FR3092450A1 - Rotating electric machine for hybrid vehicle and gearbox equipped with such a rotary electric machine - Google Patents

Abstract

Rotating electric machine (1) for a vehicle comprising a stator (2), a rotor (33) movable in rotation about an axis of rotation (3) and a cooling device (7) which surrounds the stator (2), the rotary electrical machine (1) comprising an electrical connection device (4) which supplies power to the stator (2) which comprises a distribution part (5) arranged around the stator (2) and a connection block (6) connected to a control and power device (26), the distribution part (5) and the connection block (6) together have a maximum dimension (8) measured in a plane perpendicular to the axis of rotation (3), the device cooling system (7) having a maximum dimension (9) measured in a plane perpendicular to the axis of rotation (3), characterized in that the maximum dimension (8) is strictly less than the maximum dimension (9). Figure for the abstract: Figure 6

Description

Rotating electric machine for hybrid vehicle and gearbox fitted with such a rotating electric machine

The present invention relates to a rotating electrical machine for a motor vehicle, as well as a gearbox comprising such a rotating electrical machine.

This system is particularly present in hybrid vehicles, where the rotating electrical machine makes it possible to set the vehicle in motion.

State of the art

A rotating electric machine for a hybrid motor vehicle comprises a stator and a rotor arranged around the same axis of rotation, the stator allowing the rotation of the rotor by means of electric coils housed in the stator. In order to avoid overheating, the rotating electrical machine also includes a cooling system located on the outer periphery of the stator. These coils are powered by an electrical connection device encircling the structure of the stator and connected to a control and power device external to the rotating electrical machine. Within a gearbox for a hybrid motor vehicle, the rotating electrical machine is completely covered by a structure called a clutch bell. This clutch housing has an opening through its wall through which an electrical supply passes to supply the rotating electrical machine.

To ensure the electrical connection and guarantee sealing at the level of this opening, the rotating electrical machine of the prior art comprises means which complicate the mounting of the rotating electrical machine inside the bell. Indeed, it is necessary to tilt the rotating electrical machine to enter it into the bell, introduce these means into the opening, then finally position the rotating electrical machine in the clutch bell, when the available space is already reduced. at most. Such an assembly may also require an increase in the diameter of the bell in order to make the tilting operation possible. This forms a major drawback of the known rotating electrical machine, since the mounting time of the rotating electrical machine in the clutch housing is significantly increased.

The present invention makes it possible to solve this problem by designing a rotating electrical machine which takes into account the assembly steps in the clutch housing. This machine according to the invention therefore comprises means which allow it to be installed inside the clutch bell housing by a translational movement along the axis of rotation of the machine, without tilting it. this.

The invention is in the form of a rotating electrical machine for a vehicle comprising a stator, a rotor movable in rotation around an axis of rotation and a cooling device which surrounds the stator, the rotating electrical machine comprising a electrical connection which electrically supplies the stator, the electrical connection device comprising a distribution part arranged around the stator and a connection block connected to a control and power device of the rotating electrical machine, the distribution part and the connection together have a maximum dimension measured in a plane perpendicular to the axis of rotation, the cooling device having a maximum dimension measured in a plane perpendicular to the axis of rotation, characterized in that the maximum dimension of the assembly formed by the distribution part and the connection block, measured in the plane perpendicular to the axis d e rotation, is strictly less than the maximum dimension of the cooling device, measured in a plane perpendicular to the axis of rotation.

In other words, the electrical connection device does not extend radially beyond the external dimension of the cooling device, which corresponds to the radially most extended part of the rotating electrical machine. This arrangement does not create any mechanical obstruction when the rotating electrical machine is inserted longitudinally in the clutch housing. Having a suitable electrical connection device such as that of the invention avoids all the assembly complications described above.

In this document, the maximum dimension of the assembly formed by the distribution part and the connection block can also be understood as the maximum dimension of the electrical connection device, these two formulations being equivalent here.

