Power generator for hybrid vehicles

Abstract

To improve a coupling configuration that is configured to transmit the rotation of an internal combustion engine to a rotary shaft of an axial-gap power generator.SOLUTION: A power generator 1 has an internal combustion engine 2, an axial gap generator 3 that includes a rotary shaft 5 arranged coaxially with an output shaft 2a of the internal combustion engine 2 separated by a predetermined distance and a first rotor 6 fixed to the rotary shaft 5, a magnetic coupling 4 that transmits the rotation of the output shaft 2a of the rotary shaft 5. The magnetic coupling 4 includes a first rotor 6 and a drive member 10 fixed on the output shaft 2a and opposing the first rotor 6 by a predetermined distance in an axial direction of the output shaft 2a and the rotary shaft 5.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a power generation device for a hybrid vehicle.

Background Art

[0002] In a hybrid vehicle, the rotation of an internal combustion engine is transmitted to a generator to generate electricity with the generator.

[0003] For example, Patent Document 1 discloses a flexible coupling interposed between an input shaft and an output shaft as means for transmitting rotation from the input shaft to the output shaft.

[0004] This flexible coupling has a driving disk on the input shaft side, a driven disk on the output shaft side, a permanent magnet ring positioned between the driving disk and the driven disk, a separator ring positioned between the driving disk and the driven disk and disposed on the outer periphery of the permanent magnet ring, and steel balls rotatably held in ball holding holes formed in the separator ring.

[0005] The flexible coupling of Patent Document 1 can obtain sufficient magnetic frictional force between the input shaft and the output shaft, and when slippage due to overload occurs between the input shaft and the output shaft, relative rotation is allowed to suppress the occurrence of wear, overheating, etc.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, if the flexible coupling described in Patent Document 1 is installed between the internal combustion engine and the generator of a hybrid vehicle, the axial dimensions of the power generation device consisting of the internal combustion engine and the generator become larger, making it difficult to fit it into the engine compartment.

[0008] In other words, in a configuration that transmits the rotation of an internal combustion engine to a generator via a magnetic coupling, it is necessary to consider the axial dimensions, and there is room for further improvement. [Means for solving the problem]

[0009] The power generation device for a hybrid vehicle of the present invention comprises a rotating shaft coaxially arranged at a predetermined distance from the output shaft of an internal combustion engine, and a rotating shaft fixed to the rotating shaft. disc-shaped The axial gap generator comprises a rotor member and a magnetic coupling that transmits the rotation of the output shaft to the rotating shaft, wherein the magnetic coupling is fixed to the rotor member and the output shaft and faces the rotor member at a predetermined distance apart along the axial directions of the output shaft and the rotating shaft. disc-shaped A drive member and composed of . above The magnetic coupling is positioned between the drive member and the rotor member, with a spherical crown-shaped member having a spherical surface that faces and contacts either the drive member or the rotor member. The spherical surface of the spherical crown-shaped member contacts one end face of either the drive member or the rotor member, and the spherical crown-shaped member is fixed to the end face of the drive member or the rotor member to which the spherical crown-shaped member is not fixed. [Effects of the Invention]

[0010] The power generation device for hybrid vehicles according to the present invention can absorb the misalignment between the output shaft of the internal combustion engine and the rotating shaft of the axial gap generator, while also enabling a smaller overall size and power transmission. [Brief explanation of the drawing]

[0011] [Figure 1]A schematic diagram illustrating the outline of a power generation device according to the first embodiment of the present invention. [Figure 2] A schematic diagram illustrating the general outline of a power generation device according to a second embodiment of the present invention. [Figure 3] A schematic diagram illustrating the general outline of a power generation device according to a third embodiment of the present invention. [Figure 4] A schematic diagram illustrating the general outline of a power generation device according to the fourth embodiment of the present invention. [Figure 5] A schematic diagram illustrating the outline of a power generation device according to the fifth embodiment of the present invention. [Modes for carrying out the invention]

[0012] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

[0013] Figure 1 is a schematic diagram illustrating the general outline of a power generation device 1 according to the first embodiment of the present invention.

[0014] The power generation device 1 is installed in a hybrid vehicle and comprises an internal combustion engine 2, an axial gap generator 3, and a magnetic coupling 4 that transmits the rotation of the output shaft (crankshaft) 2a of the internal combustion engine 2 to the rotating shaft 5 of the axial gap generator 3.

