WO2022042337A1 - 一种飞轮集成式电动汽车48v机电耦合驱动装置及其使用方法 - Google Patents

一种飞轮集成式电动汽车48v机电耦合驱动装置及其使用方法 Download PDF

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Publication number
WO2022042337A1
WO2022042337A1 PCT/CN2021/112525 CN2021112525W WO2022042337A1 WO 2022042337 A1 WO2022042337 A1 WO 2022042337A1 CN 2021112525 W CN2021112525 W CN 2021112525W WO 2022042337 A1 WO2022042337 A1 WO 2022042337A1
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Prior art keywords
flywheel
speed
motor
end cover
rotor
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PCT/CN2021/112525
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English (en)
French (fr)
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李洪亮
翟利云
邱将杰
王钰明
吕先洋
王涛
花一凡
望康佳
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南通大学
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Publication of WO2022042337A1 publication Critical patent/WO2022042337A1/zh

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    • 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
    • H02K7/02—Additional mass for increasing inertia, e.g. flywheels
    • H02K7/025—Additional mass for increasing inertia, e.g. flywheels for power storage
    • 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
    • B60L15/00—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles
    • B60L15/20—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
    • B60L15/2045—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed for optimising the use of energy
    • 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
    • H02K7/20—Structural association with auxiliary dynamo-electric machines, e.g. with electric starter motors or exciters
    • 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
    • B60L2240/40—Drive Train control parameters
    • B60L2240/42—Drive Train control parameters related to electric machines
    • B60L2240/423—Torque
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/16—Mechanical energy storage, e.g. flywheels or pressurised fluids
    • 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
    • Y02T10/72—Electric energy management in electromobility

Definitions

  • the invention belongs to the technical field of automobile engineering, and more particularly, relates to a flywheel integrated electric vehicle 48V electromechanical coupling drive device and a method for using the same.
  • the cost of the power battery is still one of the key factors restricting the development of the electric vehicle market.
  • the service life of the electrochemical energy storage system directly affects the braking energy recovery and its reuse efficiency.
  • power battery technology has developed rapidly, it is still not suitable for charging and discharging under high power conditions.
  • the power battery is repeatedly charged and discharged, reducing its service life;
  • the power battery When running uphill, if the power battery is the only energy source of the vehicle, the power battery will be in a state of high current discharge, which will also have an adverse effect on the service life; in addition, when the car is braked in an emergency, the power battery is limited by the charging characteristics, and its energy recovery The storage is limited, and the braking energy recovery and utilization efficiency is not high. Therefore, there is still a certain gap between the cruising range of electric vehicles and the expected effect.
  • the flywheel hybrid power devices used in automobiles are mainly divided into two types: energy storage type and mechanical type.
  • the recovery and reuse of the braking energy is completely realized by the mutual conversion of kinetic energy and electric energy.
  • the power mainly depends on the capacity of the electric drive system.
  • the double conversion of energy increases the overall energy consumption and reduces the efficiency of the entire system;
  • the transmission is coupled with the automobile transmission system, and the recovery and reuse of its braking energy is completely realized through kinetic energy transmission.
  • the power mainly depends on the efficiency and load capacity of the transmission system, but it needs to be equipped with a clutch to realize the power coupling.
  • the control is complicated and the overall weight of the system is large.
  • FIG. 1 Chinese patent publication number: CN 106183800 A; publication date: December 7, 2016; discloses a 48V electric drive system for a dual-clutch planetary hybrid vehicle, including a front planetary row, a rear planetary row, a dual clutch, 48V motor and box body; front planetary row includes power input shaft, front row sun gear, front row planetary carrier, common ring gear; rear planetary row includes intermediate drive shaft, rear row sun gear, rear row planetary carrier, and common ring gear; The dual clutch is composed of a low-speed clutch and a high-speed clutch; switching between different working modes can be realized by controlling the engagement and disengagement of the low-speed clutch and the high-speed clutch; the 48V motor output shaft is connected with the power input shaft.
  • the drive system of this application improves the performance of the electric vehicle during acceleration and hill climbing, and improves the life and stability of the electric drive system, it still cannot effectively utilize energy during acceleration or deceleration.
  • a flywheel-integrated electric vehicle 48V electromechanical coupling drive device includes: a box body, which is a hollow structure, and the inside is from left to right.
  • the 48V drive motor, flywheel rotor, 48V speed regulating motor and power output shaft are arranged in sequence; among them, the 48V driving motor and the flywheel rotor are connected by the flywheel shaft; the flywheel rotor and the 48V speed regulating motor are connected by a planetary mechanism, and the sun gear of the planetary mechanism is connected. It is connected with the end of the flywheel shaft, and the planetary gear of the planetary mechanism is connected with the 48V speed regulating motor;
  • the 48V drive motor and the flywheel rotor form a 48V electromechanical flywheel energy storage system.
  • the 48V speed regulating motor and the planetary mechanism form a 48V electric drive stepless speed regulation system.
  • Both the 48V drive motor and the 48V speed regulating motor have motor mode, generator mode and There are three operating states in neutral mode. In motor mode, it corresponds to the output speed and torque of the motor. In neutral mode, the corresponding motor is idling. In generator mode, the corresponding motor recovers kinetic energy.
  • the 48V electromechanical flywheel energy storage system is The main power source
  • the 48V electric drive stepless speed regulation system is the auxiliary power source.
  • the 48V drive motor and the 48V speed regulating motor pass through different operating states according to the rotor speed of the flywheel.
  • the combination of modes, and finally output or energy recovery through the power take-off shaft has high braking energy recovery efficiency, good acceleration performance, low manufacturing cost, and significant energy-saving effect.
  • the flywheel rotor includes a flywheel hub, which is an H-shaped hollow structure, and the flywheel shaft passes through the hollow structure and is drive-connected to the flywheel hub.
  • the outer circumference is wound to form a winding layer.
  • the flywheel hub is made of aluminum alloy material.
  • the flywheel rotor replaces a part of the flywheel structure of aluminum alloy by forming a winding layer on the outer periphery of the flywheel hub to reduce the speed of the flywheel. weight.
  • the outer circumference of the flywheel hub is sequentially fixed and wound from the inside to the outside to form a flywheel inner winding layer, a flywheel middle winding layer and a flywheel outer winding layer, wherein
  • the inner winding layer of the flywheel is S2 glass fiber material
  • the inner winding layer of the flywheel is carbon fiber material
  • the outer winding layer of the flywheel is M40J carbon fiber material.
  • the flywheel rotor is in a high-speed rotation environment for a long time during use. The closer it is to the outer circumference, the greater the load it receives. Therefore, while reducing the weight of the flywheel rotor, it is also necessary to select appropriate materials to ensure the strength of each part of the flywheel rotor.
  • This scheme The selection of materials for each winding layer of the flywheel can ensure that the strength of each part of the flywheel rotor is reliable at a speed of 30,000 rpm, and the effective service life is long, and it can ensure the optimal weight of the flywheel rotor.
  • the planetary carrier of the planetary mechanism includes a front-row planetary carrier and a rear-row planetary carrier, both of which are hollow square disk structures with bosses,
  • the front planet carrier and the rear planet carrier are evenly provided with countersunk holes at the same position along the circumferential direction, and the planetary gear is connected with the countersunk hole through the pin shaft of the planet wheel;
  • the front planet carrier is sleeved outside the flywheel shaft, and the rear planet
  • the frame is connected with the end of the power output shaft in a driving manner; the front row planet carrier and the rear row planet carrier are connected by a connecting plate.
