WO2018029720A1 - Kit for electrically supplying a vehicle - Google Patents

Kit for electrically supplying a vehicle Download PDF

Info

Publication number
WO2018029720A1
WO2018029720A1 PCT/IT2017/000172 IT2017000172W WO2018029720A1 WO 2018029720 A1 WO2018029720 A1 WO 2018029720A1 IT 2017000172 W IT2017000172 W IT 2017000172W WO 2018029720 A1 WO2018029720 A1 WO 2018029720A1
Authority
WO
WIPO (PCT)
Prior art keywords
connecting portion
stator
caliper
kit according
main body
Prior art date
Application number
PCT/IT2017/000172
Other languages
French (fr)
Inventor
Luca ALTOBELLI
Francesco ANTONIELLA
Francesco VENTURINI
Original Assignee
Hybrid4Kit S.R.L.S.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hybrid4Kit S.R.L.S. filed Critical Hybrid4Kit S.R.L.S.
Publication of WO2018029720A1 publication Critical patent/WO2018029720A1/en

Links

Classifications

    • 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
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2793—Rotors axially facing stators
    • H02K1/2795—Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0061—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electrical machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/10—Electric propulsion with power supplied within the vehicle using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines
    • B60L50/16—Electric propulsion with power supplied within the vehicle using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines with provision for separate direct mechanical propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/61—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/102—Structural association with clutches, brakes, gears, pulleys or mechanical starters with friction brakes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/14—Structural association with mechanical loads, e.g. with hand-held machine tools or fans
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1846—Rotary generators structurally associated with wheels or associated parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00—Type of vehicles
    • B60L2200/46—Vehicles with auxiliary ad-on propulsions, e.g. add-on electric motor kits for bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2220/00—Electrical machine types; Structures or applications thereof
    • B60L2220/40—Electrical machine applications
    • B60L2220/44—Wheel Hub motors, i.e. integrated in the wheel hub
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/10—Vehicle control parameters
    • B60L2240/36—Temperature of vehicle components or parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2270/00—Problem solutions or means not otherwise provided for
    • B60L2270/40—Problem solutions or means not otherwise provided for related to technical updates when adding new parts or software
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/62—Hybrid vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/16—Information or communication technologies improving the operation of electric vehicles