[0015] The internal combustion engine 2 is a so-called spark-ignition internal combustion engine, and drives the axial gap generator 3 via a magnetic coupling 4. In the first embodiment, the internal combustion engine 2 is used solely for power generation, and the rotation of the output shaft 2a is not transmitted to the drive wheels of the hybrid vehicle.

[0016] The axial-gap generator 3 has a rotating shaft 5 arranged coaxially and spaced apart from the output shaft 2a of the internal combustion engine 2, a disk-shaped first rotor 6 and a second rotor 7 that are fixed to the rotating shaft 5 and arranged spaced apart from each other along the axial direction of the rotating shaft 5, and a disk-shaped (cylindrical) stator 8 that is positioned between the first rotor 6 and the second rotor 7 and arranged to face the first rotor 6 and the second rotor 7 at a predetermined distance. The axial-gap generator 3 has a pair of rotors 6, 7 and a stator 8 arranged side by side along the axial direction of the rotating shaft 5. The first rotor 6 corresponds to a rotor member and is fixed to one end of the rotating shaft 5.

[0017] In other words, the axial-gap generator 3 has a rotating shaft 5 arranged coaxially and spaced apart from the output shaft 2a of the internal combustion engine 2 by a predetermined distance, a first rotor 6 as a rotor member fixed to one end of the rotating shaft 5, and a stator 8 arranged to face the first rotor 6 at a predetermined distance along the axial direction of the rotating shaft 5.

[0018] A plurality of permanent magnets (not shown) are arranged annularly side by side in the circumferential direction on the first rotor 6 and the second rotor 7. The first rotor 6 and the second rotor 7 are fixed to the rotating shaft 5 so that the center of rotation is coaxial with the axis of the rotating shaft 5. The first rotor 6 is formed such that the surface facing the drive member 10 to be described later is a smooth plane.

[0019] The stator 8 is fixed to the casing 9 of the axial-gap generator 3, for example, at an intermediate position between the first rotor 6 and the second rotor 7 in the axial direction of the rotating shaft 5. The stator 8 is arranged such that its center position is coaxial with the axis of the rotating shaft 5. The casing 9 houses the first rotor 6, the second rotor 7, the stator 8, the rotating shaft 5, etc. inside, and is formed in a cylindrical shape, for example.

[0020] Note that the rotating shaft 5 of the axial-gap generator 3 is supported by, for example, a stopper or a thrust bearing so that the distance between the first rotor 6 and the drive member 10 (to be described later) does not change, and the movement of the rotating shaft 5 in the axial direction is restricted.

[0021] Note that the rotating shaft 5 of the axial-gap generator 3 is supported by, for example, a stopper or a thrust bearing (not shown), so that the stator 8 can maintain a constant distance from the first rotor 6 and the second rotor 7. In other words, the axial movement of the rotating shaft 5 of the axial-gap generator 3 is restricted so as not to be drawn into the internal combustion engine 2 side by the magnetic force of the magnetic coupling 4.

[0022] The magnetic coupling 4 utilizes a disk-shaped drive member 10 fixed to one end of the output shaft 2a of the internal combustion engine 2 and the first rotor 6 of the axial-gap generator 3. The drive member 10 is made of, for example, a metal material, and the end face facing the first rotor 6 is a smooth plane.

[0023] The magnetic coupling 4 transmits the rotation of the output shaft 2a of the internal combustion engine 2 to the rotating shaft 5 of the axial-gap generator 3, and utilizes the first rotor 6 and the disk-shaped drive member 10 fixed to one end of the output shaft 2a. That is, the magnetic coupling 4 has a drive member 10 fixed to the output shaft 2a and a first rotor 6 as a driven member fixed to the rotating shaft 5 so as to face the drive member 10 at a predetermined distance along the axial direction of the output shaft 2a and the rotating shaft 5. The first rotor 6 is a common component of the axial-gap generator 3. In other words, the axial-gap generator 3 has the first rotor 6 as a common component of the magnetic coupling 4. Also, in the magnetic coupling 4, the driven member paired with the drive member 10 is a common component of the axial-gap generator 3.

