WO2023213345A1

WO2023213345A1 - Electric vehicle, and retarder module for the electric vehicle

Info

Publication number: WO2023213345A1
Application number: PCT/DE2023/100276
Authority: WO
Inventors: Simon Ortmann
Original assignee: Schaeffler Technologies AG & Co. KG
Priority date: 2022-05-05
Filing date: 2023-04-17
Publication date: 2023-11-09
Also published as: DE102022111122A1

Abstract

For busses and trucks above a certain weight, a retarder or an auxiliary brake is required according to the statutory requirements and for technical safety. The invention relates to an electric vehicle (1) comprising an electric drive motor (2) for generating a drive torque, the electric drive motor comprising a cardan shaft (6) for transmitting the drive torque in the electric vehicle (1) and comprising a retarder module (7) for decelerating the cardan shaft (6), the retarder module (7) implementing a frictional deceleration of the cardan shaft (6).

Description

Electric vehicle and retarder module for the electric vehicle

The invention relates to an electric vehicle with the features of the preamble of claim 1. The invention further relates to a retarder module for the electric vehicle.

For buses and trucks over a certain weight, legal requirements and technical safety require a continuous brake or auxiliary brake. This is often implemented using eddy current brakes or hydraulic retarders. With a continuous brake based on eddy current, braking is induced by a magnetic field. With hydraulic partners, drag torque is introduced by a hydraulic fluid in order to implement the function of the permanent brake or auxiliary brake.

It is an object of the present invention to propose an adapted solution for a continuous brake and/or auxiliary brake for an electric vehicle. This task is solved by an electric vehicle with the features of claim 1 and by a retarder module with the features of claim 10. Preferred or advantageous embodiments emerge from the subclaims, the following description and the attached figures.

The subject of the invention is an electric vehicle, wherein the electric vehicle has an electric drive motor for generating a drive torque for the electric vehicle. The electric vehicle is preferably designed as a BEV (battery electric vehicle). In particular, the electric vehicle is designed as a truck or bus, in particular a coach for more than 30 people. For example, the electric vehicle has a total loaded weight of more than 10t, in particular more than 20t. The electric drive motor may include a plurality of individual motors or only a single electric motor to generate the drive torque. In particular, the electric drive motor has a power of more than 100 kW, in particular more than 200 kW.

The electric vehicle has a cardan shaft for transmitting the drive torque or part of the drive torque to the driven wheels, in particular rear wheels of the electric vehicle. The cardan shaft extends in the longitudinal direction of the vehicle and rotates around an axis of rotation during operation.

The electric vehicle preferably has a mid-engine as an electric drive motor. In particular, the mid-engine is arranged in the longitudinal direction of the vehicle between the front axle and at least one rear axle. In a drive train of the electric vehicle, differential devices and/or transfer cases can be arranged before or after the cardan shaft.

According to the invention, the electric vehicle has a retarder module for braking the cardan shaft. The retarder module is designed in particular as a continuous brake and/or as an auxiliary brake. In particular, the retarder module meets the legal requirements for such a continuous brake and/or auxiliary brake. It is proposed that the retarder module implements frictional braking of the cardan shaft.

It is one consideration of the invention that previously known concepts for a continuous brake or auxiliary brake in electric vehicles have clear disadvantages. In cyclone-based continuous braking, braking is induced by the magnetic field, so that electricity has to be applied and valuable energy from the battery is used up. This current heats a continuous brake disc, which is air-cooled, whereby the electrical energy introduced and also the braking energy are lost. Electric vehicles need electricity for braking be pulled from the battery, so that the range of the electric vehicle is reduced.

The problem with hydraulic retarders is that drag torque is generated and the hydraulic system has to be dragged along, which also uses up valuable energy from the battery. Furthermore, in the transition from internal combustion engines to electric drive motors, hydraulic retarders together with the hydraulic starting clutches are eliminated, so that the system engineering effort for exclusive hydraulic retarders without starting clutches would be high.

