Apparatus having an electric machine and a thermal management device

Abstract

The invention relates to an apparatus having an electric machine (2) arranged in a housing (20), and having a thermal management device (10), wherein: the thermal management device (10) has at least one electric pump which is designed to convey a cooling medium; the thermal management device (10) comprises a hydraulic block (12) having flow channels (31; 31; 32; 33; 34; 35; 36); the electric pump (15) is designed to convey the cooling medium into at least one of the flow channels (31; 32; 33; 34; 35; 36; 37) during operation. According to the invention, the thermal management device (10) has a carrier part (11), wherein: at least the electric pump (15), the hydraulic block (12) having the flow channels (31; 31; 32; 33; 34; 35; 36), at least one electrohydraulic control valve (14), and an electronic circuit part (13) which is electrically connected to the electrohydraulic control valve (14) and to the electric pump (15) are arranged on the carrier part (11); the at least one electrohydraulic control valve (14) is designed to control the cooling medium flowing in at least one of the flow channels (31; 32; 33; 34; 35; 36; 37); and at least the carrier part (11) with the electric pump (15), with the hydraulic block (12), with the electrohydraulic control valve (14) and with the electronic circuit part (13) is arranged entirely within the housing (20).

Description

[0001] R. 416294

[0002] - 1 -

[0003] Description

[0004] title

[0005] Device with an electric machine and a thermal management device

[0006] State of the art

[0007] As is well known, electric battery-powered vehicles or hybrid vehicles have an electric drivetrain. The electric drivetrain usually comprises at least one electric motor for propelling the vehicle and a transmission coupled to the electric motor, which transmits torque to an output shaft. The output shaft transmits the torque converted by the transmission to the vehicle's wheels. Devices are known in which the electric motor and the transmission are arranged in a common housing. The combination of an electric motor and a transmission in a common housing, sometimes also in combination with power electronics mounted on the housing, is referred to in the industry as an e-axle.In many cases, the housing contains an oil sump, and the electric drive train includes a pump designed to transfer oil from the oil sump into at least one lubrication or cooling circuit. An electric drive train with an electric machine arranged in a housing and with an oil pump is known, for example, from DE 10 2011 076 525 A1.

[0008] Furthermore, electrical machines designed as electrical generators are known, for example, for use in hybrid vehicles.

[0009] Electrically powered vehicles can have various components, such as an electric motor, a transmission, or a battery, which generate heat during operation or vehicle use. R. 416294

[0010] - 2 -

[0011] On the one hand, there is a need to cool some units; on the other hand, the heat emitted by one unit can optionally be used to heat another unit. A thermal management device can serve to organize the necessary heat management. For example, DE 102020216288 A1 discloses a device with an electric machine arranged in a housing and with a thermal management device, in which an electric pump and a heat exchanger are mounted on a plate-shaped hydraulic block provided with flow channels, wherein the electric pump is designed to pump a cooling medium, and wherein the thermal management device comprises a hydraulic block with flow channels, and wherein the electric pump is designed to pump the cooling medium into at least one of the flow channels during operation. The thermal management device is mounted externally on the housing of the device.

[0012] Disclosure of the invention

[0013] The invention describes a device with an electric machine arranged in a housing and with a thermal management device, wherein the thermal management device has at least one electric pump configured to pump a cooling medium, wherein the thermal management device has a hydraulic block with flow channels, wherein the electric pump is configured to pump the cooling medium into at least one of the flow channels during operation.According to the invention, the thermal management device comprises a support part, wherein at least the electric pump, the hydraulic block with the flow channels, at least one electrohydraulic control valve, and an electronic circuit part electrically connected to the electrohydraulic control valve and the electric pump are arranged on the support part, wherein the at least one electrohydraulic control valve is designed to control the cooling medium flowing in at least one of the flow channels, and wherein at least the support part with the electric pump, the hydraulic block, the electrohydraulic control valve, and the electronic circuit part is arranged completely within the housing. R. 416294.

[0014] - 3 -

[0015] In the context of this application, a thermal management device is understood to be a device comprising at least one pump for conveying a liquid cooling medium and at least one flow channel in which the cooling medium flows. The flow channel may be part of a fluid circuit, which may also include hydraulic fluid lines that are not located in the hydraulic block.

