Generator module

Abstract

This invention provides a generator module that offers a high degree of design flexibility and can be made compact and inexpensive. [Solution] The system comprises a generator 1, a gear mechanism 2, a housing that accommodates the generator 1 and the gear mechanism 2, and an oil circulation mechanism 4. The gear mechanism 2 has a first gear 21 and a second gear 22 that meshes with the first gear 21. The oil circulation mechanism 3 has a catch tank 41 that receives the oil scooped up by the rotation of the first gear 21 and circulates it inside the motor shaft 11.

Description

Technical Field

[0001] The present invention relates to a generator module mounted on a vehicle.

Background Art

[0002] Conventionally, a generator module used in a hybrid vehicle is known (see, for example, Patent Document 1). In the generator module described in Patent Document 1, the motor shaft of the generator is directly connected to the output shaft of the engine, reducing the number of gears.

[0003] The generator module described in Patent Document 1 is integrated with a motor that rotates the vehicle axle, a reduction gear connected to the motor shaft, a differential device connected to the reduction gear and rotating the vehicle axle around the operating shaft, and a generator capable of supplying power to the motor.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] If a differential device, a reduction gear, and a motor are integrated with a generator as in the generator module described in Patent Document 1, the size can be reduced. However, since all of them are arranged on the front wheel side, the degree of freedom in the arrangement space is low. For example, in the case of a rear-wheel drive hybrid vehicle, by arranging the motor on the rear wheel side, it is possible to eliminate the propeller shaft. However, the differential device, the reduction gear, and the motor cannot be integrated with the generator. Further, when the differential device, the reduction gear, and the motor are integrated with the generator, the oil circulation structure becomes complicated and the cost increases.

[0006] Therefore, there is a need for a generator module that has a high degree of freedom in arrangement and can be made compact at a low cost. [Means for solving the problem]

[0007] The characteristic configuration of the generator module according to the present invention is that it comprises a generator having a motor shaft to which engine power is transmitted, a gear mechanism connecting the output shaft of the engine and the motor shaft, a housing that houses the generator and the gear mechanism, and an oil circulation mechanism that circulates oil scooped up by the rotation of the gear mechanism to the generator, wherein the gear mechanism has a first gear connected to the output shaft and a second gear connected to the motor shaft and meshing with the first gear, and the oil circulation mechanism has a catch tank that receives the oil scooped up by the rotation of the first gear and circulates it inside the motor shaft. [Effects of the Invention]

[0008] This invention provides a generator module that offers a high degree of flexibility in placement and can be made compact and inexpensive. [Brief explanation of the drawing]

[0009] [Figure 1] This figure shows an overall overview of the hybrid vehicle according to this embodiment. [Figure 2] This is a side view illustrating the concept of the generator module according to this embodiment. [Figure 3] This is a side view including a partial cross-section of the generator module according to this embodiment. [Figure 4] This is a front view illustrating the generator module according to the first and second embodiments. [Figure 5] This is a front view illustrating a generator module according to the first embodiment. [Figure 6] This is a front view illustrating a generator module according to a modified example of the first embodiment. [Figure 7] This is a front perspective view of the generator module according to the second and third embodiments. [Figure 8]This is a side view of the generator module according to the second and third embodiments. [Figure 9] This is a side view illustrating a generator module according to the second embodiment. [Figure 10] This is a side view illustrating a generator module according to the first modified example of the second embodiment. [Figure 11] This is a side view illustrating a generator module according to a second modified example of the second embodiment. [Figure 12] This is a perspective view of the generator module according to the third embodiment. [Figure 13] This is a rear view of the generator module according to the third embodiment. [Modes for carrying out the invention]

[0010] Embodiments of the generator module according to the present invention will be described below with reference to the drawings. In this embodiment, the generator module 100 will be described as a hybrid vehicle X located at the front of the vehicle. However, the invention is not limited to the following embodiment, and various modifications are possible without departing from the spirit of the invention.

[0011] [Overview] The generator module 100 according to this embodiment will be explained using Figures 1 to 4. In the drawings, the front of the vehicle is indicated as "F", the rear of the vehicle as "B", and the vertical direction as "Z". As shown in Figure 1, the generator module 100 is located at the front of the hybrid vehicle X. The hybrid vehicle X in this embodiment is a so-called parallel 4WD hybrid system or series hybrid system in which the engine E outputs power for power generation or front-wheel drive, and the rear wheels BW are rotated by the driving force of the motor M. This hybrid vehicle X is configured to be able to charge the battery B from an external power source, and it is also possible to store the electricity generated by the generator module 100 using the power of the engine E in the battery B and supply power to the outside. The engine E is an internal combustion engine that burns fuel such as gasoline or diesel oil, and is composed of a gasoline engine or a diesel engine, etc.

