This application is related to and claims priority from Japanese Patent Application No. 2012-43093 filed on Feb. 29, 2012, the contents of which are hereby incorporated by reference.
1. Field of the Invention
The present invention relates to double drive shaft motors of a magnetic flux modulation type for use in hybrid vehicles such as hybrid electric vehicles, equipped with an internal combustion engine, a main drive motor and a battery, driven by power of both the internal combustion engine and the main drive motor.
2. Description of the Related Art
There are conventional techniques relating to a hybrid vehicle drive system. For example, a patent document, Japanese patent laid open publication No. JP 2011-157068 discloses a conventional drive system used by a hybrid vehicle having an internal combustion engine, wheels, a reduction gear mechanism, a reduction ratio changing means, a clutch mechanism, a main drive motor and a power dividing means. The internal combustion engine generates mechanical power. The wheels are driven by the mechanical power (such as rotation power) generated by the internal combustion engine. The reduction gear mechanism adjusts the rotation speed between the internal combustion engine and the wheels. The clutch mechanism connects the wheels with the internal combustion engine, and disconnects the wheels from the internal combustion engine. The motor generates electromotive power. The power dividing means synthesizes, divides and distributes the mechanical power generated by the internal combustion engine and the electromotive power generated by the motor.
In the drive system disclosed in the patent document, Japanese patent laid open publication No. JP 2011-157068, because the motor, the clutch mechanism, the power dividing means, etc. are independently arranged to each other, the drive mechanism has a large size or an increased size. As a result, this increases a manufacturing cost and selects a specified type of vehicles, for example a vehicle having a front-engine rear-wheel-drive layout, on which the drive mechanism is mounted.
It is therefore desired to provide a double drive shaft motor of a magnetic flux modulation type having a compact-size drive mechanism having assembled components.
An exemplary embodiment provides a double drive shaft motor of a magnetic modulation type. The double dive shaft motor has a field rotor, a magnetic induction rotor, a stator, a first rotating shaft, a second rotating shaft, a motor housing casing, a first rotation limitation section and a second rotation limitation section. The field rotor has n pole pairs. That is, the number of the pole pairs in the field rotor is n (n is a natural number). The pole pairs are comprised of a north magnetic pole (N pole) and a south magnetic pole (S pole) which are alternately arranged in a circumferential direction of the field rotor. The magnetic induction rotor is concentrically arranged with a gap at one of a radially outer side and a radially inner side of the field rotor. The magnetic induction rotor has k soft magnetic members (k is a natural number). The k soft magnetic members make a magnetic path arranged at regular intervals with a gap in a circumferential direction of the magnetic induction rotor. The stator is concentrically arranged with a gap at one of a radially outer side of a first rotor and a radially inner side of a second rotor. The stator has a multi-phase winding having the number of pole pairs which is one of a sum and a difference between the number n and the number k, where the first rotor is one of the field rotor and the magnetic induction rotor which is arranged at a radially outer side. The second rotor is one of the field rotor and the magnetic induction rotor which is arranged at a radially inner side. The first rotating shaft is configured to support the field rotor. The second rotating shaft is configured to support the magnetic induction rotor. The motor housing casing is configured to rotatably support the first rotating shaft and the second rotating shaft. The first rotation limitation section is configured to allow the first rotating shaft to rotate in one rotation direction to the motor housing casing, and to limit the first rotating shaft to rotate in the other rotation direction to the motor housing casing. The second rotation limitation section is configured to switch between a neutral state and a locked state. The neutral state allows the second rotating shaft to rotate in both directions, namely bi-directions within the motor housing casing. The locked state prevents the second rotating shaft from rotating in one of the both directions within the motor housing casing.