  • the hollow part of the front planetary wheel is connected with the flywheel shaft through the No. 4 bearing, the hollow part of the rear planetary wheel is provided with an internal spline structure, and the left end of the power output shaft is provided with an external spline structure, and the two are matched and connected.
  • the planetary mechanism has stable structure, reliable transmission, and small occupied volume, which is suitable for the working intensity of the device in this scheme under the working conditions.
  • flywheel-integrated electric vehicle 48V electromechanical coupling drive device optionally, there are four planetary gears of the planetary mechanism.
  • this scheme selects the planetary gear The number is four, which ensures that the production cost of the device is reduced under the condition that the carrying capacity reaches the standard.
  • the box body includes a left end cover, a middle end cover and a right end cover from left to right, and the adjacent end covers are connected by connecting bolts;
  • the left end cover is a stepped cylindrical structure, the inner left end is provided with a base, and the center of the base is provided with a blind hole, the shape of which matches the shape of the outer wall of the bearing, the left end of the flywheel shaft is installed in the blind hole through the No.
  • the right end of the cover is provided with several connecting holes along the circumferential direction for installing connecting bolts;
  • the middle end cover is a stepped cylindrical structure with a middle seat in the middle, a No. 1 through hole is opened in the middle of the middle seat, the shape of the left end of the No. 1 through hole matches the shape of the outer wall of the bearing, and the middle of the flywheel shaft passes through the No. 5 bearing.
  • the right end cover is a cylindrical structure, the inner right end is provided with a No. 2 through hole in the middle, the shape of the left end of the No. 2 through hole matches the shape of the outer wall of the bearing, and the middle part of the power transmission shaft is installed in the No. 2 through hole through the No. 3 bearing,
  • the left end of the right end cover is provided with several connecting holes along the circumferential direction for installing connecting bolts;
  • flange which is a hollow structure and is integrally formed in the outer middle of the right end of the right end cover.
  • the three-part split box structure greatly facilitates the installation of each component of the device, and the blind holes, No. At the same time, it ensures the stability and reliability of the connection structure after the bearing and other mechanisms are connected, and ensures the effective service life of the device; the flange plate integrally formed on the right end cover facilitates the stable installation of the device in the corresponding position of the vehicle.
  • the end faces where the left end cover and the middle end cover are connected are machined with a stop hole that cooperates with each other; the middle end cover and the right end cover The connected end faces are machined with mutually matched spigots; the right end of the through hole on the middle seat of the middle end cover is provided with a sealing groove in the circumferential direction, and the outer casing of the middle part of the flywheel shaft is provided with a sealing ring to be fitted in the sealing groove.
  • the spigot is a step-like structure formed by the connection of the end caps.
  • the spigot is matched and connected and then tightened by connecting bolts to form a closed structure at the joint to prevent dust and impurities from entering the device from the joint and affecting each mechanism.
  • the inner space of the left end cover and the middle end cover is completely closed, which ensures the cleanliness of the working environment of the 48V electromechanical flywheel energy storage system and greatly prolongs the Its effective service life and energy storage efficiency.
  • the inner space formed after the left end cover and the middle end cover are connected is a vacuum environment, and the vacuum pressure is 5-10 mbar.
  • the space environment is controlled to a vacuum environment with a vacuum pressure of 5-10 mbar, which can minimize the energy loss and further ensure the energy utilization rate.
  • a method for using a flywheel-integrated electric vehicle 48V electromechanical coupling drive device is provided:
  • the 48V drive motor If the speed of the flywheel rotor is greater than the low value, the 48V drive motor is in neutral mode, the flywheel rotor directly outputs kinetic energy, and the 48V speed regulating motor is in motor mode, outputting speed and torque; if the speed of the flywheel rotor is less than Low value, the 48V drive motor is in motor mode, which drives the flywheel rotor to rotate, and the 48V speed regulating motor is in motor mode, outputting speed and torque;
  • both the 48V drive motor and the 48V speed regulating motor are in generator mode; if the speed of the flywheel rotor is less than the high value, the 48V drive motor is in neutral mode, and the 48V speed regulating motor for generator mode.
  • the flywheel rotor is coaxially connected to the 48V drive motor, so the speed of the flywheel rotor can be detected by detecting the speed of the 48V drive motor.
  • the 48V drive motor When the vehicle accelerates, if the speed of the flywheel rotor is greater than the set low value, the 48V drive motor will idle and the flywheel will rotate.
  • the rotor inputs kinetic energy, namely rotational speed and torque, to the planetary mechanism through the sun gear, and the 48V speed regulating motor inputs the adapted rotational speed and torque to the planetary mechanism through the planetary gear according to the driving requirements.
  • the power is output from the rear planetary carrier to the power take-off shaft, and then drives the vehicle to drive after the deceleration device decelerates and increases the torque; when the vehicle accelerates, if the speed of the flywheel rotor is less than the set low value, the 48V drive motor drives the flywheel rotor to rotate.
  • the flywheel rotor inputs kinetic energy to the planetary mechanism through the sun gear, and the 48V speed regulating motor inputs the adapted speed and torque to the planetary mechanism through the planetary gear according to the driving requirements.
  • the planet carrier is output to the power take-off shaft, and the vehicle is driven to drive after deceleration and torque increase by the reduction device;
  • both the 48V drive motor and the 48V speed regulating motor are in generator mode, recovering the kinetic energy and electrical energy of the flywheel rotor, and the 48V driving motor and the 48V speed regulating motor are in the process of generating electricity.
  • the induced electromagnetic torque generated is the braking torque, which is fed back to the power take-off shaft from the rear planetary carrier after coupling by the planetary mechanism, and the vehicle braking is realized after the torque is increased by the deceleration device; when the vehicle decelerates, if the speed of the flywheel rotor is less than The set high value, the 48V drive motor is idling, the 48V speed regulating motor is in generator mode, the kinetic energy of the flywheel rotor is recovered, the kinetic energy of the flywheel rotor input to the planetary mechanism and the induced electromagnetic torque generated by the 48V speed regulating motor in the process of power generation are passed through the planet. After the mechanism is coupled, the output of the rear planet carrier is fed back to the power output shaft, and the vehicle braking is realized after the torque is increased by the deceleration device.
  • the low value is 2800-3200 rpm; the high value is 23000-27000 rpm.
  • the braking energy during vehicle braking is mainly recovered and reused in the form of kinetic energy, which can not only effectively avoid the high power peak during the charging process of the power battery in the early stage of braking, but also can directly use the kinetic energy in the process of starting and accelerating the vehicle.
  • the 48V electric drive stepless speed regulation system of the present invention couples the flywheel rotor, the speed regulating motor and the power output shaft together, the control strategy under different vehicle operating conditions is simple, the transmission is stable and the transmission efficiency is high, Reduce the frustration of mechanical braking, which can effectively improve the comfort of the vehicle;
  • the flywheel integrated electric vehicle 48V electromechanical coupling drive device of the present invention has low electrical equipment power and low production cost, which can not only effectively reduce the cost of the battery, motor and controller of the vehicle, but also greatly improve the power of the vehicle, especially Suitable for urban low-speed small electric vehicles.
