Disc-type hybrid powertrain and electric vehicle

Abstract

The present application provides a disc-type hybrid powertrain and an electric vehicle. The disc-type hybrid powertrain is configured to be driven by an engine of an electric vehicle to generate power and is used for driving wheels of the electric vehicle to rotate. The disc-type hybrid powertrain comprises a disc-type stator, two disc-type rotors, and two rotating shafts. The two disc-type rotors are respectively arranged on two sides of a stator iron core in the axial direction. A group of stator windings are arranged on the side of the disc-type stator facing one of the disc-type rotors, and the group of stator windings and said disc-type rotor are opposite in the axial direction to form a disc-type motor; and the other group of stator windings are arranged on the side of the disc-type stator facing the other disc-type rotor, and the other group of stator windings and the other disc-type rotor are opposite in the axial direction to form the other disc-type motor. One of the two rotating shafts is configured to be transmittingly connected to the engine and drive the corresponding disc-type rotor to rotate, so as to generate power. The other rotating shaft is used for rotating along with the other disc rotor and driving the wheels.

Description

Disc-type hybrid assembly and electric vehicle

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the State Intellectual Property Office of the People's Republic of China on December 18, 2023, with application number 202311745618.6 and invention name "A disc hybrid assembly and electric vehicle", the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the field of motor technology, and in particular to a disc-type hybrid assembly and an electric vehicle. Background Art

[0004] Disc motors, also known as axial-field permanent magnet motors or axial-flux motors, offer high torque and power density due to their large air gap, compact structure, and short axial dimensions. Disc motors offer significant advantages over radial-flux motors in applications with size and weight constraints, such as electric vehicle drive motors.

[0005] Summary of the Invention

[0006] The present application provides a disc-type hybrid assembly and an electric vehicle. The disc-type hybrid assembly makes the entire disc-type hybrid assembly more compact, simpler in structure, and lower in cost.

[0007] In a first aspect, the present application provides a disc-type hybrid powertrain system, which is used to generate electricity from an electric vehicle's engine and drive the vehicle's wheels. The disc-type hybrid powertrain system comprises a disc stator, two disc rotors, and two rotating shafts. One disc stator comprises a stator core and two sets of stator windings. The stator core includes two sets of stator slots, with the openings of the two sets of stator slots facing opposite directions along the axial direction of the disc hybrid powertrain system. The two sets of stator slots are respectively used to wind two sets of stator windings. Two disc rotors are arranged on either side of the stator core along the axial direction of the disc hybrid powertrain system. The disc stator has a set of stator windings on the side facing one disc rotor, axially opposing the disc rotor, forming a disc motor. The disc stator has another set of stator windings on the side facing the other disc rotor, axially opposing the other disc rotor, forming another disc motor. One of the two rotating shafts is connected to the engine and drives a disc rotor to generate electricity, making the disc motor a generator. The other rotating shaft rotates with the other disc rotor and drives the wheels, making the other disc motor a drive motor. In this technical solution, the hybrid system includes two disc motors, reducing the axial length of the disc hybrid system and making the entire system smaller. The stators of the two disc motors are integrated into a single structure, making the entire disc hybrid system more compact. Furthermore, the disc hybrid system is rich in functions while being simple in structure and low in cost.

[0008] In one technical solution, the distance between one rotating shaft and the other rotating shaft along the axial direction of the disc hybrid assembly is smaller than the distance between the two disc rotors. This allows the two rotating shafts to operate independently. One rotating shaft axially passes through one disc rotor to improve the reliability of the rotational connection between the first disc rotor and the housing. The other rotating shaft axially passes through the other disc rotor to improve the reliability of the rotational connection between the second disc rotor and the housing.

[0009] In one technical solution, one end of the second rotating shaft is connected to a wheel, and the other end of the second rotating shaft includes a shaft hole. The opening of the shaft hole is axially oriented toward the first rotating shaft, along the disc hybrid assembly. The shaft hole is used to accommodate one end of the first rotating shaft, and the other end of the first rotating shaft is connected to the engine. This improves the coaxiality of the first and second rotating shafts, and the shaft hole of the second rotating shaft can limit and support the first rotating shaft, improving the reliability of the assembly of the two rotating shafts.

[0010] The shaft hole of the other rotating shaft can be a blind hole or a through hole. In one technical solution, the shaft hole of the other rotating shaft is a through hole, which passes through the other rotating shaft along the axial direction of the disc hybrid assembly, and the length of one rotating shaft is greater than the length of the other rotating shaft.

[0011] In one technical solution, one end of the rotating shaft is exposed from the shaft hole and is used for transmission connection to the wheel. The electric vehicle may further include another transmission mechanism, wherein the end of the rotating shaft exposed from the shaft hole is connected to the other transmission mechanism, and the other end of the rotating shaft is connected to the engine. The other transmission mechanism is connected to the wheel, so that the engine drives the wheel through the rotating shaft and the other transmission mechanism.

[0012] The outer diameter of one rotating shaft is smaller than the inner diameter of the shaft hole of the other rotating shaft, which is beneficial for assembling one rotating shaft into the shaft hole of the other rotating shaft and improving the degree of freedom of rotation of the rotating shaft.

[0013] To assemble the disc stator and two disc rotors, the disc hybrid assembly includes a housing that secures the disc stator and accommodates the two disc rotors. The housing includes multiple bearing holes and bearings, each of which secures a bearing. In one technical solution, the multiple shaft holes are aligned with the multiple bearings.

