CN106797154B - 具有经由压铆部紧固至毂的转子的混合动力驱动模块 - Google Patents
具有经由压铆部紧固至毂的转子的混合动力驱动模块 Download PDFInfo
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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- B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
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Abstract
一种混合动力驱动模块,包括:扭矩转换器,该扭矩转换器具有盖、叶轮和涡轮;用于电动马达的转子;毂,该毂以不可旋转的方式连接至转子和盖且该毂包括周向表面以及从周向表面径向向外地延伸的多个突起;以及端板,该端板设置在多个突起与转子之间且与端板和转子接合。所述多个突起由形成毂的材料形成并且对端板和转子相对于毂在轴向方向上进行限制。
Description
相关申请的交叉引用
本申请根据美国法典第35卷第119(e)节要求于2014年10月9号提交的美国临时专利申请No.62/061,798的权益,上述申请的内容通过参引全部并入本文。
技术领域
本公开总体上涉及包括用于电动马达的转子的混合动力驱动模块,该转子经由铸铝毂的压铆部(staking)紧固至毂。
背景技术
已知使用内燃发动机与电动马达的混合动力组合对车辆提供动力。对于设计成使得转子的内径关于毂的外径是“间隙配合”(也称为“滑动配合”或“滑移配合”)的电动马达转子而言,需要一种将转子轴向地保持在毂上的装置。通常地,毂的一个侧部具有成形凸缘,从而为毂的该侧部提供轴向保持。然而,毂的另一侧部需要下述装置:该装置不干涉转子和毂的组装且在转子和毂的组装之后轴向地保持转子。
已知的是,将转子经由毂上的成形凸缘紧固至毂并且在安装转子之后经由螺母螺纹连接至毂。车螺纹操作及螺母的使用增加了成本、复杂性和形成组件的部件数量。还已知的是,将转子经由毂上的成形凸缘紧固至毂,并且在转子安装到毂上之后使毂的一部分弯曲来形成一个或更多个突出部以轴向地保持转子。突出部不能为具有较大质量的转子提供足够的轴向保持。还已知的是,使用上述方法将旋转变压器转子紧固至毂。
发明内容
根据本文示出的方面提供了一种混合动力驱动模块,该混合动力驱动模块包括:具有盖、叶轮和涡轮的扭矩转换器;用于电动马达的转子;毂,该毂以不可旋转的方式连接至转子和盖且包括周向表面以及从所述周向表面径向向外地延伸的多个突起;以及端板,该端板设置在多个突起与转子之间且与端板和转子接合。多个突起由形成毂的材料形成且在轴向方向上对端板和转子相对于毂进行限制。
根据本文示出的方面提供了一种混合动力驱动模块,该混合动力驱动模块包括:具有盖、叶轮和涡轮的扭矩转换器;用于电动马达的转子;端板;弹簧,该弹簧位于端板与转子之间且沿第一轴向方向迫压转子;以及毂,该毂以不可旋转的方式连接至转子和盖且包括周向表面和多个突起。多个突起从所述周向表面径向向外地延伸且由形成毂的材料形成,并且所述多个突起与端板接合,并且所述多个突起沿与第一轴向方向相反的第二轴向方向对端板和转子相对于毂进行限制。
根据本文示出的方面提供了一种将部件紧固至混合动力驱动模块的毂的方法,该混合动力驱动模块包括扭矩转换器和分离离合器,所述方法包括:将用于电动马达的转子以不可旋转的方式连接至毂的周向表面;将端板安置在第一周向表面上;使用冲头使形成毂的材料变形来形成从周向表面径向向外地延伸的多个突起;使端板与多个突起相接触;以及利用多个突起限制端板和转子相对于毂在轴向方向上的移位,将毂与用于扭矩转换器的盖以不可旋转的方式连接;将毂与用于扭矩转换器的盖以不可旋转的方式连接。
附图说明
参照示意性附图仅通过示例的方式公开了各种实施方式,其中,相应的附图标记表示相应的部件,在附图中:
图1是表明了本申请中使用的空间术语的圆柱坐标系的立体图;
图2是混合动力驱动模块的截面图,示出了由端板和压铆部紧固的电动马达的转子;
图3是混合动力驱动模块的截面图,示出了由端板、弹簧和压铆部紧固的电动马达的转子;
图4A和图4B示出了将部件紧固至包括扭矩转换器和分离离合器的混合动力驱动模块的毂的方法;以及
图5A和图5B示出了将部件紧固至包括扭矩转换器和分离离合器的混合动力驱动模块的毂的方法。
具体实施方式
首先,应当理解的是,不同附图上的相同附图标记表示本公开的相同的、或者功能相似的结构元件。应当理解的是,要求保护的本公开不局限于所公开的方面。