Recuperation alone, which is in principle possible with the electric vehicle, is not sufficient, as massive braking power is generated when driving downhill, which could put a strain on the battery. If the battery is full, continuous braking would no longer be possible.

The frictional retarder module has the advantage that it has a very simple structure, no unnecessary energy is wasted and can be or is coupled to the recuperation of the electric drive motor, so that both systems can be used in a complementary or supplementary manner as a continuous brake and/or auxiliary brake . This creates an adapted solution for a continuous brake and/or auxiliary brake for an electric vehicle.

In a preferred implementation, the retarder module has at least or exactly one multi-disc brake for frictionally braking the cardan shaft. In particular, the multi-disc brake is arranged coaxially to the cardan shaft and/or rotation axis. The retarder module, in particular the multi-disc brake, has at least or exactly one inner disc pack with inner discs and at least or exactly one outer disc pack with outer discs. Preferably, the inner and/or the outer slats extend in a radial plane to the cardan shaft and/or the axis of rotation of the cardan shaft. The The inner disk pack, in particular the inner disks, is/are arranged in a rotating manner on the cardan shaft. The outer disk pack, in particular the outer disks, are supported in the electric vehicle. For example, the outer disk pack can be supported, in particular indirectly, on a chassis. The inner slats and the outer slats are arranged alternately in the axial direction of the rotation axis and/or the cardan shaft. Particularly preferably, the slats or a subset of the slats can carry friction linings, so that the inner and outer slats can engage in frictional engagement.

In a preferred development of the invention, the retarder module has an actuator device, the actuator device actuating the multi-disc brake. The actuator device can be designed pneumatically or hydraulically. When designed as a hydraulic actuator device, it can be supplied hydraulically via an actuator in the electric vehicle. In the pneumatic design, a compressed air reservoir, which is already present in the electric vehicle, can be used, so that the retarder module can be integrated cost-effectively. A further function, namely the function of supplying the continuous brake and/or auxiliary brake, can be assigned to the already existing compressed air reservoir, such as the one used for the chassis. The electric vehicle preferably has a corresponding compressed air reservoir. Particularly preferably, the disk packs are subjected to a braking force on both sides in the axial direction by the actuator device in order to implement the retarder module particularly effectively and efficiently.

Particularly preferably, the actuator device is annular and/or coaxial with the cardan shaft and/or with the axis of rotation. The actuator device is particularly preferably implemented as an annular cylinder-piston system. For example, the actuator device can have an annular cylinder and/or annular piston, or the actuator device is implemented by a plurality of annularly and/or coaxially arranged individual cylinder-individual piston devices. Through this The retarder module can be implemented in a particularly simple design.

In a preferred embodiment, the electric vehicle has a medium cooling device for cooling the retarder module, in particular the disk packs and in particular the disks. The medium cooling device has a cooling medium, the cooling medium being designed, for example, as oil. In particular, the cooling medium is in physical contact with the disk packs, in particular with the disks. The media cooling device is designed to transport away the heat energy generated during frictional braking of the cardan shaft from the retarder module. The electric vehicle preferably has a thermal management arrangement, wherein the thermal management arrangement is designed to reuse the thermal energy and, in the event that the thermal energy cannot be further utilized, to optionally release the thermal energy into the environment, for example through a cooler. The thermal management arrangement can, for example, be designed to use the thermal energy to bring or maintain the battery of the electric vehicle to operating temperature or to regulate the temperature of the driver's cab for the driver.

In a preferred structural implementation of the invention, the retarder module has a housing. The housing is arranged annularly and/or coaxially to the cardan shaft and/or to the axis of rotation. The housing is supported in the electric vehicle in order to be able to derive the braking torque from the retarder module. Alternatively or additionally, the housing is rotatably mounted on the cardan shaft, for example via bearing devices.

The housing preferably forms an inner and an outer annular space, the cooling medium of the medium cooling device being guided from the inner annular space via the plate packs, in particular via the slats, into the outer annular space becomes. The annular spaces can take any shape. By guiding the cooling medium, the disk packs, in particular the disks, are lubricated and, on the other hand, the heat energy generated between the disks is dissipated from the point of origin.