[0012] Hybrid vehicle X includes an engine E disposed in front of the vehicle, a generator module 100 that generates electricity using the power output from the engine E, a battery B that can be charged by the DC power output from the generator module 100, a drive inverter IN that converts the DC power output from the generator module 100 or the battery B into AC power, a motor M that rotates by the AC power converted by the drive inverter IN, and a reduction differential device G that transmits the driving force of the motor M to the rear wheels BW. Since these battery B, drive inverter IN, motor M, and reduction differential device G are of known configurations, detailed descriptions thereof are omitted. Although not shown, the front wheels can be rotated by the power output from the engine E.

[0013] As shown in FIGS. 1 and 2, the generator module 100 includes a generator 1 having a motor shaft 11 to which the power of the engine E is transmitted, a gear mechanism 2 that connects the output shaft Ea of the engine E and the motor shaft 11, and a housing 3 that houses the generator 1 and the gear mechanism 2. The generator module 100 rotates the motor shaft 11 by the power transmitted from the output shaft Ea of the engine E to generate AC power, and converts this AC power into DC power by an inverter 5 and outputs it (see FIG. 4). One end of the output shaft Ea of the engine E is connected to the gear mechanism 2, and the other end is connected to the drive shaft Ec of the engine E via a damper Eb. The damper Eb can absorb vibrations caused by torque fluctuations of the engine E.

[0014] As shown in FIGS. 2 and 3, the generator 1 includes a rotor 12 that rotates about the motor shaft 11 as an axis, and a stator 13 in which magnetic flux flows between the rotor 12 to generate electricity. The motor shaft 11 is a hollow shaft having an axial hole portion 11a with openings formed on both axial sides, and oil flows through the axial hole portion 11a. The motor shaft 11 is held at both ends by the inner ring of a first ball bearing 11b whose outer ring is fixed to the partition wall 31 of the housing 3 and the inner ring of a second ball bearing 11c whose outer ring is fixed to the holding wall 32 of the housing 3.

[0015] The rotor 12 has a rotor core 12a formed by laminating a plurality of magnetic steel plates and a magnet (not shown) fixed to the outer peripheral side of the rotor core 12a. The stator 13 has a stator core 13a formed by laminating a plurality of magnetic steel plates and a coil 13b wound around the stator core 13a via an insulator 13c. The generator 1 outputs the induced electromotive force generated in the coil 13b as AC power when magnetic flux flows from the rotor 12 rotating about the motor shaft 11 to the stator 13.

[0016] The gear mechanism 2 includes a first gear 21 connected to the output shaft Ea of the engine E and a second gear 22 connected to the motor shaft 11 and meshing with the first gear 21. The first gear 21 is composed of a spur gear having a rotation axis below the axis of the motor shaft 11 in the vertical direction Z2. The second gear 22 is composed of a spur gear having a tooth portion formed on a part of the outer surface of the gear shaft 22A and having a rotation axis on the axis of the motor shaft 11. The outer diameter of the first gear 21 is formed larger than the outer diameter of the second gear 22, and the second gear 22 rotates at a high speed at a rotation speed higher than the rotation speed of the first gear 21. Note that the first gear 21 and the second gear 22 are not limited to spur gears and may be bevel gears, helical gears, or the like.

[0017] The gear shaft 22A has one end fitted onto the motor shaft 11, which is held by the inner ring of the first ball bearing 11b, and the other end is held by the inner ring of the third ball bearing 11d, whose outer ring is fixed to the oil passage wall 33 of the housing 3. Since one end of the gear shaft 22A is fitted onto the motor shaft 11, the power output from the engine E rotates the second gear 22 via the first gear 21, causing the gear shaft 22A and the motor shaft 11 to rotate together. In addition to the axial hole 11a of the motor shaft 11, the gear shaft 22Aa also has an axial hole 22Aa, and the axial hole 11a of the motor shaft 11 and the axial hole 22Aa of the gear shaft 22A are in communication with each other. The oil flowing through the axial bore 22Aa of the gear shaft 22A moves to the outer circumference of the generator 1 by centrifugal force accompanying the rotation of the motor shaft 11, passing through multiple radial bore 22Ab of the gear shaft 22A and multiple radial bore 11e of the motor shaft 11. Alternatively, the multiple radial bore 22Ab of the gear shaft 22A may be omitted, and only the multiple radial bore 11e of the motor shaft 11 may be used.