[0014] In one technical solution, two bearings from the multiple bearings are arranged on either side of a disc rotor along the axial direction of the disc hybrid assembly, and the two bearings are used to drive and connect to a rotating shaft. Supporting one disc rotor from both sides improves the reliability of the assembly of the disc rotor. Another two bearings from the multiple bearings are arranged on either side of another disc rotor, and the other two bearings are used to drive and connect to another rotating shaft. Supporting the other disc rotor from both sides improves the reliability of the assembly of the other disc rotor.

[0015] Alternatively, in a technical solution, along the axial direction of the disc hybrid assembly, one of the multiple bearings is arranged on the side of a disc rotor facing away from the other disc rotor. The other two bearings of the multiple bearings are arranged on both sides of the other disc rotor, supporting the other disc rotor from both sides of the other disc rotor, thereby improving the reliability of the assembly of the other disc rotor. Specifically, one bearing is used for transmission connection to one end of a rotating shaft, and the other end of a rotating shaft is used for coupling to one end of another rotating shaft. One of the other two bearings is used for transmission connection to one end of another rotating shaft, and the other of the other two bearings is used for transmission connection to the other end of another rotating shaft. This technical solution uses three bearings to realize the assembly of two rotating shafts, the disc hybrid assembly has fewer parts, and the assembly process is relatively simple.

[0016] Along the axial direction of the disc hybrid assembly, the thickness of one of the other two bearings is greater than the thickness of one bearing, and the thickness of one of the other two bearings is greater than the thickness of the other of the other two bearings. This helps to improve the assembly stability of the two rotating shafts.

[0017] In a specific technical solution, along the radial direction of the disc-type hybrid assembly, the inner diameters of the other two bearings are larger than the inner diameters of the one or two bearings connected to the rotating shaft. The diameter of the other rotating shaft is larger than that of the first rotating shaft, and the inner diameter of the bearings used to assemble the two rotating shafts is sleeved onto the outer surface of the rotating shaft, facilitating assembly of the two rotating shafts.

[0018] In one technical solution, the maximum power generated by one disc rotor is less than the maximum driving power of the other disc rotor. In this solution, the disc hybrid assembly outputs a higher driving power, which helps improve the drive capability of the disc hybrid assembly.

[0019] The distance between one of the two bearings used to assemble the other shaft and the bearing used to assemble one shaft is equal to the distance between one of the two bearings used to assemble the other shaft and the other of the two bearings used to assemble the other shaft. If the three bearings are evenly distributed along the axial direction, the forces on the two shafts will be more evenly distributed.

[0020] In one technical solution, the axial width of one group of stator windings of the disc-type stator is smaller than or equal to the axial width of another group of stator windings.

[0021] The magnetic field generated by one set of stator windings and the magnetic field generated by the other set of stator windings have a gap along the axial direction. The magnetic fields generated by the two disc motors are not coupled, so the two disc motors can operate independently and reduce mutual influence.

[0022] In a specific technical solution, the axial spacing between one set of stator slots and another set of stator slots is greater than the maximum circumferential distance between two adjacent stator slots in one set, and greater than the maximum circumferential distance between two adjacent stator slots in the other set. This ensures sufficient spacing between one set of stator windings and the other set of stator windings, creating a gap between the magnetic fields generated by one set of stator windings and the magnetic fields generated by the other set of stator windings along the axial direction of the disc-type hybrid assembly, achieving magnetic field decoupling between the two sets of stator windings.

[0023] In one technical solution, the spacing between one set of stator slots and another set of stator slots along the axial direction of the disc hybrid assembly is greater than or equal to a preset value ly, and the preset value ly satisfies:

[0024] When q1>1 and q2>1, ly≥max(q1*t1 / 2,q2*t2 / 2);

[0025] When q1≤1 and q2>1, ly≥max(t1,q2*t2 / 2);

[0026] When q1>1 and q2≤1, ly≥max(q1*t1 / 2, t2);

[0027] When q1=1 and q2=1, ly≥max(t1, t2);

[0028] Among them, q1=N1 / (2*m1*p1); q2=N2 / (2*m2*p2), N1 is the number of slots in one group of stator slots, N2 is the number of slots in the other group of stator slots, t1 is the maximum radial distance between adjacent stator slots in one group of stator slots, t2 is the maximum radial distance between adjacent stator slots in the other group of stator slots, m1 is the number of phases of one disc motor, m2 is the number of phases of the other disc motor, p1 is the number of pole pairs of one disc motor, and p2 is the number of pole pairs of the other disc motor.

[0029] To facilitate the manufacture of the stator core, the number of slots in one set of stator slots and the number of slots in another set of stator slots in the stator core have a greatest common divisor greater than 1. In the embodiment of the stator core of the disc-type stator formed by winding silicon steel, the number of stator slots on both sides of the stator core of the disc-type stator has a greatest common divisor, which facilitates the simplification of the silicon steel punching process.

[0030] In a second aspect, the present application also provides an electric vehicle comprising wheels, a transmission mechanism, and a disc-type hybrid assembly. Another rotating shaft is connected to the transmission mechanism, and the other rotating shaft drives the wheels through the transmission mechanism. The electric vehicle provided in the present application is a hybrid electric vehicle, and the disc-type hybrid assembly has a high degree of integration and a small size.