The structure of the double drive shaft motor according to the exemplary embodiment of the present invention makes it possible to independently change the rotating speed of the first rotating shaft and the second rotating shaft. In addition to this feature, this structure makes it possible to connect the first rotating shaft with the second rotating shaft, and to disconnect the first rotating shaft from the second rotating shaft. When the double drive shaft motor of a magnetic modulation type according to the exemplary embodiment is used for a drive system of a hybrid electric vehicle, it is possible to add electromotive force to the power of an internal combustion engine mounted to the electric magnetic vehicle. Further, it is possible to regenerate electric power by receiving rotational force from the second rotational force. That is, the double drive shaft motor according to the exemplary embodiment of the present invention is a compact-size motor, and can use mechanical force and electromotive force easily. This makes it possible to provide the double drive shaft motor as a complex functional motor capable of executing a rotation speed changing control, power dividing and power synthesizing characteristics, and a motor generating characteristic. It is thereby possible to provide a driving system for a hybrid electric vehicle with a simple structure and a reduced side.
A preferred, non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. In the following description of the various embodiments, like reference characters or numerals designate like or equivalent component parts throughout the several diagrams.
A description will be given of a double drive shaft motor 1 of a magnetic flux modulation type according to a first exemplary embodiment with reference to
A description will now be given of the structure of the double drive shaft motor 1 of a magnetic flux modulation type.
The first rotating shaft 3 and the second rotating shaft 4 are supported by the motor housing casing 2. The field rotor 6 is supported by the first rotating shaft 3 through a hub 5. The hub 5 is made of magnetic material. The magnetic induction rotor 8 is arranged at a radially outer side of the field rotor 6. The magnetic induction rotor 8 is arranged concentrically with the field rotor 6. The magnetic induction rotor 8 is supported by the second rotating shaft 4 through a hub 7. The hub 7 is made of non-magnetic material. The stator 9 is arranged at a radially outer side of the magnetic induction rotor 8 through a gap and arranged concentrically with the magnetic induction rotor 8. The stator 9 is supported by the motor housing casing 2.
The first rotation limitation section is arranged between the motor housing casing 2 and the first rotating shaft 3. The second rotation limitation section is arranged between motor housing casing 2 and the second rotating shaft 4. The third rotation limitation section is arranged between the first rotating shaft 3 and the second rotating shaft 4.
The motor housing casing 2 is made of non-magnetic material such as aluminum. The motor housing casing 2 is fixed to an internal combustion engine (not shown) of the hybrid electric vehicle on which the double drive shaft motor 1 according to the first exemplary embodiment is mounted.
As shown in
A water inlet section 11 and a cooling water discharge section 12 are formed in the motor housing casing 2. Through the cooling water inlet section 11, cooling water is introduced into the cooling water supply passage 10. Through the cooling water discharge section 12, cooling water is discharged to the outside of the cooling water supply passage 10. The cooling water supply passage 10 is connected to a cooling water circuit (not shown) for the internal combustion engine through a pipe (not shown).
The first rotating shaft 3 is connected to an output shaft (or a crank shaft) of the internal combustion engine through an overdrive gearbox. The first rotating shaft 3 and the hub 5 are assembled together. The hub 5 supports the field rotor 6. The second rotating shaft 4 is connected to wheel shafts through a reduction gear shaft (not shown) and a moving direction changing gear which switches the moving direction of the wheels forward and backward. The hub 7 supporting the magnetic induction rotor 8 is meshed with an outer periphery of the second rotating shaft 4, as shown in
As shown in
For example, the ring shaped rotor core 6a is comprised of magnetic steel sheets which are stacked. The sixteen rare-earth magnets 13 are arranged at regular intervals along a circumferential direction of the ring-shaped rotor core 6a. The sixteen rare-earth magnets 13 are magnetized in a direction shown in a radial direction designated by arrows in
As shown in
As shown in
The stator core 9b is comprised of magnetic steel sheets having a ring shape which are stacked. The stator winding 9c is a multi-phase winding. The number of pole pairs in the multi-phase winding is m. The number m of pole pairs is a sum (n+k) or a subtraction (n−k) of the number n of pole pairs of the field rotor 6 and the number k of pole pairs of the magnetic induction rotor 8. Specifically, the stator winding 9 is a three-phase winding wound around the overall periphery of the stator core 9b at a pitch which divides the overall circumference of the stator core 9b by 24. That is, the number m of pole pairs is 12 (m=12).