[0016] The thermal management system can be designed, for example, to dissipate heat generated by a vehicle component by exchanging this heat between the cooling medium, which flows through at least one flow channel of the thermal management system, and another medium. The cooling medium can flow in a cooling circuit. The other medium can be, for example, air, including ambient air, or another liquid. In this way, the heat absorbed by the cooling medium can be transferred to another medium, which, for example, circulates in a further fluid circuit of the vehicle that is thermally coupled to the vehicle battery and / or the vehicle interior, and which comprises a liquid or a gas. The thermal management system can, for example, transfer heat to or absorb heat from this further fluid circuit.The thermal management device can be connected to at least one heat exchanger via a fluid flow. The heat exchanger need not be located inside the device housing, but can also be positioned outside the housing, for example on an outer wall, and hydraulically connected to the hydraulic block inside. A pump can circulate a flow of the cooling medium through at least one of the flow channels of the hydraulic block. This flow can pass through the thermal management device and through components outside the thermal management device. The cooling medium can, for example, flow wholly or partially through the heat exchanger and / or, in particular, through the electric motor and / or a gearbox or parts thereof.

[0017] In the context of this application, an electric machine includes both electric motors that generate electrical energy (see R. 416294).

[0018] - 4 -

[0019] The conversion of kinetic energy, as well as electrical generators that convert kinetic energy into electrical energy, is understood.

[0020] A housing is understood to be a container in which at least the electric machine is arranged. Further components, such as a gearbox or a vehicle differential connected to the output side of the gearbox, may also be arranged in the housing. The housing may have one or more internal chambers sealed oil-tight from the outside. Openings may be formed between the internal chambers. For example, one internal chamber may house a gearbox and another an electric machine. The housing may be composed of several housing parts. The housing may have a single-piece main body fitted with one or more cover parts. An oil sump may be arranged in at least one of the internal chambers. The entire housing may have one or more cover parts that close the internal chamber(s).The casing can be made entirely or partially of metal or plastic.

[0021] A fluid connection between two components is understood to be a connection which allows a liquid medium to pass from a channel or interior of one of the components into a channel or interior of the other component.

[0022] In the context of this application, a flow channel is understood to be a flow space which, in at least one cross-section perpendicular to the flow direction of the medium, is at least partially enclosed on all sides by a wall. The cross-section of a flow channel is, for example, circular or rectangular. A flow channel can be long and traverse a larger section of the hydraulic block, or it can be relatively short and, for example, form a simple opening between two adjacent flow channels. A flow channel can be straight or curved. Further flow channels can branch off from a flow channel. A flow channel can have two ends to which further flow channels with different cross-sectional geometries are connected. R. 416294

[0023] - 5 - connect and / or those fluid-connected to inlet and outlet openings for the cooling medium or to the inputs of a control valve.

[0024] A cooling circuit is understood to be a flow path formed by the flow path of the cooling medium, in which the cooling medium is taken from, for example, a source location, such as an oil sump, and fed to at least one flow channel, flows through the flow channel, and, if necessary, after passing through one or more units, returns at least partially to the source location, in particular the oil sump.

[0025] A hydraulic block is a channel guide component in which at least one or more flow channels are formed. The hydraulic block can be made of metal or plastic. The hydraulic block may have openings for electro-hydraulic control valves.

[0026] Advantages of the invention

[0027] According to the presented invention, the central components of a thermal management device are completely integrated within the housing of a device in which at least one electric motor is also arranged. According to the invention, a support element of the thermal management device, together with the electric pump, the hydraulic block, the electro-hydraulic control valve, and the electronic circuitry, is arranged entirely within the housing. A heat exchanger, a filter element, or a connector of the thermal management device can be arranged inside or outside the housing. This advantageously saves space within the housing, making it easier to install, for example, in a vehicle. The components arranged within the housing are also advantageously protected against external influences and corrosive materials such as moisture or road salt.The electrical wiring effort between the electro-hydraulic control valves, the electric pump, and the electronic circuitry can be advantageously reduced to a minimum by routing the electrical cables through the support structure. R. 416294.