  • FIG. 1 shows a schematic cross-sectional structure diagram of the 48V electromechanical coupling drive device of the flywheel integrated electric vehicle of the present invention on the front view;
  • Fig. 2 shows the exploded schematic diagram of the planetary mechanism of the flywheel-integrated electric vehicle 48V electromechanical coupling drive device of the present invention
  • FIG. 3 shows a schematic cross-sectional structure diagram of the 48V drive motor of the flywheel integrated electric vehicle 48V electromechanical coupling drive device of the present invention
  • Fig. 4 shows the flywheel rotor sectional structure schematic diagram of the flywheel integrated electric vehicle 48V electromechanical coupling drive device of the present invention
  • FIG. 5 shows a schematic cross-sectional structure diagram of a 48V speed-regulating motor of the flywheel-integrated electric vehicle 48V electromechanical coupling drive device of the present invention
  • Figure 6 shows a schematic half-section structure of the left end cap, the middle end cap and the right end cap of the present invention
  • Fig. 7 shows the schematic diagram of the flywheel shaft of the present invention
  • Fig. 8 shows the schematic diagram of the power take-off shaft of the present invention
  • Speed-adjusting motor rotor core 22, the outer snap ring of the pin shaft of the planetary gear; 23, the rear planet carrier; 24, the sun gear; 25, the flange plate; 26, the second bearing; 27, the third bearing; 28, the power output shaft; 29, the third No. spacer; 30, inner snap ring; 31, flywheel shaft outer snap ring; 32, flywheel shaft; 33, No. 4 bearing; 34, planetary gear; 35, planetary pin shaft; 36, sliding bearing; 37, front row Star frame; 38, sealing ring; 39, No. 5 bearing; 40, flat key; 41, connecting plate; 100, blind hole; 101, mouth; 140, No. 1 through hole; 141, middle seat; 142, sealing groove ; 170, No. 2 through hole.
  • the present invention is designed based on the following ideas: 48V drive system can be used as a low-cost solution to be applied to micro-hybrid hybrid vehicles or electric vehicles, which can effectively avoid the disadvantages of complex configuration of the hybrid system and high motor power requirements, and the flywheel has With the advantages of long service life, low manufacturing cost and high power density, it is suitable for application scenarios with short energy storage period, many charge-discharge cycles and high peak power demand. After coupling the 48V drive system with the flywheel, it can not only meet the high energy density and high power density requirements of the power system, but also prolong the service life of the power system at a lower cost.
  • the flywheel-integrated electric vehicle 48V electromechanical coupling drive device of the present invention integrates a 48V motor and a flywheel.
  • the 48V drive system can effectively avoid the high cost of the high-voltage system and the power limitation of the low-voltage system; on the other hand, the flywheel can meet the braking requirements of the vehicle. High power requirements during driving and driving, miniaturization of the motor, light weight of the battery, and a longer life cycle.
  • the flywheel integrated electric vehicle 48V electromechanical coupling drive device of the present invention includes a 48V electromechanical flywheel energy storage system composed of a 48V drive motor and a flywheel rotor, and a 48V electric drive stepless regulation composed of a 48V speed regulating motor and a planetary mechanism. Speed system and box.
  • the flywheel shaft 32 is a stepped shaft, the shape is shown in Figure 7, the left end is supported and installed in the blind hole 100 of the left end cover 1 through the No. 24 is connected, the flywheel shaft 32 is supported and installed in the No. 1 through hole 140 in the middle of the middle seat 141 of the middle end cover 14 through the No. 5 bearing 39, and the No. 1 bearing 2 and the No. 5 bearing 39 are a pair of angular contact ball bearings;
  • the 48V drive motor of the 48V electromechanical flywheel energy storage system is shown in Figure 1, including the drive motor controller 4, the drive motor stator core 5, the drive motor stator coil winding 6, the drive motor rotor squirrel cage winding 7 and the drive motor rotor iron Core 8, the right end of the drive motor rotor core 8 is positioned through the shoulder of the flywheel shaft 32, and the left end is positioned through the No.
  • the drive motor rotor core 8 and the flywheel shaft 32 are connected by interference fit;
  • the core 8 is embedded in the driving motor rotor squirrel cage winding 7 along the circumferential direction;
  • the driving motor stator core 5 is fixedly connected to the inner circumferential surface of the left end cover 1, and is embedded in the driving motor stator coil winding 6 along the circumferential direction;
  • the driving motor stator core 5 and the An air gap is left between the rotor cores 8 of the drive motor;
  • the flywheel hub 12 is an H-shaped hollow structure and is connected with the flywheel shaft 32 through a flat key 40.
  • the left end of the flywheel hub 12 is positioned through the shoulder of the flywheel shaft 32, and the right end of the flywheel hub 12 is positioned through the No. 2 spacer 13.
  • the outer circumferential direction is fixedly wound from the inside to the outside.
  • the inner winding layer 11 of the flywheel, the winding layer 10 in the flywheel and the outer winding layer 9 of the flywheel are successively wound; rotor, as shown in Figure 4;
  • the 48V speed regulating motor of the 48V electric drive stepless speed regulating system is shown in Figure 1, including the speed regulating motor controller 16, the speed regulating motor stator iron core 18, the speed regulating motor stator coil winding 19, and the speed regulating motor rotor permanent magnet 20 and the rotor iron core 21 of the speed regulating motor, the stator iron core 18 of the speed regulating motor is fixedly connected to the inner circumferential surface of the right end cover 17, and the stator iron core 18 of the speed regulating motor is embedded in the stator coil winding 19 of the speed regulating motor along the circumferential direction;
  • the rotor core 21 is a hollow ring structure, supported on the power output shaft 28 by the No. 2 bearing 26, and positioned axially by the inner snap ring 30; the No.
  • the 2 bearing 26 is an angular contact ball bearing; the No. 3 spacer 29 and the power output
  • the shaft shoulder of the shaft 28 is positioned;
  • the rotor core 21 of the speed regulating motor is embedded in the permanent magnet 20 of the rotor of the speed regulating motor along the circumferential direction of the outer ring, and the cylindrical helical gear ring gear is processed along the circumferential direction of the inner ring;
  • the stator core 18 of the speed regulating motor is connected to the speed regulating motor An air gap is left between the rotor cores 21 of the motor;
  • the planetary mechanism is shown in Figures 1 and 2, the sun gear 24 is a helical cylindrical gear, the left end is positioned by the shoulder of the flywheel shaft 32, the right end is positioned by the outer snap ring 31 of the flywheel shaft, and is connected with the flywheel shaft 28 by splines;
  • the row planet carrier 37 is supported on the flywheel shaft 32 by the fourth bearing 33; the fourth bearing is an angular contact ball bearing;
  • the rear row planet carrier 23 is an inner spline structure, which is matched with the outer spline at the left end of the power output shaft 28;
  • the right end of the planetary carrier 23 is positioned by the shoulder of the power output shaft 28;
  • the planetary gear pin 35 is a solid optical axis, and is fixedly installed between the front row planetary carrier 37 and the rear row planetary carrier 23;
  • the planetary gear 34 is a helical gear cylinder
  • the gear is sleeved on the planetary pin shaft 35 through the sliding bearing 36, and is constantly me
  • the No. 1 bearing 2, the No. 2 bearing 26, the No. 3 bearing 27, the No. 4 bearing 33 and the No. 5 bearing 39 are all angular contact ball bearings, and each bearing is arranged in the corresponding installation position such as a blind hole or a through hole. , and stably positioned by the shaft shoulder of the shaft member or by setting the spacer, so that the device has a bearing system with stable structure and low friction resistance, which reduces the loss of the operation of the device, improves the effective service life of the device, and improves the the energy conversion efficiency.