As shown in
The inverter 15 is an electric power conversion device capable of transforming DC power to AC power. For example, the inverter 15 is comprised of a plurality of transistors 15a and diodes 15b. Each transistor 15a is reversely connected to the corresponding diode 15b. An inverter electric control unit (inverter ECU, not shown) executes the operation control of the inverter 15. The inverter ECU is connected to a vehicle ECU (not shown).
A first rotation limitation section has a one-way clutch 17. The one-way clutch 17 allows the first rotating shaft 3 (as the input shaft) to rotate in a power rotating direction, and to prevent the first rotation limitation section from rotating in opposite direction of the power rotating direction.
Throughout the description, the power rotating direction is a direction to which the first rotating shaft 3 rotates by the power transmitted from an internal combustion engine of the hybrid electric vehicle.
On the other hand, the one-way clutch 17 is a known device. A description will now be given of a structure of the one-way clutch 17.
As shown in
When a rotating power in an opposite direction to the power rotating direction is supplied to the first rotating shaft 3, the roller 20 is mated with a wedge-shaped gap formed between the inner ring 18 and the outer ring 19. This structure makes it possible to prevent the first rotating shaft 3 from rotating in an opposite direction to the power rotating direction. A roller bearing 21 is arranged adjacent to the one-way clutch 17 between the first rotating shaft 3 and the motor housing casing 2.
The first rotating shaft 3 is rotatably supported by motor housing casing 2 through the roller bearing 21.
The second rotation limitation section switches between a neutral state and a locked state. The neutral state allows the second rotating shaft 4 (as the output shaft) to rotate in a forwardly rotating direction and a reversely rotating direction. The reversely rotating direction is opposite to the forwardly rotating direction. The locked state prevents the second rotating shaft 4 to rotate in both the forwardly rotating direction and the reversely rotating direction. That is, the locked state allows the second rotating shaft 4 to rotate in the forwardly rotating direction or the reversely rotating direction only. Throughout the description, the forwardly rotating direction of the second rotating shaft 4 corresponds to a forward movement of the hybrid electric vehicle. The reversely rotating direction of the second rotating shaft 4 corresponds to a backward movement of the hybrid electric vehicle. The second rotation limitation section corresponds to a magnetic bi-directional clutch 22. The magnetic bi-directional clutch 22 releases the neutral state of the second rotating shaft 4 by a magnetic force generated by an electrical magnet. The magnetic bi-directional clutch 22 switches the second rotating shaft 4 into the locked state by using the rotational force of the second rotating shaft 4 after releasing the second rotating shaft 3 from the neutral state by the magnetic force generated by the electromagnet.
The magnetic bi-directional clutch 22 is comprised of a clutch mechanism section, a clutch control section and the electrical magnet.
As shown in
The inner ring 23 is mated with the outer periphery of the second rotating shaft 4. The outer ring 24 is fixed to the inner periphery of the motor housing casing 2. The bearing 25 supports both the inner ring 23 and the outer ring 24 and to allow the inner ring 23 and the outer ring 24 to rotate relative to each other. The rollers 26 are arranged between the inner ring 23 and the outer ring 24. The supporting section 27 supports the rollers 26. The switch spring supports the supporting section 27 by its spring force.
As shown in
When each roller 26 is supported at the corresponding central section of the cam surface 23a, the inner ring 23 and the outer ring 24 rotate relative to each other because there is a gap between the outer ring 24 and the roller 26. The state in which each roller 26 is supported at a central part of the corresponding cam surface 23a is called the neutral state. During the neutral state, the inner ring 23 and the outer ring 24 can rotate relative to each other.
