This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2018-119937 filed on Jun. 25, 2018, the content of which is incorporated herein by reference.
This invention relates to a vehicle drive apparatus for traveling a vehicle by a power of an electric motor.
Conventionally, there is a known vehicle drive apparatus of this type, in which an electric motor is installed under a vehicle seat in a state with an axis of rotation of the motor oriented in vehicle height direction and torque of the motor is transmitted to a horizontally extending shaft through a pair of bevel gears. Such an apparatus is described in Japanese Unexamined Patent Publication No. 2012-029369 (JP2012-029369A), for example. In the apparatus described in JP2012-029369A, a bevel gear is provided on an upper end portion of a shaft fitted on a center part of a rotor of the motor, so that a bevel gear provided on an end portion of the horizontally extending shaft meshes therewith.
However, since the apparatus described in JP2012-029369A is configured to transmit torque of the motor to the horizontally extending shaft through the pair of bevel gears, it is necessary to increase diameters of the bevel gears in order to transmit large torque to the horizontally extending shaft. As a result, the vehicle drive apparatus becomes vertically large, and it is difficult to install the vehicle drive apparatus capable of transmitting large torque in a vehicle's limited available space in the vertical direction.
An aspect of the present invention is a vehicle drive apparatus, including: an electric motor including a rotor rotating about a first axial line in a vertical direction and a stator disposed around the rotor; a first rotating shaft extended along the first axial line to rotate integrally with the rotor and including a first gear at an end portion thereof; a pair of left and right second rotating shafts extended along a pair of left and right second axial lines parallel to the first axial line in a state separate from each other in a left-right direction, and including second gears at end portions thereof so as to mesh with the first gear respectively and worm gears rotating about the pair of left and right second axial lines; a pair of left and right worm wheels rotatable about a third axial line in the left-right direction and provided so as to mesh with the worm gears, respectively; and a pair of left and right drive shafts to which torques from the pair of left and right worm wheels are input, respectively.
The objects, features, and advantages of the present invention will become clearer from the following description of embodiments in relation to the attached drawings, in which:
An embodiment of the present invention will be described with reference to
The electric motor 1 includes a rotor 11 that rotates around an axis CL1 extending in the up-down direction and a stator 12 disposed around the rotor 11. The electric motor 1 is, for example, an magnet-embedded synchronous motor, and multiple permanent magnets are circumferentially embedded in the rotor 11 (rotor core). The electric motor 1 may be a synchronous reluctance motor, switched reluctance motor, or the like, which includes no magnet.
The stator 12 includes an approximately cylindrical stator core disposed around the axis CL1 and radially spaced from the outer circumferential surface of the rotor 11 (rotor core) by a predetermined length. Multiple slots that are oriented radially outward are circumferentially provided on the inner circumferential surface of the stator core. A winding (coil) is disposed in each slot by concentrated winding or distributed winding. By passing a three-phase alternating current through the windings, a rotating magnetic field occurs and rotates the rotor 11.
The rotor 11 contains a first rotating shaft 13 that extends along the axis CL1. The first rotating shaft 13 is coupled to the rotor 11, for example, by spline coupling and rotates integrally with the rotor 11. The upper end of the first rotating shaft 13 protrudes from the upper end surface of the rotor 11 and is provided with a first gear 14 having a smaller diameter than the rotor 11. The first gear 14 is coupled to the first rotating shaft 13, for example, by spline coupling and rotates integrally with the first rotating shaft 13. The first gear 14 is formed in, for example, a spur gear or helical gear.
A pair of left and right second rotating shafts 21 are disposed on sides (rear-right and rear-left sides) of the electric motor 1 so as to be rotatable around axes CL2 extending in the up-down direction. The upper ends of the pair of second rotating shafts 21 are provided with second gears 22. The second gears 22 are coupled to the second rotating shafts 21, for example, by spline coupling and rotate integrally with the second rotating shafts 21. The left and right second gears 22 have the same configuration and consist of spur gears or helical gears. The first gear 14 and the pair of second gears are located at the same height and are engaged with each other above the rotor 11 (on the inner diameter side of the inner circumferential surface of the stator 12).