The maximum dimension corresponds for example to a longest straight line measured between a radial end furthest from the connection block and a radial end of the distribution part opposite to the radial end furthest from the connection block. The radial end of the distribution part can be a tangent passing an outer radial face of the distribution part, while the radial end farthest from the connection block can be formed by an edge of this connection block.

The cooling device is a component that surrounds the stator, being in contact with the latter so as to extract the calories generated by the stator. The cooling device comprises a chamber delimited by an internal wall in contact with the stator and by an external wall. The maximum dimension is the largest radial dimension measured at the outer wall.

The maximum dimension of the assembly formed by the distribution part and the connection block, measured in the plane perpendicular to the axis of rotation, may be a diameter of a circle passing through the corners of the connection block.

Rather than being defined in a singular way, the maximum dimension is a diameter in accordance with the invention which applies all around the electrical connection device.

This is the virtual diameter of a circle passing through the radially projecting corners or edges of the connection block. Like the maximum dimension measured in the plane perpendicular to the axis of rotation, the circle corresponding to this diameter does not extend radially beyond the maximum dimension measured in a plane perpendicular to the axis of rotation.

Such a dimension can advantageously also be a diameter of a circle in which an outer face of the outer wall of the cooling device is inscribed.

This guarantees that the maximum size of the electrical connection device does not negatively impact the method of mounting the rotating electrical machine in the clutch housing. This makes it possible to insert this rotating electrical machine in the clutch housing according to a translational movement parallel to an axis of a gearbox primary shaft which opens into the clutch housing.

The distribution part which is part of the electrical connection device comprises at least one electrically conductive track, one end of which extends into the connection block.

The track extends circumferentially around the stator according to an angular sector between 240° and 360°, measured from one end to the other, in order to supply the entire stator with electrical energy. The electrically conductive track(s) are therefore closed rings or open rings.

One end of the track extends into the termination block, which allows the track to be electrically connected to an electrical lug that comes from the control and power device. The connection block comprises a housing which receives the end of the track, such a housing providing mechanical support for the end of the track to prevent the latter from rotating when the electrical terminal is screwed onto the end of the track which extends into the connection block.

The electrical connection device comprises an electrically insulating casing which houses at least the electrically conductive track.

The case has cavities which receive the conductive tracks making up the distribution part of the electrical connection device. These cavities are, for example, circular slots made in a portion of the casing constituting the distribution part of the electrical connection device. These cavities are organized so that the electrically conductive tracks are radially distant from each other. Terminations for the electrical connections of the coils are arranged in a regular manner along this portion of the casing of the electrical connection device, so as to electrically supply the coils of the stator.

Advantageously, a first portion of the casing constituting the distribution part and a second portion of the casing constituting the connection block are formed in a single block. In other words, the casing comprises at least two portions, of which a first portion surrounds the stator and carries the electrically conductive tracks which distribute the electric current to the coils of the stator, and a second portion which is part of the connection block and which delimits a housing where the ends of the tracks are arranged, with a view to being connected to the control and power device. The first portion and the second portion are one-piece and unitary, that is to say from the same material and the same manufacturing step.

This box is made of an electrically insulating material, for example a synthetic material. It can in particular be designed in polymer or in any other material with electrically insulating properties.

According to an exemplary embodiment, the second portion of the box has a substantially rectangular shape. This second portion is intended to receive the end of the track which will be connected to the control and power device. The substantially rectangular shape of the second portion is observed in a plane perpendicular to the axis of rotation of the rotor.

The connection block is intended to be electrically connected to a control and power device external to the rotating electrical machine. To do this, the connection block is arranged on the outer periphery of the electrical connection device. In other words, the connection block forms a protrusion which emerges from the distribution part of the electrical connection device.

The connection block of the electrical connection device comprises a signal connector allowing an electrical control connection with the control and power device. It is through this signal connector that control, signal and/or diagnostic information passes between the rotating electrical machine and the electrical control device.