As shown in
In the clutch control section, the armature 28 is attracted to the slide section 30 (toward the right side in
When a relative rotation is generated between the inner ring 23 and the outer ring 24 after the clutch control section releases the clutch mechanism section from the neutral state, as shown in
When the relative rotation between the inner ring 23 and the outer ring 24 is generated in an opposite direction to the direction shown in
The limitation state which prevents the relative rotation between the inner ring 23 and the outer ring 24 by the roller 26, in other words, the state which allows the second rotating shaft 4 to rotate in the forward rotation direction or in the backward rotation direction only is called the locked state.
As shown in
Further, as shown in
The magnetic induction yoke 32 is comprised of an outer peripheral yoke, an outer surface yoke, and an inner surface yoke. The outer peripheral yoke penetrates the motor housing casing 2 in a thickness direction (the right and left sides in
The third rotation limitation section switches between a direct connection state and a disconnection state. The direct connection state connects the first rotating shaft 3 with the second rotating shaft 4. The disconnection state disconnects the first rotating shaft 3 from the second rotating shaft 4.
The third rotation limitation section corresponds to a magnetic bi-directional clutch 33. The magnetic bi-directional clutch 33 releases the disconnection state between the first rotating shaft 3 and the second rotating shaft 4 by a magnetic force generated by an electrical magnet, and switches to the direct connection state between the first rotating shaft 3 and the second rotating shaft 4 by using the rotational force of the first rotating shaft 3 after releasing the disconnection state between the first rotating shaft 3 and the second rotating shaft 4 by the magnetic force generated by the electromagnet.
Because the third rotation limitation section has the same structure of the second rotation limitation section, the explanation for the third rotation limitation section is omitted here for brevity.
A description will now be given of a mechanism of the magnetic bi-directional clutch 33 to provide a magnetic field to the clutch control section. This mechanism of the magnetic bi-directional clutch 33 is different from the mechanism of the magnetic bi-directional clutch 22 to supply the magnetic field.
The magnetic bi-directional clutch 33 uses a magnetic induction yoke. As shown in
As shown in
The inner yoke 35 is fixed to the hub 7. The hub 7 supports the magnetic induction rotor 8. The outer peripheral end in a radial direction of the inner yoke 35 is arranged with a gap to face the radially inner side of the outer yoke 34. The inner peripheral end in a radial direction of the inner yoke 35 is arranged to close a slide section (not shown).
As shown in
When electric power is supplied to the excitation coil 36, magnetic flux flows in a magnetic flux passage comprised of the outer yoke 34, the stator core 9b, the magnetic induction rotor 8, the field rotor 6 and the inner yoke 35 in the magnetic bi-directional clutch 33.
Like the operation of the magnetic bi-directional clutch 22 as previously explained, the clutch control section operates by the magnetic flux flowing through the magnetic flux passage. As a result, when a difference in rotation speed is generated between an inner ring 37 fixed to the second rotating shaft 4 and the outer ring 38 fixed to the hub 5 of the first rotating shaft 3, roller 39 is mated with gap between the inner peripheral surface of the outer ring 38 and the cam surface of the inner ring 37, and as a result, this prevents relative rotation between the inner ring 37 and the outer ring 38.
Next, a description will now be given of the basic operation of the magnetic circuit formed in the double drive shaft motor 1 according to the first exemplary embodiment of the present invention with reference to
When the field rotor 6 moves toward the positive direction designated by reference character “+” and the arrow in
Accordingly, when the stator 9 has the winding of the number of pole pairs capable of receiving the sum or the difference in frequency components between the eight pole pairs and the twenty pole pairs, that is, when the stator 9 has a multi-phase winding of twenty eight pole pairs or twelve pole pairs, it is possible to transmit magnetic energy between the field rotor 6 and the magnetic induction rotor 8 with high efficiency. It is possible to realize the double drive shaft motor 1 of a magnetic modulation type in which electromagnetic force is transmitted between the stator 9, the field rotor 6 and the magnetic induction rotor 8 with high efficiency. It is thereby possible for the double drive shaft motor 1 to operate as a planetary gear of a mechanical type, namely, as a planet gear mechanism of a known type.
