DE102019207438A1 - Electrically assisted turbocharger - Google Patents

Abstract

The present invention relates to an electrically assisted turbocharger (100) comprising a compressor housing (106), a stator package (108) connected to the compressor housing (106) of an electric motor (104) coupled to the turbocharger (100) and a stator package (108) has a subsequent electronics housing (110) of the electric motor (104), with coolant channels (112) being arranged in the stator package (108), which fluidically connect the compressor housing (106) and the electronics housing (110) to one another and through connecting channels (300) are fluidically interconnected in the compressor housing (106) and in the electronics housing (110)

Description

Field of invention

The invention relates to an electrically assisted turbocharger.

State of the art

The DE 10 2017 207 532 A1 describes an electrical media splitting machine for a compressor and / or a turbine, turbocharger and / or turbine.

Disclosure of the invention

Against this background, the approach presented here is used to present an electrically assisted turbocharger according to the independent claim. Advantageous developments and improvements of the approach presented here emerge from the description and are described in the dependent claims.

Advantages of the invention

Embodiments of the present invention can advantageously enable an electrically assisted turbocharger to be integrated into a cooling circuit of a vehicle and to control the temperature. In this case, a cooling medium for controlling the temperature of an electric motor of the turbocharger and for controlling the temperature of a compressor of the turbocharger can be fed via a common inflow and a common outflow.

An electrically assisted turbocharger is proposed, the turbocharger having a compressor housing, a stator pack connected to the compressor housing of an electric motor coupled to the turbocharger, and an electronics housing of the electric motor connected to the stator pack, with coolant channels being arranged in the stator pack, which the compressor housing and the Connect electronics housings fluidly to one another and are fluidically interconnected by connecting channels in the compressor housing and in the electronics housing.

Ideas for embodiments of the present invention can be viewed, inter alia, as being based on the thoughts and knowledge described below.

In the case of an electrically assisted turbocharger, a compressor wheel of the turbocharger is coupled to an electric motor and can be driven by the electric motor. An electric motor can be understood as an electrical machine that can convert electrical power into mechanical power. To simplify the language, the electric machine is referred to here as an electric motor.

The turbocharger can be used to supply an increased amount of combustion air to an internal combustion engine. To do this, the turbocharger draws in air and compresses it. During operation, the turbocharger therefore has a higher air pressure at an air outlet than at an air inlet. The air pressure at the air outlet can be referred to as boost pressure. The electric motor can provide at least a portion of the power required to compress the air. If the turbocharger is an exhaust gas turbocharger, the compressor wheel can also be operated in a working area when an exhaust gas turbine of the exhaust gas turbocharger cannot provide sufficient power.

The electric motor can be designed as a media gap motor. In a media gap motor, a medium, i. for example an intake flow of the turbocharger, passed between a rotor of the media gap motor and a stator of the media gap motor. In the case of the turbocharger, the medium can in particular be air.

A stator packet can consist of essentially similar, mutually aligned and stacked metal sheets. A compressor housing can be referred to as a volute housing. The compressor housing can have stationary parts of the compressor, such as guide vanes, and at least one air outlet duct.

An electronics housing can accommodate the electrical and electronic components required for operating the electric motor, such as control electronics and power electronics. The electronics housing can be designed as a hollow cylinder around an intake duct of the turbocharger.

The stator package can have two opposing contact surfaces, which are aligned essentially parallel to one another, with the compressor housing and the electronics housing. The coolant channels can be continuous recesses in the stator core from contact surface to contact surface. The coolant channels can be fluid-tight. Connection channels can run essentially transversely to the coolant channels. A connecting channel can connect at least two of the coolant channels.

The coolant channels can be designed as flow channels and return channels in the stator package. The connecting channels in the electronics housing can be designed as distribution channels and as collector channels separate from the distribution channels. A coolant inlet of the electronics housing can be connected to the flow ducts through the distribution ducts. The return channels can be connected to a coolant outlet of the electronics housing through the collector channels. The flow channels and the return channels can be connected by the connecting channels in the compressor housing.