[0031] The electric vehicle may further include another transmission mechanism, wherein one end of the rotating shaft is connected to the engine, and the other end is connected to the other transmission mechanism. The engine drives the wheels to rotate through the rotating shaft and the other transmission mechanism to increase the power of the electric vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG1 is a schematic structural diagram of an electric vehicle according to an embodiment of the present application;

[0033] FIG2 is a schematic structural diagram of a disc-type hybrid assembly according to an embodiment of the present application;

[0034] FIG3 is a schematic diagram of an assembly structure of a disc stator and a disc rotor in an embodiment of the present application;

[0035] FIG4 is a schematic structural diagram of a disc-type stator in an embodiment of the present application;

[0036] FIG5 is a schematic structural diagram of a disc-type hybrid assembly provided in an embodiment of the present application;

[0037] FIG6 is a schematic structural diagram of a disc-type hybrid assembly provided in an embodiment of the present application;

[0038] FIG7 is a schematic structural diagram of a disc-type hybrid assembly provided in an embodiment of the present application;

[0039] FIG8 is a schematic diagram of a partial structure of a stator core in an embodiment of the present application;

[0040] FIG9 is a schematic structural diagram of a disc rotor in an embodiment of the present application;

[0041] FIG10 is a schematic structural diagram of a disc rotor in an embodiment of the present application.

[0042] Figure numerals: 100-frame; 200-output part; 300-transmission mechanism; 400-disc hybrid assembly; 500-engine; 1-housing; 11-an axial end plate; 12-sleeve; 13-another axial end plate; 2-disc stator; 21-stator core; 22-a set of stator windings; 23-another set of stator windings; 3-disc rotor; 31-a disc rotor; 311-a first back yoke; 312-a first permanent magnet; 32-another disc rotor; 41-a rotating shaft; 42-another rotating shaft; 5-bearing. DETAILED DESCRIPTION

[0043] In order to make the purpose, technical solutions and advantages of this application more clear, this application will be further described in detail below with reference to the accompanying drawings. Obviously, the embodiments described herein are only part of the embodiments of this application, not all of them.

[0044] The terms used in the following embodiments are for the purpose of describing specific embodiments only and are not intended to limit the present application. References to "one embodiment" or "a specific embodiment" in this specification mean that one or more embodiments of the present application include a specific feature, structure, or characteristic described in conjunction with the embodiment.

[0045] In the various embodiments of the present application, unless otherwise specified or there is a logical conflict, the terms and / or descriptions between different embodiments are consistent and can be referenced by each other. The technical features in different embodiments can be combined to form new embodiments according to their inherent logical relationships.

[0046] In order to facilitate the understanding of the disc hybrid assembly and electric vehicle provided in the embodiments of the present application, the following first introduces its application scenarios. At present, vehicles are used in more and more scenarios in production and life, especially the application of electric vehicles is also gradually increasing, and the motor, as the power component of the electric vehicle, plays a vital role in the performance of the electric vehicle. Similarly, the motor is used as a power component for various electric equipment, so the performance of the motor plays an important role for the electric equipment. The disc motor has a compact structure, a short axial dimension, and has the characteristics of high torque density and high power density. It has obvious advantages in application scenarios with restrictions such as size and weight, and the miniaturization and lightweighting of electric equipment is also an important development direction. To this end, the present application provides a disc hybrid assembly and an electric vehicle to improve the integration of the hybrid assembly and reduce the volume of the hybrid assembly.

[0047] The disc hybrid assembly in the embodiment of the present application can be applied to different types of electric equipment. For example, the above-mentioned electric equipment can be various types of electric vehicles such as electric vehicles (EV), pure electric vehicles / battery electric vehicles (PEV / BEV), hybrid electric vehicles (HEV), range extended electric vehicles (REEV), plug-in hybrid electric vehicles (PHEV), and new energy vehicles. In addition, the above-mentioned electric equipment can also be battery management equipment (Battery Management), motor & driver equipment (Motor & Driver), power converter equipment (Power Converter), reducer (Reducer), elevator or aircraft, etc. In some embodiments, from the perspective of application scenarios or functions, the above-mentioned electric vehicles include passenger cars and various special operation vehicles with specific functions, such as engineering rescue vehicles, sprinkler trucks, sewage suction trucks, cement mixer trucks, crane trucks, medical vehicles, etc.

[0048] Disc motors can be used as drive motors to provide power or as generators to generate electricity. For example, in electric vehicles, disc motors can be used as drive motors to output power, or as range extenders to generate electricity. In elevators, disc motors can power the elevator car. In aircraft, disc motors can also provide propulsion.

[0049] The technical solution of the present application is briefly described below with reference to the accompanying drawings, taking an electric vehicle as an example of an electric device.

[0050] FIG1 is a schematic diagram of the structure of an electric vehicle according to an embodiment of the present application. Referring to FIG1 , the electric device according to the embodiment of the present application includes a frame 100, an output unit 200, a transmission mechanism 300, a disc hybrid assembly 400, and an engine 500. The output unit 200, transmission mechanism 300, disc hybrid assembly 400, and engine 500 are mounted on the frame 100, and the disc hybrid assembly 400 is connected to the output unit 200 via the transmission mechanism 300. The disc hybrid assembly 400 is used to convert electrical energy into mechanical energy. The transmission mechanism 300 is connected to the disc hybrid assembly 400 and is used to transmit the mechanical energy to the output unit 200 of the electric device. The output unit 200 is used to output the mechanical energy generated by the disc hybrid assembly 400. The engine 500 is connected to the disc hybrid assembly 400 to drive the disc hybrid assembly 400 to generate electricity. The disc hybrid assembly 400 provided in the present application is used to receive power from the engine of an electric vehicle to generate electricity and to drive the wheels of the electric vehicle to rotate.

[0051] In a specific embodiment, as shown in FIG1 , the electric device is an electric vehicle, which includes wheels, a transmission mechanism 300, a disc-type hybrid assembly 400, and an engine 500. The wheels serve as the output unit 200 of the electric vehicle. The disc-type hybrid assembly 400 drives the wheels through the transmission mechanism 300, thereby enabling the electric vehicle to travel.

