric machine. An input shaft configured to be coupled to either the first rotor or the second rotor is eccentrically arranged with respect to an output shaft configured to be coupled to the other of the first rotor or the second rotor. The internal-rotor electric machine has a rotor arranged radially inside the stator. The external-rotor electric machine has a rotor arranged radially outside the stator. In this embodiment, both rotors are surrounded by the innermost and outermost stators. For example, the permanent magnets of the second rotating electric machine can be arranged radially inside the rotor shell, which simplifies the arrangement of the magnets on the rotor shell because the centrifugal force acting on the magnets is directly absorbed by the rotor shell. In this embodiment, the stator of the second electric machine is arranged inside the two rotors.

[0027] It is a topological advantage that the second stator must enter the machine centrally along the axis of rotation so that the second rotor can be advantageously supported, preferably at both axial ends. The second stator must withstand the torque of electromagnetic forces, provide a cooling fluid, and, in some embodiments, withstand the torque of the current conductors. Therefore, the second rotor of the second electric machine cannot exit the device centrally because the center is occupied by the second stator. In one embodiment, the second rotor can have the shape of a hollow shaft equipped with a gear and configured to engage an eccentrically arranged output shaft via the gear. In this embodiment, the output shaft can also have a gear. A gear stage, e.g., a spur gear stage or a bevel gear stage, is formed between the hollow shaft of the rotor and the output shaft. The gear stage has a gear transmission ratio of, e.g., 4:1.

[0028] In one embodiment, the input shaft is located at one axial end of the electromechanical device, and the output shaft is located at the other axial end, opposite the electromechanical device. For example, the input shaft is connected to a first rotor, and the output shaft is connected to a second rotor. This combined input and output shaft arrangement allows the bearings of the electromechanical device to be located relatively close to the rotating shaft, reducing bearing wear. The input and / or output shafts may be, for example, integrally formed with the respective rotors, form-fit, press-fit, screwed, etc., or positioned differently on the respective rotors.

[0029] According to one embodiment, the electric machine includes a gear table arranged between at least one of the input shaft and the first rotor, the input shaft and the second rotor, the first rotor and the output shaft, and the second rotor and the output shaft. The gear table allows for the rotational parameters between the input shaft and the first rotor and between the second rotor and the output shaft to be changed directly within the electric machine, which is advantageous in particular in terms of installation space requirements. The gear table also allows for the rotational parameters to be changed to ideally operate the respective rotating electric machine, in particular to operate the combustion engine providing the input in a preferred speed range. The gear table may be, for example, a spur gear table or a bevel gear table.

[0030] According to one embodiment, the first stator and the second stator each comprise a spirally laminated stack of a spirally wound strip of magnetically permeable material having a plurality of turns. The strip has two major surfaces and two side surfaces, at least one of the two major surfaces having an insulating coating. In a further embodiment, the first rotor and the second rotor each comprise a spirally laminated stack of a spirally wound strip of magnetically permeable material having a plurality of turns. The strip has two major surfaces and two side surfaces. At least one of the two major surfaces has an insulating coating. The strip has a spirally formed bevor shape, which is an elongated rectangular parallelepiped, with two major surfaces, two side surfaces (typically smaller than the major surfaces), two end faces, and a tip. According to this embodiment, at least one of the two major surfaces of the elongated rectangular parallelepiped shape has an insulating coating. In other words, one of the two main surfaces may have an insulating coating, for example, the upper main surface, the lower main surface, or both main surfaces. Typical of ironless stators, the stator irons have a simple ring-cylindrical shape. This allows the use of a spiral lamination stack, which offers significant cost advantages, as described above, instead of a conventional lamination stack with a complex shape, including slots for windings, which must be produced, for example, by pressing or laser cutting.

[0031] In the spiral configuration, a major surface of a first turn or winding of the spirally wound strip faces a major surface of an immediately adjacent or subsequent turn or winding of the spiral strip. One side faces radially inward, i.e., toward the common axis of rotation, and the other side faces radially outward, i.e., away from the common axis of rotation. In this way, each turn or winding of the spirally wound strip only contacts the adjacent turn or winding, if at all, through its respective coated major surface. The insulating coating therefore has the effect of preventing induced currents from being conducted directly from one winding to the next, thereby achieving the desired reduction in eddy currents generated by the stator windings of the electric machine during operation. While induced currents still flow from one winding to the next, they must flow around the entire circumference rather than axially directly to the next winding (e.g., 0.3 mm), which does not significantly affect the performance of the rotating electric machine, as compared to conventional lamination stacks that are ring-cylindrical sheets. A spirally wound strip of magnetically permeable material conforms to a helical shape to form a spiral laminate stack having a plurality of turns, and the spirally wound strip is preferably made of an iron alloy.

[0032] The advantages of having an ironless stator are that the rotating electric machine has higher electrical efficiency and requires less space in the radial dimension, particularly in a cylindrical shape with a smaller radial dimension. The increased electrical efficiency is due to smaller losses in the narrow stator irons. The reduced size of the ring-cylindrical ironless stator also advantageously reduces the weight of the corresponding rotating electric machine. Furthermore, rotating electric machines with ironless stators do not exhibit significant cogging effects. However, ironless stators have typically been applied primarily to small-sized and small-power electric motors or electric motors requiring high positioning accuracy. Similar considerations apply to the first and second rotors with spiral lamination stacks according to this embodiment. The first and second rotating electric machines according to this embodiment provide the necessary electromagnetic characteristics, even for high-power industrial or automotive applications using ironless stators and corresponding rotors.

[0033] According to one embodiment, the first stator and the second stator each include a continuous hairpin winding having at least two winding layers, or a continuous wave winding having at least two winding layers. In a further embodiment, the first rotor includes a permanent magnet or a continuous hairpin winding having at least two winding layers, or a continuous wave winding having at least two winding layers. In a further embodiment, the second rotor includes a permanent magnet or a continuous hairpin winding having at least two winding layers, or a continuous wave winding having at least two winding layers. The coils for electrical excitation in the first stator and the second stator according to this embodiment may be continuous hairpin windings. The coils for electrical excitation in the first rotor and the second rotor according to this embodiment may be continuous hairpin windings.

