AT510748B1 - POWER GENERATION UNIT - Google Patents

Abstract

The invention relates to a power generator, in particular for use as a range extender in electrically powered motor vehicles, with an internal combustion engine and a generator (30), wherein the internal combustion engine is designed as a rotary piston engine, which at least one with an eccentric portion (12) of a drive shaft (10) has rotating piston (20) and the generator (30) has a generator rotor (50) which is arranged on the common drive shaft (10), wherein a balance weight (51) on the generator rotor (50) radially inside the generator winding (42 ) is arranged. In order to enable a compact construction, it is provided that the balance weight (51) is integrally formed with the rotor hub (53) and extends outwardly in its radial outer region from the rotor hub (53) both in the axial and in the radial direction , wherein the balance weight (51) in the axial direction does not protrude beyond the stator.

Description

Austrian Patent Office AT510 748B1 2014-06-15

The invention relates to a power generator, in particular for use as a range extender in electrically powered motor vehicles, with an internal combustion engine and a generator, wherein the internal combustion engine is designed as a rotary piston engine, which at least one with an eccentric portion of a drive shaft rotating piston and the generator has a generator rotor which is arranged on the common drive shaft, wherein a balance weight on the generator rotor is arranged radially within the generator winding.

The AT 505 950 A2 describes a power generator for range extension of an electric vehicle with an internal combustion engine formed by a rotary piston engine and a generator which is arranged coaxially with the output shaft of the internal combustion engine. The rotor of the generator is connected to a balancing mass for mass balance or forms a unit with this.

From US 2005/0279542 A1 an autonomously operable portable power generator for a range extender is known, which has an internal combustion engine and a coaxially arranged to this generator, wherein the internal combustion engine and generator are arranged in a common housing. The common housing, which is divided by a partition into two areas, is flowed through by cooling air, wherein both the rotor of the generator and the output shaft of the internal combustion engine for conveying the cooling air fan blades have.

An important requirement of such generators is a space-saving, compact design. Generating units usually have a drive shaft on which at least one piston of the internal combustion engine and the generator rotor is arranged. In operation, in particular due to the operation of the internal combustion engine with usually eccentrically arranged on the drive shaft piston results in an imbalance, which vibrations or vibrations, noise and wear of the drive elements and thus causes a shorter life of the associated components. Such a so-called imbalance on the drive shaft can be avoided by a mass balance.

The avoidance of imbalance takes place by balancing the mass distribution of the rotating body, which can be positive or negative. When positive compensation additional balancing weights are attached, z. B. by welding, gluing or screwing weights. In the case of negative compensation, masses are removed at suitable points of the rotating elements, for example by machining processes.

The object of the invention is to provide an improved power generator with a mass balance, which allows a compact design available. This object is achieved by a device according to claim 1, to preferred developments of this device are the subject of the dependent claims.

To solve this problem, a power generator is proposed with an internal combustion engine and a generator, wherein the internal combustion engine is designed as a rotary piston engine, which has at least one rotating with an eccentric portion of a drive shaft piston. The generator rotor is seated on the common drive shaft with the internal combustion engine and a balance weight is arranged radially inside the generator winding on the generator rotor. The inventive solution is that the balance weight is formed integrally with the rotor hub and extending in its radial outer region of the rotor hub in both the axial and in the radial direction to the outside, wherein the balance weight in the axial direction does not protrude beyond the stator.

In the following, the invention will be described in relation to a range extender with a rotary engine, in which a substantially triangular piston rotates on a arranged in a motor housing eccentric shaft. However, the invention is also applicable to a rotary piston engine having two, four or more piston corners and AT510 748B1 2014-06-15. Furthermore, the invention can also be used in rotary engines with two, three or more juxtaposed pistons.

Under a power generator is in the context of the invention means a device in which chemically bound energy, preferably by an exothermic reaction, first in mechanical and then converted into electrical power. Advantageously, an internal combustion engine with internal combustion and more advantageously a rotary piston engine is used to convert the chemically bound energy into mechanical power. To convert this mechanical power into electrical power, an electric generator is used as the electromechanical energy converter.

Under a rotary piston engine in the context of the invention is preferably to understand a rotary piston engine, a device in which the preferably substantially triangular rotary piston during operation of the internal combustion engine in the housing in particular performs a rotation about a major axis, wherein the piston to a its own axis turns, but this axis moves to another on its own orbit. The advantage of the use of a rotary piston engine as an internal combustion engine of the power generator is the higher smoothness of such a machine compared with a reciprocating engine.