  • the box body is composed of right and left end caps 1 , middle end caps 14 and right end caps 17 , wherein the left end cap 1 is a stepped cylindrical structure with a base, and there are several connecting holes along the circumferential direction.
  • the base is provided with a blind hole 100 with a bearing seat hole, which is used to install the No. 1 bearing 2;
  • the middle end cover 14 is a stepped cylindrical structure with a middle seat 141, along the circumference of the left and right ends
  • the middle seat 141 is provided with a No. 1 through hole 140 for installing a bearing, which is used to install a No.
  • the ring 38; the right end cover 17 is a cylindrical structure, and there are several connecting holes in the circumferential direction for installing the connecting bolts 15, and the base is provided with a No. 2 through hole 170 for installing a bearing, which is used for installing the No.
  • the flange 25 is a circular disc-shaped structure with a number of through holes along the circumferential direction, and is processed into one with the right end cover 17; the right end of the left end cover 1, the left and right ends of the middle end cover 14, and the right end of the right end cover 17 are processed There is a stop 101 that cooperates with each other, the middle end cover 14 is connected with the left end cover 1 and the right end cover 17 respectively through the connecting bolt 15, the space formed after the left end cover 1 and the middle end cover 14 are connected is a closed vacuum environment, and the vacuum pressure is 5 ⁇ 10mbar.
  • the front-row planetary carrier 37 and the rear-row planetary carrier 23 are both hollow square disk structures with bosses, and four countersunk holes are opened at the same position along the circumferential direction. It is used to install four planetary pin shafts 35; the number of planetary wheels 34 is four, the number of sliding bearings 36 matched with it is four, and the number of outer snap rings 22 of the planetary wheel pins is eight; The front row planet carrier 37 and the rear row planet carrier 23 are fixedly connected through the connecting plate 41 .
  • the type of the 48V drive motor in this embodiment is an asynchronous induction motor, which is powered by a vehicle-mounted 48V power battery;
  • the number of slots in the stator core 5 of the drive motor is 24, which are used to embed the stator coil winding 6 of the drive motor;
  • the number of slots of the driving motor rotor iron core 8 is 32, which are used for embedding into the driving motor rotor squirrel cage winding 7;
  • the bars and end rings of the driving motor rotor squirrel cage winding 7 are made of pure copper material.
  • the outer edge of the flywheel hub 12 is formed by winding three layers of different fiber epoxy resin composite materials. From the inside to the outside are the flywheel inner winding layer 11, the flywheel middle winding layer 10 and the flywheel outer winding layer. 9.
  • the flywheel hub 12 is made of aluminum alloy material, the flywheel inner winding layer 11 adopts S2 glass fiber material, the flywheel middle winding layer 10 adopts T700 carbon fiber material, and the flywheel outer winding layer 9 adopts M40J carbon fiber material.
  • the type of the 48V speed regulating motor in this embodiment is a permanent magnet synchronous induction motor, which is powered by a vehicle-mounted 48V power battery; the number of slots of the speed regulating stator iron core 18 is 24, which are used to embed the stator coil of the driving motor. Winding 6; the number of slots of the rotor core 21 of the speed regulating motor is 24, which are used to embed the permanent magnet 20 of the rotor of the speed regulating motor; above.
  • the flywheel-integrated electric vehicle 48V electromechanical coupling drive device of this embodiment when the flywheel-integrated electric vehicle 48V electromechanical coupling drive device of this embodiment is in use, the vehicle-mounted 48V power battery is used for power supply, the 48V electromechanical flywheel energy storage system is the main power source, and the 48V electric drive stepless speed regulation system is the auxiliary.
  • Power source, 48V drive motor and 48V speed regulating motor have three operating states: motor mode, generator mode and neutral mode. The corresponding operating mode is determined according to the speed of the flywheel rotor.
  • the 48V drive motor When the vehicle accelerates: if the speed of the flywheel rotor is If the rotational speed is greater than the low value, the 48V drive motor is in neutral mode, the flywheel rotor directly outputs kinetic energy, and the 48V speed regulating motor is in motor mode, and the output speed and torque are determined according to the driving needs; if the rotational speed of the flywheel rotor is less than the low value, the 48V drive motor is The motor mode drives the flywheel rotor to rotate, and the 48V speed regulating motor is the motor mode, and the output speed and torque are determined according to the driving needs; the flywheel rotor drives the sun gear 24 to rotate, and the rotor core of the speed regulating motor drives the 21-moving planetary gear 34 to rotate.
  • the rotational speed and torque of the motor are decoupled by the planetary mechanism, and the power is output from the rear planetary carrier 23 to the power take-off shaft 28, which is decelerated and torque-increased by the deceleration device to drive the vehicle.
  • the vehicle decelerates and brakes for energy recovery if the speed of the flywheel rotor is greater than the high value, the 48V drive motor and the 48V speed regulating motor are in generator mode; if the speed of the flywheel rotor is less than the high value, the 48V drive motor is in neutral mode, 48V The speed regulating motor is in generator mode; the induced electromagnetic torque generated by the 48V drive motor and the 48V speed regulating motor during the power generation process is the braking torque.
  • the vehicle braking is realized after the torque is increased by the deceleration device.
  • the drive motor controller 4 and the speed regulating motor controller 16 are installed outside the box, respectively control the speed and torque of the flywheel rotor and the speed regulating motor rotor core 21, and realize the speed and torque adjustment of the power take-off shaft 28 to match Different driving needs.
  • the above-mentioned low value is 2800-3200 rpm, and the high value is 23,000-27,000 rpm. More specifically, for urban low-speed small electric vehicles, the low value set in this embodiment is 3000 rpm. , the high value is 25000 rpm.
  • the settings of the low and high values are suitable for the working conditions of urban low-speed small electric vehicles, which help them to adjust the running state mode of the two motors in a timely and effective manner. It can effectively avoid high power peaks during the charging process of the power battery in the initial stage, and can directly provide auxiliary power in the form of kinetic energy during the starting and acceleration of the vehicle, extending the service life of the power battery and mechanical brake components.