[0018] Housing 3 houses the generator 1 and the gear mechanism 2 in a sealed state. Note that only a portion of housing 3 is shown in Figure 3. Housing 3 has a first housing chamber 3A for housing the generator 1, a second housing chamber 3B for housing the gear mechanism 2, and a partition wall 31 separating the first housing chamber 3A and the second housing chamber 3B. The first housing chamber 3A is formed between the retaining wall 32 and the partition wall 31. The second housing chamber 3B is formed between the oil passage wall 33 and the partition wall 31. An oil tank T for storing oil in the lower region of the first gear 21 is provided at the bottom of the second housing chamber 3B. The partition wall 31 has a through hole 31a that allows oil to flow from the first housing chamber 3A to the second housing chamber 3B.

[0019] The generator module 100 is equipped with an oil circulation mechanism 4 that circulates oil, which is churned up by the rotation of the gear mechanism 2, to the generator 1. As shown in Figures 3 and 4, the oil circulation mechanism 4 includes a catch tank 41 that receives the oil churned up by the rotation of the first gear 21 and circulates it inside the motor shaft 11, an axial hole 11a of the motor shaft 11 connected to the catch tank 41, a radial hole 11e of the motor shaft 11 communicating with the axial hole 11a, and an oil tank T that stores oil in the lower region of the first gear 21. The oil circulation mechanism 4 does not have an oil pump, and the oil from the catch tank 41 circulates to the axial hole 11a, moves to the outer circumference of the generator 1 by centrifugal force from the radial hole 11e, and then falls by gravity from the through hole 31a into the oil tank T.

[0020] As shown in Figure 3, specifically, first, the oil stored in the oil tank T is stirred up by the rotation of the first gear 21 and received by the catch tank 41. The oil in the catch tank 41 flows through the oil passage 33a formed in the oil passage wall 33 due to gravity and flows to the third ball bearing 11d and the shaft bore 22Aa of the second gear 22. The oil in the shaft bore 22Aa of the second gear 22 flows to the shaft bore 11a of the motor shaft 11, and is discharged radially outward from multiple radial holes 22Ab of the gear shaft 22A and multiple radial holes 11e of the motor shaft 11 due to the centrifugal force accompanying the rotation of the motor shaft 11. The oil discharged from the multiple radial holes 22Ab and radial holes 11e moves to the outer circumference of the generator 1, cools the stator 13, and is then temporarily stored at the bottom of the first housing chamber 3A that houses the generator 1. The oil at the bottom of the first containment chamber 3A falls by gravity through the through-hole 31a of the partition wall 31 into the oil tank T, where it is again churned up by the rotation of the first gear 21, thus circulating the oil. As will be described in detail in the second embodiment, the oil stored in the oil tank T is cooled by heat exchange with the cooling water that flows through the flow path chamber 35 after the inverter 5 has been cooled.

[0021] As described above, the generator module 100 in this embodiment includes a gear mechanism 2 that connects the output shaft Ea of the engine E to the motor shaft 11. The gear mechanism 2 has a first gear 21 connected to the output shaft Ea of the engine E and a second gear 22 connected to the motor shaft 11 that meshes with the first gear 21. Furthermore, since the diameter of the second gear 22 is smaller than the diameter of the first gear 21, the generator 1 can be miniaturized, and the generator module 100 can be made compact and inexpensive. In addition, in this embodiment, a housing 3 is provided to accommodate the generator 1 and the gear mechanism 2, so the differential gear, reduction gear and motor can be arranged separately from the generator 1, providing a high degree of flexibility in arrangement.

[0022] Furthermore, the oil circulation mechanism 4 of this embodiment has a catch tank 41 that receives the oil scooped up by the rotation of the first gear 21 and circulates it inside the motor shaft 11, thus simplifying the oil circulation structure. In this way, the generator module 100 has a high degree of freedom in placement, is inexpensive and compact, and has a simple oil circulation structure. The oil in the catch tank 41 circulates through the axial hole 11a and moves to the outer circumference of the generator 1 from the radial hole 11e by centrifugal force, and then falls into the oil tank T through the through hole 31a of the partition wall 31, so an oil pump is not required, and the generator module 100 can be constructed inexpensively.