Alternatively, the connecting channels in the compressor housing can be designed as distributor channels and as collector channels that are separate from the distributor channels. A coolant inlet of the compressor housing can be connected to the supply ducts through the distributor ducts. The return ducts can be connected to a coolant outlet of the compressor housing through the collector ducts. The flow channels and the return channels can be connected by the connecting channels in the electronics housing. Coolant can be routed from a cooler in supply channels. In return ducts, already heated coolant can be directed towards the cooler. A constant mean temperature of the electronics, the stator and the compressor housing can be achieved by feeding the cooling medium back and forth.

Alternatively, the connection channels in the electronics housing can be designed as distribution channels. The connecting channels in the compressor housing can be designed as collector channels. A coolant inlet of the electronics housing can be connected to the coolant channels through the distribution channels. The coolant channels can be connected to a coolant outlet of the compressor housing through the collector channels. The electronics can be cooled with cool coolant so that it heats up on the way to the compressor and from there can be returned to the cooler. A temperature of the electronics can be kept at a low value by routing the coolant from the electronics through the stator to the compressor. The heated coolant can also be passed through a charge air cooler.

In the approach presented here, the coolant inlet and the coolant outlet can be positioned freely. This means that structural conditions in the vehicle can be taken into account.

The coolant channels can be designed as axially aligned tubes in the stator core. The stator package usually consists of laminated metal sheets. Leaks can occur between the sheets. Pipes can have an uninterrupted wall. A tightness of the coolant channels can be ensured by pipes. The tubes can be made of a different material than the stator core. For example, the tubes can have a better thermal conductivity than the stator core.

The tubes can be pressed into the stator package. A press fit can ensure good heat transfer between the tubes and the stator.

The stator package can have at least one coolant channel per coil of the electric motor. The coolant channels can be arranged inside a stator yoke of the stator core. The coolant channels can be arranged in the area of a transition between the stator yoke and stator teeth of the stator.

The connecting channels can be designed as a labyrinth in the electronics housing and / or in the compressor housing. A channel routing via at least one detour can be referred to as a labyrinth. In particular, a channel guide with at least one approximately 180 ° curve can be used as a labyrinth. The curve can be called a turn. A connecting channel of the labyrinth can for example run from the flow channel in the direction of the return channel. The connecting channel can be guided past the return channel in the direction of the next flow channel. Shortly before the next flow channel, the connecting channel can have its 180 ° curve and run in the opposite direction to the return channel. The compressor housing and / or the electronics housing can be cooled by a labyrinth over a complete contact surface with the stator package.

The connecting channels can be designed in the electronics housing and / or in the compressor housing as recesses in a contact surface to the stator package. The connecting channels can be milled into the contact surface. The connection channels can be sealed by a seal between the stator package and the electronics housing or the compressor housing. The electronics housing and / or the compressor housing can be manufactured in a simplified manner by an arrangement in the area of the contact surface, since the connecting channels can be introduced into the contact surface in the same clamping in which the contact surface is milled flat in order to achieve the tightness.

The stator packet can have a heat dissipation surface on an outside. The stator package can be visible on the outside. Narrow edges of the stator laminations can be exposed on the outside. The outside can be structured in order to obtain an enlarged heat dissipation surface. For example, the stator laminations can have slightly different dimensions on the outside in order to produce a structure similar to cooling fins.

Figure list

• 1 zeigt eine Darstellung eines elektrisch unterstützten Turboladers gemäß einem Ausführungsbeispiel mit Kühlmittelanschlüssen an einem Elektronikgehäuse des Turboladers;
• 2 zeigt eine Darstellung eines elektrisch unterstützten Turboladers gemäß einem Ausführungsbeispiel mit Kühlmittelanschlüssen an einem Verdichtergehäuse des Turboladers;
• 3 zeigt eine Darstellung eines Elektronikgehäuses eines elektrisch unterstützten Turboladers gemäß einem Ausführungsbeispiel;
• 4 zeigt eine Darstellung eines Statorpakets eines elektrisch unterstützten Turboladers gemäß einem Ausführungsbeispiel; und
• 5 zeigt eine Schnittdarstellung eines Statorpakets und eines Elektronikgehäuses eines elektrisch unterstützten Turboladers gemäß einem Ausführungsbeispiel.