此外,应当理解的是,本公开不局限于所描述的特定方法、材料和修改,并且因此当然可以对其改变。还应当理解的是,本文中所使用的术语仅意在描述特定方面而非旨在限制本公开的范围。
除非特别指出,否则本文中所使用的全部技术术语及科学术语均具有本发明所属领域中的普通技术人员普遍理解的意义。应当理解的是,与本文中描述的那些方法、装置或材料类似或等同的任何方法、装置或材料可以用于本公开的实践或测试中。
通过“以不可旋转的方式连接的”第一部件和第二部件,这表示,第一部件连接至第二部件使得任何时候第一部件旋转,第二部件与第一部件一起旋转,并且任何时候第二部件旋转,第一部件与第二部件一起旋转。第一部件与第二部件之间可以存在轴向移位。
图1是表明了用于描述本公开的空间术语的圆柱坐标系10的立体图。本公开至少部分地在圆柱坐标系下进行描述。系统10包括纵向轴线11,纵向轴线11用作以下方向及空间术语的参考。轴向方向AD平行于轴线11。径向方向RD正交于轴线11。周向方向CD由绕轴线11旋转的半径R(正交于轴线11)的端点限定。
对象12、对象13和对象14用于清楚地说明空间术语。轴向表面比如对象12的表面15由与轴线11共面的平面形成。轴线11穿过平面表面15;然而,与轴线11共面的任何平面表面均是轴向表面。径向表面比如对象13的表面16由正交于轴线11的平面形成且与半径例如半径17共面。半径17穿过平面表面16;然而,与半径17共面的任何平面表面均是径向表面。对象14的表面18形成周向或柱形表面。例如,周缘19穿过表面18。作为另一示例,轴向运动平行于轴线11,径向运动正交于轴线11,并且周向运动平行于周缘19。旋转运动相对于轴线11。
副词“轴向地”、“径向地”和“周向地”分别指平行于轴线11、半径17和周缘19的取向。例如,轴向设置的表面或边缘沿方向AD延伸,径向设置的表面或边缘沿方向R延伸,并且周向设置的表面或边缘沿方向CD延伸。副词“轴向地”、“径向地”和“周向地”还涉及与相应的平面平行的取向。
图2是混合动力驱动模块100的截面图,示出了由端板和压铆部紧固的电动马达的转子。混合动力驱动模块100(以下称为模块100)包括:旋转轴线AR;扭矩转换器110;毂105;端板125;以及包括转子122的电动马达120。扭矩转换器110包括盖112、叶轮113、涡轮114和定子116。毂105例如通过至少一个铆钉109以不可旋转的方式连接至盖112。毂105包括周向表面107和突起106。转子122与表面107接合且例如通过花键143以不可旋转的方式连接至毂105。板125与转子122接合。突起106从周向表面107沿方向RD径向向外地延伸且由形成毂105的材料形成,并且突起106与板125相接触且在方向AD1上对板125和转子122进行限制。
在示例性实施方式中,突起106限制板125和转子122在与方向AD1相反的轴向方向AD2上的相对运动。也就是说,突起106固定转子122在毂105上的轴向位置。例如,突起106与板125相接触,这迫使转子122与毂的肩部137相接触。因而,转子122不能在任一方向AD1或AD2上移位。
图3是混合动力驱动模块的截面图,示出了由端板、弹簧和压铆部紧固的电动马达的转子。在示例性实施方式中,模块100包括端板125和弹簧124,例如膜片弹簧124。端板125设置在突起106与转子122之间且与突起106接合。弹簧124设置在端板125与转子122之间且与端板125和转子122接合。弹簧124反作用于端板125来迫压转子122沿方向AD2与肩部137相接触,从而提供动力以将转子122轴向地固定抵靠在肩部137上且更好地维持转子相对于毂的特定的轴向位置。在示例性实施方式中,突起106与板125相接触。在示例性实施方式中,弹簧124与端板125相接触。
除非另外指出,以下内容适用于图2和图3。在示例性实施方式中,转子122包括至少一个磁体140,端板125由非磁性材料制成以防止电短路及磁短路,并且端板125在方向AD1上对磁体140进行保持或限制。也就是说,端板125阻挡磁体140沿方向AD1的运动。
在示例性实施方式中,毂105包括周向表面138和突起139,并且模块100包括与表面138接合的旋转变压器转子128。突起139从周向表面138沿方向RD径向向外地延伸且由形成毂105的材料形成,并且突起139将转子128固定至毂105。固定至壳体115的旋转变压器127检测旋转变压器转子128在毂105上的旋转位置以便控制电动马达120的旋转及功率输出。