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Abstract

本发明公开了一种飞轮集成式电动汽车48V机电耦合驱动装置及其使用方法，属于汽车工程技术领域。装置包括箱体，其为中空结构，其内从左到右依次布置有48V驱动电机、飞轮转子、48V调速电机和动力输出轴；48V驱动电机与飞轮转子通过飞轮轴传动连接；飞轮转子与48V调速电机通过行星机构连接，行星机构的太阳轮与飞轮轴端部传动连接，行星机构的行星轮与48V调速电机传动连接；动力输出轴一端与行星机构的行星架传动连接，另一端伸出箱体外。本发明使车辆制动时的制动能量主要以动能形式回收和再利用，既可在制动初期有效避免动力电池充电过程中的高功率峰值，又能在车辆起步和加速过程中直接以动能形式提供辅助功率，延长动力电池和机械制动部件的使用寿命。

Description

一种飞轮集成式电动汽车48V机电耦合驱动装置及其使用方法 技术领域
本发明属于汽车工程技术领域，更具体地说，涉及一种飞轮集成式电动汽车48V机电耦合驱动装置及其使用方法。
背景技术
目前，动力电池成本仍然是制约电动汽车市场发展的关键因素之一，电化学储能系统的使用寿命直接影响制动能量回收及其再利用效率。虽然动力电池技术发展迅速，但仍不适合在高功率状态下进行充电和放电，首先，制动-加速频繁的城市工况下，动力电池反复充放电，降低其使用寿命；其次，汽车加速或者上坡运行时，若动力电池是车辆的唯一能量源，动力电池将处于大电流放电状态，对使用寿命也有不利的影响；另外，汽车紧急制动时，动力电池受充电特性限制，其电能回收存储有限，制动能量回收与利用效率不高。因此，电动汽车的续航里程与预期效果之间仍存在一定差距。
当前，汽车上采用的飞轮混合动力装置主要分为储能式和机械式两种，存在的不足之处为：储能式中飞轮通过电动机/发电机和电子转换装置实现能量的转换和传输，其制动能量的回收和再利用完全通过动能与电能的相互转化实现，功率主要取决于电力传动系统容量，能量双重转换增加了总体能耗，降低了整个系统效率；机械式中飞轮通过机械无极变速器与汽车传动系统耦合，其制动能量的回收和再利用完全通过动能传递实现，功率主要取决于传动系统效率及负荷能力，但需要配置离合器实现动力耦合，控制复杂且系统总体重量较大。
经检索，中国专利公开号：CN 106183800 A；公开日：2016年12月07日；公开了一种双离合器行星式混合动力汽车48V电驱动系统，包括前行星排、后行星排、双离合器、48V电机和箱体；前行星排包括动力输入轴、前排太阳轮、前排行星架、公共齿圈；后行星排包括中间传动轴、后排太阳轮、后排行星架、公共齿圈；双离合器由低速离合器与高速离合器组成；通过控制低速离合器与高速离合器的接合与分离可以实现不同工作模式的切换；48V电机输出轴与动力输入轴相连接。该申请案的驱动系统，虽然提高了电动汽车加速、爬坡时的性能，且提高了电驱动系统的寿命与稳定性，但是加速或减速时仍无法达到对能源的有效利用。
发明内容
为了解决上述技术问题至少之一，根据本发明的一方面，提供了一种飞轮集成式电动汽车48V机电耦合驱动装置，该装置包括：包括箱体，其为中空结构，其内从左到右依次布置有48V驱动电机、飞轮转子、48V调速电机和动力输出轴；其中，48V驱动电机与飞轮转子通过飞轮轴传动连接；飞轮转子与48V调速电机通过行星机构连接，行星机构的太阳轮与飞轮轴端部传动连接，行星机构的行星轮与48V调速电机传动连接；动力输出轴一端与行星机构的行星架传动连接，另一端伸出箱体外。
48V驱动电机与飞轮转子构成了48V机电飞轮储能系统，48V调速电机与行星机构构成了48V电驱无级调速系统，48V驱动电机与48V调速电机均具有电动机模式、发电机模式和中性模式三种运行状态，电动机模式下，对应电机输出转速和转矩，中性模式下，对应电机空转，发电机模式下，对应电机回收动能电能，本方案中48V机电飞轮储能系统为主动力源，48V电驱无级调速系统为副动力源，在车辆起步、加速、减速、制动过程中，根据飞轮转子转速的不同，48V驱动电机与48V调速电机通过不同的运行状态模式的组合，最后通过动力输出轴输出或进行能量回收，制动能量回收效率高、加速性能好、制造成本低、节能效果显著。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述飞轮转子包括飞轮轮毂，其为H型空心结构，飞轮轴穿过空心结构与飞轮轮毂传动连接，飞轮轮毂的外圆周缠绕形成有缠绕层。
飞轮轮毂为铝合金材料，飞轮转子在工作过程中为了提高其极限角速度，最大限度的发挥其储能效果，通过在飞轮轮毂外周形成缠绕层来代替一部分的铝合金的飞轮结构，以减轻飞轮的重量。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，飞轮轮毂的外圆周由内向外依次固定缠绕形成有飞轮内缠绕层、飞轮中缠绕层和飞轮外缠绕层，其中飞轮内缠绕层为S2玻璃纤维材料，飞轮中缠绕层为碳纤维材料，飞轮外缠绕层为M40J碳纤维材料。
飞轮转子使用过程中长期处于高速旋转的环境下，越靠近外周，受到的载荷越大，因此，在减轻飞轮转子重量的同时，还需要选定合适的材料保证飞轮转子各部分的强度，本方案中飞轮各缠绕层材料的选取能保证飞轮转子在30000转/分钟的转速下各部分的强度可靠，有效使用寿命长，且能保证飞轮转子重量最优。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述行星机构的行星架包括前排行星架和后排行星架，均为带凸台的空心方盘结构，前排行星架和后排行星架沿圆周方向在相同位置处均匀开设有沉头孔，行星轮通过行星轮销轴与沉头孔连接；前排行星架套设于飞轮轴外，后排行星架与动力输出轴端部传动连接；前排行星架与后排行星架通过连接板连接。
前排行星轮中空部分通过四号轴承与飞轮轴连接，后排行星轮中空部分设有内花键结构，动力输出轴的左端部设有外花键结构，两者相配合连接，本方案的行星机构结构稳定，传动可靠，且占用体积小，适用于本方案的装置使用工况环境下的工作强度。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述行星机构的行星轮设有四个。
行星轮的个数越多，承载能力越大，但相应的，对加工及配合精度的要求就越高，会大大增加成本，根据本发明适用的转速范围及功率要求，本方案选定行星轮数量为四个，确保了承载能力达标的情况下，降低了装置生产成本。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述箱体从左至右包括左端盖、中端盖和右端盖，相邻两端盖通过连接螺栓连接；
所述左端盖为阶梯状圆筒形结构，内部左端设有底座，底座中心开设有盲孔，其形状与轴承外壁形状相匹配，飞轮轴的左端部通过一号轴承安装于盲孔中，左端盖的右端部 沿圆周方向开设若干连接孔，用于安装连接螺栓；
所述中端盖为阶梯状圆筒形结构，内部中间设有中间座，中间座中部开设一号通孔，一号通孔左端形状与轴承外壁形状相匹配，飞轮轴的中部通过五号轴承安装于一号通孔中，中端盖的左端部和右端部均沿圆周方向开设若干螺纹孔，用于装配连接螺栓；
