阅读说明：本技术 电动车辆 (Electric vehicle ) 是由 W·迈尔 J·格罗特 于 2019-03-12 设计创作，主要内容包括：本发明涉及一种具有电动机(18)的电动车辆(10),所述电动机具有：(a)第一电动机模块(38.1),所述第一电动机模块具有第一转子(42.1),所述第一转子具有第一转子轴(40.1),并且所述第一电动机模块的转子轴(40.1)具有第一轴耦合结构(46a)；和(b)至少一个第二电动机模块(38.2),所述第二电动机模块具有第二转子(42.2),所述第二转子具有第二转子轴(40.2),并且所述第二电动机模块的第二转子轴(40.2)具有第二轴耦合结构(46b)；和(c)旋转支承部(68),所述第一转子轴(40.1)借助所述旋转支承部支承,(d)其中,所述第一转子轴(40.1)和所述第二转子轴(40.1)借助这些轴耦合结构(46)形状锁合地彼此耦合。根据本发明设置,所述轴耦合结构(46)至少部分地被所述旋转支承部(68)包围。(The invention relates to an electric vehicle (10) having an electric motor (18) which has: (a) a first motor module (38.1) having a first rotor (42.1) with a first rotor shaft (40.1), and the rotor shaft (40.1) of the first motor module having a first shaft coupling structure (46 a); and (b) at least one second motor module (38.2) having a second rotor (42.2) with a second rotor shaft (40.2), and the second rotor shaft (40.2) of the second motor module having a second shaft coupling structure (46 b); and (c) a rotary bearing (68) by means of which the first rotor shaft (40.1) is supported, and (d) wherein the first rotor shaft (40.1) and the second rotor shaft (40.1) are coupled to one another in a form-fitting manner by means of the shaft coupling structures (46). According to the invention, the shaft coupling (46) is at least partially surrounded by the rotary bearing (68).)

1. An electric vehicle (10) having an electric motor (18) comprising:

(a) a first motor module (38.1),

-the first motor module has a first rotor (42.1) with a first rotor shaft (40.1), and

-the rotor shaft (40.1) of the first motor module has a first shaft coupling structure (46 a); and

(b) at least one second electric motor module (38.2),

-the second motor module has a second rotor (42.2) with a second rotor shaft (40.2), and

-the second rotor shaft (40.2) of the second motor module has a second shaft coupling structure (46 b); and

(c) a rotation bearing (68) by means of which the first rotor shaft (40.1) is supported,

(d) wherein the first rotor shaft (40.1) and the second rotor shaft (40.2) are coupled to each other in a form-locking manner by means of the shaft coupling structures (46),

it is characterized in that the preparation method is characterized in that,

(e) the shaft coupling structures (46) are at least partially surrounded by the rotary bearing (68).

2. The electric vehicle (10) of claim 1,

(a) each rotor of each motor module is supported by two rotary bearings, so that the motor modules can be operated independently of one another, and

(b) at least two electric motor modules (38.1, 38.2) are identical in construction.

3. Electric vehicle (10) according to any of the preceding claims, characterized in that at least two motor modules (38.1, 38.2) are permanent magnet excited synchronous motors.

4. Electric vehicle (10) according to any of the preceding claims,

-the rotary bearing (68) has a first rotary bearing (62a.1) with a first set of rolling bodies (64) arranged annularly, and

-the rotary bearing (68) has a second rotary bearing (62a.2) with a second set of rolling bodies (66) arranged annularly and offset from the first set of rolling bodies, and

-the shaft coupling structure (46) is at least partially surrounded by the first and second rotational bearings (62a.1, 62 a.2).

5. Electric vehicle (10) according to any of the preceding claims,

(a) the first shaft coupling structure (46a) has a projection (58) extending in an axial direction,

(b) the second shaft coupling structure (46b) has a retraction portion extending in the axial direction, such that the first shaft coupling structure (46a) and the second shaft coupling structure (46b) are along a contact surface (K) in the axial direction_i) Are abutted against each other, and

(c) the contact surface (K)_i) Forms an angle of at most 5 DEG with an angle measurement plane (E) containing the rotational axis (D) of the rotor (42).

6. Electric vehicle (10) according to any of the preceding claims,

(a) the electric motor (18) has a rotary encoder (76) with a rotary encoder coupling structure (80) having a projection (58) extending in an axial direction, and

(b) the rotary encoder (76) is connected in a form-fitting manner to a shaft coupling (46) of a motor module (38).

7. Electric vehicle (10) according to any of the preceding claims,

(a) the electric motor (18) has a brake (78) with a brake coupling structure (82) having a projection (58) extending in an axial direction, and

(b) the brake (78) is connected in a form-fitting manner to a shaft coupling (46) of a motor module (38) or to a shaft coupling of the rotary encoder (76).

8. Electric vehicle (10) according to any of the preceding claims,

the first rotor shaft (40.1) and the second rotor shaft (40.2) have cooling channels (84).

9. The electric vehicle (10) of claim 1,

the electric motor (18) is formed by a first motor module (38.1) and a second motor module (38.2),

(a) the first motor module has:

-a first rotor (42.1) having a first rotor shaft (40.1); and

-a rotary bearing (68) by means of which the first rotor shaft (40.1) is supported, and

-the first rotor shaft (40.1) of the first motor module has a first shaft coupling structure (46a),

(b) the second motor module having a second rotor (42.2) with a second rotor shaft (40.2) having a second shaft coupling structure (46b),

(c) wherein the first rotor shaft (40.1) and the second rotor shaft (40.2) are coupled to each other in a form-locking manner by means of the shaft coupling structure (46),

(d) wherein the shaft coupling structure (46) is at least partially surrounded by the rotation bearing (68) and

(e) the cooling channel extends through the first rotor (42.1) and the second rotor (42.2).