The connection block of the electrical connection device comprises a paste, for example a polymer, sealing the connection block with respect to its external environment. Such a paste blocks any rising oil that could come from the first portion of the electrical connection device, and thus migrate out of the rotating electrical machine. The paste, which acts as a seal, extends between the ends of the tracks, the signal connector and an internal wall of the connection block.

The invention also covers a gearbox for a motor vehicle comprising a clutch housing which houses the rotating electrical machine.

The clutch bell is made of metal, preferably aluminum. It has an internal volume intended to receive the rotating electrical machine. The clutch housing is a part which houses and protects against external aggressions a clutch module arranged between an internal combustion engine and the gearbox.

According to one aspect of the invention, the clutch housing has an internal template, measured in a plane perpendicular to the axis of rotation of the rotor, greater than the maximum dimension of the cooling system of the rotating electrical machine, measured in a plane perpendicular to this same axis of rotation.

Thus, the shapes of the rotating electrical machine adapt to those of the clutch housing of the gearbox, and this without the connection block of the electrical connection device interfering mechanically with the clutch housing, when assembling the electric machine in it.

The clutch housing has a wall provided with an opening of a shape complementary to that of the connection block and formed opposite the connection block of the electrical connection device. The shape of the opening is substantially rectangular.

The interior gauge mentioned above is a maximum dimension measured in a plane identical to that used to measure the dimension of the cooling device, between two points farthest from an internal face of the wall of the clutch housing .

There is an opening through the clutch housing of the gearbox, opposite the connection block of the electrical connection device, so that it remains accessible from outside the clutch housing. When the rotating electrical machine is placed in the clutch housing, the opening in the wall of the clutch housing and the connection block of the electrical connection device are facing each other and this therefore makes it possible to electrically connect the rotating electrical machine with its control and power device, the latter being arranged outside the clutch housing.

Presentation of figures

represents an overall view of the rotating electrical machine,

is a top view of part of the electrical connection device that equips the rotating electrical machine of Figure 1,

is an enlarged perspective view of a connection block of the electrical connection device,

is a top view of the connection block visible in Figure 3 and which incorporates the ends of electrically conductive tracks,

shows a perspective view of a clutch housing of a gearbox,

is an exploded view of the rotating electrical machine and the clutch housing,

is a schematic representation of the dimensions of the various parts of the rotating electrical machine and of the clutch housing.

Figure 1 is a representation of a rotating electrical machine 1 comprising a stator 2 and a rotor 33 rotatable about an axis of rotation 3. In the axial extension at the end of the stator 2, an electrical connection device 4 allows to supply coils 34 of stator 2.

The electrical connection device 4 comprises a casing 10. The electrical connection device 4 extends circumferentially around the stator 2. The casing 10 comprises a first circular portion 35 and a second portion 11 extending radially outside the circular shape of the first portion 35, up to one end delimited by at least one angle 28. At the top of the box 10, slots 22 intended to maintain the electrical connections between the coils 34 and the electrical connection device 4 are arranged evenly around a circumference of the housing 10.

A cooling device 7 is arranged at a part of the stator 2 comprising the coils 34. The cooling device 7 extends around the stator 2, so that an outer diameter of the stator 2 is equal to a internal diameter of the cooling system 7. The cooling device 7 is thus in contact with the stator 2.

The cooling system 7 comprises a pocket in which glycol water circulates, for example, intended to cool the coils 34. According to this embodiment, the cooling system 7 is circular. A maximum dimension measured in a plane perpendicular to the axis of rotation 3 of the rotor 33 is represented by an arrow referenced 9. In accordance with the invention, a maximum dimension 8 of the electrical connection device 4, measured in the plane perpendicular to the axis of rotation 3, extends from the end of the second portion 11 to the opposite end of the case 10 and is less than the maximum dimension 9 of the cooling device 7, measured in a plane perpendicular to the axis of rotation 3. In other words, no element of the rotating electrical machine 1 extends radially beyond the outer limits of the cooling device 7.