[0024] The magnetic coupling 4 transmits the rotation of the output shaft 2a of the internal combustion engine 2 to the rotating shaft 5 of the axial-gap generator 3 by utilizing the permanent magnet of the first rotor 6 and the permanent magnet of the drive member 10. Therefore, the magnetic coupling 4 can transmit power from the internal combustion engine 2 to the axial-gap generator 3 without requiring the operating energy necessary for power transmission.

[0025] The drive member 10 is positioned opposite the first rotor 6 at a predetermined distance along the axial directions of the output shaft 2a and the rotation shaft 5. Multiple permanent magnets (not shown) are arranged in a ring shape in the circumferential direction on the drive member 10.

[0026] The power generator 1 is configured such that the distance between the drive member 10 and the first rotor 6 is greater than the distance between the stator 8 and the first rotor 6, and the distance between the stator 8 and the second rotor 7. In other words, the power generator 1 is configured such that the gap of the magnetic coupling 4 is greater than the gap of the axial gap generator 3.

[0027] In the power generation device 1 of the first embodiment described above, the magnetic coupling 4 is configured using the first rotor 6 of the axial gap generator 3. In other words, in the power generation device of the first embodiment, the driven member of the magnetic coupling 4, which is paired with the driving member 10, also serves as the rotor of the axial gap generator 3. To put it another way, the power generation device 1 of the first embodiment has a configuration in which the first rotor 6 of the axial gap generator 3 and the driven member of the magnetic coupling 4 are shared.

[0028] Therefore, the power generation device 1 of the first embodiment has a reduced number of parts overall, resulting in reduced cost and weight, and the axial lengths of the output shaft 2a and the rotating shaft 5 are shortened, allowing for overall miniaturization.

[0029] In the first embodiment of the power generator 1, the drive member 10 and the first rotor 6 constituting the magnetic coupling 4 are spaced apart and not mechanically connected to each other. Therefore, the magnetic coupling 4 can absorb the misalignment between the output shaft 2a of the internal combustion engine 2 and the rotating shaft 5 of the axial gap generator 3, while power can be transmitted from the internal combustion engine 2 to the axial gap generator 3. The rotating shaft 5 of the axial gap generator 3 is supported by ball bearings or roller bearings, so its axis does not fluctuate. However, the output shaft 2a of the internal combustion engine 2 (i.e., the crankshaft) is a fluid bearing (a sliding bearing using lubricating oil), so its axis changes slightly due to the influence of combustion pressure, etc. As a result, misalignment occurs between the output shaft 2a of the internal combustion engine 2 and the rotating shaft 5 of the axial gap generator 3.

[0030] In the first embodiment, the power generation device 1 has no mechanical fitting part between the internal combustion engine 2 and the axial gap generator 3, eliminating the need to install a damper between them and thus enabling weight reduction.

[0031] In the power generation device 1 of the first embodiment, the magnetic coupling 4 is detachable from the driving member 10 which is the driving side and the first rotor 6 which is the driven side, making assembly easy.

[0032] Other embodiments of the present invention will be described below. Note that components identical to those in the first embodiment described above are denoted by the same reference numerals, and redundant descriptions are omitted.

[0033] The power generation device 21 of the second embodiment of the present invention will be described using Figure 2. Figure 2 is a schematic explanatory diagram showing the outline of the power generation device 21 of the second embodiment of the present invention.

[0034] The power generation device 21 of the second embodiment has substantially the same configuration as the power generation device 1 of the first embodiment described above, but a leaf spring 22 is placed between the drive member 10 and the first rotor 6 as an elastic member that allows the drive member 10 to tilt while keeping the distance between the two (drive member 10 and first rotor 6) constant.

[0035] The leaf spring 22 is fixed to the drive member 10. The leaf spring 22 is made of, for example, a metal material, and the side facing the first rotor 6 is partially in contact with the first rotor 6. The leaf spring 22 may also be fixed to the first rotor 6. However, the productivity of the power generation device 21 is improved if the leaf spring 22 is attached to the drive member 10 on the internal combustion engine 2 side.

[0036] Furthermore, in the second embodiment of the power generation device 21, since a leaf spring 22 is arranged between the drive member 10 and the first rotor 6, the distance between the drive member 10 and the first rotor 6 is stabilized, and the desired transmission torque characteristics can be stably obtained. In addition, it is possible to prevent the output shaft 2a from sliding in the direction of the rotation axis 5, which would cause the drive member 10 and the first rotor 6 to attract each other and impair the misalignment absorption function.