[0034] A continuous hairpin winding comprises wires that are hairpin-shaped and extend parallel to a common axis of rotation, providing straight wire segments. Following a first straight segment, the wire is bent at one or both ends of the straight segment so that a second straight segment is anti-parallel to the first straight segment at a fixed distance, preferably a half-pole distance. A hairpin winding is continuous in that each hairpin wire section defined by one or more straight segments is continuous with the next hairpin wire section. Notably, no electrical joints created by welding, soldering, or similar techniques are required between hairpin wire sections. However, the wires of a continuous hairpin winding, i.e., the input and / or output leads, may eventually be joined at their ends by some welding or similar technique, for example, to star-ground or delta-connect different phases of the continuous hairpin winding. A continuous hairpin winding may have two alternating layers of hairpin wire when viewed radially. For example, a given wire, when viewed from the circumference of a continuous stator winding, may have a first straight segment disposed in a first layer, and then bent and repositioned from a first layer to a second layer, or vice versa, such that the second or subsequent straight segment is disposed in the second layer.

[0035] Continuous hairpin windings are up to 30% more efficient in terms of torque and power compared to wave windings due to the superior layout of the wire segments. In a hairpin design, the wire segments are parallel, for example, within the area of ​​the permanent magnet, conducting current parallel to the magnetic poles, while in a wave design, the conductors only partially overlap the magnetic field, which can reduce the driving force exerted on the wave winding by the permanent magnetic field during motor operation, or reduce the effective magnetic field by inducing backflow in the wave winding during generator operation.

[0036] According to this embodiment, the continuous hairpin or continuous wave windings function as coils for the corresponding rotating electrical machines and require a relatively small radial installation space, which facilitates coaxial, interleaved arrangement of the first and second rotating electrical machines without requiring large radial dimensions for the resulting electrical machine arrangement.

[0037] According to one embodiment, the first rotating electric machine has a first machine thickness, from its outermost extension of its maximum radius in the interleaved region to its innermost extension of its minimum radius in the interleaved region, in the range of 30 mm to 15 mm, preferably 25 mm to 20 mm, more preferably 22 mm.

[0038] According to one embodiment, the second rotating electric machine has a second machine thickness, from its outer extension of its maximum radius in the interleaved region to its inner extension of its minimum radius in the interleaved region, in the range of 30 mm to 15 mm, preferably 25 mm to 20 mm, more preferably 22 mm.

[0039] The machine thickness is the radial distance between the housing or shell of the outer rotor or stator of a rotating electric machine and the housing or shell of the inner rotor or stator in the interleaved region of the electric machine. For example, a first rotating electric machine includes a stator shell including a cooling means, a spiral lamination stack, a continuous hairpin winding as a coil, a magnet, and a rotor shell, where the stator shell, the spiral lamination stack, and the coil form the stator, and the magnet or rotor coil and the rotor shell form the rotor. The radial distance between the radially outermost stator shell and the innermost rotor shell is the machine thickness in this embodiment. These parts allow the first and second rotating electric machines to be advantageously constructed with such small machine thicknesses without compromising on power output.

[0040] According to one embodiment, the first rotating electric machine has an outer diameter of the largest radius in the interleaving region in the range of 100 mm to 1000 mm, preferably 150 mm to 350 mm, more preferably 300 mm. The outer diameter of the largest radius of the first rotating electric machine is the distance across the electric machine in the interleaving region and therefore the overall diameter required for the installation of the electric machine.

[0041] According to one embodiment, the ring-shaped, axially extending gap in the interleaving region between the first and second rotating electric machines has a thickness of less than 10 mm, preferably less than 5 mm. The ring-shaped, axially extending gap defines the distance between the first and second rotating electric machines. Having a relatively small gap in the interleaving region reduces the radial installation space required for the entire electric machine. In particular, a relatively small gap, e.g., only 5 mm, can be achieved because tolerances and bearing supports allow for precise rotation of the different rotating components during operation of the electric machine. Furthermore, the gap is required to provide airflow for cooling between the first and second rotating machines.

[0042] In one embodiment, an electromechanical device includes at least one first bearing at a first axial end of the device and at least one second bearing at a second, opposite axial end of the device. The first bearing and the second bearing are disposed between two parts selected from the group consisting of a first stator, a second stator, a first rotor, and a second rotor. According to this embodiment, the first stator, the second stator, the first rotor, and the second rotor are all coupled at both axial ends by bearings that are concentrically mounted about a common rotation axis, thereby increasing the stability of the electromechanical device, reducing vibrations, and helping to balance the different parts, thereby enabling the electromechanical device to produce high torque and high power, especially at high rotational speeds.

[0043] According to one embodiment, the support for the first rotor comprises a first bearing arranged between the first stator and the first rotor on one axial end of the electric machine and a second bearing arranged between the second rotor and the first rotor on the other axial end of the electric machine. According to this embodiment, the first rotor is advantageously supported on both axial ends, which advantageously improves rotational stability and accuracy, particularly for high-speed rotation. This embodiment allows the first rotor to rotate about a common rotation axis relative to the first and second stators. According to this embodiment, the first rotor is supported by first and second bearings on the first stator and second rotor of the second rotating electric machine. This allows the first rotor to be supported on both axial ends of the first rotor, which in turn improves rotational stability and reliability during operation of the first rotating electric machine.

[0044] According to one embodiment, the support for the second rotor includes a first bearing disposed on one axial end of the electric machine between the first stator and the second rotor, and a second bearing disposed on the other axial end of the electric machine between the second rotor and the first rotor. The support for the second rotor further includes a second bearing disposed between the second rotor of the second rotating electric machine and the first rotor of the first rotating electric machine. The second rotor is supported on the second stator of the second rotating electric machine and on the first rotor of the first rotating electric machine by the first and second bearings. According to this embodiment, the second rotor is supported on both axial ends, thereby improving the stability and reliability of rotation during operation of the second rotating electric machine.

[0045] According to one embodiment, at least the radially innermost part of the second rotating electric machine is present in the interleaved region, which is designed as a hollow shaft, thereby forming a radial cavity inside the second rotating electric machine. The cavity is the result of the radially compact first and second electric machines. This demonstrates, without further calculations, the light weight of the electric machine arrangement, since a significant volume is hollow and not filled with heavy metals. Light weight is a further advantage of the disclosed arrangement, which is an important advantage in many applications, especially in the automotive industry.