Definitions

  • This invention relates to a kit for electrically supplying a vehicle.
  • the invention relates to a kit, that is to a say, a series of components, to be applied to an existing building to allow it to be supplied not only by the vehicle's original propulsion system but also electrically.
  • the aim of this invention is to provide a kit for electrically supplying a vehicle which has reduced costs for the relative construction and the mounting on an existing vehicle.
  • a further aim of this invention is to provide a kit for electrically supplying a vehicle which can be easily mounted on a vehicle by individuals who do not possess specific professional skills.
  • Another aim of this invention is to provide a kit for electrically supplying a vehicle which comprises parts and components with a high rigidity but a reduced weight.
  • Another aim of this invention is to provide a kit for electrically supplying a vehicle which significantly reduces the fuel consumption of the original thermal engine of the vehicle, whilst guaranteeing adequate performance of the vehicle.
  • This invention relates specifically to a kit for electrically supplying a vehicle to allow the motion of a vehicle of the type comprising at least one shaft which is rotatable in an idle fashion and at least one idle wheel, which is provided with a rim and connectable with the at least one shaft, a braking system, comprising at least one brake disc and at least one caliper operating on the at least one brake disc to perform a braking action, and a support member for supporting the at least one caliper; the kit also comprising an electric motor with an axial flux comprising: a rotor provided with at least one permanent magnet; connecting means for connecting, when in use, the rotor with the rim; and a stator comprising a main body which is substantially flat, lying on a first plane and having an extension which is at least partially circular and a central hole and equipped with at least one electric winding, and a connecting portion which is substantially flat, lying on a second plane substantially parallel to the first plane and having an extension at least partially circular and an opening communicating and substantially aligned with
  • the connecting portion can be configured in such a way as to be arranged, when in use, between the support member and the at least one caliper.
  • the connecting portion can comprise connecting means, preferably at least one through hole, for connecting, when in use, the at least one caliper to the connecting portion.
  • the connecting portion can have an angular extension which is equal to or greater than 180°.
  • the main body has a substantially circular ring arc shape.
  • the main body can have an angular extension which is equal to or greater than 180°.
  • the rotor can have a substantially circular shape.
  • the at least one permanent magnet has a substantially circular shape.
  • the at least one permanent magnet can comprise a plurality of permanent magnets which are arranged along two circular trajectories which are concentric to each other.
  • the distance existing between the rotor and the stator can be comprised between 0.1 mm and 10 mm.
  • the kit may comprise a support having a substantially circular concave shape and a central portion which is configured to couple with the rim, when in use, and a peripheral portion which is configured to couple with the rotor.
  • the kit can comprise a cooling system operating on the stator to cool, when in use, the at least one electric winding and increase performances of the electric motor.
  • Figure 1 is an exploded view of a kit for electrically supplying a vehicle according to an embodiment of this invention
  • Figure 2 is a view of the kit of Figure 1 , in a mounted configuration
  • Figure 3 is a perspective view of a part of the kit of Figures 1 and 2, in an assembled configuration
  • Figure 4 is an exploded view of the kit shown in Figures 1 to 3;
  • Figure 5 is a perspective view of a component of the kit of Figures 1 to 4;
  • Figure 6 is a side view of the component shown in Figure 5;
  • Figure 7 is a perspective view of a component of the vehicle which interacts with the kit of Figures 1 to 4;
  • Figure 8 is a perspective view of an optional component of the kit according to the invention.
  • Figure 9 is a first perspective view of a portion of stator forming part of a kit for electrically supplying a vehicle according to a variant embodiment of this invention.
  • Figure 10 is a second perspective view of the portion of stator shown in Figure 9.
  • Figures 1 to 7 show a kit for electrically supplying a vehicle.
  • the kit comprises two electric motors 1 of the axial flux type (only one of the two motors is shown in the accompanying drawings), for example of the "brushless" type, designed to mounted, respectively, inside rims 2 of the non-drive wheels of the vehicle.
  • This invention can also be conveniently applied to the case wherein the above-mentioned electric motors are not of the brushless type, as they are of the axial flux type.
  • each electric motor 1 comprises a rotor 3 fixed, by example with bolts, to the inner front wall 4 of the rim 2.
  • the rotor 3 has the shape of a disc equipped with a central hole 3', preferably, but without limiting the scope of the invention, made of composite material to increase the lightness.
  • the inner face 3a of the rotor 3 that is, the one facing in the opposite direction to the inner front wall 4 of the rim 2, there are a plurality of cavities in which are housed a corresponding plurality of permanent magnets 5, for example, circular in shape and arranged in two concentric circular rows.
  • the permanent magnets 5 could also adopt shapes different to the circular one shown in the accompanying drawings.
  • This kit also comprises a stator 6 formed by a main body 6a which is substantially flat and in the shape of a circular ring arc preferably having an angular extension greater than 180°, and an anchor plate 6b, which is also substantially flat and in the shape of a circular ring arc, positioned on a plane parallel to the main body 6a at the empty space 7 complementary to the main body 6a, in such a way as to form a further empty space between the anchor plate 6b and the main body 6a.
  • the stator 6 may be made, for example, by die casting, or by assembly of components, or by mechanical, chemical or electrochemical removal of material, or by lamination of composite materials.
