This invention relates to support and assembly of a motor/generator for an electromechanical transmission.
A hybrid electromechanical vehicular transmission utilizes interactive planetary gear arrangements that are operatively connected to an engine and two motor/generators. Selective utilization of torque transfer devices enables power transfer via the planetary gear arrangements from the engine and/or motor/generators to the output member of the transmission.
A power transmission in an electromechanical transmission is described in commonly owned U.S. Provisional Application No. 60/590,427 entitled Electrically Variable Transmission with Selective Fixed Ratio Operation, filed Jul. 22, 2004, and hereby incorporated by reference in its entirety.
Motor/generators in an electromechanical transmission are typically cooled by directing transmission fluid from a fluid source such as a pump to the motor/generators. A cooling system that requires a minimum of added machining and assembly steps, added components and minimal or no increase in pump capacity is desirable.
The invention provides novel stator and rotor support and packaging to enable reliable positioning of the stator and rotor with minimal relative variation. Pursuant to the invention, an electromechanical transmission includes a motor/generator having a stator and a rotor and including a structural support member that at least partially supports the stator in a fixed relationship and the rotor in a rotational relationship. By supporting both the stator and the rotor, the structural support member substantially controls a spatial relationship (i.e., the gap in which a magnetic field is created and which allows relative movement) between the stator and rotor.
In one aspect of the invention, the structural support member is an end cover that partially encloses the rotor and the stator within an interior space of the transmission. Alternatively, the structural support member may be a center support located within the interior space for supporting a more inwardly-located motor/generator. An end cover-type structural support member and a center support-type structural support member may be used together in one transmission to each respectively support a stator and a rotor of a first and a second motor/generator, respectively. In that instance, the end cover-type structural support member and the center support-type structural support member may respectively support rotor hubs of the motor/generators with respect to a common grounding member, such as a transmission case. Because the rotor hubs are supported with respect to a common grounding member, radial loads resulting from the two motors are balanced.
In another aspect of the invention, a rotor hub that is connected to and rotates with the rotor is at least partially supported by the structural support member. Preferably, a bearing is located between the structural support member and the rotor hub. Accordingly, the gap in which the magnetic field between the stator and the rotor is created is dependent only upon dimensional tolerances of the structural support member, the stator, the rotor, the rotor hub and the bearing.
In a further aspect of the invention, the structural support member is made of iron. Because a portion of the structural support member is located radially outward of the stator and a portion is located radially inward of the rotor, the iron supplements magnets in the stator to increase the magnetivity of the motor/generator, thereby increasing torque capacity. Additionally, because the iron structural support member has the same thermal expansion properties as the iron in the motors, the spatial relationship of the stator to the rotor is maintained despite thermal expansion.
In another aspect of the invention, an annular stator support is rigidly connected to and supported by the structural support member. The stator is supported by the annular stator support. The annular stator support is located radially outward of the stator. At least a portion of the structural support member is located radially inward of the rotor. Preferably, both the annular stator support member and the structural support member are iron, to increase magnetivity and torque capacity of the motor/generator, as described above.
The invention also provides a motor/generator module that may be preassembled before attachment to the rest of the transmission. The module includes the structural support member, the stator, the rotor and the rotor hub. By preassembling these components, the gap is determined and may be more easily inspected for compliance purposes prior to final installation of the module.
A method of assembling an electromechanical transmission includes providing the structural support member, the rotor hub and the bearing. The rotor hub is connected to the structural support member in rotatable relationship thereto with the bearing disposed between the structural support member and the rotor hub. The rotor is connected to the rotor hub. The stator is press-fit to the structural support member to form a motor/generator module. The entire module is then guided onto a shaft of the transmission.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
Motor Cooling System
Referring to the drawings wherein like reference numbers refer to like components,
Referring now to
As may be better viewed in
Referring again to
A center support 54 is rigidly supported with respect to the main shaft 16′ about the center axis 14 and supports the stator 22A as described below. A third flow passage 56 is formed within the center support 54 and is in fluid communication with the valve body 42 through a fourth flow passage 58 formed in the first portion 30 of the transmission case. Cooling fluid is supplied to first end (i.e., left side) stator windings 48A of the stator 22A via the third and fourth flow passages 56, 58. A drilled bore 55 in the center support 54 intersects an annular cavity 57. An annular plate 59 having an orifice 61 is press fit into the cavity 57. Fluid flows from the third passage 56, into the bore 55, into the cavity 57 and through the orifice 61 to cool the first end stator windings 448A. The center support 54 is formed with a third annular recess 60 which is in fluid communication with a third set of circumferentially-spaced radial openings 62 which are also formed in the center support 54. Cooling fluid is supplied to second end (i.e., right side) stator windings 50A of the stator 22A from the valve body 42 via a fifth flow passage 64 in fluid communication with the third annular recess 60 and through the third set of circumferentially-spaced radial openings 62.