[0023] [First Embodiment] The generator module 100 according to the first embodiment will be explained using Figures 5 and 6. In this embodiment, the oil circulation mechanism 4 of the generator module 100 has an oil circulation structure that smoothly guides the oil scooped up by the rotation of the first gear 21 to the catch tank 41.

[0024] Housing 3 has a guide section 34 that curves to protrude inward into the second storage chamber 3B and guides the oil to the catch tank 41. The catch tank 41 is positioned between the guide section 34 and the second gear 22, and the tangential direction from the first gear 21 toward the catch tank 41 is away from the guide section 34. In other words, the oil guided by the guide section 34 moves toward the catch tank 41 along the tangential direction of the first gear 21. As a result, the oil can be moved smoothly into the catch tank 41.

[0025] Furthermore, the first perpendicular H1 passing through the axis of the output shaft Ea is located closer to the guide section 34 than the second perpendicular H2 passing through the axis of the motor shaft 11. As a result, the oil scooped up by the first gear 21 is directed towards the catch tank 41 rather than the guide section 34. Consequently, the oil can be smoothly moved into the catch tank 41.

[0026] Furthermore, the lowest point of the outermost circumference 1a of the generator 1 (the lowest point of the outermost circumference of the stator 13) is located vertically above Z1 from the bottom surface Ta of the oil tank T. As described above, there is an oil tank T that stores oil in the lower region of the first gear 21, and since the outermost circumference 1a of the generator 1 is located vertically above Z1 from the bottom surface Ta of the oil tank T, the oil can be allowed to fall into the oil tank T by gravity. As a result, an oil pump is not required, and the generator module 100 can be constructed at a low cost.

[0027] In this embodiment, as shown in Figure 5, when the bottom of the catch tank 41 is near the axis of the motor shaft 11, the lowest end of the outermost circumference 1a of the generator 1 is located vertically upward Z1, maintaining a sufficient distance from the bottom surface Ta of the oil tank T. In the modified example shown in Figure 6, the catch tank 41 is located on the first perpendicular H1 passing through the axis of the output shaft Ea, and the bottom of the catch tank 41 is located vertically upward Z1 from the axis of the motor shaft 11. Even in this case, the lowest end of the outermost circumference 1a of the generator 1 is located vertically upward Z1 from the bottom surface Ta of the oil tank T. This allows oil that has fallen downward into the generator 1 to fall by gravity through the through-hole 31a of the partition wall 31 towards the oil tank T (see also Figure 3).

[0028] [Second Embodiment] The generator module 100 according to the second embodiment will be explained using Figures 7 to 11. This embodiment is a cooling structure for cooling the oil circulating in the oil circulation mechanism 4 of the generator module 100 by heat exchange with cooling water. The cooling water is composed of ethylene glycol, propylene glycol, long-life coolant, etc.

[0029] As described above, the oil circulation mechanism 4 has an oil tank T for storing oil in the lower region of the second storage chamber 3B. In addition, a flow channel chamber 35 is formed in the lower region of the housing 3, which serves as a water jacket through which cooling water that exchanges heat with the oil stored in the oil tank T flows. In other words, by forming the flow channel chamber 35 in the lower region of the housing 3, the oil stored in the oil tank T can be cooled by passing through the through-hole 31a of the partition wall 31, thus simplifying the oil circulation structure. Thus, the generator module 100 has a high degree of freedom in placement, is inexpensive and compact, and has a simple oil circulation structure.

[0030] As shown in Figures 7 to 9, the flow chamber 35 is constructed by covering an opening 36 formed on the engine E side of the housing 3 with a cover 51. In this embodiment, the cover 51 is made of a bell housing that protects rotating parts such as the flywheel, clutch, and torque converter from external influences. This makes it easy to process the opening 35. Furthermore, since the opening 36 formed on the engine E side of the housing 3 can be used interchangeably with the bell housing provided at the connection between the output shaft Ea of the engine E and the gear mechanism 2, the number of parts can be reduced.

[0031] Furthermore, as shown in Figure 10, the flow path chamber 35 may be constructed by covering an opening 37 formed in the lower region of the second housing chamber 3B on the generator 1 side of the housing 3 with a cover 52. This embodiment is applicable when the generator 1 does not overlap with the flow path chamber 35 in the vertical direction Z. This makes it easy to process the opening to form the flow path chamber 35. Also, if the opening 37 is formed in the lower region of the second housing chamber 3B on the generator 1 side of the housing 3, the cover 52 can be made smaller, resulting in a simpler sealing structure.