  • the main body 6a and the anchor plate 6b of the stator 6 can be made with the same material or with materials different from each other and connected, if it is made in two or more parts, in a permanent manner, for example by welding or gluing, or in a removable manner using bolts or other mechanical connecting means.
  • a central through hole 6a' and an opening 6b' communicating and substantially aligned with each other, that is to say, facing one another.
  • the main body 6a and the anchor plate 6b are rigidly connected together by means of two arms 8a, 8b which extend from their ends.
  • an inner side 9' facing towards the anchor plate 6b, and an outer side 9" opposite the inner side 9'.
  • the outer side 9" of the main body 6a is equipped with a plurality of electric windings 10 arranged in a circular fashion on the entire extension of the outer side 9".
  • the stator 6 must be mounted on the brake disc 1 1 of the vehicle, normally formed by a circular plate 1 1 a, designed to be gripped by the brake caliper 12 of the vehicle for performing the braking action on the wheel, and by an axially hollow protruding portion 1 1 b, which extends axially from the circular plate 1 1 a to allow the relative fixing to the rim 2 of the wheel.
  • the brake caliper 12 is normally located in a tangential position relative to the circular plate 1 1 a of the brake disc 1 to grip a peripheral portion of the circular plate 11 a.
  • the above-mentioned kit is applicable to the calipers of both fixed and floating brakes.
  • stator 6 must be mounted on the brake disc 1 1 in such a way that the circular plate 11a positions itself between the main body 6a and the anchor plate 6b and that the brake caliper 12 of the vehicle is housed in the empty space 7 defined by the main body 6a.
  • the protruding portion 1 1 b of the brake disc 1 1 on which is also mounted the stator 6, is inserted in the central hole 3' of the rotor 3 fixed in turn to the inner front wall 4 of the rim 2, in such a way that the main body 6a of the rotor 6 is positioned between the rotor 3 and the brake disc 1 1 and that the plurality of electric windings 10 faces the above-mentioned plurality of electric magnets 5.
  • the air gap that is, the space between the rotor 3 and the main body 6a of the stator 6 is preferably between 0.1 mm and 10 mm, and more preferably approximately 2 mm.
  • the brake disc 1 1 on which is mounted the stator 6, is also rigidly connected to the rim 2, interposing the relative protruding portion 1 1 b between the hub of the rim 2 and the flange 13 of the shaft 14 of the wheel of the vehicle and fixing the flange 13 and the protruding portion 11 b to the hub by means of a series of connecting bolts.
  • the above- mentioned shaft 14 passes through a central through hole 6a' of the main body 6a and the opening 6b' in the anchor plate 6b.
  • the shaft 14 of the vehicle is also fitted with the original support member 15 of the vehicle, to be fixed, in turn, to the suspension of the vehicle.
  • the support member 15 comprises a through hole 16, through which the shaft 14 passes, and two protrusions 17a, 17b, that is, two elongate portions which extend radially with respect to the shaft 14 passing through the above-mentioned through hole 16.
  • two through holes 20, 21 are provided in the anchor plate 6b of the stator 6 to allow the passage of corresponding bolts for the connection between the anchor plate 6b and the protrusions 17a, 7b of the support member 15.
  • the above-mentioned anchor plate 6b is positioned between the support member 15 and the brake caliper 12, and integrally connected with these latter two elements, whilst the brake caliper 12 occupies the empty space 7 defined by the main body 6a of the stator 6, thereby reducing the overall axial size of the electric motor 1.
  • the kit also comprises one or more batteries, preferably housed in the boot of the vehicle, to supply, by inverter, electricity to the above- mentioned plurality of the electric windings 10 of the stator 6 for the generation of a magnetic field.
  • the magnetic field generated by the stator 6 induces the rotor 3 to rotate, due to the effect of the interaction of the lines of the field with above-mentioned plurality of permanent magnets 5, and with it also the rim 2 and therefore the wheel of the vehicle.
  • the kit according to the invention can comprises a control system for adjusting, instant by instant, the power emitted by the above-mentioned electric motors as a function of the power dispensed by the thermal engine of the vehicle.
  • kit according to this invention can also comprise a liquid or air cooling system acting on the stator 6 to increase the performance of the electric motor 1 by cooling the electric windings 10.
  • the kit for electrically supplying a vehicle according to this invention can also comprises a support 18, as shown in Figure 8, to facilitate the fixing of the rotor 3 to the rim 2 of the wheel.
  • the support 18 has a circular concave form with, in the relative central part, a series of through holes 19 to allow the fixing, by bolting, to the hub of the wheel of the vehicle and to the flange 13 of the shaft 14.
  • the rotor 3 on the other hand, is fixed to a peripheral circular portion of the support 18 for example by structural gluing, bolting, welding of every type, riveting, brazing or braze welding.
  • the above-mentioned support 18 can be conveniently formed as one piece with the rotor 3.
  • FIG. 9 there may be, for the stator, a different anchor plate 22 with a circular extension having an angular extension equal to or greater than 180° and two through holes 23, 24 provided at end portions of the anchor plate 22 to allow the fixing to the two protrusions 17a, 17b of the support member 15 by bolting.
  • the opening 25 is in communication and aligned with the central through hole 6a' of the main body 6a to allow the crossing of the shaft 14 of the wheel of the vehicle.
  • the stator with the anchor plate 22 is considerably light in weight as well as having an excellent resistance to traction forces, allowing the transformation of tangential forces into forces on the plane on which the anchor plate 22 lies, which has a considerable resistance to these forces.
  • the lightness of the stator can be further increased by providing one or two openings in its structure.
  • the kit for electrically supplying a vehicle comprises electric motors such as to be mounted in the rims of the wheels of the vehicle in a simple and fast manner, replacing only a reduced number of the original components of the vehicle.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
  • Forklifts And Lifting Vehicles (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