Referring to
Stator Support and Motor/Generator Packaging Module
Referring to
A first rotor hub 70B is rotatably supported by the end cover 26 at a bearing 72B and is welded to the main shaft 16. The rotor 24B is rigidly connected to the first rotor hub 70B and is rotatable therewith with respect to the end cover 26. A gap 74B is achieved between the stator 22B and the rotor 24B and is controlled by the radial dimensions of the rotor 24B and the stator 22B and the distance between an exterior surface 76 of the first rotor hub 70B and the inner surface 68 of the end cover 26. Because the rotor hub 70B is mounted at the shaft bearing 72B and is supported by the end cover 26 which also forms the inner surface 68, variability in the gap 74B due to build tolerances is minimized (i.e., the dimensions of one element, the end cover 26, influence the positioning and dimensional play at both ends (the exterior surface 76 of the first rotor hub 70B and the inner surface 68 of the end cover 26) of the space in which the motor/generator 20B is packaged).
The stator 22A includes a plurality of segmented portions spaced about an inner surface 78 of the center support member 54. The inner surface 78 of the center support member 54 may be provided with slots coordinating with extensions on the segmented portions of the stator 22A for fixedly connecting the segments to the center support member 54.
A second rotor hub 70A consists of welded outer portion 71 and inner portion 73. The rotor 24A is rigidly connected to the second rotor hub 70A and is rotatable therewith with respect to the center support 54. The second rotor hub 70A is partially supported by the center support 54 at bearing 72A. A gap 74A is achieved between the stator 22A and the rotor 24A and is controlled by the radial dimensions of the rotor 24A and the stator 22A and the distance between an outer surface 80 of the second rotor hub 70A and the inner surface 78 of the center support member 54. Because the second rotor hub 70A is supported by the center support member 54, the dimensions of one component (the center support member 54) influence the positioning and dimensional play at both ends (i.e., the inner side 78 of the center support member 54 and the exterior surface 80 of the rotor hub 70A) of the space in which the motor/generator 20A is packaged.
Support of the rotor 24B is further provided by bearing 75B, disposed between the shaft 16 and the rotor hub 70A, because the weight of the motor 20B and rotor hub 70B are distributed to the shaft 16 since the rotor hub 70B is welded to the shaft 16. Likewise, support of the rotor 24A is further provided by shaft bearing 75A disposed between the rotor hub 70A and the center support 54. Thus, support of the rotors 24A, 24B is cantilevered, rather than provided on either side of each rotor, as is typically done. The rotors 24A and 24B are both grounded or steadied by a common member, the shaft 16. Rotor 24B is steadied by the shaft 16 because the rotor hub 70B is welded to it. Rotor 24A is steadied by the shaft 16 via the shaft bearing 75B. By supporting the rotors 24A, 24B at a common member (the shaft 16), unintended run out between the rotors 24A, 24B is minimized.
Because for each motor/generator 20A and 20B, the rotor 24A, 24B and stator 22A, 22B are supported by a common member (the center support 54 and end cover 26, respectively) the invention allows each motor/generator 20A, 20B to be easily prepackaged as a module prior to attachment with the transmission 11. The motor/generator module 82 for motor/generator 20B includes the end cover 26 having the stator 22B fit at the inner surface 68. The rotor 24B is rigidly connected to the rotor hub 70B, which is then fit to the end cover 26 at the bearing 72B. The entire module 82 (end cover 26, stator 22B, rotor 24B, bearing 72B and rotor hub 70B) may then be piloted on to the shaft 16 and welded thereto as a unit. Similarly, the motor/generator module 84 for motor/generator 20A includes the center support 54 having stator 22A fit at the inner surface 78. The rotor 24A is rigidly connected to the rotor hub 70A, which is then fit to the center support 54 at bearing 72A and bearing 75A. The entire module 84 (which includes center support 54, stator 22A, rotor 24A and rotor hub 70A) may then be piloted on to the shaft 16 over bearing 75B as a unit.