[0046] In one embodiment, both the first and second rotating electric machines are configured to operate in engine mode as electric engines. In this embodiment, the output shafts of the first and second rotating electric machines can be driven completely independently. Applications of such devices include, for example, high-end automotive technology involving individual power supply to each wheel of a powered axle. In one embodiment, the first and second rotating electric machines are controlled such that the resulting rotational speed and resulting power of each powered wheel, powered by the corresponding output shaft, are selected for optimal cornering stability / track alignment depending on the current track and the current position of the wheel on the track. In one embodiment, the electrical energy required to drive the first and second rotating electric machines is provided, for example, by a battery and / or an internal combustion engine mechanically connected to a generator. This embodiment allows for improved cornering stability, for example, by applying a higher torque to the outer wheel via the first or second rotating electric machine. The disclosed device has significant advantages over prior art solutions with two separate engines, which require approximately twice the installation space.

[0047] In one embodiment, the first stator comprises a first stator shell, a first lamination stack, preferably a first spirally wound strip, and a first coil, preferably a first continuous hairpin winding. The second stator comprises a second stator shell, a second lamination stack, preferably a second spirally wound strip, and a second coil, preferably a second continuous hairpin winding. According to this embodiment, the first stator shell has a different radial extension (radius) compared to the second stator shell, which allows other components of the electric machine to be positioned between the first and second stators. In a further embodiment, at least one of the rotors, preferably both rotors of the electric machine, is positioned between the first and second stators.

[0048] According to another aspect of the present disclosure, a transmission unit for changing an operating parameter is specified. The operating parameter may be, for example, a rotational speed, rotational acceleration and / or deceleration, torque, or any combination of such parameters. The transmission unit includes the electric machine device described above and below and an electrical component configured to receive an electric current generated during operation of the first or second rotating electric machine and to transmit the electric current to the other of the first or second rotating electric machine to drive an output shaft. In other words, the electrical component of the transmission unit is configured to transmit electric energy received from the first or second rotating electric machine operating in a generator mode to the other of the first or second rotating electric machine operating in an engine mode.

[0049] The transmission unit further comprises a transmission unit battery connected to the electrical components, the transmission unit battery configured to store electrical power received from the electric machine and to supply electrical power to the electric machine, in particular the rotating electric machine configured to drive the output shaft. The transmission unit battery may be further configured to at least one of buffer the difference in electrical power demand of the two rotating electric machines, supply power to the output shaft, start the combustion engine, enable a pure electric drive mode of the vehicle with the transmission unit, recover electrical power in a braking mode, be charged by a stationary external power station, and any combination of these features.

[0050] According to one embodiment, the electrical component comprises a converter configured to convert a received electrical current having a first electrical characteristic, in particular a first AC frequency, into a desired electrical current having a second electrical characteristic, in particular a second AC frequency, for rotating an electrical machine configured to drive an output shaft. According to this embodiment, the electrical component not only routes the received electrical current to a corresponding rotating electrical machine, but also modifies the electrical characteristics of the received current into a desired current for the corresponding rotating electrical machine configured to operate in engine mode.

[0051] The first and second rotating electric machines can operate completely independently with respect to rotational speed. They are not connected by a mechanical transmission with fixed or discrete gear ratios, as in a geared connection. Despite being located within each other, each machine can operate at its own optimized working point completely independently of the other. Thus, the transmission unit operates as a continuous "gearbox" limited only by power and frequency conversion, not by mechanical requirements. In automotive applications, the internal combustion engine that can drive the input shaft of the electric machine can operate at its optimal working point, independent of wheel speed, for low fuel consumption and low CO2 emissions. The internal combustion engine can be shut down as long as power is available from the transmission unit battery and / or the vehicle battery.

[0052] According to one embodiment, the electrical component comprises a control unit for controlling the characteristics of the current sent to the first or second rotating electrical machine so as to achieve a desired transmission ratio, in particular a variable or continuously variable transmission ratio, between the input shaft of the first rotating electrical machine and the output shaft of the second rotating electrical machine. The transmission ratio is, for example, the ratio of the rotational speed of the output shaft to the rotational speed of the input shaft. According to this embodiment, the electrical component is configured to change the characteristics of the current sent to the electrical machines operating in engine mode, for example by changing the frequency of the current. The desired transmission ratio is determined, for example, by input parameters received at the control unit, which are converted by the control unit into control commands for the electrical components.

[0053] According to a further aspect of the present disclosure, a vehicle, such as a passenger car, truck, motorbike, or electric aircraft, in particular a vehicle with an internal combustion engine, a hybrid vehicle, or an electric vehicle, is specified, which is equipped with a transmission unit as described above or below.

[0054] According to one embodiment, the vehicle includes an internal combustion engine configured to propel an input shaft of the electric machine and a drivetrain mechanically connected to an output shaft of the electric machine and configured to propel the vehicle. The vehicle may further include a vehicle battery electrically connected to the electrical components and configured to store electrical power received from the electric machine and to supply electrical power to the vehicle, in particular the electric machine. In one embodiment, the vehicle battery is the same battery as the transmission unit battery. In another embodiment, the vehicle battery is an additional battery. The battery is electrically connected to the electric machine and configured to at least temporarily receive a portion of the electrical current produced by the rotating electric machine operating in generator mode and / or to supply electrical energy to the rotating electric machine operating in engine mode. According to this embodiment, the vehicle battery is configured to operate as an electrical buffer for the vehicle. Furthermore, the vehicle battery additionally supplies electrical energy to the rotating electric machine operating in engine mode.

[0055] In additional or alternative embodiments, a vehicle battery may be used as a storage medium for electrical energy that can be recharged from an external power source, such as a power grid and / or a photovoltaic cell.

[0056] According to a further aspect of the present disclosure, a conversion kit is provided that includes the electromechanical device described above and below or the transmission unit described above and below. The conversion kit is used to convert a conventional internal combustion engine vehicle into a hybrid vehicle. The electromechanical device, for example, replaces a conventional gearbox in a conventional drivetrain. For example, an input shaft of the electromechanical device is connected to the internal combustion engine, and the remaining part of the vehicle's drivetrain (without the gearbox) is connected to an output shaft of the electromechanical device. The internal combustion engine can be operated at its optimum working point, with the required transmission being performed by the newly installed transmission unit. [Brief explanation of the drawings]

[0057] The present disclosure will now be explained in more detail, by way of example, with reference to the following drawings in which:

[0058] [Figure 1] 1 shows a schematic longitudinal cross-sectional view of an electromechanical device according to a first embodiment of the present disclosure; [Figure 2] 1 shows a schematic cross-sectional view in a radial plane of an electromechanical device according to a first embodiment of the present disclosure; [Figure 3] 2 shows a schematic longitudinal cross-sectional view of an electromechanical device according to a second embodiment of the present disclosure; [Figure 4] FIG. 2 shows a side view of an electromechanical device according to a second embodiment of the present disclosure. [Figure 5] 1A and 1B show schematic perspective views of a spiral laminate stack according to a first exemplary embodiment; [Figure 6] 1A and 1B show schematic perspective views of an electromechanical device according to one embodiment of the present disclosure, with cross sections cut away to show the interior of the device; [Figure 7] 1A and 1B are schematic diagrams illustrating a perspective view of a cylindrical continuous hairpin winding according to a first exemplary embodiment; [Figure 8] 1 illustrates a schematic representation of a transmission unit with an electromechanical device according to an exemplary embodiment; [Figure 9] 1 illustrates a schematic representation of a vehicle equipped with a transmission unit according to an exemplary embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0059] 1 and 2 schematically illustrate an electric machine 100 according to a first embodiment. FIG. 1 illustrates a longitudinal cross section of the electric machine 100, and FIG. 2 illustrates a radial cross section of the electric machine 100. The electric machine 100 includes a first rotating electric machine 110 and a second rotating electric machine 130. The first rotating electric machine 110 includes a first stator 112 and a first rotor 130. The first stator 112 includes a first stator shell 113, a first lamination stack 114 preferably including a first spirally wound strip 115, and a first coil 116 preferably including a first continuous hairpin winding 117. The first rotor 120 includes a first rotor shell 121 and a first magnet 118. The second rotating electric machine 130 includes a second stator 132 and a second rotor 140. The second stator 132 comprises a second stator shell 133, a second lamination stack 134 preferably comprising a second spirally wound strip 135, and a second coil 136 preferably comprising a second continuous hairpin winding 137. The second rotor 140 comprises a second rotor shell 141 and a second magnet 138.

[0060] According to another embodiment (not shown), the first rotor comprises a winding for electrical excitation, preferably a continuous hairpin winding, in place of the first magnet 118. Additionally, the second rotor preferably comprises a winding for electrical excitation, preferably a continuous hairpin winding, in place of the second magnet 138. In this embodiment, the first rotor and the second rotor may also each comprise a respective lamination stack with a spirally wound strip.

[0061] As best shown in FIGS. 1, 2, and 3, the first rotating electric machine 110, and in particular the first rotor 120, are configured to rotate about a common rotational axis 122 during operation. The second rotating electric machine 130, and in particular the second rotor 140, are configured to rotate about the common rotational axis 122 during operation. The figures further illustrate that the first rotating electric machine 110 and the second rotating electric machine 130 are interleaved, thereby forming an interleaving region 176. The interleaving region 176 is an axial extension of the electric machine arrangement 100 where the first rotating electric machine 110 and the second rotating electric machine 130 overlap. The coaxial interleaving of the two rotating electric machines 110, 130 advantageously reduces the required installation space. The figures further illustrate that the second rotating electric machine 130 is located entirely within the first rotating electric machine 110.

[0062] The stators 112, 132 of each rotating electric machine 110, 130 are configured to induce a magnetic field within the corresponding rotating electric machine 110, 130. The stator shells 113, 133 are configured to act as housings for the stators 112, 132 and hold other portions of the stators 112, 132 in place during operation of the electric machine device 100. The stator shells 113, 133 may additionally comprise cooling means (not shown) for cooling the respective electric machines 110, 130. The lamination stacks 114, 134, including the spirally wound strips 115, 135, are configured to reduce eddy currents and increase the efficiency of the rotating electric machines 110, 130. The coils 116, 136 are configured to induce a current in the corresponding stators 112, 132. In the embodiments shown in the figures, the coils 116, 136 preferably comprise continuous hairpin windings 117, 137.

[0063] As best shown in FIGS. 6 and 7 , the continuous hairpin winding 117, 137 includes at least two layers 1171, 1172. The two layers include wire providing straight wire segments extending parallel to the common axis of rotation 122 in a hairpin shape. Next to a first straight segment, a subsequent second straight segment is bent at one or both ends of the straight segment to extend anti-parallel at a distance relative to the first straight segment. The hairpin winding 117, 137 is continuous in that each hairpin wire section, defined by one, two, or several straight segments, is continuous, i.e., integral with the next hairpin wire section. Notably, no electrical joints, created by welding, soldering, or similar techniques, are required between the hairpin wire sections. However, the wires of the continuous hairpin windings 117, 137 may eventually be joined at their ends by some welding or similar technique, for example, for star-grounding or delta-connecting the various phases of the continuous hairpin windings.

[0064] The continuous hairpin winding 117, 137 has two overlapping layers of hairpin windings 1171, 1172 when viewed radially. A given wire changes position, for example, from the first layer 1171 to the second layer 1172 or vice versa, when viewed around the continuous hairpin winding 117, 137, such that a first straight segment is disposed on the first layer 1171 and then folded, and a second or subsequent straight segment is disposed on the second layer 1172. According to the present embodiment, the continuous hairpin winding 117, 137 or continuous wave winding serves as the coils 116, 136 for the corresponding rotating electric machines 110, 130, but these coils require a relatively small radial installation space, which is useful for coaxially and alternately arranging the first and second rotating electric machines 110, 130 without requiring a large radial dimension.

[0065] First rotating electric machine 110 is configured to operate as either an electric motor or a generator, depending on the application required for electromechanical device 100. Second rotating electric machine 130 is also configured to operate as either an electric motor or a generator, depending on the application required for electromechanical device 100.

[0066] 1 and 2 show a first variant of the electric machine 100. In this variant, the first rotating electric machine 110 and the second rotating electric machine 130 are designed as internal-rotor electric machines. In other words, the respective rotors 120, 140 are arranged radially inside the respective stators 112, 132. According to this embodiment, the input shaft 160 of the electric machine 100 is formed integrally with the second rotor shell 141. Different couplings between the input shaft 160 and the second rotor shell 141 are also conceivable. The output shaft 170 of the electric machine 100 is formed integrally with the first rotor shell 121 in this embodiment. Different couplings between the output shaft 170 and the first rotor shell 121 are also conceivable. The first output shaft 160 and the second output shaft 170 are arranged coaxially with each other and with respect to the common rotation axis 122.

