Modular electric drive unit assembly

Abstract

The invention relates to a modular electric drive unit (EDU) assembly for an electric and / or hybrid agricultural vehicle comprising a gearbox having two or more speeds with neutral position (1A) associated with an electric motor (2A), controlled by a frequency inverter (3A), and a rotation shaft (4A), characterized in that the gearbox having two or more speeds with neutral position (1A), the electric motor (2A), the frequency inverter (3A), and the rotation shaft (4A) form an EDU module (A, A') which is mounted on a cantilever support (B), such that the electric motor (2A) is positioned offset relative to the rotation shaft (4A).

Description

MODULAR ELECTRIC POWER UNIT ASSEMBLY Field of Invention

[0001] The present invention patent is in the fields of engineering and agriculture. More specifically, the present invention relates to a modular electric drive unit (EDU) assembly intended for the propulsion of electric and / or hybrid agricultural vehicles, i.e., heavy vehicles that use electric motors proportional to their high demand. The modular EDU assemblies are used to drive the driving wheels of heavy vehicles, such as agricultural machines and tractors, in which the movement of the driving wheels is the result of the work performed by the modular EDU assemblies of the invention, which transmit tractive force to the soil. Background of the Invention

[0002] Electric vehicles have advantages over internal combustion vehicles. Among the reasons is that the efficiency of electric systems leads to a reassessment of the components of the propulsion system and their distribution throughout the vehicle. It is possible to remove heavy mechanical transmission components and distribute the engines throughout the vehicle, taking advantage of the advantages of electric distribution.

[0003] The technique of using multiple electric motors to jointly provide the total torque required to move the wheels is often adopted in electric vehicles. An electric vehicle such as a car can be powered by three motors: a front motor and two rear motors. The rear motors can be combined into a single axle or equipped with independent half-axles. The assembly of each unit in each position has its own particularities, such as the position of the power cables, cooling, position of the axle to be moved, among others.

[0004] Each drive unit typically comes with a controller, a motor, and a reduction gear, and these components must be mounted with proper positioning to the axle or wheel to be driven. The different components of the drive units in a single vehicle may result in an excessive number of components, resulting in increased cost and complexity of production and maintenance. Another consideration to be made is the dimensions of the vehicles.

[0005] In small vehicles such as cars, the required power can be supplied by smaller engines. This leaves ample space between the wheels to position even two engines side by side along the axle. However, larger vehicles use larger engines, and arranging them becomes a challenge without increasing their lateral dimensions.

[0006] Although agricultural vehicles are specialized heavy vehicles, they are also subject to width limitations. Even if they do not operate primarily on highways, significantly exceeding the width of other vehicles can cause harm to their operation in the field or on road transport.

[0007] Transporting electric vehicles requires special considerations regarding this technology, especially when towing. The rotation of electric motors produces energy, which can cause damage to components if not properly controlled. This feature, which allows the use of regenerative braking, creates a risk and hinders the movement of electric vehicles in the event of a breakdown, requiring the vehicle to be towed with the wheels suspended.

[0008] US10703201 B2 describes a compact electric powertrain that can be used alone or in combination with another mirrored unit in a small vehicle such as a car. The size and arrangement of this set allows it to be mounted within the wheel well, providing torque independently to each wheel on an axle. However, the invention presented in this patent is limited in the size of the motor when used in conjunction with another, in which the motor must be at least smaller than half the wheelbase. Larger motors, therefore, make this solution insufficient given the same or similar wheelbase present in both small and large vehicles. Summary of the Invention Patent

[0009] The objective of the present invention is to present a modular electric drive unit (EDU) assembly that, in addition to solving the difficulties presented in the prior art, can be used in high-powered vehicles with restrictions on axle width. The improvements described below make the electrification of propulsion systems more compact, efficient and economical for production and maintenance.

[0010] The invention relates to a modular electric drive unit (EDU) assembly, in which the electric drive unit (EDU) comprises a frequency inverter, an electric motor and a two-speed or more gearbox with neutral position with a rotation axis to be coupled to a vehicle's wheel axle to drive it. In the EDU, the two-speed or more gearbox with neutral position is driven by an electric motor, which in turn is controlled by a frequency inverter. The electric drive unit (EDU) module is mounted on a specific support in a compact arrangement, which allows the use of more than one EDU module in a vehicle, respecting the width of the vehicle's wheel axle, that is, within the space existing between the vehicle's wheels.