Described is a kit for electrically supplying a vehicle to allow the motion of a vehicle of the type comprising at least one shaft (14) which is rotatable in an idle fashion and at least one idle wheel, which is provided with a rim (2) and connectable with the at least one shaft (14), a braking system, comprising at least one brake disc (11) and at least one caliper (12) operating on the at least one brake disc (11) to perform a braking action, and a support member (15) for supporting the at least one caliper (12). The kit also comprises an electric motor (1 ) with an axial flux comprising: a rotor (3) provided with at least one permanent magnet (5); connecting means for connecting, when in use, the rotor (3) with the rim (2); and a stator (6) comprising a main body (6a) which is substantially flat, lying on a first plane and having an extension which is at least partially circular and a central hole (6a') and equipped with at least one electric winding (10), and a connecting portion (6b, 22) which is substantially flat, lying on a second plane substantially parallel to the first plane and having an extension at least partially circular and an opening (6b') communicating and substantially aligned with the central hole (6a'), the connecting portion (6b, 22) being integral with the main body (6a) and connectable, when in use, with the support member (15), in the stator (6) being formed, between the main body (6a) and the connecting portion (6b, 22), a cavity for housing, when in use, the at least one caliper (12) in such a way that, when the connecting portion (6b, 22) is connected to the support member (15), the at least one electric winding (10) faces the at least one permanent magnet (5), the at least one shaft (14) passes through the central hole (6a') and the opening (6b'), and the at least one caliper (12) is arranged in the cavity of the stator (6).