In a preferred design implementation, the retarder module has an outer disk carrier for receiving the outer disk pack. In particular, the outer disk pack is arranged on the outer disk carrier in a rotationally fixed manner around the cardan shaft/or around the axis of rotation. The outer disk carrier has through openings between the outer disks of the outer disk pack for the cooling medium.

In this implementation, the outer annular space is formed between the outer disk carrier and the housing. This structural design ensures, on the one hand, that the cooling medium flows between the outer plates of the outer plate pack and the outer plate pack and the inner plate pack adjacent to it are cooled and/or lubricated. Furthermore, the outer disk carrier is cooled via the outer annular space, so that further heat energy is transported away here.

In a preferred implementation of the invention, the retarder module has a resetting device for resetting the multi-disc brake to a friction-free or at least low-friction state. The reset device ensures that in the unbraked state of the retarder module, little or no frictional losses are generated by the retarder module. In particular, the reset device is designed to separate the inner and outer slats from one another, in particular to space them apart.

In a simple structural design, the restoring device has a plurality of restoring springs, which are designed to have the disk packs, in particular to separate the inner and outer slats from each other. The return springs are in particular designed as compression springs, which act in the axial direction to the cardan shaft and/or rotation axis.

A further subject of the invention relates to a retarder module, wherein the retarder module is suitable and/or designed for the electric vehicle as previously described and/or according to one of the preceding claims. It is envisaged that the retarder module is designed for frictionally braking the cardan shaft. In particular, the retarder module is designed as previously described.

The invention therefore relates in particular to a multi-disc brake which is used around a central cardan shaft. In particular, a specific architecture of the electric vehicle is used, which is a truck with a central motor / an e-axle that serves two or more wheels connected via a differential and any transfer case.

The multi-disc brake is placed around the propeller shaft, with the inner discs rotating with the propeller shaft. The disk pack or disk packs are compressed via a pneumatic or hydraulic system and a braking torque is applied that brakes the drive train and thus also the wheels. This continuous brake can be coupled with recuperation by the electric motor so that both systems work in a complementary or complementary manner. In the system shown, the heat introduced into the system should also be dissipated by a cooling medium (oil). This medium can be used in the thermal management of the vehicle to heat the battery to the desired temperature, to condition the driver's interior and/or to operate a heat pump or, if this energy is not required in any form, it can be released via the radiator . Further features, advantages and effects of the invention result from the following description of a preferred exemplary embodiment of the invention and the attached figures. These show:

Figure 1 shows a schematic top view of an electric vehicle as a

Embodiment of the invention;

Figure 2 is a schematic longitudinal section through a retarder module for the

Electric vehicle in Figure 1.

Figure 1 shows a schematic top view of an electric vehicle 1 as an exemplary embodiment of the invention. The electric vehicle 1 is designed in particular as a BEV truck/heavy-duty vehicle. For example, the electric vehicle 1 is designed as a truck or as a passenger bus, in particular as a coach. For example, the electric vehicle has a total loaded mass greater than 101.

The electric vehicle 1 has an electric drive motor 2, wherein the electric drive motor 2 is designed as a mid-engine. The electric vehicle 1 has a particularly steered front axle 3 and at least one rear axle 4, with the drive motor 2 being arranged between the axles 3 and 4 or on the front axle 3, but in front of the rear axle 4.

The electric vehicle 1 can have transmission and/or differential devices 5, which are usually distributed in the drive train of the electric vehicle 1. The transmission of the drive torque from the drive motor 2 to the rear axle 4 takes place via a centrally arranged cardan shaft 6 which runs in the longitudinal direction of the electric vehicle 1. In order to transmit the drive torque from the drive motor 2, the cardan shaft 6 rotates about a rotation axis 100 during operation. The electric vehicle 1 has a retarder module 7, wherein the retarder module 7 interacts directly with the cardan shaft 6 and can be arranged, for example, at the beginning of the cardan shaft 6 or at the end of the cardan shaft 6 or at another arbitrary position.