[0067] FIG. 1 further illustrates the concept of the support 150 with different bearings in the first embodiment of the electromechanical device 100. As can be seen, all of the bearings are located relatively close to the common rotating shaft 122. This advantageously reduces the rolling speed of the bearings, thereby extending their lifespan. The bearings include a first bearing 151 located at one end of the shaft of the electromechanical device 100 and a second bearing 152 located at the other end of the shaft, opposite the electromechanical device 100. Having bearings 151, 152 at both ends of the shaft improves rotational stability and precision, allowing the rotors 120, 140 to rotate at relatively high speeds. According to this embodiment, all components of the electromechanical device 100 are rotatably connected to the common rotating shaft 122 via concentric bearings. This increases stability and reduces vibration and imbalance, thereby enabling high torque and power, especially at high rotational speeds.

[0068] 1 illustrates a first bearing 151 disposed between the first rotor shell 121 and the first stator shell 113 as a support 150 for the first rotor 120. In other words, the support 150 is a bearing concept. In this embodiment, the first stator shell 113 is connected to the second stator shell 133, and the first bearing 151 for the first rotor 120 is disposed at this connection. FIG. 1 also illustrates a second bearing 152 disposed at the opposite axial end between the first stator shell 113 and the first rotor shell 121, in particular, an output shaft 170 coupled to the first rotor shell 121 according to this embodiment.

[0069] 1 further shows one first bearing 151 as a support 150 for the second rotor 140, which is arranged between the second rotor shell 141 and the first stator shell 121, particularly at the connection between the first stator shell 121 and the second stator shell 133. One second bearing 152 is arranged at the opposite axial end of the electric machine 100 between the second rotor shell 141 and the first rotor shell 121, particularly on the output shaft 170 connected to the first rotor shell 121 in this embodiment.

[0070] FIG. 1 further shows an additional third bearing 153 arranged between the second stator shell 133 and the first rotor shell 121, and in particular an output shaft 170 for additionally or alternatively supporting the second stator shell 133 relative to the first rotor shell 121.

[0071] FIG. 2 shows a cross-sectional view through the interleaved region 176 of the variation shown in FIG. 1 . FIG. 2 advantageously illustrates the thicknesses of the different rotating electric machines 110, 130. The first rotating electric machine 110 has a first mechanical thickness 200 extending from the first stator shell 113 to the first rotor shell 121. The second rotating electric machine 130 has a second mechanical thickness 201 extending from the second stator shell 133 to the second rotor shell 141. A radially extending gap 124 is disposed between the first rotating electric machine 110 and the second rotating electric machine 130. The electric machine device 100 has an overall thickness 202 extending from the first stator shell 113 to the second rotor shell 141. In other words, the overall thickness is the sum of the first mechanical thickness 200, the second mechanical thickness 201, and the axially extending gap 124. 1 and 2 further show a radially disposed cavity 210 within the interleaved region 176, which is formed by the radially compact electric machines 110, 130. It is demonstrated without further calculation that the electromechanical device 100 is lightweight because a significant volume is hollow and not filled with heavy metals.

[0072] 3 and 4 show a second variant of the electric machine 100. According to this embodiment, the first rotating electric machine 110 is designed as an internal-rotor electric machine, and the second rotating electric machine 130 is designed as an external-rotor electric machine. In other words, the second rotor 140 is arranged radially outside the second stator 132. According to this embodiment, the input shaft 160 of the electric machine 100 is formed integrally with the first rotor shell 121. Various connections between the input shaft 160 and the first rotor shell 121 are also conceivable. According to this embodiment, the output shaft 170 of the electric machine 100 is connected to the second rotor shell 131 via a mechanical gear stage 180, in particular a spur gear stage. The first output shaft 160 and the second output shaft 170 are not arranged coaxially with each other, but instead are offset from each other. The gearbox 180 allows for the variation of the rotational characteristics between the second rotor 140 and the output shaft 170 .

[0073] FIG. 3 shows that the second stator 132 of the second electric machine 130 enters the electromechanical device 100 at the center of one shaft end. The second stator 132 is located inside the two rotors 120, 140, but in this embodiment, the stator is immotile. The second stator 132 is configured to absorb the torque of the electromechanical device 100 and to provide access to electrical connectors and cooling, e.g., water cooling. The output shaft 170 therefore cannot exit the electromechanical device 100 coaxially with the common rotation axis 122 as shown in FIG. 1 because its center is occupied by the second stator 132. This problem is overcome, as disclosed, by adding an eccentrically positioned gear carriage 180. The gear carriage 180 shifts the output shaft 170 away from the center, as best shown in FIG. 4.

[0074] 3 further illustrates the concept of a support 150 with different bearings for the second embodiment of the electromechanical device 100. As can be seen, all of the bearings are located relatively close to the rotating shafts 122, 142, which advantageously reduces the rolling speed of the bearings and therefore extends their lifespan. The bearings include a first bearing 151 located at one end of the shaft of the electromechanical device 100 and a second bearing 152 located at the other end of the shaft opposite the electromechanical device 100. Having bearings 151, 152 at both ends of the shaft improves rotational stability and precision, and allows for relatively high rotational speeds.

[0075] 3 shows a first bearing 151 as a support 150 for the first rotor 120, which is arranged between the first rotor shell 121 and the first stator shell 113. The first bearing 151 of the first rotor 120 is arranged on an input shaft 160 that is connected to the first rotor shell 121 according to the present embodiment. FIG. 3 also shows a second bearing 152 that is arranged at the opposite axial end of the electromechanical device 100, between the first rotor shell 121 and the second rotor shell 141.

[0076] 3 further shows a support 150 for the second rotor 140, which includes a first bearing 151 disposed between the second rotor shell 141 and the second stator shell 133. A second bearing 152 is disposed at the opposite axial end of the electromechanical device 100 between the second rotor shell 141 and the second stator shell 133.

[0077] 3 further shows a third bearing 153 disposed between the second stator shell 133 and the first rotor shell 121, and in particular an input shaft 160 that additionally or alternatively supports the second stator shell 133 relative to the first rotor shell 121. As shown in the embodiment of FIG. 1, the first stator 112, second stator 132, first rotor 120, and second rotor 140 are all on both shaft ends connected by concentric bearings to a common rotational axis 122. This increases stability and reduces vibration levels and imbalance, thereby enabling high torque and power output, especially at high rotational speeds.

[0078] FIG. 4 shows a side view of the second embodiment, illustrating a particularly advantageous offset of the output shaft 170 relative to the common rotational axis 122.