Worms 23 forming worm gears are provided on the left and right second rotating shafts 21 so as to be located below the second gears 22 and on sides of the electric motor 1. The left and right worms 23 have the same configuration and are threaded gears having helical and continuous teeth formed thereon. The worms 23 are coupled to the second rotating shafts 21, for example, by spline coupling and rotate integrally with the second rotating shafts 21. The worms 23 may be formed by machining the outer circumferential surfaces of the second rotating shafts 21.
A pair of left and right worm wheels (helical gears) 31 are coaxially disposed in rear of the left and right worms 23 so as to be rotatable around an axis CL3 extending in the left-right direction. The left and right worms 23 are engaged with the left and right worm wheels 31, respectively. The left and right worm wheels 31 have the same configuration and are approximately cylindrical as a whole. The worm wheels 31 are located below the second gears 22. The axis CL3 is located in a position corresponding to the central portion in the height direction of the electric motor 1, and the outer diameter of the worm wheels 31 is approximately equal to the height of the electric motor 1.
In the left and right worm wheels 31, a pair of single-pinion left and right first planetary gear mechanisms 4 having the same configuration are housed. The left and right first planetary gear mechanisms 4 each include a sun gear 41, a ring gear 42 surrounding the sun gear 41, multiple (e.g., three) pinions 43 that are circumferentially disposed and engaged with the sun gear 41 and ring gear 42, and a carrier 44 that rotatably supports the pinions 43. The sun gear 41, ring gear 42, and carrier 44 rotate around the axis CL3. The ring gear 42 is fixed to or formed on the inner circumferential surface of the worm wheel 31 and rotates integrally with the worm wheel 31.
The left and right carriers 44 extend outward in the left-right direction along the axis CL3. More specifically, the carrier 44 of the left first planetary gear mechanism 4 extends leftward, and the carrier 44 of the right first planetary gear mechanism 4 extends rightward. A pair of left and right drive shafts 45 are coupled to ends in the left-right direction of the carriers 44 by spline coupling or the like, and the carriers 44 and drive shafts 45 rotate integrally. Wheels (drive wheels; not shown) are coupled to ends of the drive shafts 45, and the drive shafts 45 and the wheels rotate integrally.
A pair of left and right rotating shafts 46 extending inward in the left-right direction along the axis CL3 are coupled to the left and right sun gears 41 by spline coupling or the like, and the left and right sun gears 41 and the left and right rotating shafts 46 rotate integrally. An electric motor 5 and a double-pinion second planetary gear mechanism 6 are serially interposed between the left and right rotating shafts 46. Hereafter, the electric motor 1 may be referred to as a first electric motor, and the electric motor 5 as a second electric motor.
The electric motor 5 includes a rotor 51 that rotates around the axis CL3 and a stator 52 disposed around the rotor 51. The electric motor 5 is, for example, a magnet-embedded synchronous motor, and multiple permanent magnets are circumferentially embedded in the rotor 51 (rotor core). The electric motor 5 may be a synchronous reluctance motor, switched reluctance motor, or the like, which include no magnet.
The stator 52 includes an approximately cylindrical stator core disposed around the axis CL3 and radially spaced from the outer circumferential surface of the rotor 51 (rotor core) by a predetermined length. Multiple slots that are oriented radially outward are circumferentially provided on the inner circumferential surface of the stator core. A winding (coil) is disposed in each slot by concentrated winding or distributed winding. By passing a three-phase alternating current through the windings, a rotating magnetic field occurs and rotates the rotor 51. A rotating shaft 51a of the rotor 51 of the electric motor 5 is coupled to the right end of the left rotating shaft 46 by spline coupling or the like so that the rotating shaft 46 rotates integrally with the rotor 51.
The second planetary gear mechanism 6 includes a sun gear 61, a ring gear 62 surrounding the sun gear 61, multiple first pinion gears 63 and multiple second pinions 64 circumferentially disposed between the sun gear 61 and ring gear 62, engaged with the sun gear 61 and ring gear 62, and engaged with each other, and a carrier 65 that rotatably supports the first pinion gears 63 and second pinions 64. The sun gear 61 and carrier 65 rotate around the axis CL3. The ring gear 62 is unrotatably fixed to a case or the like. The tooth number of the ring gear 62 is twice the tooth number of the sun gear 61.