在示例性实施方式中,模块100包括输入部件130或者布置成接合输入部件130,且模块100包括分离离合器132。部件130布置成接收例如来自内燃发动机(未示出)的扭矩。离合器132包括以不可旋转的方式连接至毂105的至少一个离合器板133、以不可旋转的方式连接至输入部件130的内承载件134、以不可旋转的方式连接至内承载件134的离合器板135、以及可轴向移动以打开和闭合离合器132的活塞板136。离合器132使得输入部件130和盖112能够选择性地连接。因而,模块100能够以至少三种模式起作用。对于第一模式而言,离合器132打开并且经由转子122的电动马达120是扭矩转换器110的唯一扭矩源。对于第二模式而言,离合器132闭合,电动马达120不驱动扭矩转换器110,并且用于扭矩转换器110的唯一的扭矩源是经由分离离合器的输入部件130。对于第三模式而言,离合器132闭合并且马达120用于对输入部件130提供扭矩,以起动附接至输入部件130的内燃发动机(未示出)。
在示例性实施方式中,扭矩转换器110包括扭转振动阻尼器111,扭转振动阻尼器111具有以不可旋转的方式连接至涡轮114的输入部件118、布置成连接至传动装置输入轴(未示出)的输出部件119、以及与输入部件118和输出部件119接合的至少一个弹簧121。
在示例性实施方式中,毂105由铸铝制成。突起106和突起139不与毂一起铸造且不通过任何类型的弯曲操作形成。而是,如下文所述,突起106和突起139通过对铸造毂压铆来制造。通过“压铆”是指用一个或更多个冲头使铸造毂的相应部分变形。变形部分形成突起106和突起139并且在没有紧固件和其他添加材料的情况下将转子和旋转变压器转子紧固至毂。具体地,通过压铆而变形和移位的材料形成突起106和突起139并且在突起106与板125之间以及突起139与转子127之间形成相应的过盈配合。
铸造工艺中形成的突起与压铆突起之间的差异是通过材料的物理特性来示例的,例如,形成铸造毂(并且不压铆或者通过压铆变形)的铝与形成变形突起的材料之间的差异。例如,形成铸造毂且不压铆或者通过压铆变形的材料(例如,不包括与突起106或突起139相邻的材料)具有每单位体积“x”个晶格缺陷,包括:点缺陷或瑕疵、线缺陷或者表面缺陷-晶界。形成突起106的材料具有每单位体积大于“x”个的“y”个晶格缺陷,包括:点缺陷或瑕疵、线缺陷或者表面缺陷-晶界。形成突起139的材料具有每单位体积大于“x”个的“z”个晶格缺陷,包括:点缺陷或瑕疵、线缺陷或者表面缺陷-晶界。晶格缺陷的增加是由于形成原始铸造毂的材料通过压铆工艺变形而引起的。
在示例性实施方式中,毂105由铝制成,这有利地减小了毂的重量及转动惯量,并且盖112由钢制成,这降低了盖112的制造成本且提高了盖的耐久性。
图4A和图4B示出了将部件紧固至混合动力驱动模块的毂的方法,该混合动力驱动模块包括扭矩转换器110和分离离合器132。以下应当根据图2、图4A和图4B进行观察。尽管为了清楚起见将本方法呈现为一系列步骤,但是除非明确说明,否则不应当根据编号推断顺序。第一步骤将用于电动马达120的转子122以不可旋转的方式连接至毂105的周向表面107,例如,使转子122与花键143接合。第二步骤将端板124安置在表面107上。第三步骤使用冲头P1使形成毂105的材料变形以形成从表面136径向向外地延伸的突起106。注意,在示例性实施方式中,在接纳冲头P1之前,毂105的端部141是平面的。第四步骤利用突起106限制端板125和转子122相对于毂105在轴向方向AD1上的移位。第五步骤将毂105以不可旋转的方式连接至扭矩转换器110的盖112。
在示例性实施方式中,第六步骤利用突起106迫压板125与转子122相接触。在示例性实施方式中,第七步骤使突起106与端板125相接触。第八步骤将布置成接收扭矩的输入部件130与内承载件134以不可旋转的方式连接。第九步骤将至少一个离合器板133以不可旋转的方式连接至毂105。第十步骤将至少一个离合器板135以不可旋转的方式连接至内承载件134。第十一步骤安装活塞板136,该活塞板136可轴向地移动以打开和闭合分离离合器132。
在示例性实施方式中:第十二步骤使旋转变压器转子128与毂105的周向表面138接合;第十三步骤使用冲头P1或冲头P2使形成毂105的材料变形以形成从周向表面138径向向外地延伸的突起139;并且第十四步骤利用突起139将旋转变压器转子固定地紧固至毂。值得注意的是,在示例性实施方式中,在接纳冲头P1或冲头P2之前,毂105的端部142是平面的。