[0011] The compact arrangement of EDU components is mounted on a cantilever support that houses the frequency inverter, supports the electric motor and comprises an integration flange that connects the electric motor to the two-speed or more gearbox with neutral position.

[0012] In the electric drive unit (EDU) of the invention, the electric motor is offset relative to the axis of rotation to be propelled, so as to allow another EDU module to be combined in a complementary, inverted mirrored position. With this configuration, the axes of rotation of each EDU are coaxially aligned. This arrangement is modular and saves lateral space, providing independent motors for each axis of each electric drive unit (EDU).

[0013] The modular electric power unit (EDU) assembly may further comprise a controller for controlling its drive and a reduction gear set. The controller is capable of operating the electric motor in either the motor or generator function, and the reduction gear set can contain a neutral position.

[0014] The modular electric drive unit (EDU) assembly, when assembled to drive the wheels of a vehicle, can also be associated with other external actuators, such as wheel reduction gears and brakes. The modular EDU assembly can be assembled to drive both the front wheel axle and the rear wheel axle, as will be better understood from reading the description of the invention in conjunction with the attached drawings. Brief Description of Figures

[0015] For better understanding and by way of example, the modular electric drive unit (EDU) assembly of the invention is schematically shown in the attached figures assembled to split the front and rear wheel axles of an agricultural tractor.

[0016] Figure 1 is an isometric view of the complete rear wheel axle containing two EDU modules installed on the structural axle covers of an agricultural tractor.

[0017] Figure 2 is an exploded isometric view of the rear wheel axle containing two EDU modules installed on the structural axle covers of an agricultural tractor.

[0018] Figure 3 is an isometric view of the complete rear wheel axle containing the two EDU modules without the structural axle covers of an agricultural tractor.

[0019] Figure 4 is an isometric view of the two-module rear wheel axle EDU assembly with each module mounted on the cantilever bracket.

[0020] Figure 5 is an isometric view of the cantilever mount of a rear wheel axle electric drive unit (EDU) module.

[0021] Figure 6 is a top view of the rear wheel axle EDU module assembly mounted in an inverted mirrored arrangement.

[0022] Figure 7 is an exploded top view of the rear wheel axle EDU two-module assembly of Figure 5.

[0023] Figure 8 is a top view of the rear wheel axle installed in the structural axle covers of an agricultural tractor with the two EDU module assembly.

[0024] Figure 9 is a side view of the rear wheel axle installed in the structural axle covers of an agricultural tractor.

[0025] Figure 10 is a top view of a front axle EDU mounted on the cantilever mount.

[0026] Figure 11 is an isometric view of the front axle EDU of Figure 9.

[0027] Figure 12 is a side view of the front axle EDU of Figure 9.

[0028] Figure 13 is an isometric view of the front axle EDU support assembly of Figure 9.

[0029] Figure 14 is a schematic view of the front and rear EDU module assemblies installed on an agricultural tractor.

[0030] Figure 15 is a schematic view of the EDU module sets, highlighting the front set with one EDU module and the rear set with two EDU modules arranged in an inverted mirror image. Detailed Description of the Invention

[0031] Figures 1 and 2 show the modular set of EDUs comprising two EDU modules (A) for splitting the left and right rear wheels, mounted respectively on structural axle covers (1) of an agricultural tractor which are inserted and protected inside the rear axle frame (2) of an agricultural tractor.

[0032] According to the invention, an additional set of reduction gears and a brake system can also be mounted at the ends of the rear wheel axle.

[0033] Figure 3 shows the modular EDU assembly comprising two EDU modules (A) coupled to the rear wheel axle (1).

[0034] As best seen in Figure 4, the rear modular assembly comprises two EDU modules (A) each mounted on a cantilever support (B). Each of the EDUs comprises a two-speed or more gearbox with neutral position (1 A) associated with an electric motor (2 A), which is controlled by a frequency inverter (3 A).