[0052] The above-mentioned disc-type hybrid assembly may further include electronic components. For example, the disc-type hybrid assembly may further include at least one of a motor control unit (MCU), an on-board charger (OBC), a DC-DC converter (DC-DC), a power distribution unit (PDU), and a battery control unit (BCU) to enrich the functionality of the hybrid assembly.

[0053] FIG2 is a schematic structural diagram of a disc-type hybrid assembly provided in an embodiment of the present application, and FIG3 is a schematic structural diagram of an assembly of a disc-type stator and a disc rotor in an embodiment of the present application.

[0054] In one embodiment, the disc hybrid assembly provided in the present application is a single-stator, dual-rotor disc hybrid assembly.

[0055] As shown in Figures 2 and 3, the disc hybrid powertrain assembly includes a housing 1, a disc stator 2, and two disc rotors 3. The housing 1 is used to secure the disc stator 2 and accommodate the two disc rotors 3. In a specific embodiment, the disc stator 2 and the two disc rotors 3 are separately assembled within the housing. The disc stator 2 is fixed to the housing 1, while the two disc rotors 3 are rotatably mounted to the housing 1. One of the two disc rotors 3, the disc stator 2, and the other of the two disc rotors 3, 32, are arranged adjacent to each other in the axial direction of the disc hybrid powertrain assembly. It will be appreciated that the two disc rotors 3 of the disc hybrid powertrain assembly are located at either end of the disc stator 2 along the axial direction of the disc hybrid powertrain assembly. In this embodiment, the disc stator 2 and disc rotors 3 are configured as a disc motor to reduce the size of the hybrid powertrain assembly.

[0056] In a specific embodiment, FIG4 is a schematic diagram of the structure of a disc-type stator 2 in an embodiment of the present application. As shown in FIG4 , in one embodiment, the disc-type stator 2 comprises a stator core 21, two sets of stator windings, and two rotating shafts. The two sets of stator windings are one set of stator windings 22 and another set of stator windings 23, and the two rotating shafts are one rotating shaft 41 and another rotating shaft 42. The stator core 21 comprises two sets of stator slots, with the openings of the two sets of stator slots facing away from each other in the axial direction of the disc-type hybrid powertrain. The two sets of stator slots are used to wind the two sets of stator windings. Specifically, the stator core 21 has one set of stator slots at one axial end and another set of stator slots at the other axial end. The stator windings 22 are wound around the set of stator slots at one end of the stator core 21, and the stator windings 23 are wound around the other set of stator slots at the other end of the stator core 21. The disc stator 2 includes two sets of stator windings, one at each axial end of a stator core 21. The disc stator 2 has a set of stator windings 22 on the side facing the disc rotor 31. This set of stator windings 22 is axially opposed to the disc rotor 31, forming a disc motor. The disc stator 2 has another set of stator windings 23 on the side facing the other disc rotor 32. This set of stator windings 23 is axially opposed to the other disc rotor 32, forming another disc motor. The disc rotor 31 is sleeved on the outside of a rotating shaft 41 and is fixedly connected to the rotating shaft 41. The other disc rotor 32 is sleeved on the outside of the other rotating shaft 42 and is fixedly connected to the other rotating shaft 42.

[0057] The hybrid disc drive assembly in the embodiments of this application can be used in hybrid electric vehicle systems. Specifically, the disc drive assembly comprises two sets of stator windings and two sets of disc rotors 3, equivalent to integrating two disc motors. The stators of the two disc motors are integrated into a single structure, making the entire disc drive assembly relatively compact. Furthermore, while the disc drive assembly offers a wide range of functions, it also features a simple structure and low cost. Furthermore, both the stator and disc rotor 3 are disc motors, reducing the axial length of the disc drive assembly and making the overall system compact.

[0058] During operation, in one embodiment, one disc motor in the disc hybrid assembly functions as a generator, while the other disc motor functions as a drive motor. A rotating shaft 41 and a set of stator windings 22 can function as a generator. One rotating shaft 41 is connected to the engine and drives a disc rotor 31 to rotate and generate electricity. Specifically, one end of one rotating shaft 41 is connected to the electric vehicle's engine. The engine drives this rotating shaft 41, and the interaction between the disc rotor 31 and the set of stator windings 22 generates electricity, with current output from the set of stator windings 22. The other rotating shaft 42 and another set of stator windings 23 function as a drive motor, rotating with the other disc rotor 32 and driving the wheels. The other rotating shaft 42 can be connected to the wheels via a transmission mechanism. The other set of stator windings 23 receives current and drives the other disc rotor 32, which in turn drives the other rotating shaft 42, which in turn drives the other rotating shaft 42 through the transmission mechanism.

[0059] The one rotating shaft 41 and the other rotating shaft 42 are coaxial, allowing one disc rotor 31 and the other disc rotor 32 to share a disc stator 2, simplifying the manufacturing process of the disc stator 2. The one rotating shaft 41 and the other rotating shaft 42 are each circumferentially connected to the disc stator 2. The circumferential rotations of the one rotating shaft 41 and the other rotating shaft 42 are independent of each other, decoupling the circumferential rotations of the two disc rotors 3, allowing the two disc motors to operate independently.

[0060] There are many options for achieving the coaxial and circumferential rotational decoupling of the above-mentioned one rotating shaft 41 and the other rotating shaft 42. As shown in Figure 2, in one implementation, one rotating shaft 41 and the other rotating shaft 42 can be rotatably assembled to the housing 1 of the disc hybrid assembly through bearings 5 ​​respectively. There is a certain distance between the two rotating shafts so that the two rotating shafts can work independently. In one embodiment, the distance between the above-mentioned one rotating shaft 41 and the other rotating shaft 42 along the axial direction of the disc hybrid assembly is smaller than the distance between the two disc rotors. In this embodiment, one rotating shaft 41 passes through a disc rotor 31 in the axial direction to improve the reliability of the rotational connection between the one disc rotor 31 and the housing 1. The other rotating shaft 42 passes through the other disc rotor 32 in the axial direction to improve the reliability of the rotational connection between the other disc rotor 32 and the housing 1.