Embodiments of the invention are described below with reference to the accompanying drawings, neither the drawings nor the description being to be interpreted as restricting the invention.

• 1 shows a representation of an electrically assisted turbocharger according to an embodiment with coolant connections on an electronics housing of the turbocharger;
• 2 shows an illustration of an electrically assisted turbocharger according to an embodiment with coolant connections on a compressor housing of the turbocharger;
• 3 shows an illustration of an electronics housing of an electrically assisted turbocharger according to an embodiment;
• 4th shows an illustration of a stator pack of an electrically assisted turbocharger according to an embodiment; and
• 5 FIG. 11 shows a sectional illustration of a stator core and an electronics housing of an electrically assisted turbocharger according to an exemplary embodiment.

The figures are only schematic and not true to scale. In the figures, the same reference symbols denote the same or similarly acting features.

Embodiments of the invention

1 Figure 3 shows an illustration of an electrically assisted turbocharger 100 according to an embodiment. The turbocharger 100 has a compressor 102 and one with the compressor 102 coupled electric motor 104 on. When the turbocharger 100 is designed as an exhaust gas turbocharger, the turbocharger 100 also one, not shown, with the compressor 102 coupled exhaust gas turbine.

A rotatable compressor wheel of the compressor 102 is in a compressor housing 106 of the compressor 102 arranged. The compressor wheel is connected to a rotor of the electric motor 104 coupled. The rotor is in a stator package 108 of the electric motor 104 rotatably mounted. In the stator package 108 Coils are arranged, which have power electronics of the electric motor 104 can be controlled to generate a rotating electromagnetic field to drive the rotor. The power electronics are in an electronics housing 110 of the electric motor 104 arranged.

The stator package 108 is between the compressor housing 106 and the electronics housing 110 arranged. The stator package 108 , the compressor housing 106 and the electronics housing 110 have common coolant channels 112 on. Here are coolant connections 114 the coolant channels 112 on the electronics housing 110 arranged.

The coolant flows from a coolant inlet in the coolant channels 112 from the electronics housing 110 through the stator package 108 to the compressor housing 106 and through the stator package 108 back to the electronics housing 110 and to a coolant outlet.

2 Figure 3 shows an illustration of an electrically assisted turbocharger 100 according to an embodiment. The turbocharger 100 essentially corresponds to the turbocharger in 1 . In contrast to this are the coolant connections 114 on the compressor housing 106 of the turbocharger 100 arranged.

The coolant flows from the coolant inlet into the coolant channels 112 from the compressor housing 106 through the stator package 108 to the electronics housing 110 and through the stator package 108 back to the compressor housing 106 and to the coolant outlet.

In one embodiment, the coolant inlet is on the electronics housing 110 arranged, while the coolant outlet on the compressor housing 106 is arranged. The coolant flows from the coolant inlet on the electronics housing 110 through the stator package 108 to the coolant outlet on the compressor housing 106 .

3 shows a representation of an electronics housing 110 an electrically assisted turbocharger according to an embodiment. The electronics housing essentially corresponds to the electronics housing in FIG 2 . The electronics housing 110 has three separate connecting channels 300 on that as sub-areas of the coolant channels 112 one flow channel each 302 of the stator core with a return duct 304 of the stator core. The stator package, not shown, therefore has three flow channels 302 and three return channels 304 on. Through the flow channels 302 the coolant is from the compressor housing, not shown, to the electronics housing 110 directed. Through the return channels 304 gets the coolant from the electronics housing 110 returned to the compressor housing. The connecting channels 300 are as recesses in a contact area 306 of the electronics housing 110 formed into the stator core. The connecting channels 300 are therefore as grooves in a wall 308 of the electronics housing 110 executed.