FIG. 2 represents a part of the electrical connection device 4 seen from above. It is divided into two parts: a distribution part 5 for distributing electrical energy to the coils 34 of the stator 2, the tracks 12 of which go around the stator 2 for example, and a connection block 6, for example formed by the second portion 11 of the box 10. The connection block 6 is delimited by two angles 28 which define the maximum dimension 8 of the electrical connection device 4.

At the distribution part 5 of the coils 34 of the stator 2, the tracks 12 are arranged circumferentially around the stator 2. They are for example organized in pairs in order to be able to supply all of the coils 34. They are also linked to the connection block 6 by their end 29, allowing them to be supplied with electrical energy. Terminations 21 arranged along the tracks 12 allow contact with the electrical connections which supply the coils 34 of the stator 2. These terminations 21 are located radially opposite the slots 22 of the box 10. Thus, an electrical connection to the stator 2 is inserted into a termination 21 of one of the tracks 12 and passes through a slot 22 of the box 10.

The tracks 12 run along the distribution part 5 of the coils 34 of the stator 2. Only their end 29 is housed in the connection block 6. The ends 29 are arranged in an "S" or "U" shape within the block connection 6 so that the same face of the ends 29 of the tracks 12 is located towards the outside of the rotating electrical machine 1. The connection block 6 is intended to be electrically connected to a control and power device 26 located at the exterior of the rotating electric machine 1. The control and power device 26 can for example be an inverter configured to transform a direct current present on the on-board network of the vehicle into an alternating current for the rotating electric machine 1. The device control and power 26 is connected to the connection block 6 by an electrical power connection 30 allowing the electrical supply of the tracks 12, as well as by an electrical signal connection 31 ensuring the exchange of control and diagnostic information between the control and power device 26 and the connection block 6.

FIG. 3 represents a more detailed view of the second portion 11 of the casing 10 devoid of any tracks of the electrical connection device 4. The stator 2 is surmounted by the electrical connection device 4 comprising the casing 10. The casing 10 is in one piece and is made by molding.

The second portion 11 of the box 10 is a constituent element of the connection block 6. The second portion 11 is of substantially rectangular shape according to an angle of view taken along a radial direction of the rotor 33 and comprises a housing 14 which receives the ends 29 of the tracks 12, as shown in Figure 2.

The box 10 also has cavities 23 intended for the insertion of the tracks 12, as well as the slots 22 for the electrical connections of the stator 2.

After positioning the conductive tracks in the cavities 23, the distribution part 5 is filled with a paste which provides a seal, thus preventing any entry of fluid into the distribution part 5.

When the ends 29 of the tracks 12 are housed in the housing 14 of the second portion 11, the connection block 6 appears as represented in FIG. 4. This is a representation of the second portion 11 of the connection block. connection 6 of the electrical connection device 4, according to an angle of view taken along a radial direction of the rotor 33. Under this angle of view, the second portion 11 therefore has a substantially rectangular shape delimited by flanges 36.

The ends 29 of the tracks 12 are aligned next to each other and are all provided with a hole 20 in order to ensure the connection with the electrical power connection 30. The ends 29 of the tracks 12 can be of two distinct shapes: some are rectangular at right angles, others are rounded on two angles. Each hole 20 of the end 29 of the tracks 12 is staggered in order to avoid mechanical clutter when connecting the connection block 6. A signal connector 13 groups together the electrical connections linked to the control or diagnosis of the electrical machine rotary 1 according to the invention. The section of the housing 14 which extends between the signal connector 13 and/or the ends 29 of the tracks 12 and the rim 36, as well as the interstices between the adjacent ends 29, are filled with a paste, for example a polymer, capable of to solidify, so as to seal the entire connection block 6.