[0061] FIG5 is a schematic structural diagram of a disc hybrid assembly provided in an embodiment of the present application. As shown in FIG5 , in one implementation, one end of the other rotating shaft 42 is used for transmission connection to the wheel, and the other end includes an axially extending shaft hole, the opening of which is axially oriented toward the other rotating shaft 42 along the axial direction of the disc hybrid assembly. The shaft hole is used to accommodate one end of a rotating shaft 41, and the rotating shaft 41 can rotate circumferentially relative to the shaft hole. The other end of the rotating shaft 41 is used for transmission connection to the engine. This solution can improve the coaxiality of the one rotating shaft 41 and the other rotating shaft 42, and the shaft hole of the other rotating shaft 42 can limit and support the one rotating shaft 41, thereby improving the reliability of the assembly of the two rotating shafts.

[0062] As shown in FIG. 5 , in one embodiment, the shaft hole is a blind hole at one end of another rotating shaft 42 facing toward one disc rotor 31 , and the blind hole accommodates a partial area of ​​one end of one rotating shaft 41 .

[0063] FIG6 is a schematic diagram of a disc-type hybrid assembly provided in an embodiment of the present application. As shown in FIG6 , in one embodiment, the shaft hole extends axially through the other rotating shaft 42 along the disc-type hybrid assembly, making the shaft hole a through hole, thereby simplifying the preparation of the shaft hole. The length of the one rotating shaft 41 is greater than the length of the other rotating shaft 42, allowing the one rotating shaft 41 to extend into the shaft hole of the other rotating shaft 42, and even to emerge from the shaft hole of the other rotating shaft 42.

[0064] As shown in Figure 6, in one embodiment, one end of a rotating shaft 41 is exposed through the shaft hole of another rotating shaft 42 and is also used for transmission connection to the wheels. One rotating shaft 41 is disposed through the shaft hole, and one end of the one rotating shaft 41 extends from the shaft hole to the other rotating shaft 42. Specifically, one rotating shaft 41 has an end surface axially located on the end of the other disc rotor 32 facing away from the first disc rotor 31, and the other rotating shaft 42 has another end surface axially located on the side of the second disc rotor 32 facing away from the first disc rotor 31. The distance between the one end surface and the surface of the second disc rotor 32 is greater than the distance between the other end surface and the surface of the second disc rotor 32. The one rotating shaft 41 extends from the end of the second disc rotor 32 facing away from the first disc rotor 31. In this case, the electric vehicle may further include another transmission mechanism, with the end of the one rotating shaft 41 exposed from the shaft hole connected to the other transmission mechanism, and the other end of the one rotating shaft 41 connected to the engine. The other transmission mechanism is connected to the wheels, so that the engine drives the wheels through the one rotating shaft 41 and the other transmission mechanism.

[0065] The disc hybrid assembly in this embodiment can include multiple operating states. In one operating state, a disc motor formed by a rotating shaft 41 and a set of stator windings 22 operates as a generator, converting the power input from the engine 500 into electrical energy for powering the electric vehicle. The other end of the rotating shaft 41 is not connected to another transmission mechanism. Another disc motor formed by another rotating shaft 42 and another set of stator windings 23 operates as a drive motor for powering the electric vehicle. In another operating state, a disc motor formed by a rotating shaft 41 and a set of stator windings 22 also operates as a transmission structure. The other end of the rotating shaft 41 is connected to another transmission mechanism for transmitting the power of the engine to the wheels of the electric vehicle. Another disc motor formed by another rotating shaft 42 and another set of stator windings 23 operates as a drive motor for powering the electric vehicle. In this operating state, both power mechanisms are used to power the electric vehicle, which is suitable for scenarios where the electric vehicle requires stronger power. In another operating state, the other end of one rotating shaft 41 is connected to another transmission mechanism, and another rotating shaft 42 and another set of stator windings 23 form another disc motor that acts as a drive motor and is also used to power the electric vehicle. The rotation of the wheel is transmitted to the aforementioned rotating shaft 41, thereby driving the rotating shaft 41 and a set of stator windings 22 to generate electricity. This operating state is suitable for scenarios where the electric vehicle is going downhill or braking. On the one hand, the rotating shaft 41 has a certain braking effect on the wheel; on the other hand, the rotation of the wheel can also be used to generate electricity, which helps to improve the energy efficiency of the electric vehicle.

[0066] In one embodiment, the outer diameter of the one rotating shaft 41 is smaller than the inner diameter of the shaft hole of the other rotating shaft 42. This embodiment facilitates the assembly of the one rotating shaft 41 into the shaft hole of the other rotating shaft 42 and improves the degree of freedom of rotation of the rotating shaft 41.

[0067] As shown in Figure 2, the housing 1 of the disc-type hybrid assembly includes multiple bearing holes and multiple bearings 5, each of which holds a bearing 5. These bearings 5 ​​are used to assemble a rotating shaft 41 and another rotating shaft 42, allowing the disc rotor 31 and the other disc rotor 32 to be rotatably assembled relative to the housing 1.