The carrier 65 extends rightward along the axis CL3. The left end of the right rotating shaft 46 is coupled to the right end of the carrier 65 by spline coupling or the like so that the carrier 65 rotates integrally with the rotating shaft 46. The right end of the rotating shaft 51a of the rotor 51 is coupled to the sun gear 61 by spline coupling or the like so that the rotor 51 rotates integrally with the sun gear 61.
The electric motor 5 is controlled in accordance with a command from a controller (ECU) 8 through a power control unit (PCU) 7. Specifically, the power control unit 7 includes an inverter, and when the inverter is controlled in accordance with a command from the controller 8, the rotation (rotation speed, rotation direction) of the electric motor 5 is controlled.
More specifically, the controller 8 includes an arithmetic processing unit having CPU, ROM, RAM, and other peripheral circuits. The controller (ECU) 8 receives signals from a vehicle speed sensor 9a that detects the vehicle speed and a steering angle sensor 9 that detects the steering angle of the steering wheel, and the electric motor 5 is controlled in accordance with these signals. The electric motor 1 is also controlled in accordance with a command from the controller 8 through the power control unit (PCU) 7. For example, the electric motor 1 is controlled in accordance with the manipulated variable or the like of an accelerator pedal. The electric motor 5, second planetary gear mechanism 6, controller (ECU) 8, and the like form a speed difference absorbing unit 101 that absorbs the speed difference between the left and right drive shafts 45 during a turn of the vehicle.
The controller 8 (CPU) calculates the target speed difference ΔN on the basis of the signals from the vehicle speed sensor 9a and steering angle sensor 9b, as well as calculates the target speed Nm corresponding to the target speed difference ΔN in accordance with the characteristics in
A main operation of the vehicle drive apparatus 100 thus configured will be described.
As shown by arrows A1, A2 in
In this case, the rotation of the electric motor 5 is stopped. Thus, as shown in
As shown by arrows B1 and B2 in
More specifically, as shown by arrows B3 and B4 in
As seen above, in the present embodiment, both during the straight travel and during the turn travel, the torque of the electric motor 1 is transmitted to the pair of left and right worm wheels 31 through the pair of left and right worms 23. Thus, a large torque can be easily transmitted to the left and right drive shafts 45. For example, when transmitting a larger torque of the electric motor 1 to a single worm wheel through a single worm gear, the diameter of the worm wheel has to be increased, and the diameter-increased worm wheel would be difficult to dispose below the second gear 22. On the other hand, in the present embodiment, the torque of the electric motor 1 is distributed to the pair of left and right worm wheels 31. This eliminates the need to increase the diameter of the worm wheels 31, allowing the worm wheels 31 to be easily disposed below the second gears 22. As a result, upsizing of the vehicle drive apparatus 100 in the height direction can be prevented.
According to the embodiment, the following operations and effects can be achieved.