[0032] Furthermore, as shown in Figure 11, the flow path chamber 35 may be constructed by covering an opening 38 formed in the lower region of the first housing chamber 3A of the housing 3, on the side opposite to the gear mechanism 2, with a cover 53. This makes it easier to process the opening to form the flow path chamber 35. Also, since the opening 38 is formed in the lower region of the first housing chamber 3A of the housing 3, on the side opposite to the gear mechanism 2, it can also be used as the cover for the generator 1, thus reducing the number of parts.

[0033] [Third Embodiment] The generator module 100 according to the third embodiment will be described using Figures 7-8 and 12-13. This embodiment shows the arrangement structure of the inverter 5 of the generator module 100.

[0034] The generator module 100 comprises a first housing 30A consisting of the housing 3 in the embodiment described above, and a second housing 30B housing an inverter 5 that converts AC power generated by the generator 1 into DC power, with the first housing 30A and the second housing 30B being integrated. Since the inverter 5 has a known configuration, a detailed explanation is omitted. In this way, because the second housing 30B housing the inverter 5 that converts AC power generated by the generator 1 into DC power is integrated with the first housing 30A, the generator module 100 can be made more compact. Thus, the generator module 100 offers a high degree of flexibility in placement and can be made compact at low cost.

[0035] As shown in Figures 12 and 13, the second housing 30B may be positioned vertically above the axis of the motor shaft 11 (see also Figure 4). Because the second housing 30B is positioned vertically above the axis of the motor shaft 11 at Z1, vibrations from the road surface are suppressed, and the inverter 5 can be protected.

[0036] Furthermore, as shown in Figures 12 and 13, the generator module 100 further includes a terminal box 30C that houses the terminals 50 (three-phase terminals for U-phase, V-phase, and W-phase) of the inverter 5 which is electrically connected to the generator 1. The terminal box 30C may be sandwiched and integrated between the first housing 30A and the second housing 30B at a position opposite to the gear mechanism 2 of the generator 1. This allows for the protection of the terminals 50 while shortening the wiring length that electrically connects the generator 1 and the inverter 5.

[0037] Furthermore, as shown in Figures 7 and 12, the second housing 30B may be integrated with the first housing 30A by fastening it with a fastening member Bt. The fastening member Bt may take any form as long as it has a structure that can be fixed to the first housing 30A. By fastening the second housing 30B, which houses the inverter 5, to the first housing 30A, which houses the gear mechanism 2 and the generator 1, with the fastening member Bt, the second housing 30B can be placed in a dead space. As a result, the generator module 100 can be made more compact.

[0038] Furthermore, although not shown in the diagram, the first housing 30A and the second housing 30B may be integrated via a partition wall. In other words, the first housing 30A and the second housing 30B are combined into a single housing 3. This increases the strength of the housing 3 and makes it easier to mount the single housing 3, which houses the gear mechanism 2, generator 1, and inverter 5, onto the vehicle.

[0039] [Other embodiments] (1) In the first and second embodiments described above, it is not necessary to integrate the first housing 30A, which consists of a housing 3 that houses the generator 1 and the gear mechanism 2, and the second housing 30B that houses the inverter 5, as in the third embodiment. In this case, the first housing 30A and the second housing 30B will be configured as separate units arranged separately. (2) In the first and third embodiments described above, the flow path chamber 35 does not need to be formed in the lower region of the housing 3 as in the second embodiment. In this case, a heat exchanger capable of exchanging heat between the oil stored in the oil tank T and the cooling water may be provided separately, or the oil may be circulated by a pump outside the generator module 100 and heat exchanged with the cooling water. (3) In the second and third embodiments described above, it is not necessary to provide the catch tank 41 as in the first embodiment. In this case, the oil may be circulated inside the housing 3 by an oil pump to cool the generator 1 and the gear mechanism 2. (4) In the embodiments described above, a hybrid vehicle X was used as an example, but the vehicle is not particularly limited as long as it is capable of mounting the generator module 100. Also, although an example was shown in which the engine E and generator module 100 are located at the front of the vehicle and the rear wheels BW are driven by the motor M, the engine E and generator module 100 may be located at the rear of the vehicle and the front wheels may be driven by the motor M. Furthermore, the engine E may drive only the front wheels or the rear wheels, and the motor M may be omitted, with the generator module 100 being used to charge the battery B.