Description

KIT FOR ELECTRICALLY SUPPLYING A VEHICLE
*****
This invention relates to a kit for electrically supplying a vehicle.
More in detail, the invention relates to a kit, that is to a say, a series of components, to be applied to an existing building to allow it to be supplied not only by the vehicle's original propulsion system but also electrically.
There are various types of electric motors designed to be connected directly to the wheels of the vehicle.
However, these prior art solutions comprise, for their application, the replacement of various components of the vehicle and, consequently, quite high manufacturing and assembly costs, as well as the need for specific professional skills to carry out the relative assembly.
In light of the above, the aim of this invention is to provide a kit for electrically supplying a vehicle which has reduced costs for the relative construction and the mounting on an existing vehicle.
A further aim of this invention is to provide a kit for electrically supplying a vehicle which can be easily mounted on a vehicle by individuals who do not possess specific professional skills.
Another aim of this invention is to provide a kit for electrically supplying a vehicle which comprises parts and components with a high rigidity but a reduced weight.
Another aim of this invention is to provide a kit for electrically supplying a vehicle which significantly reduces the fuel consumption of the original thermal engine of the vehicle, whilst guaranteeing adequate performance of the vehicle.
This invention relates specifically to a kit for electrically supplying a vehicle to allow the motion of a vehicle of the type comprising at least one shaft which is rotatable in an idle fashion and at least one idle wheel, which is provided with a rim and connectable with the at least one shaft, a braking system, comprising at least one brake disc and at least one caliper operating on the at least one brake disc to perform a braking action, and a support member for supporting the at least one caliper; the kit also comprising an electric motor with an axial flux comprising: a rotor provided with at least one permanent magnet; connecting means for connecting, when in use, the rotor with the rim; and a stator comprising a main body which is substantially flat, lying on a first plane and having an extension which is at least partially circular and a central hole and equipped with at least one electric winding, and a connecting portion which is substantially flat, lying on a second plane substantially parallel to the first plane and having an extension at least partially circular and an opening communicating and substantially aligned with the central hole, the connecting portion being integral with the main body and connectable, when in use, with the support member, in the stator being formed, between the main body and the connecting portion, a cavity for housing, when in use, the at least one caliper in such a way that, when the connecting portion is connected to the support member, the at least one electric winding faces the at least one permanent magnet, the at least one shaft passes through the central hole and the opening, and the at least one caliper is arranged in the cavity of the stator.
Further, according to the invention, the connecting portion can be configured in such a way as to be arranged, when in use, between the support member and the at least one caliper.
Advantageously, according to the invention, the connecting portion can comprise connecting means, preferably at least one through hole, for connecting, when in use, the at least one caliper to the connecting portion.
Further, according to the invention, the connecting portion can have an angular extension which is equal to or greater than 180°.
Preferably, according to this invention, the main body has a substantially circular ring arc shape.
Further, according to the invention, the main body can have an angular extension which is equal to or greater than 180°.
Again according to the invention, the rotor can have a substantially circular shape.
Preferably, according to the invention, the at least one permanent magnet has a substantially circular shape. Advantageously, according to the invention, the at least one permanent magnet can comprise a plurality of permanent magnets which are arranged along two circular trajectories which are concentric to each other.
Further, according to the invention, when in use, the distance existing between the rotor and the stator can be comprised between 0.1 mm and 10 mm.
Again according to the invention, the kit may comprise a support having a substantially circular concave shape and a central portion which is configured to couple with the rim, when in use, and a peripheral portion which is configured to couple with the rotor.
Advantageously, according to the invention, the kit can comprise a cooling system operating on the stator to cool, when in use, the at least one electric winding and increase performances of the electric motor.
The present invention is now described, by way of example and without limiting the scope of the invention, with reference to the accompanying drawings which illustrate preferred embodiments of it, in which:
Figure 1 is an exploded view of a kit for electrically supplying a vehicle according to an embodiment of this invention;
Figure 2 is a view of the kit of Figure 1 , in a mounted configuration;
Figure 3 is a perspective view of a part of the kit of Figures 1 and 2, in an assembled configuration;
Figure 4 is an exploded view of the kit shown in Figures 1 to 3;