所述右端盖为圆筒形结构，内部右端设中部开设有二号通孔，二号通孔左端形状与轴承外壁形状相匹配，动力传动轴中部通过三号轴承安装于二号通孔中，右端盖的左端部沿圆周方向开设若干连接孔，用于安装连接螺栓；
还包括，法兰盘，其为中空结构，一体成型于右端盖右端外部中部。
三部分组成的分体式箱体结构，极大的方便了本装置各个构件的安装，各端盖内部对应位置一体化形成的盲孔、一号通孔、二号通孔等形状结构在方便安装的同时保证了轴承等机构连接后连接结构的稳定性可靠性，确保本装置的有效使用寿命；一体成型于右端盖上的法兰盘方便本装置在车辆对应位置的稳定安装。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述左端盖和中端盖相接的端面上加工有相互配合的止口；所述中端盖和右端盖相接的端面上加工有相互配合的止口；所述中端盖的中间座上一号通孔的右端周向开设有密封槽，飞轮轴中部外套设有密封圈配合安装于密封槽中。
止口为各端盖连接端面上配合形成的台阶状结构，通过止口配合连接，再通过连接螺栓紧固，可以使连接处形成封闭结构，防止灰尘杂质从连接处进入本装置内部影响各机构的工作效率，进一步地，通过密封槽配合密封圈及飞轮轴的安装，将左端盖与中端盖的内部空间完全封闭，确保了48V机电飞轮储能系统工作环境的清洁，极大的延长了其有效使用寿命及储能效率。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置，可选地，所述左端盖和中端盖连接后形成的内部空间为真空环境，真空压力为5～10mbar。
飞轮转子在高速转动时在非真空环境中会产生空气摩擦力、阻力等，同时，48V驱动电机工作过程中还会产生电涡流损耗等，本方案将左端盖和中端盖连接后形成的内部空间环境控制为真空压力为5～10mbar的真空环境，能将能量损耗达到最低值，进一步确保了能量利用率。
根据本发明的另一方面，提供了一种飞轮集成式电动汽车48V机电耦合驱动装置的使用方法：
A、车辆加速时：
检测飞轮转子的转速，若飞轮转子的转速大于低值，则48V驱动电机为中性模式，飞轮转子直接输出动能，48V调速电机为电动机模式，输出转速和转矩；若飞轮转子的转速小于低值，48V驱动电机为电动机模式，驱动飞轮转子旋转，48V调速电机为电动机模式，输出转速和转矩；
B、车辆减速制动时：
检测飞轮转子的转速，若飞轮转子的转速大于高值，48V驱动电机和48V调速电机均为发电机模式；若飞轮转子的转速小于高值，48V驱动电机为中性模式，48V调速电机为发电机模式。
飞轮转子与48V驱动电机同轴传动连接，因此飞轮转子的转速可通过检测48V驱动 电机的转速检测出，车辆加速时，若飞轮转子的转速大于设定的低值，则48V驱动电机空转，飞轮转子通过太阳轮向行星机构输入动能，即转速和转矩，48V调速电机则根据驾驶需求通过行星轮向行星机构输入适应的转速和转矩，两者输入的转速和转矩经行星机构解耦，动力由后排行星架输出至动力输出轴，经减速装置减速增扭后驱动车辆行驶；车辆加速时，若飞轮转子的转速小于设定的低值，则48V驱动电机驱动飞轮转子旋转，飞轮转子通过太阳轮向行星机构输入动能，48V调速电机则根据驾驶需求通过行星轮向行星机构输入适应的转速和转矩，两者输入的转速和转矩经行星机构解耦，动力由后排行星架输出至动力输出轴，经减速装置减速增扭后驱动车辆行驶；
车辆减速时，若飞轮转子的转速大于设定的高值，48V驱动电机和48V调速电机均为发电机模式，回收飞轮转子的动能与电能，48V驱动电机和48V调速电机在发电过程中产生的感应电磁转矩为制动转矩，经行星机构耦合后由后排行星架输出反馈至动力输出轴，经减速装置增扭后实现车辆制动；车辆减速时，若飞轮转子的转速小于设定的高值，48V驱动电机空转，48V调速电机为发电机模式，回收飞轮转子的动能，飞轮转子输入行星机构的动能与48V调速电机在发电过程中产生的感应电磁转矩经行星机构耦合后由后排行星架输出反馈至动力输出轴，经减速装置增扭后实现车辆制动。
根据本发明实施例的飞轮集成式电动汽车48V机电耦合驱动装置的使用方法，可选地，所述低值为2800～3200转/分钟；所述高值为23000～27000转/分钟。
有益效果
本发明提出的技术方案相比于现有技术，至少具有如下有益效果：
(1)车辆制动时的制动能量主要以动能形式回收和再利用，既可以在制动初期有效避免动力电池充电过程中的高功率峰值，又能够在车辆起步和加速过程中直接以动能形式提供辅助功率，延长动力电池和机械制动部件的使用寿命；
(2)本发明的48V电驱无级调速系统将飞轮转子，调速电机和动力输出轴三者动力耦合在一起，不同汽车运行工况下的控制策略简单，传动平稳且传动效率高，降低机械制动时的顿挫感，能够有效改善整车舒适性；
(3)本发明的飞轮集成式电动汽车48V机电耦合驱动装置，电气设备功率小，生产成本低，既可以有效降低整车电池、电机和控制器成本，又能够大幅提高整车动力性，特别适合用于城市低速小型电动汽车。
附图说明
为了更清楚地说明本发明实施例的技术方案，下面将对实施例的附图作简单地介绍，显而易见地，下面描述中的附图仅仅涉及本发明的一些实施例，而非对本发明的限制。
图1示出了本发明的飞轮集成式电动汽车48V机电耦合驱动装置主视图上的剖面结构示意图；
图2示出了本发明的飞轮集成式电动汽车48V机电耦合驱动装置的行星机构爆炸示意图；
图3示出了本发明的飞轮集成式电动汽车48V机电耦合驱动装置的48V驱动电机剖面结构示意图；
图4示出了本发明的飞轮集成式电动汽车48V机电耦合驱动装置的飞轮转子剖面 结构示意图；
图5示出了本发明的飞轮集成式电动汽车48V机电耦合驱动装置的48V调速电机剖面结构示意图；
图6示出了本发明左端盖、中端盖和右端盖的半剖结构示意图；
图7示出了本发明飞轮轴的示意图；
图8示出了本发明动力输出轴的示意图；
附图标记：
1、左端盖；2、一号轴承；3、一号隔套；4、驱动电机控制器；5、驱动电机定子铁芯；6、驱动电机定子线圈绕组；7、驱动电机转子鼠笼绕组；8、驱动电机转子铁芯；9、飞轮外缠绕层；10、飞轮中缠绕层；11、飞轮内缠绕层；12、飞轮轮毂；13、二号隔套；14、中端盖；15、连接螺栓；16、调速电机控制器；17、右端盖；18、调速电机定子铁芯；19、调速电机定子线圈绕组；20、调速电机转子永磁体；21、调速电机转子铁芯；22、行星轮销轴外卡环；23、后排行星架；24、太阳轮；25、法兰盘；26、二号轴承；27、三号轴承；28、动力输出轴；29、三号隔套；30、内卡环；31、飞轮轴外卡环；32、飞轮轴；33、四号轴承；34、行星轮；35、行星轮销轴；36、滑动轴承；37、前排行星架；38、密封圈；39、五号轴承；40、平键；41、连接板；100、盲孔；101、止口；140、一号通孔；141、中间座；142、密封槽；170、二号通孔。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例的附图，对本发明实施例的技术方案进行清楚、完整地描述。显然，所描述的实施例是本发明的一部分实施例，而不是全部的实施例。基于所描述的本发明的实施例，本领域普通技术人员在无需创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