[0035] As can be seen in figures 4, 6 and 7, the EDU modules (A) of the rear EDU modular set are mounted parallel to each other, in an inverted mirrored arrangement, so that the rotation axes (4A) are coaxially aligned, as indicated by the dashed line in the exploded view of figure 6. The rotation axes (4A) are provided at the outer ends of each EDU (A) to be coupled to the drive axles of the rear wheels (2), so that the left rear wheel and the right rear wheel are each driven by an independent EDU (A). Still in relation to figure 6, it can be noted that the electric motors (2A) of each EDU (A) of the EDU modular set are mounted offset in relation to their respective rotation axis (4A). This configuration allows the EDUs (A) to be mounted in a nesting arrangement, in order to reduce the space to be occupied along the rear wheel axle (11) by the EDUs (A), making the assembly more compact.

[0036] In this rear arrangement, the invention presents a powerful and compact assembly that can be used to move the axles of the wheels independently, with a reduced distance between the wheels.

[0037] This construction feature of the invention seeks to solve a problem frequently found in heavy vehicles that are limited in their width. By introducing an offset of the motor (2A) relative to its axis of rotation (4A), the motors (2A) of the rear EDUs (A) can be positioned in front of or behind each other. This reduces the width between the wheels.

[0038] Figures 5 and 13 show the cantilever support (B) that is part of the modular EDU assembly of the invention.

[0039] The position and size of the EDU components (A), namely two-speed or more gearbox with neutral position (1A), motor (2A) and frequency inverter (3A) are carefully considered in the construction of the cantilever support (B) to allow the module to be compact, and to have components accessible through the vehicle maintenance windows contained in the tractor protective fairing (2).

[0040] Figures 5 and 13 refer to the rear and front cantilever support (B) respectively. However, it should be clear that the cantilever support (B) is universal for the modular EDU assemblies of the present invention, being suitable for receiving both the rear EDU modules (A) and the front EDU module (A'), shown in figures 10, 11 and 12.

[0041] The cantilever support (B) comprises a housing (1 B) for attaching the frequency inverter (3A) that controls the electric motor (2A). In turn, the electric motor (2A) is mounted on a base (2B), between the housing (1 B) of the frequency inverter (3A) and an integration flange (3B). The integration flange (3B) associates the electric motor (2A) with the two-speed or more gearbox with neutral position (1 A) that drives the rotation shaft (4A) to move the wheels coupled to the ends of the rear wheel axles (2). The cantilever support (B) positions the components of the EDU (A) in a manner that is advantageous for the installation and operation of an electric vehicle, such as a tractor.

[0042] Figure 8 represents a bottom view of the rear wheel axle (11) with the modular set of EDUs of the invention mounted inside the tractor protective fairing (2) and figure 9 represents a side view of the rear wheel axle (11) with the modular set of EDUs of the invention mounted inside the tractor's protective fairing (2).

[0043] Regarding the front EDU modular assembly shown in figures 10, 11 and 12, it comprises an EDU module (A') which is identical to any of the rear EDU modules (A) and operates independently of the rear EDU modular assembly. Unlike the rear EDU modular assembly, the front EDU modular assembly comprises only one EDU module (A'). Furthermore, the arrangement of the front EDU modular assembly also differs from the arrangement of the rear EDU modular assembly. While in the rear EDU modular assembly, the two EDU modules (A) are arranged parallel to the rear wheel axle (11), in the front EDU modular assembly, the EDU module (A') is arranged perpendicular to the front wheel axle (3), as shown in schematic figures 14 and 15.

[0044] Thus, the front EDU module (A'), which is identical to the rear EDU module (A), also comprises a two-speed or more gearbox with neutral position (1 A), an electric motor (2A) and a frequency inverter (3A) mounted on a cantilever support (B) in the same arrangement in which the rear EDU module (A) is mounted. With this, when positioned perpendicular to the front wheel axle (3), the front EDU module (A') can have its drive axle (4A) connected to a differential (4) to split and steer the front wheels.

[0045] In the modular electric drive unit (EDU) assembly of the invention, the electric drive unit (EDU) is driven by supplying high voltage electric current. In the case of a hybrid vehicle, a diesel engine associated with one or more electric generators is capable of providing high voltage electric current to the modular EDU assemblies of the invention by means of the frequency inverter (3A).

[0046] The modular EDU assemblies of the invention can also be provided with controllers capable of operating the motors as well. as generators, consuming electricity to generate motion, or producing electricity by resisting motion.

[0047] The rear EDU modules (A) may comprise brake assemblies that can be manually deactivated in the event of a breakdown.