The relationship designated by the equation (1) indicates that the rotation speed ωn of the field rotor 6, the rotation speed ωk of the magnetic induction rotor 8, and the rotation speed corn of the rotating magnetic field generated by the stator 9 can be arranged on a straight line.
A description will now be given of an operation example when the magnetic induction rotor 8 is stopped, namely, does not rotate. When the magnetic induction rotor 8 does not rotate, because the rotating speed ωk of the magnetic induction rotor 8 is zero (ωk=0), the rotation speed ωn becomes −(3/2)×ωm, that is, ωn=−(3/2)×ωm.
That is, it can be understand on the basis of a collinear graph shown in
A description will now be given of an explanation of magnetic phenomenon by using a simple model when the number of pole pairs in each of the field rotor 6, the magnetic induction rotor 8 and the stator 9 is decreased.
First, as shown in
Next, as shown in
Further, when the field rotor 6 is rotated to the state shown in
As previously explained, when the rotating magnetic field generated by the stator 9 is moved while the magnetic induction rotor 8 is fixed, the field rotor 6 is rotated in the counterclockwise direction which is opposite to the rotation direction of the rotating magnetic field. As shown in the collinear graph shown in
Next, a description will now be given of the operation of the double drive shaft motor 1 of a magnetic flux modulation type according to the first exemplary embodiment when the double drive shaft motor 1 is used in the hybrid electric vehicle with reference to
As shown in the column (a) of the collinear graph shown in
(Engine Idling after Engine Start)
As shown in the column (b) of the collinear graph shown in
As shown in the column (c) of the collinear graph shown in
As shown in the column (d) of the collinear graph shown in
Even if no current flows in the stator winding 9c, it is possible to maintain the direct connection state between the first rotating shaft 3 and the second rotating shaft 4 because the clutch mechanism section of the magnetic bi-directional clutch 33 has a roller type.
As shown in the column (e) of the collinear graph shown in
As shown in the column (f) of the collinear graph shown in
As shown in the column (g) of the collinear graph shown in
As shown in the column (h) of the collinear graph shown in
As previously described, the double drive shaft motor 1 according to the first exemplary embodiment independently changes the rotation speed of the first rotating shaft 3 and the rotation speed of the second rotating shaft 4, respectively, and makes the connection state and the disconnection state between the first rotating shaft 3 and the second rotating shaft 4.
Further, the double drive shaft motor 1 supplies the electromotive power to the first rotating shaft 3 and the second rotating shaft 4, and generates electric power by receiving the rotation power supplied from the second rotating shaft 4. That is, although the double drive shaft motor 1 is a compact-size motor, the double drive shaft motor 1 freely switches between the mechanical power and the electromotive power bi-directionally, namely, in both directions. This makes it possible to provide a complex function motor having a complex function, a speed changeable function, a power dividing function, a power synthesizing function and a motor generator function. To use the double drive shaft motor 1 according to the first exemplary embodiment having the various functions previously described provides a simple vehicle drive system and a miniaturization.
A description will be given of the double drive shaft motor 1 according to the second exemplary embodiment with reference to
As shown in
As shown in
A direct-current component, that is, a zero phase component designated by the dotted lines shown in
The flow of the magnetic flux in the route makes it possible to allow the clutch control section to operate. The clutch mechanism section is thereby entered into the direct-connection state. That is, it is possible to operate the magnetic bi-directional clutch 33 by changing the control waveform of the inverter 15 (see
A description will be given of the double drive shaft motor 1 according to the third exemplary embodiment with reference to
As shown in
Although
A description will be given of the double drive shaft motor 1 according to the fourth exemplary embodiment with reference to
The first exemplary embodiment discloses the rolling type clutch as the rotation limitation sections as previously described.