除非另作定义，此处使用的技术术语或者科学术语应当为本发明所属领域内具有一般技能的人士所理解的通常意义。本发明专利申请说明书以及权利要求书中使用的“左”、“右”以及类似的词语并不表示任何顺序、数量或者重要性，而只是用来区分不同的组成部分。同样，“一个”或者“一”等类似词语也不表示数量限制，而是表示存在至少一个。
本发明基于如下思路设计：48V驱动系统可以作为一种低成本方案，应用于微混型混合动力汽车或者电动汽车，能有效规避混合动力系统构型复杂和电机功率要求高的缺点，而飞轮具有使用寿命长，制造成本低及功率密度高等优点，适用于储能周期较短，充放电循环次数较多以及峰值功率需求较高的应用场景。将48V驱动系统与飞轮耦合后既能够满足动力系统的高能量密度和高功率密度需求，同时又能以较低成本延长动力系统使用寿命。
本发明的飞轮集成式电动汽车48V机电耦合驱动装置集成了48V电机和飞轮，一方面48V驱动系统能够有效地避免高压系统的高成本和低压系统的功率限制；另一方面飞轮可以满足车辆制动时和驱动时的高功率需求，电机小型化，电池轻量化，拥有更长的寿命周期。
如图1所示，本发明的飞轮集成式电动汽车48V机电耦合驱动装置包括48V驱动电机与飞轮转子构成的48V机电飞轮储能系统、48V调速电机与行星机构构成的48V电驱无级调速系统及箱体。
其中，48V机电飞轮储能系统中，飞轮轴32为阶梯轴，形状如图7所示，其左端通过一号轴承2支撑安装在左端盖1的盲孔100中，右端通过花键与太阳轮24连接，飞轮轴32通过五号轴承39支撑安装在中端盖14中间座141中部的一号通孔140中，一号轴承2与五号轴承39为一对角接触球轴承；
48V机电飞轮储能系统的48V驱动电机如图1所示，包括有驱动电机控制器4、驱动电机定子铁芯5、驱动电机定子线圈绕组6、驱动电机转子鼠笼绕组7和驱动电机转子铁芯8，驱动电机转子铁芯8的右端通过飞轮轴32的轴肩定位，左端通过一号隔套3定位，驱动电机转子铁芯8与飞轮轴32采用过盈配合方式连接；驱动电机转子铁芯8沿圆周方向嵌入驱动电机转子鼠笼绕组7；驱动电机定子铁芯5固定连接在左端盖1的内环圆周面，沿圆周方向嵌入驱动电机定子线圈绕组6；驱动电机定子铁芯5与驱动电机转子铁芯8之间留有气隙；
飞轮轮毂12为H型空心结构，通过平键40与飞轮轴32连接，飞轮轮毂12的左端通过飞轮轴32的轴肩定位，飞轮轮毂12的右端通过二号隔套13定位，飞轮轮毂12的外圆周方向由内向外依次固定缠绕飞轮内缠绕层11、飞轮中缠绕层10和飞轮外缠绕层9；飞轮轮毂12、飞轮内缠绕层11、飞轮中缠绕层10和飞轮外缠绕层9构成飞轮转子，如图4所示；
48V电驱无级调速系统的48V调速电机如图1所示，包括调速电机控制器16、调速电机定子铁芯18、调速电机定子线圈绕组19、调速电机转子永磁体20和调速电机转子铁芯21，调速电机定子铁芯18固定连接在右端盖17的内环圆周面，调速电机定子铁芯18沿圆周方向嵌入调速电机定子线圈绕组19；调速电机转子铁芯21为空心圆环结构，通过二号轴承26支撑在动力输出轴28，通过内卡环30轴向定位；二号轴承26为角接触球轴承；通过三号隔套29和动力输出轴28的轴肩定位；调速电机转子铁芯21沿外环圆周方向嵌入调速电机转子永磁体20，沿内环圆周方向加工圆柱斜齿齿圈；调速电机定子铁芯18与调速电机转子铁芯21之间留有气隙；
行星机构如图1和图2所示，太阳轮24为斜齿圆柱齿轮，左端通过飞轮轴32的轴肩定位，右端通过飞轮轴外卡环31定位，与飞轮轴28通过花键连接；前排行星架37通过四号轴承33支撑在飞轮轴32上；四号轴承为角接触球轴承；后排行星架23为内花键结构，与动力输出轴28左端的外花键相配合；后排行星架23的右端通过动力输出轴28的轴肩定位；行星轮销轴35为实心光轴，固定安装在前排行星架37与后排行星架23之间；行星轮34为斜齿圆柱齿轮，通过滑动轴承36空套在行星轮销轴35上，与太阳轮24和调速电机转子铁芯21的圆柱斜齿齿圈常啮合；行星轮34通过一对行星轮销轴外卡环22定位；动力输出轴28为阶梯轴，如图8所示，左端为外花键结构，与后排行星架23的内花键相配合，右端设有轴颈，通过三号轴承27支撑在右端盖17的二号通孔170中，顶端开有外花键，与负载的内花键相配合；三号轴承27为角接触球轴承。
本实施例一号轴承2、二号轴承26、三号轴承27、四号轴承33和五号轴承39均采用角接触球轴承，各轴承均安置于对应的盲孔或通孔等安装位置中，并通过轴构件的轴肩或设置隔套将其稳定定位，使得本装置具有结构稳定且摩擦阻力很小的轴承系统，降低了装置的运行的损耗，提高了装置的有效使用寿命，且提高了能量转换效率。
如图6所示，本实施例中箱体右左端盖1、中端盖14和右端盖17构成，其中左端盖1为带底座的阶梯状圆筒形结构，沿圆周方向开有若干连接孔，用于安装连接螺栓15，底座开有带轴承座孔的盲孔100，用于安装一号轴承2；中端盖14为带中间座141的阶梯状圆筒形结 构，沿左右两端的圆周方向开有若干螺纹孔，中间座141开有能安装轴承的一号通孔140，用于安装五号轴承39，与飞轮轴32接触的中间座141处开有密封槽142，用于安装密封圈38；右端盖17为圆筒形结构，沿圆周方向开有若干连接孔，用于安装连接螺栓15，其底座开有能安装轴承的二号通孔170，用于安装三号轴承27；法兰盘25为圆形碟状结构，沿圆周方向开有若干通孔，与右端盖17加工为一体；左端盖1的右端，中端盖14的左端和右端，右端盖17的右端均加工有相互配合的止口101，中端盖14通过连接螺栓15分别与左端盖1和右端盖17连接，左端盖1与中端盖14连接后所形成的空间为密闭的真空环境，真空压力为5～10mbar。
如图2所示，本实施例的行星机构中，前排行星架37和后排行星架23均为带凸台的空心方盘结构，沿圆周方向相同位置均开有四个沉头孔，用于安装四个行星轮销轴35；行星轮34的个数为四个，与之配套的滑动轴承36的个数为四个，行星轮销轴外卡环22的个数为八个；前排行星架37和后排行星架23之间通过连接板41进行固定连接。
如图3所示，本实施例的48V驱动电机的型式为异步感应电机，通过车载48V动力电池供电；驱动电机定子铁芯5的槽数为24个，用于嵌入驱动电机定子线圈绕组6；驱动电机转子铁芯8的槽数为32个，用于嵌入为驱动电机转子鼠笼绕组7；驱动电机转子鼠笼绕组7的导条和端环由纯铜材料制成。
如图4所示，本实施例中飞轮轮毂12的外缘由三层不同纤维环氧树脂复合材料缠绕而成，由内向外依次是飞轮内缠绕层11，飞轮中缠绕层10和飞轮外缠绕层9，飞轮轮毂12的材料为铝合金材料，飞轮内缠绕层11采用S2玻璃纤维材料，飞轮中缠绕层10采用T700碳纤维材料，飞轮外缠绕层9采用M40J碳纤维材料。
如图5所示，本实施例的48V调速电机的型式为永磁同步感应电机，通过车载48V动力电池供电；调速定子铁芯18的槽数为24个，用于嵌入驱动电机定子线圈绕组6；调速电机转子铁芯21的槽数为24个，用于嵌入调速电机转子永磁体20；调速电机转子永磁体20的磁极安装在调速电机转子铁芯21的外圆周面之上。