[0048] The front and rear EDU modules (A, A') include two-speed or higher gearboxes with neutral position (1A), which allows the decoupling of the rotation shaft (4A), allowing, in the event of a breakdown, the vehicle to be towed without producing electrical energy.

[0049] The arrangement of the front cantilever bracket (B) allows the module to be positioned at the front of the tractor, avoiding interference with other vehicle components.

[0050] In this front arrangement, the invention presents a powerful and compact assembly that can be used to move a front wheel axle with dependent wheels through a mechanical differential (4).

[0051] The electric drive unit (EDU) can be used together, with two independent modules on independent half-axles; or separately, with a single module moving an axle, which in turn drives two wheels through a mechanical differential.

[0052] An example of an electric tractor platform that uses three EDU modules similar to those described above is shown in Figure 14. The first EDU module (A') (Figure 10) provides the torque required to split the front wheels through a mechanical differential (4) on the front axle. Two other EDU modules (A) (Figure 6) are positioned on the rear wheels, together forming the rear axle with independent wheels. Brakes and an additional set of reduction gears can be installed on the rear axle. The axle is then coupled to the protective fairing of an agricultural tractor (Figures 1, 8 and 9).

[0053] The use of independent electric drive unit modules allows individual control of speeds, which makes it possible the adoption of sophisticated traction control techniques, torque vectoring, and electronic differential that improve control and traction in extreme ground situations.

Claims

CLAIMS 1. Modular electric power unit (EDU) assembly for an electric and / or hybrid agricultural vehicle comprising a two-speed or more gearbox with neutral position (1A) associated with an electric motor (2A), controlled by a frequency inverter (3A), and a rotation shaft (4A) CHARACTERIZED in that the two-speed or more gearbox with neutral position (1A), the electric motor (2A), the frequency inverter (3A) and the rotation shaft (4A) form an EDU module (A, A') that is mounted on a cantilever support (B), such that the electric motor (2A) is arranged in a position offset in relation to the rotation shaft (4A).

2. Modular electric drive unit (EDU) assembly according to claim 1, CHARACTERIZED in that the cantilever support (B) comprises a housing (1 B) for receiving a frequency inverter (3A), a base (2B) for receiving the electric motor (2A) and an integration flange (3B) for associating the electric motor (2A) to the two-speed or more gearbox with neutral position (1 A) and to the rotation shaft (4A).

3. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the electric motor (2A) is mounted on the base (2B) of the cantilever support (B), between the housing ((1 B) of the frequency inverter (3A) and the two-speed or more gearbox with neutral position (1 A), in which an integration flange (3B) is arranged between the electric motor (2A) and the two-speed or more gearbox with neutral position (1 A) forming an EDU module (A, A').

4. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that it can comprise only one front EDU module (A') to be coupled to the front wheel axle (3) to split said front wheel axle (3).

5. A modular electric power unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED by the front EDU module (A') is arranged perpendicular to the front wheel axle (3).

6. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the rotation axis (4A) of the front EDU module (A') can be coupled to a mechanical differential (4) to drive and steer the front wheeled axle (3).

7. Modular electric power unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that it can comprise two rear EDU modules (A), arranged parallel to the rear wheel axle (1) and parallel to each other, in an inverted mirrored arrangement, in which the rotation axes (4A) of the two rear EDU modules (A) are coaxially aligned.

8. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the rotation axis (4A) of one of the rear EDU modules (A) is coupled to one of the wheelsets of the rear wheelset axle (1) and the rotation axis (4A) of the other EDU module (A) is coupled to the other wheelset of the rear wheelset axle (1), such that the rear EDU modules (A) act independently of each other.

9. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the two rear EDU modules (A) and the front EDU module (A') act independently.

10. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the rear EDU modules (A) may further comprise a set of reduction gears and brakes.

11. Modular electric power unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED by further comprising motor controllers capable of acting electrically in reverse, consuming or producing energy.

12. Modular electric drive unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the front and rear (EDU) modules (A, A') include two-speed or more gearboxes with neutral position (1A), for decoupling the rotation shaft (4A) in the event of a breakdown.

13. Modular electric power unit (EDU) assembly according to any one of the preceding claims, CHARACTERIZED in that the arrangement of the EDU modules (A, A') can be mounted inside a protective fairing (2) of a vehicle.

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