Figure 5 is a perspective view of a component of the kit of Figures 1 to 4;
Figure 6 is a side view of the component shown in Figure 5;
Figure 7 is a perspective view of a component of the vehicle which interacts with the kit of Figures 1 to 4;
Figure 8 is a perspective view of an optional component of the kit according to the invention;
Figure 9 is a first perspective view of a portion of stator forming part of a kit for electrically supplying a vehicle according to a variant embodiment of this invention; and
Figure 10 is a second perspective view of the portion of stator shown in Figure 9.
The similar parts in the various drawings are labelled with the same reference numerals.
Figures 1 to 7 show a kit for electrically supplying a vehicle.
The kit comprises two electric motors 1 of the axial flux type (only one of the two motors is shown in the accompanying drawings), for example of the "brushless" type, designed to mounted, respectively, inside rims 2 of the non-drive wheels of the vehicle.
This invention can also be conveniently applied to the case wherein the above-mentioned electric motors are not of the brushless type, as they are of the axial flux type.
More in detail, each electric motor 1 comprises a rotor 3 fixed, by example with bolts, to the inner front wall 4 of the rim 2.
The rotor 3 has the shape of a disc equipped with a central hole 3', preferably, but without limiting the scope of the invention, made of composite material to increase the lightness.
In the inner face 3a of the rotor 3, that is, the one facing in the opposite direction to the inner front wall 4 of the rim 2, there are a plurality of cavities in which are housed a corresponding plurality of permanent magnets 5, for example, circular in shape and arranged in two concentric circular rows.
According to further variants of the kit, the permanent magnets 5 could also adopt shapes different to the circular one shown in the accompanying drawings.
This kit also comprises a stator 6 formed by a main body 6a which is substantially flat and in the shape of a circular ring arc preferably having an angular extension greater than 180°, and an anchor plate 6b, which is also substantially flat and in the shape of a circular ring arc, positioned on a plane parallel to the main body 6a at the empty space 7 complementary to the main body 6a, in such a way as to form a further empty space between the anchor plate 6b and the main body 6a. The stator 6 may be made, for example, by die casting, or by assembly of components, or by mechanical, chemical or electrochemical removal of material, or by lamination of composite materials.
Moreover, the main body 6a and the anchor plate 6b of the stator 6 can be made with the same material or with materials different from each other and connected, if it is made in two or more parts, in a permanent manner, for example by welding or gluing, or in a removable manner using bolts or other mechanical connecting means.
In the main body 6a and in the anchor plate 6b, respectively, are defined a central through hole 6a' and an opening 6b' communicating and substantially aligned with each other, that is to say, facing one another.
The main body 6a and the anchor plate 6b are rigidly connected together by means of two arms 8a, 8b which extend from their ends.
On the main body 6a are defined an inner side 9', facing towards the anchor plate 6b, and an outer side 9" opposite the inner side 9'.
The outer side 9" of the main body 6a is equipped with a plurality of electric windings 10 arranged in a circular fashion on the entire extension of the outer side 9".
The stator 6 must be mounted on the brake disc 1 1 of the vehicle, normally formed by a circular plate 1 1 a, designed to be gripped by the brake caliper 12 of the vehicle for performing the braking action on the wheel, and by an axially hollow protruding portion 1 1 b, which extends axially from the circular plate 1 1 a to allow the relative fixing to the rim 2 of the wheel.
The brake caliper 12 is normally located in a tangential position relative to the circular plate 1 1 a of the brake disc 1 to grip a peripheral portion of the circular plate 11 a.
The above-mentioned kit is applicable to the calipers of both fixed and floating brakes.
More specifically, the stator 6 must be mounted on the brake disc 1 1 in such a way that the circular plate 11a positions itself between the main body 6a and the anchor plate 6b and that the brake caliper 12 of the vehicle is housed in the empty space 7 defined by the main body 6a. As shown in Figure 4, in the mounted configuration of the electric motor 1 , the protruding portion 1 1 b of the brake disc 1 1 , on which is also mounted the stator 6, is inserted in the central hole 3' of the rotor 3 fixed in turn to the inner front wall 4 of the rim 2, in such a way that the main body 6a of the rotor 6 is positioned between the rotor 3 and the brake disc 1 1 and that the plurality of electric windings 10 faces the above-mentioned plurality of electric magnets 5.
In the mounted configuration of the electric motor 1 , the air gap, that is, the space between the rotor 3 and the main body 6a of the stator 6 is preferably between 0.1 mm and 10 mm, and more preferably approximately 2 mm.
The brake disc 1 1 , on which is mounted the stator 6, is also rigidly connected to the rim 2, interposing the relative protruding portion 1 1 b between the hub of the rim 2 and the flange 13 of the shaft 14 of the wheel of the vehicle and fixing the flange 13 and the protruding portion 11 b to the hub by means of a series of connecting bolts.