Figure 2 shows a schematic longitudinal section through the retarder module 7, which is placed directly on the cardan shaft 6. The retarder module 7 has a multi-disc brake 8, wherein the multi-disc brake 8 can frictionally brake the cardan shaft 6 as a braking partner. In particular, the retarder module 7 is designed as a continuous brake and/or as an auxiliary brake for the electric vehicle 1. The other braking partner of the disk brake 8 is formed by a braking partner fixed to the vehicle; for example, the retarder module 7 can be supported on the chassis or on other components of the electric vehicle 1.

The disk brake 8 has an inner disk pack 9 and an outer disk pack 10. The inner disk pack 9 has a plurality of inner disks 11, the outer disk pack 10 has a plurality of outer disks 12, the inner disks 11 and the outer disks 12 being arranged alternately along the rotation axis 100 and/or along the cardan shaft 6.

The inner disk pack 9 is connected to the cardan shaft 6 in a rotationally fixed manner around the cardan shaft 6 and/or the rotation axis 100. In contrast, the inner slats 11 are arranged to move in the axial direction. The inner disks 11 carry a friction lining 13 pointing in the axial direction on both sides. The outer disks 12 and/or the outer disk pack 10 are arranged in a rotationally fixed manner relative to the electric vehicle 1, with the outer disks 12 also being arranged in an axially displaceable manner. The inner slats 11 and the outer slats 12 extend in a radial plane to the cardan shaft 6 and / or to the rotation axis 100. For frictional braking of the cardan shaft 6 the first disk pack 9 and the outer disk pack 10 are acted upon by an axially acting braking force 101. The braking force 101 is designed to act from both axial directions. For example, the retarder module 7 has an actuator device 14, wherein the actuator device 14 is designed to actuate the multi-disc brake 8 in order to achieve frictional braking. The actuator device 14 can be designed to be pneumatic or hydraulic.

In this exemplary embodiment, the actuator device 14 has an annular cylinder 15 on each side, in which an annular piston 16 is mounted to move in the axial direction and is sealed in a fluid-tight manner with respect to an annular cylinder space 17 via seals 18. The annular cylinder space 17 can be subjected to a working pressure by compressed air or hydraulic fluid, so that the annular pistons 16 are displaced in the axial direction and press against the disk packs 9, 10 with the braking force 101 in order to achieve frictional braking of the cardan shaft 6.

The retarder module 7 has a medium cooling device 19, the medium cooling device 19 being designed to cool and/or lubricate the retarder module 7, in particular the disk packs 9, 10 and in particular the individual disks 11, 12. For this purpose, the medium cooling device 19 uses a cooling medium which directly cools the slats 11, 12.

The retarder module 7 has a housing 20, the housing 20 having a housing base 21 and a housing pot 22, which together form a sealed housing space 23 around the cardan shaft 6. The housing 20 is rotatably arranged on the cardan shaft 6 via bearing devices 24, designed in this exemplary embodiment as ball bearing devices. The housing 20 is designed to transmit the braking torque from the retarder module 7 to the electric vehicle 1. The housing space 23 is sealed via contacting sealing devices 25, which are each arranged at the ends of the housing 20 and which include the bearing devices 24 in the housing space 23. The housing 20 has an inner annular space 26 and an outer annular space 27, the medium cooling device 19 being designed to transport the cooling medium from the inner annular space 26 via the disk packs 9, 10 and in particular the disks 11, 12 to the outer annular space 27. From there, the cooling medium can be transported away and, if necessary, cooled.