[0068] Please continue to refer to Figures 2 and 5. In one embodiment, along the axial direction of the disc hybrid assembly, two bearings 5 ​​of the multiple bearings 5 ​​are respectively arranged on both sides of a disc rotor 31, and the two bearings are used to transmit and connect a rotating shaft 41. A rotating shaft 41 is assembled to the housing 1 through two bearings 5. The housing 1 includes an axial end plate 11, a sleeve 12 and another axial end plate 13 arranged along the axial direction. The sleeve 12 is located radially inside the stator core 21. The bearing hole of one bearing 5 of the two bearings 5 ​​is located inside the sleeve 12, and the bearing hole of the other bearing 5 is located on the other axial end plate 13. In this way, the above-mentioned disc rotor 31 is supported from both sides of the disc rotor 31, thereby improving the reliability of the assembly of the disc rotor 31.

[0069] Continuing with Figures 2 and 5 , in one embodiment, two of the multiple bearings 5 ​​are arranged on either side of another disc rotor 32 along the axial direction of the disc hybrid assembly. These two bearings 5 ​​are used for transmission connection to another rotating shaft 42. Specifically, the other rotating shaft 42 is assembled to the housing 1 via the two bearings 5. The interior of the housing sleeve 12 has a bearing hole for assembling the other of the two bearings 5. An axial end plate 11 has a bearing hole for assembling the other of the two bearings 5. The other disc rotor 32 is positioned between the sleeve 12 and the axial end plate 11. Thus, the two bearings support the other disc rotor 32 from both sides, improving the assembly reliability of the other disc rotor 32.

[0070] In one embodiment, along the radial direction of the disc-type hybrid assembly, the inner diameters of the other two bearings 5 ​​are larger than the inner diameters of one or both bearings connected to the rotating shaft. The diameter of the other rotating shaft 42 is larger than that of the first rotating shaft 41, allowing one end of the first rotating shaft 41 to extend into the axial hole of the second rotating shaft 42. Using four bearings to assemble the two rotating shafts improves assembly reliability.

[0071] Figure 7 is a schematic diagram of a disc-type hybrid assembly provided in an embodiment of the present application. As shown in Figure 7 , in one embodiment, along the axial direction of the disc-type hybrid assembly, one of the multiple bearings 5 ​​is arranged on the side of one disc rotor 31 facing away from the other disc rotor 32, while the other two bearings 5 ​​are arranged on either side of the other disc rotor 32. One bearing 5 is drivingly connected to one end of a rotating shaft 41, while the other end of one rotating shaft 41 is coupled to one end of the other rotating shaft 42. One of the other two bearings 5 ​​is drivingly connected to one end of the other rotating shaft 42, while the other of the other two bearings 5 ​​is drivingly connected to the other end of the other rotating shaft 42. Thus, the two bearings 5 ​​support the other disc rotor 32 from both sides, improving the assembly reliability of the other disc rotor 32. One end of the rotating shaft 41 is mounted to the housing 1 via a bearing 5. The bearing hole of the bearing 5 is located in the other axial end plate 13, and the other end of the rotating shaft 41 is mounted to the shaft hole of the other rotating shaft 42. In this embodiment, the shaft hole of the other rotating shaft 42 can limit and support one rotating shaft 41, thereby improving the reliability of the assembly of the two rotating shafts. In addition, the assembly of the two rotating shafts can be achieved using three bearings 5. The number of accessories of the disc hybrid assembly is relatively small, and the assembly process is relatively simple.

[0072] Continuing with Figure 7, in one embodiment, along the axial direction of the disc hybrid assembly, the thickness of one of the other two bearings 5 ​​is greater than the thickness of the aforementioned bearing 5, and the thickness of one of the aforementioned two bearings 5 ​​is greater than the thickness of the other of the other two bearings 5. The thickness of one of the two bearings 5 ​​used to assemble the other rotating shaft 42 is greater than the thickness of the one bearing 5 used to assemble the one rotating shaft 41, and greater than the thickness of the other of the two bearings 5 ​​used to assemble the other rotating shaft 42. The three bearings 5 ​​are arranged sequentially along the axial direction of the disc hybrid assembly, and the thickness of the middle bearing 5 of the three bearings 5 ​​is greater than the thickness of the bearings 5 ​​on either side. The middle bearing 5 of the three bearings 5 ​​supports the two rotating shafts, and increasing the thickness of this bearing 5 helps improve the assembly stability of the two rotating shafts.

[0073] In one embodiment, the axial distance between the three bearings 5 ​​located between the two disc rotors is the same as the two bearings 5 ​​located on either side of the two disc rotors. The distance between one of the two bearings 5 ​​used to assemble the other rotating shaft 42 and one of the bearings 5 ​​used to assemble the one rotating shaft 41 is equal to the distance between one of the two bearings 5 ​​used to assemble the other rotating shaft 42 and the other of the two bearings 5 ​​used to assemble the other rotating shaft 42. When the three bearings 5 ​​are evenly distributed along the axial direction, the forces acting on the two rotating shafts are more evenly distributed.

[0074] In one embodiment, the distance between one of the two bearings 5 ​​for assembling the other rotating shaft 42 and one of the bearings 5 ​​for assembling the one rotating shaft 41 is greater than the distance between one of the two bearings 5 ​​for assembling the other rotating shaft 42 and the other of the two bearings 5 ​​for assembling the other rotating shaft 42. The diameter of one rotating shaft 41 is smaller than the diameter of the other rotating shaft 42, and therefore its axial stability is relatively poor. In this embodiment, the two support points of one rotating shaft 41 are closer, which helps to improve the support effect and stability of the one rotating shaft 41.

[0075] Continuing with Figure 7, in one embodiment, the maximum power generated by one disc rotor 31 is less than the maximum drive power generated by the other disc rotor 32. In this technical solution, the disc hybrid assembly outputs a higher drive power, which improves its driving capability. In one embodiment, along the axial direction of the disc hybrid assembly, the width of one set of stator windings 22 of the disc stator is less than or equal to the width of the other set of stator windings 23.