[0037] In addition, the power generation device 21 of the second embodiment may also have an elastic member other than the leaf spring 22 (for example, a disc spring) placed between the drive member 10 and the first rotor 6 to maintain a constant distance between the drive member 10 and the first rotor 6.

[0038] The power generation device 31 of the third embodiment of the present invention will be described using Figure 3. Figure 3 is a schematic explanatory diagram showing the outline of the power generation device 31 of the third embodiment of the present invention.

[0039] The power generation device 31 of the third embodiment has substantially the same configuration as the power generation device 1 of the first embodiment described above, but a plurality of metallic balls 32 are rotatably arranged between the drive member 10 and the first rotor 6 to maintain a constant distance between them (the drive member 10 and the first rotor 6) to prevent the drive member 10 from tipping over, and to absorb misalignment between the output shaft 2a and the rotation shaft 5.

[0040] These multiple balls 32 are spaced apart from each other on the circumference of a circle that is concentric with the centers of the drive member 10 and the first rotor 6 on a plane parallel to the plane perpendicular to the output shaft 2a or the rotation shaft 5.

[0041] The ball 32 corresponds to a spherical member and is rotatably held by an annular support member 33. The support member 33 is made of, for example, a metal material and is sandwiched between the drive member 10 and the first rotor 6 and fixed to the drive member 10. The support member 33 may also be fixed to the first rotor 6. However, the productivity of the power generation device 31 is improved if the support member 33 is attached to the drive member 10 on the internal combustion engine 2 side.

[0042] Furthermore, in the third embodiment of the power generation device 31, since a plurality of balls 32 are arranged between the drive member 10 and the first rotor 6, the distance between the drive member 10 and the first rotor 6 is stabilized, and the desired transmission torque characteristics can be stably obtained. In addition, it is possible to prevent the output shaft 2a from sliding in the direction of the rotation axis 5, causing the drive member 10 and the first rotor 6 to become attracted to each other and impairing the misalignment absorption function.

[0043] The power generation device 41 of the fourth embodiment of the present invention will be described using Figure 4. Figure 4 is a schematic explanatory diagram showing the outline of the power generation device 41 of the fourth embodiment of the present invention.

[0044] The power generation device 41 of the fourth embodiment has substantially the same configuration as the power generation device 1 of the first embodiment described above, but a convex member 42 is arranged between the drive member 10 and the first rotor 6, which allows the drive member 10 to tilt while keeping the distance between the two (drive member 10 and first rotor 6) constant, and which can absorb misalignment between the output shaft 2a and the rotation shaft 5.

[0045] The convex member 42 is made of, for example, a metal material and is fixed to the first rotor 6. The convex member 42 has a base surface 42a fixed to the first rotor 6 and a spherical surface 42b facing the drive member 10. The convex member 42 has a spherical crown shape, for example, a spherical crown shape formed by cutting off a part of a sphere with a flat surface. The base surface 42a is a flat surface. The spherical surface 42b is a curved surface that constitutes the surface of a sphere, and the tip on the drive member 10 side is in contact with the drive member 10.

[0046] The convex member 42 is fixed to the center of the first rotor 6 so as to be coaxial with the rotating shaft 5 of the axial gap generator 3 and the output shaft 2a of the internal combustion engine 2.

[0047] The convex member 42 may also be fixed to the drive member 10. In other words, the base surface 42a of the convex member 42 is fixed to either the drive member 10 or the first rotor 6. Also, the spherical surface 42b of the convex member 42 is in contact with either the drive member 10 or the first rotor 6 (the one whose base surface 42a is not fixed).

[0048] The productivity of the power generation device 41 is improved by attaching the convex member 42 to the drive member 10 on the internal combustion engine 2 side.

[0049] Furthermore, in the fourth embodiment of the power generation device 41, since a convex member 42 is arranged between the drive member 10 and the first rotor 6, the distance between the drive member 10 and the first rotor 6 is stabilized, and the desired transmission torque characteristics can be stably obtained. In addition, it is possible to prevent the output shaft 2a from sliding in the direction of the rotation axis 5, causing the drive member 10 and the first rotor 6 to be attracted to each other and impairing the misalignment absorption function.