The end cover 26 as well as the center support 54 may be iron. By forming these components from iron, magnetivity of the motor/generators 20A and 20B is increased as the iron in the end cover 26 and the center support 54 (which will be disposed both above the stators and below the rotors) supplements the magnets in the respective motor/generators 20B, 20A to increase torque capacity.
Motor Cooling System
Referring to
The first annular stator support 86A′ is formed with an annular recess 36′. Furthermore, flow passage 40′ is formed in the first portion 30′ of the housing member. A valve body 42′ is in fluid communication with a fluid source such as a pump (not shown) and is capable of delivering pressurized fluid via the flow passage 40′ to the annular recess 36′. For illustrative purposes, the valve body 42′ is shown directly adjacent to the flow passage 40′; however, the valve body 42′ may be more remotely located and connected via hydraulic passages to the flow passage 40′. An o-ring 33′ is disposed between the first portion of the housing 30′ and the first annular stator support 86A′ to help prevent leakage of fluid from a space formed between the annular recess 36′ and the first portion 30′ of the housing. Additionally, the fluid source or pump may be located anywhere on the vehicle and fluidly connected with the valve body 42′, as will be understood by those skilled in the art.
A plurality of circumferentially-spaced radial openings 46A′ are formed in first the annular stator support 86A′ to permit fluid communication between the annular recess 36′ and the interior space 28′. Specifically, the circumferentially-spaced radial openings 46A′ direct fluid onto first end (i.e., left side) stator windings 48B′ of the stator 22B′ to cool the windings 48B′. The circumferentially-spaced radial openings 46A′ may be designed to present the fluid in the form of a mist over the stator windings 48B′ to prevent wear associated with high velocity fluid spray (e.g., by varying the diameter of the openings or by tapering the openings). Alternatively, nozzles may be fit within the radially-spaced openings 46A′ and configured to present the fluid in the form of a mist. Yet another alternative is to connect a deflector to the end cover 26′ or to the first annular stator support 86A′, positioned adjacent to the circumferentially-spaced radial openings 46A′ similarly to the positioning of deflector 49 of
A second set of circumferentially-spaced radial openings 46B′ are formed in the first annular stator support 86A′ such that they are in fluid communication with the annular recess 36′. Pressurized fluid from the fluid source flows from the valve body 42′ through the flow passage 40′ and the annular recess 36′ to the circumferentially-spaced radial openings 46B′ and onto the second end (i.e., right side) stator windings 50B′ for cooling thereof. As with the first set of circumferentially-spaced radial openings 46A′, the second set of circumferentially-spaced radial openings 46B′ may be configured to supply fluid to the second end stator winding 50B′ in the form of a mist.
A center support 54′ is rigidly supported with respect to the main shaft 16′ about the center axis 14′. A second annular stator support 86B′ is welded to a support element 88 which in turn is bolted to the center support 54′ via 90A and 90B. Bolt 90A also connects both the support element 88 and the second annular stator support 86B′ to the first portion 30′ of the housing member. Alternatively, the second annular stator support 86B′ and the support element 88 may be formed as a unitary component. A fourth flow passage 58′ and a fifth flow passage 64′ are formed in the first portion 30′ of the transmission case in fluid communication with the valve body 42′. Sixth and seventh flow passages 65, 67 are formed in the second annular stator support 86B′ in fluid communication with the fourth and fifth flow passages 58′, 64′, respectively. First and second ring-shaped sleeves or annular spray rings 44B, 44C are press-fit against an inner surface 94 of the first portion 30′ of the housing member. A third set 62′ and a fourth set 96 of circumferentially-spaced radial openings are formed in the respective annular spray rings 44C, 44B, such that they are in fluid communication with the seventh and sixth flow passages 67, 65, respectively, of the second annular stator support 86B′. Cooling fluid is supplied to first end (i.e., left side) stator windings 48A′ of the stator 22A′ via the fourth and sixth flow passages 58′ and the fourth set of circumferentially-spaced radial openings 96. Cooling fluid is supplied to second end (i.e., right side) stator windings 50A′ of the stator 22A′ from the valve body 42 via a fifth flow passage 64′ in fluid communication with the seventh flow passage 67 through the third set of circumferentially-spaced radial openings 62′.
A motor cooling system 66′ for the motor/generator 20B′ includes the second annular stator support 86B′ having the sixth and seventh flow passages 65, 67. Furthermore, the motor cooling system 66′ may include the ring-shaped sleeves 44B, 44C having the fourth and third sets of radially-spaced openings 96, 62′ for cooling the left side and right side stator windings 48A′, 50A′, respectively.