[0076] Furthermore, the magnetic fields generated by the stator windings on both sides of the disc stator are not coupled to each other. Specifically, there is a gap between the magnetic fields generated by one set of stator windings 22 and the magnetic fields generated by the other set of stator windings 23 along the axial direction of the disc hybrid assembly. The uncoupled magnetic fields generated by the two disc motors allow them to operate independently, minimizing mutual influence.

[0077] In one embodiment, the spacing between one set of stator slots and another set of stator slots along the axial direction of the disc hybrid assembly is greater than the maximum circumferential distance between two adjacent stator slots in one set of stator slots, and greater than the maximum circumferential distance between two adjacent stator slots in the other set of stator slots. This ensures sufficient spacing between one set of stator windings 22 and the other set of stator windings 23, creating a gap between the magnetic fields generated by one set of stator windings 22 and the magnetic fields generated by the other set of stator windings 23 along the axial direction of the disc hybrid assembly, thereby achieving magnetic field decoupling between the two sets of stator windings.

[0078] Figure 8 is a schematic diagram of a partial structure of the stator core in an embodiment of the present application. As shown in Figure 8, in one embodiment, the spacing between one group of stator slots and another group of stator slots along the axial direction of the disc hybrid assembly is greater than or equal to a preset value ly, and the preset value ly is determined by the number of slots N1 of one group of stator slots, the number of slots N2 of the other group of stator slots, the maximum radial distance t1 between adjacent stator slots of one group of stator slots, the maximum radial distance t2 between adjacent stator slots of the other group of stator slots, the number of phases m1 of one disc motor, the number of phases m2 of the other disc motor, the number of pole pairs p1 of one disc motor, and the number of pole pairs p2 of the other disc motor.

[0079] In a specific embodiment, the above-mentioned preset value ly satisfies:

[0080] When q1>1 and q2>1, ly≥max(q1*t1 / 2,q2*t2 / 2);

[0081] When q1≤1 and q2>1, ly≥max(t1,q2*t2 / 2);

[0082] When q1>1 and q2≤1, ly≥max(q1*t1 / 2, t2);

[0083] When q1=1 and q2=1, ly≥max(t1, t2);

[0084] Among them, q1=N1 / (2*m1*p1); q2=N2 / (2*m2*p2).

[0085] By designing the stator slots of the stator core according to the above principles, the two disc motors can be decoupled more reliably.

[0086] In one embodiment, the disc stator 2 has a set of stator slots on the side facing the one disc rotor 31, and a set of stator windings 22 is wound around the set of stator slots. The disc stator 2 has another set of stator slots on the side facing the other rotating shaft 42, and another set of stator windings 23 is wound around the other set of stator slots. The set of stator slots includes a plurality of stator slots, and the number of stator slots in the set is the same as the number of magnetic poles of the disc rotor 31; the other set of stator slots also includes a plurality of stator slots, and the number of stator slots in the other set is the same as the number of magnetic poles of the other disc rotor 32. The number of stator slots in the set of stator slots is the same as or different from the number of stator slots in the other set of stator slots. In one embodiment, the number of stator slots in the set of stator slots and the number of stator slots in the other set of stator slots have a greatest common divisor, and the greatest common divisor is greater than 1. In one embodiment, the stator core 21 of the disc stator 2 can be formed by winding silicon steel. In this embodiment, the numbers of stator slots on both sides of the stator core 21 of the disc stator 2 have a greatest common divisor, which is conducive to simplifying the silicon steel punching process.

[0087] Specifically, the number of stator slots in the above-mentioned group of stator slots is the same as or different from the number of stator slots in the other group of stator slots. For the sake of convenience of description, it is assumed that the number of stator slots in the above-mentioned group of stator slots is N1, and the number of stator slots in the other group of stator slots is N2. In one embodiment, the number of stator slots N1 in the above-mentioned group of stator slots and the number of stator slots N2 in the other group of stator slots satisfy: N1 = N2, that is, the number of stator slots in one group of stator slots is the same as the number of stator slots in the other group of stator slots. In one embodiment, the number of stator slots in the above-mentioned group of stator slots is greater than the number of stator slots in the other group of stator slots, and the number of stator slots N1 in the one group of stator slots and the number of stator slots N2 in the other group of stator slots satisfy: N1 = k·N2, where k = 2, 3, or 3 / 2, which is a rational number greater than or equal to 2. In one embodiment, the number of stator slots in the above-mentioned group of stator slots is less than the number of stator slots in the other group of stator slots, and the number of stator slots N1 in one group of stator slots and the number of stator slots N2 in the other group of stator slots satisfy: N1 = K·N2, where K = 1 / 3, 1 / 2 or 2 / 3, or other rational numbers less than 1.

[0088] In one embodiment, a disc motor formed by a disc rotor 31 and a set of stator windings 22 functions as a generator. In this case, the structure of the disc rotor 31 has multiple options. For example, in one embodiment, the disc rotor 31 is a permanent magnet disc rotor; in another embodiment, the disc rotor 31 is an asynchronous motor disc rotor.

[0089] FIG9 is a schematic diagram of the structure of a disc rotor in an embodiment of the present application, and FIG10 is a schematic diagram of the structure of a disc rotor in an embodiment of the present application. As shown in FIG7 and FIG8, in an embodiment in which the disc rotor 31 is a permanent disc disc rotor, the disc rotor 31 includes a first back yoke 311 and a first permanent magnet 312, and the first permanent magnet 312 is fixed to the first back yoke 311. As shown in FIG7, in one implementation, the first permanent magnet 312 is attached to the surface of the first back yoke 311; as shown in FIG8, in one implementation, the first permanent magnet 312 is embedded in the interior of the first back yoke 311.