A clutch housing 16 of a gearbox is shown in Figure 5. The clutch housing 16 comprises a wall 37 delimiting an internal volume intended to receive the rotary electrical machine 1 and possibly a clutch module. The wall 37 of the clutch housing 16 is slightly conical. The wall 37 of the clutch housing 16 delimits a volume in which the rotary electrical machine 1 is housed. The clutch housing 16 is equipped with a fixing base 25 which makes it possible to secure the gearbox to a combustion engine internal of a hybrid traction chain. This fixing base 25 is present on either side of the wall 37 and has holes allowing the insertion of a fixing means.

A circular hole 27 is present at the top of the clutch housing 16 and allows the passage of a primary shaft (not shown) of the gearbox. An opening 18, of a shape complementary to the shape of the connection block, is present on the wall 37 of the clutch housing 16. Seen radially, this opening is of substantially rectangular shape. This is the zone in front of which the connection block 6 extends, when the rotating electrical machine 1 is received in the clutch housing 16. This opening 18 gives access to the connection block 6 of the connection device electric 4 from outside the clutch housing 16, so as to electrically connect the electrical connection device 4.

FIG. 6 diagrams the installation of the rotary electric machine 1 in the internal volume of the clutch housing 16. The rotary electric machine 1 is in this figure equipped with a fixing base 24 comprising clamping points making it possible to fix the rotating electrical machine 1 in the clutch housing 16.

The cooling device 7 is defined by its maximum dimension 9 measured in a plane perpendicular to the axis of rotation 3. As indicated above, the maximum dimension 8 measured in the plane perpendicular to the axis of rotation 3 is strictly less than the maximum dimension 9 defining the cooling chamber 7. The clutch housing 16 has an internal template 17 measured at the level of the internal volume delimited by an internal face of the wall 37 of the clutch housing 16. This internal template 17 is greater to the maximum dimension 9 of the cooling device 7. Such an internal template 17 defines an inlet mouth of the clutch housing 16 allowing the insertion of the rotating electrical machine 1 within the internal volume of the clutch housing 16.

When the rotating electric machine 1 is housed in the clutch housing 16, the clamping points of the fixing base 24 of the rotating electric machine 1 and the holes of the fixing base 25 of the clutch housing 16 are in look at each other, thus allowing the fixing of the two systems by a fixing means.

When the rotary electric machine 1 is placed in the clutch housing 16, the second portion 11 of the housing 10 of the electrical connection device 4 of the rotary electric machine 1 and the opening 18 of the clutch housing 16 are facing each other. The connection block 6 is then accessible from outside the clutch housing 16 through the opening 18.

Figure 7 is a schematic representation seen from above of the dimensions of the various parts of the rotating electrical machine 1 and of the clutch housing 16, when the rotating electrical machine 1 is housed therein. Several circles centered around the same axis of rotation 3 schematize different elements, thus demonstrating the absence of mechanical interference. The circle with the smallest diameter corresponds to the distribution part 5 of the electrical connection device 4. The connection block 6 emerges radially from the distribution part 5, the assembly then forming the electrical connection device 4. The circle referenced 32 of diameter 38 corresponds to a circle centered around the axis of rotation 3 and passing through the corners 28 of the connection block 6.

The maximum dimension 8 measured in the plane perpendicular to the axis of rotation 3 of the electrical connection device 4 is also represented and extends from one of the corners 28 of the connection block 6 to a tangent which passes through the distribution part 5 of the coils 34 of the stator 2 which is diametrically opposed to it.

According to the invention, the distribution part 5 associated with the connection block 6 of the electrical connection device 4, the virtual circle 32 and the maximum dimension 8 of the electrical connection device 4 are all included in a section of the rotating electrical machine 1 delimited by the maximum dimension 9 of the cooling device 7, measured in a plane perpendicular to the axis of rotation 3.

Still according to the invention, this same maximum dimension 9 of the cooling device 7 is lower than that of the inner template 17 of the clutch housing 16, thus guaranteeing insertion of the rotary electric machine 1 according to a translational movement carried out parallel to the axis of rotation 3.

If all of these conditions are met, then the rotating electrical machine 1 according to the invention can be integrated within the internal volume of the clutch housing 16 without mechanical interference.