[0079] FIG. 5 shows a perspective view of a first or second lamination stack 114, 134 used, for example, in a first or second rotating electric machine 110, 130. The spiral lamination stack 114, 134 is formed from a spirally wound strip 115, 135 of a magnetically permeable material, for example, an iron alloy. The strip 115, 135 preferably has a rectangular cross section. Thus, the strip 115, 135 has two main surfaces 1151 and two side surfaces 1152. The main surfaces 1151 are arranged parallel to each other and form a surface with the greatest extent in terms of area. The side surfaces 1152 are also arranged parallel to each other. Furthermore, the side surfaces 1152 are arranged perpendicular to the main surface 1151 and are interconnected with the two main surfaces 1152. The main surface 1151 and the side surfaces 1152 define a mantle of the strip 115, 135. The thickness of the strips 115, 135 is the length of the short extension between the side surfaces 1152. The width of the strips 115, 135 is the length of the short extension between the major surfaces 1151. The other or long extension of the major surfaces 1151 and the side surfaces 1152 defines the length of the strips 115, 135. The strips 115, 135 are terminated or completed by two end faces that form the tips of the strips 115, 135. FIG. 5 further shows an insulating coating 1153 disposed on at least one of the two major surfaces 1151. The insulating coating 1153 is configured to electrically insulate two adjacent major surfaces 1151 of different numbers of turns or windings of the spiral laminate stack 114, 134. In another embodiment, the insulating coating 1153 is disposed on both major surfaces 1151. In one embodiment, the spiral lamination stack 114, 134 forms a segment that is positioned with other segments on the stator shell 113, 133, for example.

[0080] In one embodiment, the spiral lamination stack 114, 134 is a multiple geared lamination stack (not shown in FIG. 5). A multiple geared lamination stack is formed from multiple spirally wound strips 115, 135 having the same inclination or pitch angle. Different strips 115, 135 may have different thicknesses, be composed of different materials, and / or have different insulating coatings.

[0081] FIG. 6 is a schematic illustration of an electric machine 100 according to one embodiment of the present disclosure, with a cutaway cross section to show the interior of the electric machine 100. FIG. 6 partially illustrates one embodiment of a first rotating electric machine 110. FIG. 6 shows a first stator shell 113, a first lamination stack 114 including a first spirally wound strip 115, a first coil 116 including a first continuous hairpin winding 117, and a first magnet 118 disposed in a first rotor shell 121. Additionally, a common axis of rotation 122 is shown. The first continuous hairpin winding 117 has a first winding layer 1171 and a second winding layer 1172. A second rotating electric machine 130 is disposed within the first rotor shell 121 (not shown in FIG. 6).

[0082] In this embodiment, the spiral lamination stack 114 is connected to the first stator shell 113 by a permanent connection. This connection may be formed, for example, by a form fit, a press fit, a force fit, or a chemical connection. For example, the spiral lamination stack 114 may be press-fit, screwed, shrink-fit, and / or glued into or onto the first stator shell 113.

[0083] The continuous hairpin winding 117 may have two sets of three phase windings U1, V1, W1, U2, V2, and W2. The first set of phase winding U1 and the corresponding second set of phase winding U2 have the same electrical phase (and may be joined together, for example, not shown in FIG. 7 ). The continuous hairpin winding 117 has input leads. The input leads include wires for each of the phase windings U1, V1, W1, U2, V2, and W2 within the same region of the electromechanical device 100 to ensure efficient and uncomplicated electrical connections of the continuous hairpin winding 114. In particular, all of the input leads are in a common, preferably small azimuthal region. The end of each phase winding U1, V1, W1, U2, V2, and W2 is electrically joined to at least one other of the phase windings U1, V1, W1, U2, V2, and W2, for example, to form a star ground 24 or a delta connection. The continuous hairpin winding 114 comprises straight segments that extend parallel to the axis 122, bent segments that include offset bends, and folded segments.

[0084] As can be seen in FIG. 6 , the first stator shell 113 forms part of the ironless stator of the rotating electric machine 110. Specifically, the first helical lamination stack 114, the first stator shell 113, and the first hairpin winding 117 comprise the first ironless stator 112. The first continuous hairpin winding 117 is covered by the helical lamination stack 114 along its entire axial extension (i.e., its extension parallel to the axis of rotation 122). The inner surface of the first helical lamination stack 114 is positioned adjacent to the first continuous hairpin winding 117 and holds the continuous hairpin winding 117 in place. The continuous hairpin winding 117 is positioned entirely within the first stator shell 113, thereby protecting it from mechanical damage, impact, and contamination.

[0085] The first stator 112 has an advantageously small radial extension while at the same time being highly efficient, making it suitable for large scale industrial or automotive applications.

[0086] FIG. 7 schematically illustrates a cylindrical continuous hairpin winding 117, 137 according to a first exemplary embodiment, for use in, for example, the first or second rotating electric machine 110, 130. As shown, all of the phase windings U1, V1, W1, U2, V2, and W2 have input leads on the same side of the continuous hairpin winding 117, 137 and within the same relatively small azimuthal angle range. This is beneficial for electrically connecting the continuous hairpin winding to, for example, a power source and / or motor controller. Furthermore, the opposite ends of the wires from the input leads are also within the same region, which facilitates forming star-ground or delta connections between the phase windings U1, V1, W1, U2, V2, and W2. Each of the first set of phase windings U1, V1, and W1 and its corresponding second set of phase windings U2, V2, and W2 has the same phase. Such optimized shape of the continuous hairpin winding 117, 137 is required, particularly for electric machines 110, 130, to have a very small gap 124 between the continuous hairpin winding 117, 137 and the respective rotor 120, 140. Having a small gap is clearly advantageous, particularly with respect to the embodiment of the electromechanical device 100, for achieving higher electromagnetic efficiency.

[0087] In one embodiment, the continuous hairpin windings 117, 137 can be potted with a curable potting material. Strong mechanical and thermal bonding of the hairpin windings 117, 137 to the laminate stacks 114, 134 is beneficial for reliable torque transmission and optimized heat conduction. This provides additional structural support, improves electrical insulation between the wires, and improves heat conduction from the wires.

[0088] FIG. 8 schematically illustrates a block diagram of a transmission unit 10 according to an exemplary embodiment. The transmission unit 10 includes an electric machine 100 having first and second electric machines 110, 130 arranged coaxially and interleaving with one another. FIG. 8 further illustrates an input shaft 160 and an output shaft 170. The transmission unit 10 further includes an electric component 300 configured to receive an electric current generated during operation of the first or second rotating electric machine 110, 130 and to transmit the electric current to the other of the first or second rotating electric machine 110, 130 to drive the output shaft 170. The electric component 300 includes a converter 302. According to the present embodiment, the converter 302 is configured to convert the received electric current having a first electric characteristic, in particular a first AC frequency, into a desired electric current having a second electric characteristic, in particular a second AC frequency, to rotate the rotating electric machines 110, 130, which are configured to drive the output shaft 170 as desired.