[0090] In an embodiment where the disc rotor is an asynchronous motor disc rotor, the disc rotor comprises an iron core and a disc rotor winding, wherein the iron core comprises slots for accommodating the disc rotor winding. In this embodiment, a squirrel cage is embedded in the slots of the iron core.

[0091] The other disc rotor and another set of stator windings form a disc motor that serves as the motor. In this case, the other disc rotor is a permanent disc disc rotor. In a specific embodiment, the other disc rotor includes a second back yoke and a second permanent magnet, which is fixed to the second back yoke. In one implementation, the second permanent magnet is attached to the surface of the second back yoke; in another implementation, the second permanent magnet is embedded within the second back yoke.

[0092] The above are only specific embodiments of the present application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

Claims

1. A disc-type hybrid assembly, characterized in that: The disc-type hybrid assembly is used to receive the engine drive of the electric vehicle to generate electricity and to drive the wheels of the electric vehicle to rotate. The disc-type hybrid assembly includes: A disc-type stator, the disc-type stator comprising a stator core and two groups of stator windings, the stator core comprising two groups of stator slots, the openings of the two groups of stator slots facing away from each other along the axial direction of the disc-type hybrid assembly, and the two groups of stator slots are respectively used to wind the two groups of stator windings; Two disc rotors, which are arranged on both sides of the stator core along the axial direction of the disc hybrid assembly; Two rotating shafts, one of which is used for transmission connection with the engine and drives one of the disc rotors to rotate and generate electricity, and the other rotating shaft is used for rotating with the other disc rotor and driving the wheels.

2. The disc-type hybrid assembly according to claim 1, characterized in that: Along the axial direction of the disc-type hybrid assembly, the distance between the one rotating shaft and the other rotating shaft is smaller than the distance between the two disc rotors.

3. The disc-type hybrid assembly according to claim 1, characterized in that: One end of the other rotating shaft is used for transmission connection to the wheel, and the other end of the other rotating shaft includes an axial hole, the opening of the axial hole is axially toward the one rotating shaft along the disc hybrid assembly, the axial hole is used to accommodate one end of the one rotating shaft, and the other end of the one rotating shaft is used for transmission connection to the engine.

4. The disc-type hybrid assembly according to claim 3, characterized in that: The shaft hole passes through the other rotating shaft along the axial direction of the disc-type hybrid assembly, and the length of the one rotating shaft is greater than the length of the other rotating shaft.

5. The disc-type hybrid assembly according to claim 4, characterized in that: One end of the rotating shaft is exposed from the shaft hole and is used for transmission connection with the wheel.

6. The disc-type hybrid assembly according to any one of claims 3 to 5, characterized in that: The outer diameter of the one rotating shaft is smaller than the inner diameter of the shaft hole of the other rotating shaft.

7. The disc-type hybrid assembly according to any one of claims 1 to 6, characterized in that: The disc-type hybrid assembly comprises a housing, and the housing is used to fix the one disc-type stator and accommodate the two disc-type rotors, wherein: The housing includes a plurality of bearing holes and a plurality of bearings, and each of the bearing holes is fixed with a bearing.

8. The disc-type hybrid assembly according to claim 7, characterized in that: Along the axial direction of the disc-type hybrid assembly, two of the plurality of bearings are respectively arranged on both sides of the one disc-type rotor, and the other two of the plurality of bearings are respectively arranged on both sides of the other disc-type rotor, wherein: The two bearings are used for transmission connection with the one rotating shaft, and the other two bearings are used for transmission connection with the other rotating shaft.

9. The disc-type hybrid assembly according to claim 7, characterized in that: Along the axial direction of the disc-type hybrid assembly, one of the plurality of bearings is arranged on a side of the disc rotor away from the other disc rotor, and the other two of the plurality of bearings are arranged on both sides of the other disc rotor, respectively, wherein: The one bearing is used for transmission connection with one end of the one rotating shaft, and the other end of the one rotating shaft is used for coupling with one end of the other rotating shaft; One of the other two bearings is used for transmission connection to one end of the other rotating shaft, and the other of the other two bearings is used for transmission connection to the other end of the other rotating shaft.

10. The disc-type hybrid assembly according to claim 9, characterized in that: Along the axial direction of the disc-type hybrid assembly, a thickness of one of the other two bearings is greater than a thickness of the one bearing and a thickness of the other of the other two bearings.

11. The disc-type hybrid assembly according to any one of claims 8 to 10, characterized in that: Along the radial direction of the disc-type hybrid assembly, the inner diameters of the other two bearings are larger than the inner diameter of the one or two bearings drivingly connected to the one rotating shaft.

12. The disc-type hybrid assembly according to any one of claims 1 to 11, characterized in that: The maximum power generation power of the rotation of the one disk rotor is smaller than the maximum driving power of the rotation of the other disk rotor.

13. The disc-type hybrid assembly according to any one of claims 1 to 12, characterized in that: The spacing between the one group of stator slots and the other group of stator slots along the axial direction is greater than the maximum distance between two adjacent stator slots in the one group of stator slots along the circumferential direction, and is greater than the maximum distance between two adjacent stator slots in the other group of stator slots along the circumferential direction.

14. The disc-type hybrid assembly according to any one of claims 1 to 13, characterized in that: The number of slots of the one group of stator slots and the number of slots of the other group of stator slots have a greatest common divisor, and the greatest common divisor is greater than 1.

15. An electric vehicle, characterized in that: The electric vehicle comprises wheels, a transmission mechanism and a disc hybrid assembly as claimed in any one of claims 1 to 14, wherein the other rotating shaft is connected to the one transmission structure, and the other rotating shaft drives the wheels to rotate through the one transmission mechanism.

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