The retarder module 7 has an outer disk carrier 28, the outer disk carrier 28 being firmly connected to the housing base 21 or formed in one piece in this exemplary embodiment. On the one hand, the outer disk carrier 28 carries the outer disks 12 of the outer disk pack 10. On the other hand, the outer disk carrier 28 delimits the outer annular space 27 in the radial direction to the axis of rotation 10 inwards. The outer annular space 27 is delimited radially outwards by the housing 20, in particular by the housing pot 22. Because the outer disk carrier 28 forms part of the boundary of the outer annular space 27, in addition to the direct heat removal through the physical contact between the cooling medium and the disk packs 9, 10, an indirect heat transfer through the outer disk carrier 28 is also promoted.

Through openings 29 are made in the outer disk carrier 28, so that the cooling medium can pass through the disks 11, 12 and subsequently through the through openings 29 into the outer annular space 27.

The electric vehicle 1 has a thermal management arrangement 30, wherein thermal energy generated from the retarder module 7 by braking and dissipated via the medium cooling device 19 can be made available to the thermal management arrangement 30 via an interface 31. The interface 31 can be designed as a mechanical or other interface. The thermal management arrangement 30 can use the thermal energy can advantageously be used to control the temperature of a battery 32 of the electric vehicle 1 to supply the drive motor 2 and/or to control the temperature of the passenger compartment for the driver. Only in the worst case is the derived heat energy released to the environment by the thermal management arrangement 30, for example through a cooler.

The retarder module 7 has a reset device 33 for resetting the multi-disc brake 8. This converts the multi-disc brake 8 into a friction-free or at least low-friction state. The restoring device 33 has a plurality of restoring springs 34, the restoring springs 34 separating the disk packs 9, 10 and in particular the disks 11, 12 from one another. In particular, the reset device 33 is arranged on an inner circumference of the retarder module 7. The reset device 33 acts in particular only on the inner disk pack 9 and/or on the inner disks 11 in order to space them apart from one another. The reset device 33 is arranged in a rotationally fixed manner relative to the cardan shaft 6 and is mounted relative to the stationary part of the retarder module 7 via further bearing devices 35.

The multi-disc brake 8 is placed on the cardan shaft (or central shaft in front of a differential) 6, which essentially consists of a housing cover as a housing base 21 and a housing shell as a housing pot 22. These are connected to one another via a centering and a seal and form the housing space 23 inside. This housing 20 is mounted on the cardan shaft 6, by bearing devices 24 and sealed by radial shaft sealing ring sealing devices 25. The system can be spatially secured by a shoulder and a locking ring, as shown, or in another appropriate manner consistent with the state of the art . The housing 20 has a torque arm (not shown in the picture) (similar to an engine mount) to support the braking torque on the chassis of the electric vehicle or another part of the drive train. Screws secure the two housing halves of the Housing 20 to each other.

A geometry is shown in the inner area, which corresponds to a feather key or a similar system, which is used here to create internal gearing. This internal toothing could of course also be incorporated directly into the shaft. The internal teeth engage in the inner area of inner slats 11 so that they rotate with the cardan shaft. An external toothing is attached in a geometry that is assigned to the housing cover/housing base 21/outer disk carrier 28. The standing, outer slats 12 engage in this external toothing. Friction linings 13 are arranged between the slats 11, 12. The geometry with the external teeth in the housing 20 is characterized by bores as through openings 29, which enable oil which is pressed through the disk pack 9, 10 to be conveyed to the outside. Here, a so-called collecting space is provided as an outer annular space 27, in which the now heated oil can flow downwards and can then be pumped out. The oil is introduced spatially inside at the inner annular space 26, so that the bearing devices 24 and slats 11, 12 are supplied with cool or well-tempered oil from the inside. The hot oil is pumped out immediately after heating in order to be able to use the heat energy for other purposes, as mentioned above.

The actuation of the multi-disc brake 8 is carried out by two concentric or several circular piston systems as an actuator device 14 from both sides. These are either supplied hydraulically via an actuator or pneumatically operated via the compressed air storage in the truck. The piston systems are characterized by a simple design, with simple housings and seals. These are, for example, supplied with compressed air or hydraulic fluid axially through the housing 20.