Under a generator according to the invention is a dynamo-electric machine to understand. Such machines usually have a rotor and a stator. During a rotation of the rotor connected to the drive shaft within the stator electrical energy is generated in a generator winding. In generators usually both stator and rotor have a laminated core, wherein at least the laminated core of the stator or the rotor wear a bestrombare winding. In permanent magnet-excited generators, the generator winding is arranged on one of these components and a plurality of permanent magnets are arranged on the other component. In electrically excited generators one of these components carries a field winding and the other the generator winding.

The drive shaft of the power generating unit according to the invention has at least one eccentric portion on which or the piston of the internal combustion engine are mounted and which transmits the drive energy of the internal combustion engine to the generator by preferably concentrically rotating generator rotor rotates within the generator stator. In order to allow a compact construction of the power generator and to allow a good energy transfer, the generator in the axial direction is preferably arranged as close as possible to the internal combustion engine. As a result, the drive shaft can advantageously be made short.

In order to achieve an electric current through the generator to make a round run of the drive shaft and to avoid the disadvantages mentioned in the introduction of an imbalance such as vibrations or vibrations, noise and wear, it is necessary that from the rotating masses, whose center of gravity does not coincide with the axis of rotation of the drive shaft, to compensate for the resulting imbalance by so-called balancing of the drive shaft. This can be done by attaching mass z. B. in the form of one or more weights on the rotating unit or by a removal of mass.

The comparatively large eccentric rotating masses and the associated large imbalances of an internal combustion engine make it difficult to remove a sufficient mass of the rotating unit of a power generator. It is therefore proposed to attach additional weights to the drive shaft or associated equipment. In the present system, the unbalance is introduced mainly by the eccentrically rotating rotary piston of the internal combustion engine. In order to place a balance weight as effectively as possible close to the rotating mass of the internal combustion engine, it is proposed to arrange this on the generator rotor. In order to achieve a good compensation effect is also proposed to arrange this weight in as large a radial distance from the axis of rotation of the drive shaft. In the immediate vicinity of the generator gap resulting between the rotor and the stator, the generator winding is mounted either on the generator stator or on the generator rotor in a generator of a power generator according to the invention. Since the generator winding preferably axially projects beyond the laminated core, a rotationally symmetrical free space results within this generator winding, which can be described as essentially disk-shaped or cone-shaped. According to the invention it is proposed to arrange a balance weight on the generator rotor within the generator winding - in this free space. An advantage of this solution is that the balance weight is arranged in the axial direction close to the rotating piston of the internal combustion engine and at a large radial distance from the axis of rotation of the drive shaft. Furthermore, it is advantageous in this arrangement that the space for receiving a balance weight with a comparatively large mass is suitable, while allowing the compact construction of the power generator.

The generator can be designed as Innenpol- or Außenpolgenerator. The generator rotor is preferably constructed of several structural components. In this case, the rotor is mounted on a rotor hub preferably made of a solid material. However, according to the invention, the rotor hub can also be constructed in several parts. At the periphery of this rotor hub, a laminated core is preferably arranged, which carries in conventional generator types either a winding of conductive material or permanent magnets.

In a preferred embodiment of the power generator, the generator is designed as a permanently excited Innenpolgenerator. In this case, the stator has a laminated core, which carries a winding of an electrically conductive material. In this case, permanent magnets are arranged on the rotor hub or on the circumference of the laminated core on the rotor hub. By rotation of the rotor within the stator, a current is induced in the current-conducting winding of the stator, and in this way the mechanical energy of the internal combustion engine is converted into electrical energy.

In a further preferred embodiment of the power generator, the generator is designed as an electrically excited Innenpolgenerator. Here, the generator rotor on its periphery on the laminated core, which sits on the rotor hub, arranged excitation winding.

On a generator rotor of these two preferred embodiments - permanently or electrically excited Innenpolgenerator - the invention proposes to arrange a balance weight within the arranged on the stator generator winding. This balancing weight may also be within this, depending on the design of the generator winding.