进一步地，本实施例的飞轮集成式电动汽车48V机电耦合驱动装置在使用时，采用车载48V动力电池进行供电，48V机电飞轮储能系统为主动力源，48V电驱无级调速系统为副动力源，48V驱动电机和48V调速电机具有电动机模式、发电机模式和中性模式三种运行状态，根据飞轮转子的转速大小确定其相应的运行模式，当车辆加速行驶时：如果飞轮转子的转速大于低值，48V驱动电机为中性模式，飞轮转子直接输出动能，48V调速电机为电动机模式，根据驾驶需求确定输出转速和转矩；如果飞轮转子的转速小于低值，48V驱动电机为电动机模式，驱动飞轮转子旋转，48V调速电机为电动机模式，根据驾驶需求确定输出转速和转矩；飞轮转子驱动太阳轮24旋转，调速电机转子铁芯驱21动行星轮34旋转，二者的转速和转矩经行星机构解耦，动力由后排行星架23输出至动力输出轴28，经减速装置减速增扭后驱动车辆行驶。当车辆减速制动进行能量回收时：如果飞轮转子的转速大于高值，48V驱动电机和48V调速电机为发电机模式；如果飞轮转子的转速小于高值，48V驱动电机为中性模式，48V调速电机为发电机模式；48V驱动电机和48V调速电机在发电过程中产生的感应电磁转矩为制动转矩，经行星机构耦合后由后排行星架23输出反馈至动力输出轴28，经减速装置增扭后实现车辆制动。驱动电机控制器4和调速电机控制器16安装于箱体外，分别控制飞轮转子和调速电机转子铁芯21的转速和转矩，实现动力输出轴28的转速和转矩调节，以匹配不同驾驶需求。
进一步地，上述的低值为2800～3200转/分钟，高值为23000～27000转/分钟，更具体地说，对于城市低速小型电动汽车，本实施例设定的低值为3000转/分钟，高值为25000转/分钟，此低值、高值的设定适应于城市低速小型电动汽车的使用工况，有助于其及时有效的调整两电机的运行状态模式，既可以在制动初期有效避免动力电池充电过程中的高功率峰值，又能够在车辆起步和加速过程中直接以动能形式提供辅助功率，延长动力电池和机械制动部件的使用寿命。
本发明所述实例仅仅是对本发明的优选实施方式进行描述，并非对本发明构思和范围进行限定，在不脱离本发明设计思想的前提下，本领域工程技术人员对本发明的技术方案作出的各种变形和改进，均应落入本发明的保护范围。

Claims (10)

  1. 一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：包括箱体，其为中空结构，其内从左到右依次布置有48V驱动电机、飞轮转子、48V调速电机和动力输出轴；其中，48V驱动电机与飞轮转子通过飞轮轴传动连接；飞轮转子与48V调速电机通过行星机构连接，行星机构的太阳轮与飞轮轴端部传动连接，行星机构的行星轮与48V调速电机传动连接；动力输出轴一端与行星机构的行星架传动连接，另一端伸出箱体外。
  2. 根据权利要求1所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：所述飞轮转子包括飞轮轮毂，其为H型空心结构，飞轮轴穿过空心结构与飞轮轮毂传动连接，飞轮轮毂的外圆周缠绕形成有缠绕层。
  3. 根据权利要求2所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：飞轮轮毂的外圆周由内向外依次固定缠绕形成有飞轮内缠绕层、飞轮中缠绕层和飞轮外缠绕层，其中飞轮内缠绕层为S2玻璃纤维材料，飞轮中缠绕层为碳纤维材料，飞轮外缠绕层为M40J碳纤维材料。
  4. 根据权利要求3所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：所述行星机构的行星架包括前排行星架和后排行星架，均为带凸台的空心方盘结构，前排行星架和后排行星架沿圆周方向在相同位置处均匀开设有沉头孔，行星轮通过行星轮销轴与沉头孔连接；前排行星架套设于飞轮轴外，后排行星架与动力输出轴端部传动连接；前排行星架与后排行星架通过连接板连接。
  5. 根据权利要求4所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：所述行星机构的行星轮设有四个。
  6. 根据权利要求5所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：
    所述箱体从左至右包括左端盖、中端盖和右端盖，相邻两端盖通过连接螺栓连接；
    所述左端盖为阶梯状圆筒形结构，内部左端设有底座，底座中心开设有盲孔，其形状与轴承外壁形状相匹配，飞轮轴的左端部通过一号轴承安装于盲孔中，左端盖的右端部沿圆周方向开设若干连接孔，用于安装连接螺栓；
    所述中端盖为阶梯状圆筒形结构，内部中间设有中间座，中间座中部开设一号通孔，一号通孔左端形状与轴承外壁形状相匹配，飞轮轴的中部通过五号轴承安装于一号通孔中，中端盖的左端部和右端部均沿圆周方向开设若干螺纹孔，用于装配连接螺栓；
    所述右端盖为圆筒形结构，内部右端设中部开设有二号通孔，二号通孔左端形状与轴承外壁形状相匹配，动力传动轴中部通过三号轴承安装于二号通孔中，右端盖的左端部沿圆周方向开设若干连接孔，用于安装连接螺栓；
    还包括法兰盘，其为中空结构，一体成型于右端盖右端外部中部。
  7. 根据权利要求6所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：所述左端盖和中端盖相接的端面上加工有相互配合的止口；所述中端盖和右端盖相接的端面上加工有相互配合的止口；所述中端盖的中间座上一号通孔的右端周向开设有密封槽，飞轮轴中部外套设有密封圈配合安装于密封槽中。
  8. 根据权利要求7所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，其特征在于：所述左端盖和中端盖连接后形成的内部空间为真空环境，真空压力为5～10mbar。
  9. 一种飞轮集成式电动汽车48V机电耦合驱动装置的使用方法，其特征在于，基于权利 要求8所述的一种飞轮集成式电动汽车48V机电耦合驱动装置，方法如下，
    A、车辆加速时：
    检测飞轮转子的转速，若飞轮转子的转速大于低值，则48V驱动电机为中性模式，飞轮转子直接输出动能，48V调速电机为电动机模式，输出转速和转矩；若飞轮转子的转速小于低值，48V驱动电机为电动机模式，驱动飞轮转子旋转，48V调速电机为电动机模式，输出转速和转矩；
    B、车辆减速制动时：
    检测飞轮转子的转速，若飞轮转子的转速大于高值，48V驱动电机和48V调速电机均为发电机模式；若飞轮转子的转速小于高值，48V驱动电机为中性模式，48V调速电机为发电机模式。
  10. 根据权利要求9所述的一种飞轮集成式电动汽车48V机电耦合驱动装置的使用方法，其特征在于：所述低值为2800～3200转/分钟；所述高值为23000～27000转/分钟。
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