Also shown in Figure 2 is the reset device 33 to ensure safe release of the To ensure braking torque and to ensure that little to no drag torque is generated in normal operation (non-braking). The restoring device has the restoring springs 35, shims 36 and needle bearings as further bearing devices 34, which are arranged around a spring holder 37.

The solution shown is designed in such a way that all forces are supported inside the solution. So no axial force is introduced onto the bearing devices 25 or the cardan shaft 6. As mentioned above, only the braking torque must be supported on the chassis to prevent the solution from rotating.

Reference character list

1 electric vehicle

2 electric drive motor

3 front axle

4 rear axle

5 transmission and/or differential devices

6 cardan shaft

7 retarder module

8 multi-disc brake

9 inner plate pack

10 outer plate pack

11 inner slats

12 outer slats

13 friction lining

14 actuator device

15 ring cylinders

16 ring pistons

17 ring cylinder space

18 seals

19 medium cooling device

20 cases

21 case back

22 housing pot

23 housing space

24 storage facilities

25 sealing devices

26 outer annulus

27 inner annulus 28 outer disk carrier

29 passage openings

30 thermal management arrangement

31 Interface of the retarder module/medium cooling device 32 Battery of the electric vehicle 1

33 reset device

34 return springs

35 additional storage facilities

36 Shims 37 Spring Holders

100 rotation axis

101 braking power

Claims

Patent claims

1. Electric vehicle (1) with an electric drive motor (2) for generating a drive torque, with a cardan shaft (6) for transmitting the drive torque in the electric vehicle (1), characterized by a retarder module (7) for braking the cardan shaft (6), where the retarder module

(7) implements frictional braking of the cardan shaft (6).

2. Electric vehicle (1) according to claim 1, characterized in that the retarder module (7) comprises a multi-disc brake (8) with an inner and an outer disc pack (8, 9), the inner disc pack (8) being connected to the cardan shaft (6 ) is connected in a rotationally fixed manner and the outer disk pack (9) is supported in the electric vehicle (1), the inner and outer disk packs (8, 9) being able to engage in frictional engagement in order to implement the braking of the cardan shaft (6).

3. Electric vehicle (1) according to claim 1 or 2, characterized in that the retarder module (7) has an actuator device (14) for actuating the multi-disc brake

(8), wherein the actuator device (14) is designed to be pneumatic or hydraulic.

4. Electric vehicle (1) according to claim 3, characterized in that the actuator device (14) is annular and / or coaxial to the cardan shaft (6).

5. Electric vehicle (1) according to one of the preceding claims, characterized in that the retarder module (7) has a medium cooling device (19) with a cooling medium for dissipating thermal energy generated by braking of the retard module (7) and that the electric vehicle (1) has a thermal management arrangement (32) for dissipating and reusing the thermal energy.

6. Electric vehicle (1) according to claim 5, characterized in that the retarder module (7) has a housing (20), wherein the housing (20) is connected in a rotationally fixed manner to the second disk pack (9) and / or in the electric vehicle (1 ) is supported, an inner annular space (26) and an outer annular space (27) being provided in the housing (20), the cooling medium being transferred from the inner annular space (26) via the disk packs (8, 9) to the outer annular space ( 27) is guided.

7. Electric vehicle (1) according to claim 6, characterized in that the retarder module (7) has an outer disk carrier (28) for receiving the outer disk pack (9), the outer disk carrier (28) having through openings (29) between outer disks ( 12) of the outer disk pack (9) for the cooling medium, the outer annular space (27) being formed between the outer disk carrier (28) and the housing (20).

8. Electric vehicle (1) according to one of the preceding claims 2 to 7, characterized in that the retarder module has a reset device (33) for resetting the multi-disc brake (8) into a friction-free or at least low-friction state.

9. Electric vehicle (1) according to claim 8, characterized in that the restoring device (33) has a plurality of restoring springs (34), the restoring springs (34) being designed to separate the disk packs (8, 9) from one another.

10. Retarder module (7) for the electric vehicle (1) according to one of the preceding claims, characterized in that it is designed for frictionally braking the cardan shaft (6).