(1) The vehicle drive apparatus 100 includes the electric motor 1 including the rotor 11 that rotates around the axis (first axis) CL1 extending in the up-down direction and the stator 12 disposed around the rotor 11, the first rotating shaft 13 that extends along the axis CL1, has the first gear 14 on the end thereof, and is disposed so as to be rotatable integrally with the rotor 11, the pair of left and right second rotating shafts 21 that are disposed in a standing manner along the pair of left and right axes (second axes) CL2 parallel with the axis CL1 so as to be spaced from each other in the left-right direction, have the second gears 22 engaged with the first gear 14 on the ends thereof, and are integrally provided with the worms 23 that rotate around the axes CL2, the pair of left and right worm wheels 31 that are engaged with the worms 23 of the pair of left and right second rotating shafts 21 and are disposed so as to be rotatable around the axis (third axis) CL3 extending in the left-right direction, and the pair of left and right drive shafts 45 that receive the torque from the pair of left and right worm wheels 31 (
This configuration prevents upsizing of the vehicle drive apparatus 100 in the height direction and is able to transmit the torque of the electric motor 1 that rotates around the axis CL1 extending in the up-down direction, to the worm wheels 31 that rotate around the axis CL3 extending in the left-right direction while obtaining a sufficient reduction ratio and thus to cause the vehicle to travel with a large torque. Thus, the vehicle drive apparatus 100 can be easily disposed in a predetermined height-limited space in the vehicle. In other words, since the torque of the electric motor 1 is transmitted to the worm wheels 31 not through a bevel gear but through the second gears 22 disposed on the ends of the second rotating shafts 21 and the worms 23 provided at the second rotating shafts 21, the diameter of the second gears 22 can be increased without expanding the vehicle drive apparatus 100 in the height direction, allowing for easy transmission of a large torque to the drive shafts 45. Also, the torque of the electric motor 1 is distributed to the pair of left and right worm wheels 31 through the pair of left and right worms 23. Thus, a large torque can be easily transmitted to the drive shafts 45 without enlarging the diameter of the worm wheels 31.
(2) The vehicle drive apparatus 100 further includes the pair of left and right first planetary gear mechanisms 4 that are housed in the pair of left and right worm wheels 31 and transmit power from the pair of left and right worm wheels 31 to the pair of left and right drive shafts 45, and the speed difference absorbing unit 101 that absorbs the speed difference between the pair of left and right drive shafts 45 during a turn travel of the vehicle (
(3) The pair of left and right first planetary gear mechanisms 4 include the pair of left and right ring gears 42 connected to the pair of left and right worm wheels 31, the pair of left and right carriers 44 connected to the pair of left and right drive shafts 45, and the pair of left and right sun gears 41 (
(4) The second planetary gear mechanism 6 includes the ring gear 62 disposed in non-rotatable manner, the carrier 65 connected to one (e.g., right sun gear 41) of the pair of left and right sun gears 41, and the sun gear 61 connected to the rotating shaft 51a of the electric motor 5 (
Although, in the above embodiment, the first gear 14 is disposed above the electric motor 1, the first gear may be disposed below the electric motor. In this case, the pair of left and right second gears are disposed on the lower ends of the second rotating shafts 21 so as to be engaged with the first gear. Although, in the above embodiment, the pair of left and right second rotating shafts 21 are disposed in oblique rear positions with respect to the first rotating shaft 13, the second rotating shafts may be disposed in oblique front positions with respect to the first rotating shaft. Accordingly, the worm wheels 31 also may not be disposed as described above.
Although, in the above embodiment, the electric motor 5, second planetary gear mechanism 6, controller 8, and the like form the speed difference absorbing unit 101, a speed difference absorbing unit may be configured otherwise as long as it absorbs the speed difference between the pair of left and right drive shafts during a turn of the vehicle.
Although, in the above embodiment, the second planetary gear mechanism 6 is disposed on the right side of the electric motor 5, the second planetary gear mechanism may be disposed on the left side of the electric motor. The sun gear 61 and carrier 65 of the second planetary gear mechanism 6 may be disposed in a left-right inverted manner. Although, in the above embodiment, the sun gear 41 of the first planetary gear mechanism 4 is connected to the rotating shaft 51a of the electric motor 5, a reduction gear may be connected to the electric motor and the sun gear may be connected to the reduction gear. A clutch that is engaged during a turn travel and is disengaged during a straight travel may be disposed on the sun gear 61 or carrier 65 of the second planetary gear mechanism 6. Thus, heating of the electric motor 5 during a straight travel can be reduced.
The above embodiment can be combined as desired with one or more of the above modifications. The modifications can also be combined with one another.
According to the present invention, a vehicle drive apparatus for driving a vehicle by a power of an electric motor can be easily disposed in a predetermined height-limited space in the vehicle.
Above, while the present invention has been described with reference to the preferred embodiments thereof, it will be understood, by those skilled in the art, that various changes and modifications may be made thereto without departing from the scope of the appended claims.
Number | Date | Country | Kind |
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2018-119937 | Jun 2018 | JP | national |