[0050] The power generation device 51 of the fifth embodiment of the present invention will be described using Figure 5. Figure 5 is a schematic explanatory diagram showing the outline of the power generation device 51 of the fifth embodiment of the present invention.

[0051] The power generation device 51 of the fifth embodiment has substantially the same configuration as the power generation device 1 of the first embodiment described above, but the axial gap generator 3 has one first rotor 6 and one stator 8.

[0052] In other words, the power generation device 51 of the fifth embodiment is the same as the power generation device 1 of the first embodiment, but with the second rotor 7 omitted.

[0053] The power generation device 51 of this fifth embodiment can achieve substantially the same effects as the power generation device 1 of the first embodiment described above, and it is possible to shorten the axial length of the output shaft 2a and the rotating shaft 5 compared to the power generation device 1 of the first embodiment.

[0054] Furthermore, in the fifth embodiment of the power generation device 51, the reduction in output due to the omission of the second rotor 7 can be compensated for by increasing the diameter of the first rotor 6 and the stator 8.

[0055] Furthermore, the power generation device 51 of the fifth embodiment can achieve both optimization of the output (power generation amount) required for the axial gap generator 3 and miniaturization of the axial gap generator 3 by omitting the second rotor 7.

[0056] Although specific embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention.

[0057] For example, in the power generation device 51 of the fifth embodiment, a member (for example, the leaf spring 22 in the second embodiment, the ball 32 and support member 33 in the third embodiment, or the convex member 42 in the fourth embodiment) may be placed between the drive member 10 and the first rotor 6 to allow or prevent the drive member 10 from tilting while keeping the distance between them (the drive member 10 and the first rotor 6) constant, and to absorb the misalignment between the output shaft 2a and the rotation shaft 5.

[0058] In this case, the components that restrict the axial movement of the rotating shaft 5 of the axial gap generator 3 (such as the stopper and thrust bearing mentioned above) can be omitted.

[0059] Furthermore, the member interposed between the drive member 10 and the first rotor 6 (such as the leaf spring 22 in the second embodiment, the ball 32 and support member 33 in the third embodiment, or the convex member 42 in the fourth embodiment) may be made of a magnetic or non-magnetic material.

[0060] In the embodiments described above, the internal combustion engine 2 is used exclusively for power generation. However, in the embodiments described above, the rotation of the output shaft 2a of the internal combustion engine 2 may be made available to the drive wheels of the hybrid vehicle. Specifically, for example, a reduction gear may be connected to the rotating shaft 5 of the axial gap generator 3, and the rotation of the internal combustion engine 2 may be transmitted to the drive wheels of the vehicle via the rotating shaft 5 and this reduction gear. [Explanation of Symbols]

[0061] 1…Power generator 2…Internal combustion engine 2a... Output shaft 3…Axial gap generator 4…Magnetic coupling 5…Rotation axis 6…First Rotor 7…Rotor 2 8…Status 9…Casing 10…Driver

Claims

1. An axial gap generator comprising: a rotating shaft coaxially arranged at a predetermined distance from the output shaft of an internal combustion engine; a disc-shaped rotor member fixed to the rotating shaft; and a stator arranged in the axial direction of the rotating shaft so as to face the rotor member; The rotating shaft is equipped with a magnetic coupling that transmits the rotation of the output shaft to the rotating shaft, The magnetic coupling described above comprises a rotor member and a disc-shaped drive member fixed to the output shaft and facing the rotor member at a predetermined distance along the axial directions of the output shaft and the rotation shaft, wherein a spherical crown-shaped member having a spherical surface facing and in contact with either the drive member or the rotor member is disposed between the planar end face of the drive member and the planar end face of the rotor member. The above-mentioned spherical crown-shaped member is characterized in that the spherical surface is in contact with one end face of the drive member or the rotor member, and is fixed to the end face of the drive member or the rotor member to which the spherical crown-shaped member is not fixed.

2. The axial gap generator has a first rotor as the rotor member and a second rotor fixed to the rotating shaft and positioned spaced apart from the first rotor along the axial direction of the rotating shaft, and the first rotor is a component shared with the magnetic coupling, as described in claim 1.

3. The axial gap generator has one rotor member and one stator, and the rotor member is a component shared with the magnetic coupling, as described in claim 1.

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