[0089] According to the present embodiment, the transmission unit 10 further comprises a control unit 304 for controlling the characteristics of the current sent to the first or second rotating electric machine 110, 130 so as to achieve a desired transmission ratio between the first rotor 120 of the first rotating electric machine 110 and the second rotor 140 of the second rotating electric machine 130. This transmission ratio is, for example, the ratio of the rotational speed of the output shaft 170 to the rotational speed of the input shaft 160. According to the present embodiment, the electrical component 300 is configured to modify the characteristics of the current sent to the rotating electric machines 110, 130 operating in engine mode, for example by modifying their frequency. The desired transmission ratio is, for example, determined by input parameters received by the control unit 304 and converted by the control unit 304 into control commands for the electrical component 300.

[0090] 8 further illustrates a transmission unit battery 303 configured to store and provide electrical energy to the transmission unit 10. The transmission unit 10 is configured to convert mechanical input energy received via the input shaft 160 of the electromechanical device 100 into mechanical output energy that is transmitted via the output shaft 170 of the electromechanical device 100 to various components of the vehicle, such as the vehicle's drivetrain. By modifying the electrical characteristics of the current supplied to the rotating electric machines 110, 130 of the electromechanical device 100 operating in engine mode, desired characteristics of the mechanical output energy can be achieved.

[0091] The transmission unit battery 303 electrically connected to the electric machine device 100 may be configured such that at least a portion of the current produced by the rotating electric machines 110, 130 operating in generator mode is at least temporarily routed to the transmission unit battery 303. Alternatively or additionally, the transmission unit battery 303 may further be configured such that at least a portion of the current required by the rotating electric machines 110, 130 operating in engine mode is at least temporarily supplied by the transmission unit battery 303. According to the present embodiment, the transmission unit battery 303 is configured to operate as an electrical buffer for the transmission unit 100.

[0092] 9 shows a schematic diagram of a vehicle 400 equipped with a transmission unit 10 according to an exemplary embodiment. The vehicle 400 further comprises an internal combustion engine 401, a vehicle battery 402, and a drive train 403.

[0093] According to the present embodiment, the internal combustion engine 401 is mechanically connected to an input shaft 160 of the transmission unit 10 and is configured to drive a first or second rotating electric machine 110, 130 operating in generator mode. An output shaft 170 of the transmission unit 10 is mechanically connected to a drive train 403. The transmission unit 10, for example, replaces a conventional gearbox. The transmission unit 10 may be installed in the vehicle 400 as a replacement kit. In another embodiment, the transmission unit 10 is installed directly during the manufacture of the vehicle 400. [Explanation of symbols]

[0094] 10 Transmission Unit 100 Electromechanical Devices 110 first rotating electrical machine 112 first stator 113 First stator shell 114 first laminate stack 115 spiral wound strips 1151 Main surface 1152 Side 1153 Insulation Coating 116 First Coil 117 First continuous hairpin winding 1171 First winding layer 1172 Second Winding Layer 118 First Magnet 120 First Rotor 121 First Rotor Shell 122 Common Rotation Axis 124 Axially extending gap 130 Second rotating electrical machine 132 Second Stator 133 Second stator shell 134 Second Laminate Stack 135 Second spirally wound strip 136 Second Coil 137 Second continuous hairpin winding 138 Second Magnet 140 Second Rotor 141 Second Rotor Shell 150 Support part 151 First bearing 152 Second bearing 153 Third Bearing 160 input shaft 170 output shaft 176 Interleaved Area 180 Gear stand 200 First Machine Thickness 201 Second Machine Thickness 202 Overall thickness and radial thickness of electromechanical devices 210 cavity, hollow machine internal volume 300 Electrical Components 302 Converter, AC-AC Converter 303 Transmission unit battery 304 Control Unit 400 vehicles 401 Internal Combustion Engine 402 Vehicle Battery U1, U2, V1, V2, W1, W2 phase winding

Claims

1. An electromechanical device (100) for changing operating parameters, The aforementioned electromechanical device (100) a. A first rotating electric machine (110) comprising a first stator (112) and a first rotor (120) configured to be rotatable with respect to a common rotation axis (122), b. A second rotating electric machine (130) comprising a second stator (132) and a second rotor (140) having a smaller radial extension than the first rotating electric machine (110) and configured to be rotatable with respect to the common rotation axis (122), The second rotating electric machine (130) is arranged radially inside the first rotating electric machine (110), thereby forming an interleaved region (176) of the electric machine device (100). The first stator (112) and the second stator (132) are ironless, and as a result, the first stator (112) and the second stator (132) do not have a highly permeable material inside them, or do not have a highly permeable material extending into the region of their coils (116, 136). The first rotor (120) is a permanent magnet rotor or a rotor equipped with windings for electrical excitation. The second rotor (140) is a permanent magnet rotor or a rotor equipped with windings for electrical excitation. Electromechanical device (100).

2. The first rotating electric machine (110) and the second rotating electric machine (130) are designed as internal rotor type electric machines. The electromechanical device (100) according to claim 1, wherein an input shaft (160) configured to be connected to one of the first rotor (120) or the second rotor (140) is coaxially arranged with respect to an output shaft (170) configured to be connected to the other of the first rotor (120) or the second rotor (140).

3. The first rotating electric machine (110) is designed as an internal rotor type electric machine, and the second rotating electric machine (130) is designed as an external rotor type electric machine. The electromechanical device (100) according to claim 1, wherein an input shaft (160) configured to be connected to one of the first rotor (120) or the second rotor (140) is eccentrically positioned with respect to an output shaft (170) configured to be connected to the other of the first rotor (120) or the second rotor (140).

4. The electromechanical device (100) according to claim 2, wherein the input shaft (160) is located at one shaft end of the electromechanical device (100), and the output shaft (170) is located at the other opposite shaft end of the electromechanical device (100).

5. The electromechanical device (100) according to claim 2, wherein the electromechanical device (100) comprises a gear base (180) disposed between at least one set of the following: the input shaft (160) and the first rotor (120), the input shaft (160) and the second rotor (120), the first rotor (120) and the output shaft (170), and the second rotor (140) and the output shaft (170).