On the other hand, as shown in
That is, the third rotation limitation section is comprised of a roller type electromagnetic clutch 42 and a multiple disc clutch 44 (or a multi disc clutch) having a plurality of friction discs as friction members. The roller type electromagnetic clutch 42 prevents the relative rotation between the inner ring 37 and the outer ring 38 when the roller 39 is fitted or meshed between the inner ring 37 and the outer ring 38. The multiple disc clutch 44 converts the rotational force generated by the roller type electromagnetic clutch 42 to a pushing force. The multiple disc clutch 44 prevents the relative rotation between the second rotating shaft 4 and the second rotating shaft 4 by the pushing force which pushes the friction discs.
In more detail, when the roller type electromagnetic clutch 42 prevents the relative rotation between the inner ring 37 and the outer ring 38, the rotational force is supplied to a pushing plate 45 with grooves which moves in an axial direction to the first rotating shaft 3. A relative rotation is generated between the pushing plate 45 and a pressure plate 46 with grooves. The pressure plate 46 with grooves is movable in an axial direction to the second rotating shaft 46. The rotation of the pressure plate 46 is limited to the second rotating shaft 4. The cone shaped roller sandwiched between the pushing plate 45 and the pressure plate 46 is fitted to the cam surface of the pushing plate 45 and the cam surface of the pressure plate 46. The pressure plate 46 is thereby pushed toward an axial direction (at the left side in
The multiple disc clutch 44 has a specific characteristic of gradually executing the engaging when an electromagnetic clutch having a simple structure is turned on/off. Further, because of using an axial drive force, the multiple disc clutch 44 does not always use energy to execute the connection between the first rotating shaft 3 and the second rotating shaft 4, which is different in operation from a clutch which executes the connection by using an oil pressure generated by usual oil pump. Still further, the double drive shaft motor 1 can be easily equipped with the multiple disc clutch 44 therein, and the double drive shaft motor 1 has a compact-size motor because the multiple disc clutch 44 does not require a large oil pipe system and an oil supply circuit, which is different in operation from a clutch which continuously uses the oil pressure generated by the usual oil pump.
In the structure of the double drive shaft motor 1 according to the first exemplary embodiment, the magnetic induction rotor 8 is arranged at the radially outer periphery of the field rotor 6. However, the concept of the present invention is not limited by this structure. For example, it is possible to arrange the field rotor 6 at the radially outer periphery of the magnetic induction rotor 8. That is, the magnetic induction rotor 8 is arranged at the radially inner side and the field rotor 6 is arranged at the radially outer side.
Still further, in the structure of the double drive shaft motor 1 according to the first exemplary embodiment, the stator 9 is arranged at the radially outer side of the field rotor 6 and the magnetic induction rotor 8. However, the concept of the present invention is not limited by this structure. For example, it is possible to arrange the stator 9 at the radially inner side of the field rotor 6 and the magnetic induction rotor 8.
Although the first exemplary embodiment shows the first rotation limitation section comprised of the one-way clutch 17. However, the concept of the present invention is not limited by this structure. For example, it is possible to use a combination of the roller type electromagnetic clutch 42 and the multiple disc clutch 44 instead of using the one-way clutch 17.
Still further, although the first exemplary embodiment shows the second rotation limitation section comprised of the magnetic bi-directional clutch 22. However, the concept of the present invention is not limited by this structure. For example, it is possible to use a combination of the roller type electromagnetic clutch 42 and the multiple disc clutch 44 instead of using the magnetic bi-directional clutch 22.
While specific embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limited to the scope of the present invention which is to be given the full breadth of the following claims and all equivalents thereof.
Number | Date | Country | Kind |
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2012-043093 | Feb 2012 | JP | national |