In one embodiment the connection channels are 300 Run in a labyrinth. A connecting channel leads here 300 essentially parallel to an inner wall or an outer wall of the electronics housing 110 from its forward channel 302 in the direction of its return duct 304 . Just before his return canal 304 the connecting channel runs 300 arched on the return channel 304 past and further essentially parallel to the outer wall in the direction of the next flow channel 302 . Just before the next flow channel 302 the connection channel reverses 300 reverses its direction and runs substantially parallel to the inner wall back to its return channel 304 . This creates a predominant part of the contact area 306 and the wall 308 of the electronics housing 110 through a connecting channel 300 chilled.

4th shows an illustration of a stator core 108 an electrically assisted turbocharger 100 according to an embodiment. The stator package 108 essentially corresponds to that in the 1 and 2 shown stator package. The stator package 108 is on the electronics housing 110 shown attached. Between the stator package 108 and the electronics housing 110 is a seal 400 arranged. Additionally, here are the coils 402 and an air duct 404 of the electric motor 104 shown. As in 3 assigns the stator core 108 six coolant channels 112 on. The coolant channels 112 are as transverse to the stator laminations of the stator core 108 running tubes formed. The tubes are for example in the stator package 108 pressed in.

The electric motor 104 has six coils here 402 on, each on a radial to an axis of rotation of the electric motor 104 aligned stator tooth are arranged. The coolant channels 112 are in the area of nodes of the stator teeth and an annular stator yoke of the stator core 108 arranged.

The air duct 404 covers an annular media gap of the electric motor 104 out. The media gap extends annularly between the coils 402 and a centrally arranged rotor housing of the electric motor 104 . The stator teeth extend from the stator yoke into the rotor housing. In the area of the media gap, the stator teeth are through the air duct 404 aerodynamically clad.

5 shows a sectional view of a stator core 108 and an electronics housing 110 an electrically assisted turbocharger 100 according to an embodiment. The stator package 108 and the electronics housing 110 essentially correspond to the representation in 4th . The stator package 108 and the electronics housing 110 are through one of the coolant channels 112 shown cut. The tube stands over the stator package on both sides 108 over and penetrates into the electronics housing 110 and the compressor housing, not shown. The groove of the distribution channel 300 in the electronics housing 110 is deeper than the pipe in the electronics housing 110 penetrates. In this way, the coolant also gets close to the one in the electronics housing 110 arranged power electronics 500 and can heat loss from power electronics 500 transport away.

The stator package 108 is exposed on one outside. This can cause heat loss 502 of the coils 402 in addition to the heat transport via the coolant channels 112 are released into the environment over the entire outside.

In other words, a common water circuit of an e-machine with a compressor housing is presented.

With the approach presented here, the stator package of the motor, the power electronics and the heat input from the compressor housing into the electronics housing (eTA housing) can be minimized and at the same time the temperature of the compressor can be reduced. ETA stands for electrical support for a turbocharger (electrical Turbo Assist)

The stator package of the motor and the power electronics are cooled and the heat input from the compressor to the electronics housing and the heating of the compressor are minimized, which leads to a significant efficiency advantage for the compressor, with which higher pressure ratios can be achieved.

Both the direction from the electronics housing to the compressor and the direction from the compressor to the electronics housing can be implemented as the cooling water flow direction. The flow direction from the electronics housing to the compressor is preferably used, since the electronics housing or the electronics particularly benefit from lower cooling water temperatures. For example, the service life of the solder points or the bond connections can be improved.

Due to the common cooling system, the electronics housing and the exhaust gas turbocharger (ATL), additional piping and two water connections are not required. This preliminary cooling in the compressor also relieves the load on the charge air cooler (CAC), especially when a small charge air cooler is already integrated at the compressor outlet.

The compressor can also be protected against laking due to thermally degraded oil residues. With the approach presented here, only two water connections on the exhaust gas turbocharger are required for the low-temperature circuit. The bearing housing can be used as a third heat source be included. A particularly advantageous flow sequence then results from the electronics housing with the electronics to the stator to the compressor housing with a charge air cooler optionally integrated into the compressor housing and to the bearing housing or a fuselage group.