[0028] - 6 -

[0029] The thermal management device advantageously includes at least one electrohydraulic control valve for controlling the flow of the cooling medium through at least one of the flow channels. At least one electrohydraulic control valve is advantageously controlled by the electronic circuitry integrated into the housing. Preferably, several electrohydraulic control valves are provided. The electrohydraulic control valves can, for example, be designed as electrically controlled switching valves or pressure regulating valves. The electronic circuitry comprises an electronic control circuit for controlling the electrohydraulic control valves.

[0030] The electronic circuitry can automatically control the electro-hydraulic control valves and the pump, or, for example, based on signals transmitted to the electronic circuitry by a central vehicle control unit and / or based on signals transmitted to the circuitry by vehicle sensors. The electronic circuitry can comprise a printed circuit board populated with the electronic components forming the control circuit and, for example, based on the operating states of a vehicle or the operating states of individual vehicle components, such as the electric motor, a transmission coupled to the electric motor, or a vehicle battery, can automatically control the heat dissipation from individual components and / or the heat input to individual components.

[0031] Advantageous embodiments and further developments of the invention enable the features contained in the dependent claims.

[0032] Although the device according to the invention is not limited to applications in a motor vehicle, a particularly advantageous embodiment of the device comprises an electric machine designed as an electric motor for driving a vehicle, in particular a motor vehicle, and a transmission coupled to the electric machine which transmits a torque to an output shaft, wherein the electric machine and the transmission are arranged together in the housing, wherein the housing has an oil sump, wherein the electric pump is designed to draw oil from the oil sump as a cooling medium into at least one of the R. 416294

[0033] - 7 -

[0034] To promote flow channels. The device, with its thermal management components integrated into the housing, can be easily installed in a motor vehicle. The components installed in the housing are better protected against environmental influences and corrosion. The flow channels formed in the hydraulic block can be easily connected to the electric motor and / or the transmission, since the hydraulic block is located inside the housing.

[0035] A heat exchanger or filter element located in the outer space of the housing can advantageously be fluid-connected to the flow channels of the hydraulic block via hydraulic fluid lines.

[0036] In one embodiment, a heat exchanger of the thermal management device can advantageously be arranged outside the housing to simplify heat transfer between the cooling circuit, which flows through the flow channels of the hydraulic block, and an external fluid circuit.

[0037] At least one of the flow channels can be fluid-connected to at least one filter element. A filter element can, for example, be arranged inside the housing on the support structure. Alternatively or additionally, a filter element can be arranged outside the housing.

[0038] A heat exchanger located outside the housing and / or a filter element located outside through the housing can be fluidly connected to the flow channels of the hydraulic block located in the housing in a simple manner via hydraulic fluid lines.

[0039] The carrier part may additionally incorporate a connector for electrical contact with the electronic circuitry. The connector may, for example, extend through the housing to the outside. Electrical connections between the electronic circuitry, the electric pump, and / or the electrohydraulic control valve may be at least partially integrated into the carrier part. The carrier part may, for example, have metallic conductor tracks overmolded with insulating material. R. 416294

[0040] - 8 -

[0041] Brief description of the drawings

[0042] Possible embodiments of the invention are explained below with reference to the accompanying figures. The drawings show:

[0043] Figure 1 shows a schematic representation of a vehicle with an electric powertrain,

[0044] Figure 2 shows a thermal management device,

[0045] Figure 3 shows a thermal management device installed in the housing of an electric drive train.

[0046] Figure 4 shows an embodiment of the device according to the invention with a thermal management device.

[0047] Embodiments of the invention

[0048] Figure 1 shows a schematic representation of a vehicle 100 with a device 1 according to the invention. In this embodiment, the device 1 is designed as an electric drive system, in particular an e-axle, and comprises at least one electric machine 2 and a transmission 3. An output side of the electric machine 2 is connected to an input shaft 4 of the transmission 3, so that a torque generated by the electric machine 2 can be transmitted to the input shaft 4 of the transmission 3. The transmission 3 can enable a simple transmission of the torque in one or more gear ratios. An output shaft 5 of the transmission 3 can be operatively connected to a differential 6. The differential 6 transmits the torque applied to the output shaft 5 to output shafts 7, each of which is connected to a wheel of the vehicle 100.The electric motor 2, the gearbox 3, and optionally the differential 6 are arranged in a common housing 20. An example of the housing 20's construction is shown in Figure 3. R. 416294.