图5A和图5B示出了将部件紧固至混合动力驱动模块的毂的方法,该混合动力驱动模块包括扭矩转换器110和分离离合器132。以下应当根据图3、图5A和图5B进行观察。尽管为了清楚起见将本方法呈现为一系列步骤,但是除非明确说明,否则不应当根据编号推断顺序。第一步骤将用于电动马达120的转子122以不可旋转的方式连接至毂105的周向表面107,例如,从而使转子122与花键143接合。第二步骤将端板124安置在表面107上。第三步骤将弹簧124插置于端板125与转子之间。第四步骤使用冲头P3压缩端板125与转子122之间的弹簧。第五步骤利用弹簧沿轴向方向AD2迫压转子。第六步骤使用冲头P4使形成毂105的材料变形以形成从表面136径向向外地延伸的突起106。值得注意的是,在示例性实施方式中,在接纳冲头P4之前,毂105的端部141是平面的。第七步骤利用突起106限制端板125和转子122相对于毂105在轴向方向AD1上的移位。第八步骤将毂105以不可旋转的方式连接至扭矩转换器110的盖112。
在示例性实施方式中,第九步骤利用突起106迫压板125与弹簧124相接触。在示例性实施方式中,第十步骤使端板125与突起106相接触。第十一步骤将布置成接收扭矩的输入部件130与内承载件134以不可旋转的方式连接。第十二步骤将至少一个离合器板133以不可旋转的方式连接至毂105。第十三步骤将至少一个离合器板135以不可旋转的方式连接至内承载件134。第十四步骤安装活塞板136,该活塞板136可轴向地移动以打开和闭合分离离合器132。
在示例性实施方式中:第十五步骤使旋转变压器转子128与毂105的周向表面138接合;第十六步骤使用冲头P4或冲头P5使形成毂105的材料变形以形成从周向表面138径向向外地延伸的突起139;并且第十七步骤利用突起139将旋转变压器转子固定地紧固至毂。注意,在示例性实施方式中,在接纳冲头P4或冲头P5之前,毂105的端部142是平面的。
可以理解的是,上文公开的各个方面及其他特征和功能或其替代方案可以根据需要结合到许多其他不同系统或应用中。本领域中的普通技术人员随后可以做出本发明的各种当前不可预见或不可预料的替换、修改、变型或改进,所述替换、修改、变型或改进也被包括在所附权利要求书中。
Claims (11)
1.一种混合动力驱动模块,包括:
扭矩转换器,所述扭矩转换器包括盖、叶轮、以及涡轮;
用于电动马达的转子;
端板;
弹簧,所述弹簧设置在所述端板与所述转子之间且沿第一轴向方向迫压所述转子;以及
毂,所述毂以不可旋转的方式连接至所述转子和所述盖,并且所述毂包括第一周向表面以及多个第一突起,所述多个第一突起径向向外延伸超出所述第一周向表面;所述多个第一突起由形成所述毂的材料形成;并且,所述多个第一突起沿与所述第一轴向方向相反的第二轴向方向对所述转子相对于所述毂进行限制。
2.根据权利要求1所述的混合动力驱动模块,其中:
所述多个第一突起与所述端板相接触;并且
所述弹簧反作用于所述端板以沿所述第一轴向方向迫压所述转子。
3.根据权利要求1所述的混合动力驱动模块,其中:
形成所述毂的材料,除所述多个第一突起和与所述多个第一突起相邻的材料以外,具有每单位体积第一数量的晶格缺陷,所述第一数量的晶格缺陷包括:点缺陷、线缺陷或表面缺陷;以及
形成所述多个第一突起的材料具有大于所述每单位体积第一数量的晶格缺陷的每单位体积第二数量的晶格缺陷,所述第二数量的晶格缺陷包括:点缺陷、线缺陷或表面缺陷。
4.根据权利要求1所述的混合动力驱动模块,其中:
所述转子包括至少一个磁体;
所述端板由非磁性材料制成;并且
所述端板沿所述第二轴向方向对所述至少一个磁体进行限制。
5.根据权利要求1所述的混合动力驱动模块,其中,所述毂包括:
第二周向表面;以及
多个第二突起,所述多个第二突起从所述第二周向表面径向向外地延伸;并且,所述多个第二突起由形成所述毂的材料形成,
所述混合动力驱动模块还包括旋转变压器转子,所述旋转变压器转子与所述第二周向表面接合,其中,所述多个第二突起将所述旋转变压器转子固定地紧固至所述毂。
6.根据权利要求1所述的混合动力驱动模块,还包括:
输入部件,所述输入部件布置成接收扭矩;以及
分离离合器,包括:
至少一个第一离合器板,所述至少一个第一离合器板以不可旋转的方式连接至所述毂;
内承载件,所述内承载件以不可旋转的方式连接至所述输入部件;
至少一个第二离合器板,所述至少一个第二离合器板以不可旋转的方式连接至所述内承载件;以及
活塞板,所述活塞板能够轴向地移动以打开和闭合所述分离离合器。
7.根据权利要求6所述的混合动力驱动模块,其中:
对于第一模式而言:
所述分离离合器打开以使得所述毂和所述内承载件能够独立旋转;并且,
所述转子是用于所述扭矩转换器的唯一扭矩源;
对于第二模式而言:
所述分离离合器闭合以将所述毂和所述内承载件以不可旋转的方式连接;并且,
所述输入部件是所述扭矩转换器的唯一扭矩源;并且,
对于第三模式而言:
所述分离离合器闭合以将所述毂和所述内承载件以不可旋转的方式连接;并且,
所述转子经由所述分离离合器对所述输入部件提供扭矩。
8.一种将部件紧固至混合动力驱动模块的毂的方法,所述混合动力驱动模块包括扭矩转换器和分离离合器,所述方法包括:
将用于电动马达的转子以不可旋转的方式连接至毂的第一周向表面;
将端板安置在所述第一周向表面上;
将弹簧插置于所述端板与所述转子之间;
压缩所述端板与所述转子之间的所述弹簧;以及
利用所述弹簧沿与第一轴向方向相反的第二轴向方向迫压所述转子;
使用第一冲头使形成所述毂的材料变形以形成从所述第一周向表面径向向外地延伸的多个第一突起;以及
利用所述多个第一突起限制所述端板和所述转子相对于所述毂沿第一轴向方向的移位。
9.根据权利要求8所述的方法,还包括:
将旋转变压器转子与所述毂的第二周向表面接合;
使用所述第一冲头或第二冲头使形成所述毂的材料变形以形成从所述第二周向表面径向向外地延伸的多个第二突起;以及
利用所述多个第二突起将所述旋转变压器转子固定地紧固至所述毂。
10.根据权利要求8或9所述的方法,还包括:
使形成所述毂的材料变形,使得:
形成所述毂的材料,除所述多个第一突起和与所述多个第一突起相邻的材料以外,具有每单位体积第一数量的晶格缺陷,所述第一数量的晶格缺陷包括:点缺陷、线缺陷或表面缺陷;以及
形成所述多个第一突起的材料具有大于所述每单位体积第一数量的晶格缺陷的每单位体积第二数量的晶格缺陷,所述第二数量的晶格缺陷包括:点缺陷、线缺陷或表面缺陷。
11.根据权利要求8所述的方法,还包括:
将所述毂和用于所述扭矩转换器的盖以不可旋转的方式连接。
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PCT/US2015/053509 WO2016057307A1 (en) | 2014-10-09 | 2015-10-01 | Hybrid drive module having a rotor secured to a hub via staking |
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JP6714458B2 (ja) * | 2016-07-15 | 2020-06-24 | 株式会社エクセディ | トルクコンバータ、及び動力伝達装置 |
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WO2018131693A1 (ja) * | 2017-01-13 | 2018-07-19 | 日本電産株式会社 | センサマグネットアセンブリ、およびモータ |
US10850605B2 (en) | 2017-03-13 | 2020-12-01 | Schaeffler Technologies AG & Co. KG | Hybrid drive module having a rotor secured to a hub utilizing staking of an end ring |
US10559989B2 (en) * | 2017-08-07 | 2020-02-11 | Schaeffler Technologies AG & Co. KG | Rotor carrier and locking diaphragm spring |
US11121605B2 (en) * | 2017-08-07 | 2021-09-14 | Schaeffler Technologies AG & Co. KG | Hybrid module with clutch balance chamber |
US10486520B2 (en) * | 2017-09-15 | 2019-11-26 | Schaeffler Technologies AG & Co. KG | Hybrid module shipping assembly |
US10797548B2 (en) | 2017-12-15 | 2020-10-06 | Schaeffler Technologies AG & Co. KG | Hybrid module including motor rotor clamp ring staked to rotor hub |
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