The compressor housing and the charge air cooler can alternatively be flowed through in reverse order or also in parallel.

The 1 and 2 show a basic structure of an electrically assisted turbocharger with a compressor housing in which the coolant is introduced at the electronics housing and is guided through the stator to the compressor housing, as well as the reverse flow of media with coolant inlet at the compressor housing with passage through the stator.

Cooling water is fed into the electronics housing, where it is carried through the stator laminated core in the number of coils to the compressor via a labyrinth-like contour. The heat generated from the stator is dissipated directly. The channel guide in the housing is used to dissipate heat from the power electronics, which are arranged opposite the channel guide. The stator laminated core is also cooled by radiating heat on the outer circumference. The coolant flow is guided into the volute housing or back again to the electronics housing by protruding connecting elements, shown here as tubes. This closes the water cycle.

Finally, it should be pointed out that terms such as “having”, “comprising”, etc. do not exclude other elements or steps and that terms such as “a” or “an” do not exclude a plurality. Reference signs in the claims are not to be regarded as a restriction.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102017207532 A1 [0002]

Claims (10)

Electrically assisted turbocharger (100), with a compressor housing (106), a stator package (108) connected to the compressor housing (106), an electric motor (104) coupled to the turbocharger (100) and an electronics housing (110) connected to the stator package (108) ) of the electric motor (104), coolant ducts (112) being arranged in the stator package (108), which fluidically connect the compressor housing (106) and the electronics housing (110) to one another and through connecting ducts (300) in the compressor housing (106) and in the electronics housing (110) are fluidically interconnected. Turbocharger (100) according to Claim 1 , in which the coolant channels (112) in the stator core (108) are designed as flow channels (302) and return channels (304) and the connecting channels (300) in the electronics housing (110) are designed as distributor channels and as collector channels separate from the distributor channels, with a The coolant inlet of the electronics housing (110) is connected to the flow channels (302) through the distribution channels and the return channels (304) are connected to a coolant outlet of the electronics housing (110) through the collector channels, the flow channels (302) and the return channels (304) through the connecting channels (300) in the compressor housing (106) are connected. Turbocharger (100) according to Claim 1 , in which the coolant channels (112) in the stator package (108) are designed as flow channels (302) and return channels (304) and the connecting channels (300) in the compressor housing (106) are designed as distributor channels and as collector channels separate from the distributor channels, with a The coolant inlet of the compressor housing (106) is connected to the flow channels (302) through the distribution channels and the return channels (304) are connected to a coolant outlet of the compressor housing (106) through the collector channels, the flow channels (302) and the return channels (304) through the connection channels (300) in the electronics housing (110) are connected. Turbocharger (100) according to Claim 1 , in which the connection channels (300) in the electronics housing (110) are designed as distribution channels and the connection channels (300) in the compressor housing (106) are designed as collector channels, with a coolant inlet of the electronics housing (110) through the distribution channels with the coolant channels (112) is connected and the coolant channels (112) are connected through the header channels to a coolant outlet of the compressor housing (106). Turbocharger (100) according to one of the preceding claims, in which the coolant channels (112) are designed as tubes axially aligned in the stator core (108). Turbocharger (100) according to Claim 5 , in which the tubes are pressed into the stator core (108). Turbocharger (100) according to one of the preceding claims, in which the stator package (108) has at least one coolant channel (112) per coil (402) of the electric motor (104). Turbocharger (100) according to one of the preceding claims, in which the connecting channels (300) in the electronics housing (110) and / or in the compressor housing (106) are designed as a labyrinth. Turbocharger (100) according to one of the preceding claims, in which the connecting channels (300) in the electronics housing (110) and / or in the compressor housing (106) are designed as recesses in a contact surface (306) to the stator package (108). Turbocharger (100) according to one of the preceding claims, in which the stator package (108) has a heat dissipation surface on an outside.

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