[0049] - 9 -

[0050] Figure 2 shows a thermal management device 10, which has a carrier part 11 as a common support for various components. The carrier part 11 is preferably made of plastic. An electric pump 15, a hydraulic block 12 with flow channels (not visible in Figure 2), several electrohydraulic control valves 14, and an electronic circuit part 13, which is electrically connected to the electrohydraulic control valves 14 and the electric pump 15, are arranged on the carrier part 11. The electronic circuit part 13 is, for example, arranged on a printed circuit board. The electronic circuit part 13 is mounted on a lower side of the carrier part 11, while the pump 15 and the hydraulic block 12 are mounted on the upper side and can be attached to the carrier part 11 by means of screw-type fasteners. The electrohydraulic control valves 14 are mounted in receiving openings in the carrier part 11.Each of the electro-hydraulic control valves 14 can have a valve part and a solenoid part. Each solenoid part has a solenoid coil and, when energized, can, for example, actuate a spool valve formed in the valve part. The operating principle of such control valves, which can be configured as switching valves or pressure regulating valves, is known and is therefore not explained here. The valve parts of the electro-hydraulic control valves are fluidly connected to the flow channels in the hydraulic block 12, so that the flow of the cooling medium in one or more of the flow channels can be controlled, as will be explained later. A connector 18 for the electrical connection and a filter element 17 can also be mounted on the carrier part 11. In addition, the thermal management device 10 can have a heat exchanger 16, which is fluidly connected to the flow channels in the hydraulic block 12 via fluid lines.

[0051] Figure 3 shows how the thermal management device 10 from Figure 2 can be installed in a housing 20 of an electric drive system. The housing 20 has a first housing section 21 with a first housing compartment for an electric machine (not visible in Figure 3) and a second housing section 22 (shown open in Figure 3) with a second housing compartment containing an oil sump 23, in which, for example, a gearbox can be mounted. The support part 11 with the electric motor is located in the second housing compartment of the housing 20. R. 416294

[0052] - 10 -

[0053] Pump 15, hydraulic block 12, electro-hydraulic control valve 14, electronic circuit part 13, and filter element 17 are fully arranged, while the heat exchanger 16 and another filter element

[0054] 19 may be arranged outside the housing 20.

[0055] Figure 4 shows an embodiment of the device 1 according to the invention with a thermal management unit 10. Figure 4 depicts a housing 20 with an interior in which an electric motor 2 and a gearbox 3 connected to it are arranged. The housing 20 has an oil sump 23 containing oil. The oil serves as a lubricant and also as a cooling medium. Only the individual components of the thermal management unit 10 are shown in Figure 4. The design of the thermal management unit 10 in Figure 4 can be the same as that described in Figure 2 or Figure 3. For the sake of clarity, the support element 11 and the hydraulic block 12 have been omitted from Figure 4. It can be seen that the first filter element 17 is fluidly connected to the electric pump 15 via a flow channel 37.During operation, the electric pump 15 pumps oil as a cooling medium from the oil sump 23 via the filter element 17 into the flow channel 31 of the hydraulic block 12. The flow channel 31 is connected to a fluid line 50, which leads out of the housing 20 and to another filter element 19. From there, the cooling medium returns to the housing via another fluid line.

[0056] 20 to an electro-hydraulic control valve 14a. The electro-hydraulic control valve 14 can adjust whether the cooling medium flows to a heat exchanger 16 via a further flow channel 32, which is coupled to a further fluid line leading out of the housing, or bypasses the heat exchanger 16 via a flow channel 33 of the hydraulic block 12 designed as a bypass line and flows to a further flow channel 34.