[0040] In the embodiment described above, the following configuration can be envisioned.

[0041] [First Embodiment] The characteristic configuration of the generator module according to the first embodiment is that it comprises a generator having a motor shaft to which engine power is transmitted, a gear mechanism connecting the output shaft of the engine and the motor shaft, a housing that accommodates the generator and the gear mechanism, and an oil circulation mechanism that circulates oil scooped up by the rotation of the gear mechanism to the generator, wherein the gear mechanism has a first gear connected to the output shaft and a second gear connected to the motor shaft and meshing with the first gear, and the oil circulation mechanism has a catch tank that receives the oil scooped up by the rotation of the first gear and circulates it inside the motor shaft.

[0042] The generator module in this configuration includes a gear mechanism that connects the engine's output shaft and the motor shaft. The gear mechanism has a first gear connected to the engine's output shaft and a second gear connected to the motor shaft that meshes with the first gear. As a result, the diameter of the second gear can be made smaller than that of the first gear, allowing for a smaller generator and a more affordable and compact generator module. Furthermore, since this configuration includes a housing to accommodate the generator and gear mechanism, the differential, reduction gear, and motor can be positioned separately from the generator, providing greater flexibility in placement.

[0043] Furthermore, this oil circulation mechanism has a catch tank that receives the oil churned up by the rotation of the first gear and circulates it inside the motor shaft, eliminating the need for an oil pump and simplifying the oil circulation structure. Thus, it is a generator module that offers a high degree of design flexibility, is inexpensive and compact, and has a simple oil circulation structure.

[0044] Other notable features include the fact that the housing has a guide portion formed therein for guiding the oil to the catch tank, the catch tank is positioned between the guide portion and the second gear, and the tangential direction from the first gear toward the catch tank is away from the guide portion.

[0045] In this configuration, a catch tank is positioned between the guide section and the second gear, and the tangential direction from the first gear toward the catch tank is away from the guide section. In other words, the oil guided by the guide section moves toward the catch tank along the tangential direction of the first gear. As a result, the oil can be smoothly moved into the catch tank.

[0046] Another characteristic feature is that the first perpendicular line passing through the axis of the output shaft is located closer to the guide section than the second perpendicular line passing through the axis of the motor shaft.

[0047] As in this configuration, if the first perpendicular passing through the axis of the output shaft is located closer to the guide section than the second perpendicular passing through the axis of the motor shaft, the oil scooped up by the first gear will move towards the catch tank rather than the guide section. As a result, the oil can be moved smoothly into the catch tank.

[0048] Another characteristic feature is that the oil circulation mechanism has an oil tank for storing the oil in the lower region of the first gear, and the outermost circumference of the generator is located vertically above the bottom surface of the oil tank.

[0049] As in this configuration, if there is an oil tank for storing oil in the lower region of the first gear, and the outermost circumference of the generator is positioned vertically above the bottom surface of the oil tank, the oil can be allowed to fall into the oil tank by gravity. As a result, an oil pump is not required, and the generator module can be constructed at a low cost.

[0050] Other characteristic features of the oil circulation mechanism include an axial bore of the motor shaft connected to the catch tank, a radial bore of the motor shaft communicating with the axial bore, a through-hole formed in the partition wall separating the generator and the gear mechanism of the housing, and an oil tank for storing the oil in the lower region of the first gear. The oil in the catch tank flows through the axial bore, moves out of the radial bore to the outer circumference of the generator by centrifugal force, and then falls from the through-hole into the oil tank.

[0051] As in this configuration, if the oil in the catch tank flows through the axial bore and moves to the outer circumference of the generator from the radial bore by centrifugal force, and then falls into the oil tank through the through-hole in the bulkhead, an oil pump becomes unnecessary, and the generator module can be constructed at a low cost.

[0052] [Second Embodiment] The characteristic configuration of the generator module according to this embodiment is that it comprises a generator having a motor shaft to which engine power is transmitted, a gear mechanism connecting the output shaft of the engine and the motor shaft, a housing that houses the generator and the gear mechanism, and an oil circulation mechanism that circulates oil spurted up by the rotation of the gear mechanism to the generator, wherein the housing has a first housing chamber for housing the generator, a second housing chamber for housing the gear mechanism, and a partition wall that separates the first and second housing chambers and has through holes formed therein for circulating the oil from the first housing chamber to the second housing chamber, wherein the oil circulation mechanism has an oil tank for storing the oil in the lower region of the second housing chamber, and a flow path chamber is formed in the lower region of the housing through which cooling water that exchanges heat with the oil circulates.