In another preferred embodiment of the power generator, the generator is designed as a Außenpolgenerator. In this case, the rotor has a laminated core preferably arranged on the rotor hub, which carries a generator winding. The stator preferably has on its circumference a generator winding arranged on a laminated core or permanent magnets arranged thereon. By rotation of the rotor within the stator, a current is induced in the current-conducting winding of the rotor, and in this way the mechanical energy of the internal combustion engine is converted into electrical energy. On the generator rotor of this preferred embodiment, a counterweight is arranged according to the invention within the generator winding arranged thereon.

All embodiments of the invention have in common that the balance weight is preferably designed and arranged on the generator rotor, that a large part of its mass is arranged at the greatest possible distance from the axis of rotation of the rotor. The balance weight can be made in one piece with a structural component of the rotor, such as the rotor hub. In another embodiment, one or more balancing masses can be fastened to the generator rotor by means of a material connection such as, for example, a weld or adhesive bond, a non-positive connection such as a screw connection or a positive connection such as riveting. Preferably, a leveling compound as a component may have a high density material, more preferably such material is lead or preferably tungsten. It is also possible to provide one or more balancing masses in the form of an insert, which may be connected to the rotor at least substantially positively, but in addition also materially or non-positively. In this case, the balance weight can be executed in one piece as well as in several parts. Also, the balance weight can be made of a material with a high specific weight, in multi-part balancing weights sub-masses can also consist of different materials.

In a preferred embodiment, the hub of the generator rotor is designed in one piece with the balance weight. In this case, the balance weight is preferably arranged at a radially large distance from the rotation axis and preferably has a large mass. The mass of the balance weight can be adjusted, for example, before installation of the generator rotor in a power generator with a specific drive shaft and specific associated rotating masses, preferably in accordance with the present compensation requirements by, for example, a machining material removal. In the same way, it is also possible to arrange one or more additional balancing weights on the generator rotor, preferably within the generator winding, if the balancing mass is connected too low in one piece.

In a preferred embodiment, the hub of the generator rotor is not designed in one piece with the balance weight. In this case, preferably, the position of the balance weight in the radial direction is adjustable. Preferably, the balance weight is adjustable by a threaded device or a guide device in particular for balancing the generator rotor in its radial position, in particular, the balance weight is set before the first startup of the power generator. This embodiment provides a particularly simple way of balancing the generator rotor.

If the balancing weight in a further preferred embodiment is not made in one piece with a structural component of the generator rotor, it is advantageously possible, in particular the material, the shape and the number of balancing weights, which are arranged within the generator winding, according to the requirements of the compensated Adjust imbalance.

Further advantages, features and applications of the present invention will become apparent from the following description taken in conjunction with the figures. Fig. 1: Fig. 2a: Fig. 2b: Fig. 2c: Fig. 3a: Fig. 3b: a drive shaft of a power generator with mounted thereon rotary piston and generator, the drive shaft of the generator set mounted thereon generator rotor, the hub of the generator rotor in a view from the front, the hub of the generator rotor in a view from the rear, the generator of the generator with generator stator and generator rotor in an axial view and the generator the power generator with generator stator and generator rotor in a radial view.

Fig. 1 shows a drive shaft 10 of a power generator with mounted thereon rotary piston 20 and generator 30. The rotary piston 20 of the internal combustion engine is mounted at a short distance from the generator 30 to the drive shaft 10, whereby the power generator has a compact construction. The generator 30 is a permanent-magnet internal pole generator. On the stator 40 of the generator 30, a laminated core 41 is arranged, on which a current-flowable conductor is wound. In Fig. 1, the winding carried by the laminated core 41 of the stator 40 - the generator winding 42 - easily recognizable. Radially inside the stator 40 of the generator of the generator rotor 4/9 Austrian Patent Office AT510 748B1 2014-06-15 50 is arranged. At the rotor hub, a balance weight 51 is integrally formed, which is arranged both radially and axially within the generator winding 42.

Fig. 2a shows the drive shaft 10 of the power generator in the same perspective as Fig. 1. In the illustration of Fig. 2a are compared to the illustration of Fig. 1, the rotary piston 20 and the generator stator 40 is removed. On the drive shaft 10 is now the eccentric to the drive shaft axis arranged portion 12 for supporting the rotary piston 20 can be seen, the central axis rotates on a circular path about the axis of rotation of the drive shaft 10. On the rotor 50 permanent magnets 52 are shown, which are arranged with alternating poles on a rotor hub 53 arranged on the laminated core 54 around the circumference of the laminated core, and in the rotation of the rotor 50 within the current-carrying generator winding 42 of the stator 40, a current in this winding induce. The balance weight 51 integrally formed on the rotor hub 53 extends outward from the rotor hub 53 in both the axial and radial directions, leaving a substantial portion of its mass axially adjacent to the lamination stack 54 and the permanent magnets 52 to rotate within the generator winding 42 extends.