6. a. The first stator (112) and the second stator (132) each comprise a helical stack (114, 134) of helical wound strips (115, 135) of magnetically transparent material having multiple turns, wherein each strip (115, 135) has two main surfaces (1151) and two side surfaces (1152), and at least one of the two main surfaces (1151) has an insulating coating (1153), and / or b. The electromechanical device (100) according to claim 1, wherein the first rotor (120) and the second rotor (140) each comprise a helical stack (114, 134) of helical wound strips (115, 135) of a magnetic permeable material having multiple turns, and each strip (115, 135) comprises two main surfaces (1151) and two side surfaces (1152), and at least one of the two main surfaces (1151) has an insulating coating (1153).

7. a. The first stator (112) and the second stator (132) each comprise a continuous hairpin winding (116, 117, 136, 137) having at least two winding layers (1171, 1172), or each comprises a continuous wave winding having at least two winding layers. b. The first rotor (120) comprises a permanent magnet or a continuous hairpin winding (117, 137) having at least two winding layers (1171, 1172), or a continuous wave winding having at least two winding layers, and c. The electromechanical device (100) according to claim 1, wherein the second rotor (140) comprises a permanent magnet or a continuous hairpin winding (117, 137) having at least two winding layers (1171, 1172), or a continuous wave winding having at least two winding layers.

8. The electromechanical device (100) according to claim 1, wherein the first rotating electromechanism (110) has a first machine thickness (200) in the range of 30 mm to 15 mm or 25 mm to 20 mm, from the outer extension of the maximum radius in the interleaved region (176) to the inner extension of the minimum radius in the interleaved region (176).

9. The electromechanical device (100) according to claim 1, wherein the second rotating electromechanism (130) has a second machine thickness (201) in the range of 30 mm to 15 mm or 25 mm to 20 mm, from the outer extension of its maximum radius in the interleaved region (176) to the inner extension of its minimum radius in the interleaved region (176).

10. The electromechanical device (100) according to claim 1, wherein the first rotating electromechanism (110) has an outer diameter of the maximum radius in the interleaved region (176) in the range of 100 mm to 1000 mm or 150 to 350 mm.

11. The electromechanical device (100) according to claim 1, wherein the ring-shaped axially extending gap (124) in the interleaved region (176) between the first rotating electromechanism (110) and the second rotating electromechanism (130) has a thickness of less than 10 mm or less than 5 mm.

12. The electromechanical device (100) has a first bearing (151) at its first shaft end and a second bearing (152) at its opposite second shaft end. The electromechanical device (100) according to claim 1, wherein the first bearing (151) and the second bearing (152) are positioned between two components selected from the group consisting of a first stator (112), a second stator (132), a first rotor (120), and a second rotor (140).

13. The support portion (150) of the first rotor (120) is a. A first bearing (151) positioned between the first stator (112) and the first rotor (120) on one shaft end of the electromechanical device (100), b. A second bearing (152) positioned between the second rotor (140) and the first rotor (120) on the other shaft end of the electromechanical device (100), The electromechanical device (100) according to claim 12, comprising:

14. The support portion (150) of the second rotor (140) is a. A first bearing (151) positioned between the first stator (112) and the second rotor (140) on one shaft end of the electromechanical device (100), b. A second bearing (152) positioned between the second rotor (140) and the first rotor (120) on the other shaft end of the electromechanical device (100), The electromechanical device (100) according to claim 12, comprising:

15. The first stator (112) comprises a first stator shell (113), a first stacked stack (114), and a first coil (116), The electromechanical device (100) according to claim 1, wherein the second stator (132) comprises a second stator shell (133), a second stacked coil (134), and a second coil (136).

16. The electromechanical device (100) according to claim 1, wherein the material extending inside the first stator (112) and / or the second stator (132) or into the region of its coils (116, 136) has a permeability of less than 300 or less than 40.

17. A transmission unit (10) for changing operating parameters, wherein the transmission unit (10) a. An electromechanical device (100) according to any one of claims 1 to 16, b. An electrical component (300) configured to receive current generated during the operation of the first or second rotating electric machine (110, 130) and to send current to the other of the first or second rotating electric machine (110, 130) to drive an output shaft (170), c. A transmission unit battery (303) connected to the electrical component (300), configured to store power received from the electromechanical device (100), and configured to supply power to a rotating electric machine (110, 130) configured to drive the electromechanical device (100), A transmission unit (10) equipped with the following.

18. The transmission unit (10) according to claim 17, wherein the electrical component (300) comprises a converter (302) configured to convert the received current having first electrical characteristics into a desired current having second electrical characteristics in order to rotate a rotating electric machine (110, 130) configured to drive the output shaft (170).

19. The transmission unit (10) according to claim 18, wherein the converter (302) is configured to convert the received current having a first AC frequency into a desired current having a second AC frequency.

20. The transmission unit (10) according to claim 17, wherein the electrical component (300) comprises a control unit (304) for controlling the characteristics of the current sent to the first or second rotating electric machine (110, 130) so that a desired gear ratio is achieved between the first rotor (120) and the second rotor (140).

21. The transmission unit (10) according to claim 20, wherein the desired gear ratio between the first rotor (120) and the second rotor (140) is a continuously variable gear ratio.

22. A vehicle comprising the transmission unit (10) according to claim 17, wherein the vehicle is a. An internal combustion engine configured to propel the input shaft (160) of an electromechanical device (100), b. A drivetrain mechanically connected to the output shaft (170) of the electromechanical device (100) and configured to propel the vehicle, c. A vehicle battery, which is electrically connected to the electrical component (300), and configured to store power received from the electromechanical device (100) and supply power to the vehicle, A vehicle equipped with even more features.

23. The vehicle according to claim 22, wherein the vehicle battery is configured to supply power to the electromechanical device (100).

24. The electromechanical device (100) according to claim 1, wherein the innermost radial portion of the second rotating electromechanism (130) is designed as a hollow shaft in at least the interleaved region (176), thereby forming a cavity (210) radially inward of the second rotating electromechanism (130).

25. The electromechanical device (100) according to claim 11, wherein the ring-shaped axially extending gap (124) provides an airflow for cooling between the first rotating electromechanism (110) and the second rotating electromechanism (130).

26. The electromechanical device (100) according to claim 1, wherein both the first rotating electromechanism (110) and the second rotating electromechanism (130) are configured to operate in engine mode as electric engines.

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