To assemble the motor/generator 20A′ within the transmission 11′, the support element 88 is bolted to the center support 54′. The second annular stator support 86B′ is press fit against the inner surface 94 of the first portion 30′ of the housing member in the interior cavity space 28′. The ring sleeves 44B, 44C are press fit against the second annular stator support 86B′. The stator 22A′ is then press fit against the inner surface 97B′ of the second annular stator support 86B′ between the spray rings 44B, 44C.
Stator Support and Motor/Generator Packaging Module
Referring to
A first rotor hub 70B′ is rotatably supported by the end cover 26′ at a bearing 72B′ and is welded to the main shaft 16′. The rotor 24B′ is rigidly connected to the first rotor hub 70B′ and is rotatable therewith with respect to the end cover 26′. A gap 74B′ is achieved between the stator 22B′ and the rotor 24B′ and is controlled by the radial dimensions of the rotor 24B′ and the stator 22B′ and the distance between an exterior surface 76′ of the first rotor hub 70B′ and the inner surface 97A of the annular stator support 86A′. Because the rotor hub 70B′ is mounted at the shaft bearing 72B′ which is supported by the end cover 26′, and because the end cover 26′ also supports the annular stator support 86A′ which forms the inner surface 97A, variability in the gap 74B′ due to build tolerances is minimized.
The stator 22A′ includes a plurality of segmented portions spaced about an inner surface 97A of the second annular stator support 86B′. The inner surface 97A may be provided with slots coordinating with extensions on the segmented portions of the stator 22A′ for fixedly connecting the segments to the annular stator support 86B′.
The rotor 24A′ is rigidly connected to a second rotor hub 70A′ and is rotatable therewith with respect to the center support 54′. The second rotor hub 70A′ is partially supported by the center support 54′ at bearing 72A′. A gap 74A′ is achieved between the stator 22A′ and the rotor 24A′ and is controlled by the radial dimensions of the rotor 24A′ and the stator 22A′ and the distance between an outer surface 80′ of the second rotor hub 70A and an inner surface 97B of the annular stator support 86B′.
Support of the rotor 24B′ is further provided by bearing 72C via a rotor flange 99B welded to the rotor hub 70B′. Likewise, support of the rotor 24A′ is further provided by bearing 72D via a rotor flange 99A welded to the rotor hub 70A′. Bearing 72D is support by separate structure, as shown in
Because for each motor/generator 20A′ and 20B′, the rotor 24A′, 24B′ and stator 22A′, 22B′ are supported by a common member (the center support 54′ and end cover 24′, respectively) the invention allows each motor/generator 20A′, 20B′ to be easily prepackaged as a module prior to attachment with the transmission 11. The motor/generator module 82′ for motor/generator 20B′ includes the end cover 26′ and the first annular stator support 86A′ having the stator 22B′ fit at the inner surface 97B. The rotor 24B′ is rigidly connected to the rotor hub 70B′, which is then fit to the end cover 26′ at the bearing 72B′. The entire module 82′ (end cover 26′, stator 22B′, rotor 24B′, rotor hub 70B′ and rotor flange 99B) may then be piloted on to the shaft 16′ and welded thereto as a unit. Similarly, the motor/generator module 84′ for motor/generator 20A′ includes the center support 54′ and the second annular stator support 86B′ having stator 22A′ fit at the inner surface 97A. The rotor 24A′ is rigidly connected to the rotor hub 70A′, which is then fit to the center support 54′ at bearing 72A′. The entire module 84′ (which includes center support 54′, bearing 72D, bearing 72A′, the annular stator support 86A′, stator 22A′, ring-shaped sleeves 44B, 44C, rotor 24A′, rotor hub 70A′ and rotor flange 99A) may then be piloted on to the shaft 16 over bearing 72D as a unit.
The end cover 26′ as well as the center support 54′ may be iron. By forming these components from iron, magnetivity of the motor/generators 20A′ and 20B′ is increased as the iron in the end cover 26′ and the center support 54′ (which will be disposed both above the stators and below the rotors) supplements the magnets in the respective motor/generators 20B′, 20A′ to increase torque capacity.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
This Application claims the benefit of U.S. Provisional Application No. 60/591,681, filed Jul. 28, 2004, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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60591681 | Jul 2004 | US |