[0053] This generator module configuration includes a gear mechanism that connects the engine's output shaft to the motor shaft, allowing for a smaller generator and a more compact and inexpensive generator module. Furthermore, this configuration includes a housing that accommodates the generator and gear mechanism, and this housing has a partition wall that separates the first and second housing chambers. This allows for the differential gear, reduction gear, and motor to be positioned separately from the generator, providing greater flexibility in placement.

[0054] Furthermore, the oil circulation mechanism in this configuration has an oil tank for storing oil in the lower region of the second housing chamber that houses the gear mechanism, and a flow chamber is formed in the lower region of the housing through which cooling water that exchanges heat with the oil flows. In other words, by forming a flow chamber in the lower region of the housing, the oil stored in the oil tank can be cooled by passing through the through-holes in the partition wall, resulting in a simple oil circulation structure. Thus, this generator module offers a high degree of freedom in placement, is inexpensive and compact, and has a simple oil circulation structure.

[0055] Another characteristic feature is that the flow chamber is constructed by covering an opening formed on the engine side of the housing with a cover.

[0056] As in this configuration, by covering the opening formed on the engine side of the housing with a cover to form a flow chamber, the processing required to form the flow chamber is simplified. Furthermore, since the opening is formed on the engine side of the housing, it can also serve as the gear cover provided at the connection point between the engine's output shaft and the gear mechanism, thus reducing the number of parts.

[0057] Another characteristic feature is that the flow path chamber is constructed by covering an opening formed in the lower region of the second housing chamber and on the generator side within the housing with a cover.

[0058] As in this configuration, by covering the opening formed in the lower region of the second housing chamber on the generator side with a cover to form a flow path chamber, the processing required to form the flow path chamber is simplified. Furthermore, since the opening is formed in the lower region of the second housing chamber on the generator side, the cover can be made smaller, resulting in a simpler sealing structure.

[0059] Another characteristic feature is that the flow path chamber is formed by covering an opening in the housing that is located in the lower region of the first housing chamber and on the opposite side from the gear mechanism with a cover.

[0060] As in this configuration, by covering the opening formed in the lower region of the housing's first chamber, on the opposite side of the gear mechanism, with a cover to form the flow path chamber, the processing required to form the flow path chamber is simplified. Furthermore, since the opening is formed in the lower region of the housing's first chamber, on the opposite side of the gear mechanism, it can also serve as the generator cover, thus reducing the number of parts.

[0061] Other characteristic features of the oil circulation mechanism include a catch tank that receives the oil scooped up by the rotation of the gear mechanism and circulates it inside the motor shaft, an axial hole of the motor shaft connected to the catch tank, a radial hole of the motor shaft communicating with the axial hole, a through hole, and an oil tank. The oil in the catch tank circulates through the axial hole, moves out of the radial hole to the outer circumference of the generator by centrifugal force, and then falls into the oil tank through the through hole.

[0062] As in this configuration, if the oil in the catch tank flows through the axial bore and moves to the outer circumference of the generator from the radial bore by centrifugal force, and then falls into the oil tank through the through-hole in the bulkhead, an oil pump becomes unnecessary, and the generator module can be constructed at a low cost.

[0063] [Third Embodiment] The characteristic configuration of the generator module according to this embodiment is that it comprises a generator having a motor shaft through which engine power is transmitted, a gear mechanism connecting the output shaft of the engine and the motor shaft, a first housing housing the generator and the gear mechanism, an inverter that converts AC power generated by the generator into DC power, and a second housing housing the inverter, wherein the first housing and the second housing are integrated.

[0064] This generator module configuration includes a gear mechanism that connects the engine's output shaft and the motor shaft. This allows the diameter of the gear connected to the motor shaft to be smaller than the diameter of the gear connected to the engine's output shaft. As a result, the generator can be miniaturized, and the generator module can be made inexpensive and compact. Furthermore, this configuration includes a first housing that accommodates the generator and gear mechanism, allowing the differential, reduction gear, and motor to be positioned separately from the generator, providing greater flexibility in placement.

[0065] Furthermore, in this configuration, the second housing, which houses the inverter that converts the AC power generated by the generator into DC power, is integrated with the first housing, allowing for a more compact generator module. Thus, this generator module offers a high degree of design flexibility and can be made compact at a low cost.