It can be seen in FIGS. 2a and 2b that the balancing weight 51 is produced in one piece with the rotor hub 53. The transmission of the torque and the positioning of the rotor 50 and thus the balance weight 51 relative to the drive shaft 10 and thus against the mass to be compensated of the rotary piston 20 takes place radially via a keyway 55, which is shown in Fig. 2b. As can also be seen in FIGS. 2 a and 2 b, material was removed from the balance weight 51 by machining in order to adapt the balance weight 51 to the mass causing an imbalance and therefore to be compensated.

As can be seen in the view shown in Fig. 2c of the rotor hub 53 of the generator rotor 50, is located in the interior of an additional integrally formed on the rotor hub balance weight 56, which, however, is arranged relatively close to the axis of rotation.

Fig. 3a shows the generator 30 of the power generator with generator rotor 50 and generator stator 40 in a view in the axial direction. In this view, it can be seen that the balance weight 51 is arranged radially inside the generator winding 42.

Fig. 3b shows the arrangement of the stator 40 and the rotor 50 in a radial plan view. In this view, it can be seen in connection with FIG. 3 a that the balance weight 51 does not protrude from the outline of the stator 40. It is covered by the generator winding 42. It is therefore also in the axial direction within the generator winding 42. Due to the arrangement of the balance weight 51 of the design inherent in the generator 30 free space used for the purpose of balancing existing imbalances, creating a compact design of a power generator is made possible. 5.9

Claims (13)

Austrian Patent Office AT510 748B1 2014-06-15 Claims 1. Generating unit, in particular for use as a range extender in electrically powered motor vehicles, with an internal combustion engine and a generator (30), wherein the internal combustion engine is designed as a rotary piston engine, which at least one with an eccentric portion (12) of a drive shaft (10) rotating piston (20) and the generator (30) has a generator rotor (50) which is arranged on the common drive shaft (10), wherein a balance weight (51) on the generator rotor ( 50) is arranged radially inside the generator winding (42), characterized in that the balance weight (51) is formed integrally with the rotor hub (53) and in its radial outer region of the rotor hub (53) in both the axial and in extends radially outwards, wherein the balance weight (51) in the axial direction not over the stator protrudes. 2. Generating unit according to claim 1, characterized in that the generator (30) is designed as Innenpolgenerator and a generator rotor (50) which rotates within a generator winding (42). 3. Generating unit according to claim 1, characterized in that the generator (30) is designed as a Außenpolgenerator and a generator rotor (50) which rotates with the generator winding (42). 4. Generator according to one of the preceding claims, characterized in that the generator (30) within the generator winding (42) has a rotationally symmetrical free space, in which the balance weight (51) is arranged. 5. Generator according to claim 4, characterized in that the balance weight (51) is arranged in the radially outer region of the rotationally symmetrical free space. 6. Generating unit according to one of the preceding claims, characterized in that the generator rotor (50) is constructed in several parts and at least one rotor hub (53), a laminated core arranged thereon (54) and a winding or permanent magnets arranged thereon (52). 7. Generating unit according to one of claims 1 to 6, characterized in that the balance weight (51) is integrally connected to the rotor (50). 8. Generating unit according to one of claims 1 to 6, characterized in that the balance weight (51) is non-positively connected to the rotor (50). 9. Generating unit according to one of claims 1 to 6, characterized in that the balancing weight (51) is positively connected to the rotor (50). 10. Generating unit according to one of claims 1 to 6, characterized in that the balancing weight (51) is provided in the form of an insert which is connected in a form-fitting manner with the rotor (50) substantially. 11. Generating unit according to claim 10, characterized in that the insert is additionally connected to the rotor (50) in a material or non-positive manner. 12. Generating unit according to one of the preceding claims, characterized in that the balancing weight (51) is made in one piece or in several parts. 13. Generating unit according to claim 1, characterized in that the mass of the balance weight (51) is adjusted by a removal of material. 3 sheets of drawings 6/9