[0057] The cooling medium can therefore flow into a flow channel 34 of the hydraulic block 12 either via the bypass line or the external heat exchanger 16 located outside the housing 20. The flow channel 34 forks at a branch point into a flow channel 35 equipped with a second electrohydraulic control valve 14b, which is fluidly connected to the stator 2a and / or the rotor 12b of the electric machine 2, and a flow channel 36 equipped with a third electrohydraulic control valve 14c, which is fluidly connected to the gearbox 3. The cooling medium can, for example, after flowing through the R. 416294

[0058] - 11 - electrical machine 2 and / or the gearbox 3 flow back into the oil sump 23 via a flow channel 40 designed as a return channel, so that a closed cooling circuit exists.

[0059] Figure 4 further shows the electronic circuit section 13, which is arranged inside the housing 20. The connector 18 of the thermal management device 10 is electrically connected to the electronic circuit section 13 and can extend through a housing wall of the housing 20 for external contact. The electronic circuit section 20 is connected to the electric pump 15 and the electrohydraulic control valves 14a, 14b, and 14c via electrical connections 60, which are shown as dashed lines in Figure 4. The electrical connections 60 can be fully or partially integrated into the support element 11, which is not shown in Figure 4.

Claims

R. 416294 - 12 - Claims 1. Device comprising an electric machine (2) arranged in a housing (20) and a thermal management device (10), wherein the thermal management device (10) comprises at least one electric pump (15) configured to pump a cooling medium, wherein the thermal management device (10) comprises a hydraulic block (12) with flow channels (31; 32; 33; 34; 35; 36), wherein the electric pump (15) is configured to pump the cooling medium into at least one of the flow channels (31; 32; 33; 34; 35; 36; 37) during operation, characterized in that the thermal management device (10) comprises a support part (11) includes at least the electric pump (15), the hydraulic block (12) with the flow channels (31; 31; 32; 33; 34; 35; 36), at least one electrohydraulic control valve (14) and an electronic circuit part (13) electrically connected to the electrohydraulic control valve (14) and the electric pump (15) are arranged on the support part (11), wherein the at least one electrohydraulic control valve (14) is designed to control the cooling medium flowing in at least one of the flow channels (31; 32; 33; 34; 35; 36; 37), wherein at least the support part (11) with the electric pump (15), the hydraulic block (12), the electrohydraulic control valve (14) and the electronic circuit part (13) is arranged completely within the housing (20).

2. Device (1) according to claim 1, characterized in that the device (1) comprises an electric machine (2) designed as an electric motor for driving a vehicle (100), in particular a motor vehicle, and a transmission (3) coupled to the electric machine (2) which transmits a torque to an output shaft (5), wherein the electric machine (2) and the transmission (3) are arranged together in the housing (20), wherein the housing (20) has an oil sump (23), wherein the electric pump (15) is designed to pump oil from the oil sump (23) as a cooling medium into at least one of the flow channels (31; 32; 33; 34; 35; 36).

3. Device (1) according to claim 1 or 2, characterized in that at least one flow channel (32) of the flow channels (31 ; 32; 33; 34; 35; 36; 37) is fluidly connected to a heat exchanger (16). R. 416294 - 13 - 4. Device (1) according to claim 3, characterized in that the heat exchanger (16) is arranged outside the housing (20).

5. Device (1) according to claim 1, characterized in that at least one flow channel (31; 37) of the flow channels (31; 32; 33; 34; 35; 36; 37) is fluidly connected to at least one filter element (17; 19).

6. Device (1) according to claim 5, characterized in that a filter element (17) is arranged inside the housing (20) on the support part (11).

7. Device (1) according to claim 5, characterized in that a filter element (19) is arranged outside the housing (20).

8. Device (1) according to at least one of the preceding claims 3 or 7, characterized in that the heat exchanger (16) and / or the filter element (19) are fluidly connected via hydraulic fluid lines (50) to the flow channels (31; 32; 33; 34; 35; 36; 37) of the hydraulic block (12) arranged in the housing (20).

9. Device (1) according to at least one of the preceding claims, characterized in that a plug part (18) for electrical contacting the electronic circuit part (13) is formed on the carrier part (11), wherein the plug part (18) is preferably led outwards through the housing (20).

10. Device (1) according to at least one of the preceding claims, characterized in that electrical connections (60) between the electronic circuit part (13), the electric pump (15) and / or the at least one electrohydraulic control valve (14) are at least partially integrated into the carrier part (11).

Images