In the mounted configuration of the anchoring plate 1 , the above- mentioned shaft 14 passes through a central through hole 6a' of the main body 6a and the opening 6b' in the anchor plate 6b.
The shaft 14 of the vehicle is also fitted with the original support member 15 of the vehicle, to be fixed, in turn, to the suspension of the vehicle.
More specifically, the support member 15 comprises a through hole 16, through which the shaft 14 passes, and two protrusions 17a, 17b, that is, two elongate portions which extend radially with respect to the shaft 14 passing through the above-mentioned through hole 16.
Rigidly connected to the two protrusions 17a, 17b, for example by bolting, are both the brake caliper 12 and the anchor plate 6b of the stator 6 in such a way that the latter is integral with the suspension of vehicle and that the brake disc 11 can, on the other hand, rotate freely in the stator 6 during motion of the vehicle.
For this purpose, two through holes 20, 21 are provided in the anchor plate 6b of the stator 6 to allow the passage of corresponding bolts for the connection between the anchor plate 6b and the protrusions 17a, 7b of the support member 15.
Therefore, in the mounted configuration of the electric motor 1 forming part of this kit, the above-mentioned anchor plate 6b is positioned between the support member 15 and the brake caliper 12, and integrally connected with these latter two elements, whilst the brake caliper 12 occupies the empty space 7 defined by the main body 6a of the stator 6, thereby reducing the overall axial size of the electric motor 1.
The kit also comprises one or more batteries, preferably housed in the boot of the vehicle, to supply, by inverter, electricity to the above- mentioned plurality of the electric windings 10 of the stator 6 for the generation of a magnetic field.
The magnetic field generated by the stator 6 induces the rotor 3 to rotate, due to the effect of the interaction of the lines of the field with above-mentioned plurality of permanent magnets 5, and with it also the rim 2 and therefore the wheel of the vehicle.
Optionally, the kit according to the invention can comprises a control system for adjusting, instant by instant, the power emitted by the above-mentioned electric motors as a function of the power dispensed by the thermal engine of the vehicle.
Again optionally, the kit according to this invention can also comprise a liquid or air cooling system acting on the stator 6 to increase the performance of the electric motor 1 by cooling the electric windings 10.
The kit for electrically supplying a vehicle according to this invention can also comprises a support 18, as shown in Figure 8, to facilitate the fixing of the rotor 3 to the rim 2 of the wheel.
More specifically, the support 18 has a circular concave form with, in the relative central part, a series of through holes 19 to allow the fixing, by bolting, to the hub of the wheel of the vehicle and to the flange 13 of the shaft 14.
The rotor 3, on the other hand, is fixed to a peripheral circular portion of the support 18 for example by structural gluing, bolting, welding of every type, riveting, brazing or braze welding. According to a further variant of the invention (not shown in the accompanying drawings), the above-mentioned support 18 can be conveniently formed as one piece with the rotor 3.
According to another variant embodiment of the invention, shown in Figures 9 and 10, as an alternative to the anchor plate 6b described above, there may be, for the stator, a different anchor plate 22 with a circular extension having an angular extension equal to or greater than 180° and two through holes 23, 24 provided at end portions of the anchor plate 22 to allow the fixing to the two protrusions 17a, 17b of the support member 15 by bolting.
In the central part of the anchor plate 22 there is an opening 25 which performs the same function described above with reference to the opening 6b'.
From the peripheral edge of the anchor plate 22 protrudes, perpendicularly, a portion of cylindrical wall 26 designed to be rigidly coupled to the above-mentioned main body 6a of the stator in such a way that the anchor plate 22 positions itself in a substantially complementary position with respect to that adopted by the anchor plate 6b in Figure 1 , in this manner covering, substantially entirely, the main body 6a of the stator.
In the coupled configuration of the anchor plate 22 and of the main body 6a, the opening 25 is in communication and aligned with the central through hole 6a' of the main body 6a to allow the crossing of the shaft 14 of the wheel of the vehicle.
The stator with the anchor plate 22 is considerably light in weight as well as having an excellent resistance to traction forces, allowing the transformation of tangential forces into forces on the plane on which the anchor plate 22 lies, which has a considerable resistance to these forces.
The lightness of the stator can be further increased by providing one or two openings in its structure.
As may be inferred from the above description and the accompanying drawings, the kit for electrically supplying a vehicle according to this invention comprises electric motors such as to be mounted in the rims of the wheels of the vehicle in a simple and fast manner, replacing only a reduced number of the original components of the vehicle.
This invention is described by way of example only, without limiting the scope of application, according to its preferred embodiments, but it shall be understood that the invention may be modified and/or adapted by experts in the field without thereby departing from the scope of the inventive concept, as defined in the claims herein.