The rotating electrical machine 1 and the clutch module are particularly suitable for use within a hybrid traction chain for a motor vehicle.

This hybrid traction chain comprises an internal combustion engine coupled to the rotating electrical machine 1 according to the invention by the clutch module. Thus, the rotating electrical machine 1 can ensure the propulsion of the motor vehicle, alone or in combination with the internal combustion engine. It also allows the internal combustion engine to be started and assists it when accelerating the vehicle. The rotating electrical machine 1 can also perform the function of an alternator or a vehicle brake. Electrical energy can also be recovered during braking of the vehicle by the rotating electrical machine 1 according to the invention.

Of course, the invention is not limited to the examples which have just been described and many adjustments can be made to these examples without departing from the scope of the invention. In particular, the different characteristics, shapes, variants and embodiments of the invention may be associated with each other in various combinations insofar as they are not incompatible or exclusive of each other. In particular, all the variants and embodiments described above can be combined with each other.

Claims (11)

Rotating electrical machine (1) for a vehicle comprising a stator (2), a rotor (33) rotatable around an axis of rotation (3) and a cooling device (7) which surrounds the stator (2), the rotating electrical machine (1) comprising an electrical connection device (4) which electrically supplies the stator (2), the electrical connection device (4) comprising a distribution part (5) disposed around the stator (2) and a block connection (6) connected to a control and power device (26) of the rotating electrical machine (1), the distribution part (5) and the connection block (6) together have a maximum dimension (8) measured in a plane perpendicular to the axis of rotation (3), the cooling device (7) having a maximum dimension (9) measured in a plane perpendicular to the axis of rotation (3), characterized in that the maximum dimension (8) of the assembly formed by the distribution part (5) and the coupling block dement (6), measured in the plane perpendicular to the axis of rotation (3), is strictly less than the maximum dimension (9) of the cooling device (7), measured in a plane perpendicular to the axis of rotation ( 3). Rotating electrical machine (1) according to Claim 1, in which the maximum dimension (8) of the assembly formed by the distribution part (5) and the connection block (6), measured in the plane perpendicular to the axis of rotation (3), is a diameter (38) of a circle (32) passing through corners (28) of the connecting block (6). Rotating electrical machine (1) according to Claim 1 or 2, in which the distribution part (5) of the electrical connection device (4) comprises at least one electrically conductive track (12), one end (29) of which extends in the connection block (6). Rotating electrical machine (1) according to the preceding claim, in which the electrical connection device (4) comprises an electrically insulating casing (10) which houses at least one electrically conductive track (12). Rotary electrical machine (1) according to the preceding claim, in which a first portion (35) of the casing (10) constituting the distribution part (5) and a second portion (11) of the casing (10) constituting the connection block (6) are formed in a single block. Rotary electric machine (1) according to the preceding claim, in which the second portion (11) of the casing (10) has a substantially rectangular shape. Rotating electrical machine (1) according to any one of the preceding claims, in which the connection block (6) of the electrical connection device (4) comprises a signal connector (13) allowing an electrical connection with the control and power (26). Rotating electrical machine (1) according to any one of the preceding claims, in which the connection block (6) of the electrical connection device (4) comprises a paste sealing the connection block (6) with respect to its environment. outside. Motor vehicle gearbox comprising a rotating electric machine (1) according to any one of the preceding claims, the gearbox comprising a clutch housing (16) which houses the rotating electric machine (1). Motor vehicle gearbox according to claim 9, in which the clutch housing (16) has an internal template (17), measured in a plane perpendicular to the axis of rotation (3), greater than the maximum dimension ( 9) of the cooling system (7), measured in a plane perpendicular to the axis of rotation (3). Motor vehicle gearbox according to claim 10, in which the clutch housing (16) has a wall (37) provided with an opening (18) of a shape complementary to the shape of the connection block (6) and opposite the connection block (6) of the electrical connection device (4).