[0066] Another characteristic feature is that the second housing is positioned vertically above the axis of the motor shaft.

[0067] In this configuration, the second housing is positioned vertically above the axis of the motor shaft, which suppresses vibrations from the road surface and protects the inverter.

[0068] Another characteristic feature is that the configuration further includes a terminal box that houses the terminals of the inverter, which are electrically connected to the generator, and the terminal box is sandwiched and integrated between the first housing and the second housing at a position opposite to the gear mechanism of the generator.

[0069] As in this configuration, if the terminal box housing the inverter terminals is sandwiched and integrated between the first and second housings, the length of the wiring that electrically connects the generator and the inverter can be shortened while protecting the terminals.

[0070] Another characteristic feature is that the second housing is integrated with the first housing by fastening it with fastening members.

[0071] As in this configuration, by fastening the second housing, which houses the inverter, to the first housing, which houses the gear mechanism and generator, with fastening members, the second housing can be placed in a dead space. As a result, the generator module can be made more compact.

[0072] Another characteristic feature is that the first housing and the second housing are integrated via a partition wall.

[0073] As in this configuration, integrating the first and second housings via a partition wall increases the strength of the housing and makes it easier to mount the gear mechanism, generator, and inverter into a single housing on a vehicle. [Industrial applicability]

[0074] This invention can be used in generator modules mounted on vehicles. [Explanation of symbols]

[0075] 1: Generator, 1a: Outermost part, 2: Gear mechanism, 3: Housing, 3A: First housing chamber, 3B: Second housing chamber, 4: Oil circulation mechanism, 5: Inverter, 11: Motor shaft, 11a: Shaft bore, 11b: First ball bearing, 11c: Second ball bearing, 11d: Third ball bearing, 11e: Radial bore, 12: Rotor, 12a: Rotor core, 13: Stator, 13a: Stator core, 13b: Coil, 13c: Insulator, 21: First gear, 22: Second gear, 22A: Gear shaft, 22Aa: Shaft bore, 22Ab: Radial bore, 30A: First housing, 30B: Second housing, 30C: Terminal bore X: Partition wall, 31a: Through hole, 32: Retaining wall, 33: Oil passage wall, 33a: Oil passage, 34: Guide section, 35: Flow chamber, 36: Opening, 37: Opening, 38: Opening, 41: Catch tank, 50: Terminal, 51: Cover, 52: Cover, 53: Cover, 100: Generator module, B: Battery, BW: Rear wheel, Bt: Fastening member, E: Engine, Ea: Output shaft, Eb: Damper, Ec: Drive shaft, G: Reduction differential, H1: First perpendicular, H2: Second perpendicular, IN: Drive inverter, M: Motor, T: Oil tank, Ta: Bottom, X: Hybrid vehicle, Z1: Upper vertical side, Z2: Lower vertical side

Claims

1. A generator having a motor shaft through which engine power is transmitted, A gear mechanism connecting the output shaft of the engine and the motor shaft, A housing that accommodates the generator and the gear mechanism, The system includes an oil circulation mechanism that circulates the oil stirred up by the rotation of the gear mechanism to the generator, The gear mechanism includes a first gear connected to the output shaft and a second gear connected to the motor shaft and meshing with the first gear. The generator module includes an oil circulation mechanism which has a catch tank that receives the oil scooped up by the rotation of the first gear and circulates it inside the motor shaft.

2. The housing is provided with a guide portion for guiding the oil to the catch tank. The catch tank is positioned between the guide section and the second gear. The generator module according to claim 1, wherein the tangential direction from the first gear toward the catch tank is toward the direction away from the guide portion.

3. The generator module according to claim 2, wherein the first perpendicular passing through the axis of the output shaft is located closer to the guide portion than the second perpendicular passing through the axis of the motor shaft.

4. The oil circulation mechanism has an oil tank for storing the oil in the lower region of the first gear. The generator module according to claim 3, wherein the outermost circumference of the generator is located vertically above the bottom surface of the oil tank.

5. The oil circulation mechanism includes a central shaft portion of the motor shaft connected to the catch tank, a radial hole portion of the motor shaft communicating with the central shaft portion, a through hole portion formed in the partition wall separating the generator and the gear mechanism of the housing, and an oil tank for storing the oil in the lower region of the first gear. The generator module according to any one of claims 1 to 4, wherein the oil in the catch tank flows through the axial bore and moves out of the radial bore to the outer circumference of the generator by centrifugal force, and then falls from the through bore into the oil tank.

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