Claims

1 . A kit for electrically supplying a vehicle to allow the motion of a vehicle of the type comprising at least one shaft (14) which is rotatable in an idle fashion and at least one idle wheel, which is provided with a rim (2) and connectable with the at least one shaft (14), a braking system, comprising at least one brake disc (1 1 ) and at least one caliper (12) operating on the at least one brake disc (1 1) to perform a braking action, and a support member (15) for supporting the at least one caliper (12); the kit comprising at least one electric motor (1 ) with an axial flux comprising: a rotor (3) provided with at least one permanent magnet (5);
connecting means for connecting, when in use, the rotor (3) with the rim (2); and
a stator (6) comprising a main body (6a) which is substantially flat, lying on a first plane and having an extension which is at least partially circular and a central hole (6a') and equipped with at least one electric winding (10), and a connecting portion (6b, 22) which is substantially flat, lying on a second plane substantially parallel to the first plane and having an extension at least partially circular and an opening (6b') communicating and substantially aligned with the central hole (6a'), the connecting portion (6b, 22) being integral with the main body (6a) and connectable, when in use, with the support member (15), in the stator (6) being formed, between the main body (6a) and the connecting portion (6b, 22), a cavity for housing, when in use, the at least one caliper (12) in such a way that, when the connecting portion (6b, 22) is connected to the support member (15), the at least one electric winding (10) faces the at least one permanent magnet (5), the at least one shaft (14) passes through the central hole (6a') and the opening (6b'), and the at least one caliper (12) is arranged in the cavity of the stator (6).
2. The kit according to claim 1 , characterized in that the connecting portion (6b, 22) is configured in such a way as to be arranged, when in use, between the support member (15) and the at least one caliper (12).
3. The kit according to claim 1 or 2, characterized in that the connecting portion (6b, 22) comprises connecting means (20, 21 ), preferably at least one through hole, for connecting, when in use, the at least one caliper (12) to the connecting portion (6b, 22).
4. The kit according to any one of the preceding claims, characterized in that the connecting portion (22) has an angular extension which is equal to or greater than 180°.
5. The kit according to any one of the preceding claims, characterised in that the main body (6a) has a substantially circular ring arc shape.
6. The kit according to claim 5, characterized in that the main body (6a) has an angular extension which is equal to or greater than 180°.
7. The kit according to one of the preceding claims, characterised in that the rotor (3) has a substantially circular shape.
8. The kit according to any one of the preceding claims, characterised in that the at least one permanent magnet (5) has a substantially circular shape.
9. The kit according to any one of the preceding claims, characterized in that the at least one permanent magnet (5) comprises a plurality of permanent magnets (5) which are arranged along two circular trajectories which are concentric to each other.
10. The kit according to any one of the preceding claims, characterized in that, when in use, the distance existing between the rotor (3) and the stator (6) is comprised between 0.1 mm and 10 mm.
1 1 . The kit according to any one of the preceding claims, characterized in that it comprises a support (18) having a substantially circular concave shape and a central portion which is configured to couple with the rim (2) when in use, and a peripheral portion which is configured to couple with the rotor (3).
12. The kit according to any one of the preceding claims, characterized in that it comprises a cooling system operating on the stator (6) to cool, when in use, the at least one electric winding (10) and increase performances of the electric motor (1 ).
PCT/IT2017/000172 2016-08-12 2017-08-11 Kit for electrically supplying a vehicle WO2018029720A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102016000084945 2016-08-12
IT102016000084945A IT201600084945A1 (en) 2016-08-12 2016-08-12 Vehicle power supply kit.

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WO2018029720A1 true WO2018029720A1 (en) 2018-02-15

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4223255A (en) * 1977-10-28 1980-09-16 Goldman Gary S Electric wheel
US20080078631A1 (en) * 2004-02-05 2008-04-03 Erlston Lester J Disc brake in combination with brushless electric motor-generator
US20120215389A1 (en) * 2007-01-16 2012-08-23 Charles Hampton Perry Machine for augmentation, storage, and conservation of vehicle motive energy
US20140267458A1 (en) * 2013-03-15 2014-09-18 Foundation Productions, Llc Vehicle wheel-based power generation and display systems

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4223255A (en) * 1977-10-28 1980-09-16 Goldman Gary S Electric wheel
US20080078631A1 (en) * 2004-02-05 2008-04-03 Erlston Lester J Disc brake in combination with brushless electric motor-generator
US20120215389A1 (en) * 2007-01-16 2012-08-23 Charles Hampton Perry Machine for augmentation, storage, and conservation of vehicle motive energy
US20140267458A1 (en) * 2013-03-15 2014-09-18 Foundation Productions, Llc Vehicle wheel-based power generation and display systems

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