10. The electric vehicle (10) of claim 1,

(a) the rotor shaft (40) has:

-a central cooling channel extending in an axial direction;

-an input branch channel (110) extending radially outwards and connected with the central cooling channel; and

-a discharge branch channel (115) extending outwards and connected with the central cooling channel,

(b) the stator (116) has:

-a cooling fluid input (120) for inputting a cooling fluid (86), in particular a cooling liquid, to the input branch channel (110); and

-a cooling fluid discharge (118) for leading out cooling fluid (86) from the discharge branch channel (115).

11. Electric vehicle (10) according to claim 1 or 10, characterized in that the cooling fluid input (88) has:

-a first shaft seal (122) and a second shaft seal (124) forming a collar shaped passage (129); and

-an input line configured for inputting a cooling fluid (86) to the annular channel.

12. Electric vehicle (10) according to any of claims 1 to 11, characterized in that said first rotor (42.1) has:

(a) a magnet carrier (54);

(b) a plurality of permanent magnets (56) secured to the magnet carrier (54); and

(c) a bypass channel (94) extending in an axial direction through the magnet carrier (54) and connected with the central cooling channel.

13. The electric vehicle (10) according to any one of claims 1-12,

(a) the permanent magnet (56) is arranged radially outside the stator electromagnet (134), and

(b) the rotor shaft (40) has:

-a first sleeve section (104) extending in a first axial direction; and

-a second sleeve section (106) extending in a direction opposite to the first axial direction,

-wherein the sleeve sections (104, 106) are symmetrical to each other, and

(c) the sleeve sections (104, 106) contain cooling channels (84).

14. The electric vehicle (10) according to any one of claims 1-13,

(a) the sleeve sections (104, 106) are configured on the tubular component (102),

(b) the tubular member (102) is secured to a web (108),

(c) the web (108) has at least one radially outwardly extending connecting channel connecting the central cooling channel with the outer channels in the tubular member.

15. Electric vehicle (10) according to any of claims 1 to 14, characterized in that the stator (116) has a cooling nozzle (130) arranged for cooling the stator electromagnet (134).

16. The electric vehicle (10) according to any one of claims 1-15,

(a) the electric motor (18) is formed by a first motor module (38.1) and at least one second motor module (38.2),

(i) the first motor module has a first rotor (42.1) with a first rotor shaft (40.1) having a first shaft coupling (46a),

(ii) the second motor module having a second rotor (42.2) with a second rotor shaft (40.2), the second motor module having a second shaft coupling structure (46b) and a second cooling channel (84.2),

(b) the first rotor (42.1) and the second rotor (42.2) are coupled to one another in a form-locking manner by means of the shaft coupling (46), and

(c) the cooling channels (84.1, 48.2) are connected to one another.

17. The electric vehicle (10) of claim 16,

(a) the first motor module (38.1) has a first module housing (44.1) with a first housing coupling structure (70a.1),

(b) the second motor module (38.2) having a second module housing (44.2) with a second housing coupling structure (70b.2),

(c) the motor modules (38) are connected to one another in a form-fitting manner by means of their housing coupling structures (44), and

(d) the housing coupling structures (70) radially surround the first rotary bearing (62 a.1).

18. The electric vehicle (10) of claim 17,

(a) the first housing coupling structure (70) is at least partially formed by a first conical housing ring,

(b) the second housing coupling structure (70.2) is formed at least partially by a second conical housing ring, and

(c) the conical housing rings are connected by means of a coupling clip (72) which has an at least partially conical inner surface.

Technical Field

The invention relates to an electric vehicle having an electric motor in the form of a permanently excited synchronous motor, comprising: (a) a first motor module having a first rotor with a first rotor shaft, and the rotor shaft of the first motor module having a first shaft coupling structure; and (b) at least one second motor module having a second rotor with a second rotor shaft, and the second rotor shaft of the second motor module having a second shaft coupling structure; and (c) a rotary bearing by means of which the first rotor shaft is supported, wherein (d) the first rotor shaft and the second rotor shaft are coupled to one another in a form-fitting manner by means of these coupling structures. The invention also relates to an electric motor having the above-mentioned properties, which is designed in particular, but not necessarily, for an electric vehicle.

Furthermore, the present invention relates to an electric vehicle having an electric motor, the electric motor having: (a) a stator having a stator electromagnet; and (b) a rotor having permanent magnets.

In its most general form, the present invention relates to an electric vehicle having an electric motor, which may, but need not, be a permanent magnet excited synchronous motor, which may in particular be an asynchronous motor. In this case, the rotor may have permanent magnets, but this is not essential.

Background

Electric vehicles, in particular passenger vehicles, are increasingly used for people and goods transport. Mass production of electric vehicles has proven to be laborious when different engine powers are to be provided in a vehicle model.

Disclosure of Invention

The invention is based on the object of avoiding the disadvantages of the prior art.

The invention solves the problem by means of an electric vehicle of this type or an electric motor of this type, wherein the coupling structure is at least partially surrounded by the rotary bearing.

The advantage of the invention is that the electric motor can be constructed very compactly in this way. Thus, according to a preferred embodiment, the connection by means of the coupling structure on the housing and the rotor shaft does not lead to an additional axial extension of the structural length.

Furthermore, it is advantageous that such a coupling structure is generally relatively simple to manufacture. Thus, the motor can be made up of two, three, four, five or more motor modules. As in any modular form of construction, the modularity of the individual components generally results in more efficient manufacturing.

Preferably, the number of motor modules is less than twenty.

According to a preferred embodiment, each rotor of each motor module is supported by two rotary bearings, so that the motor modules can be operated independently of one another. In other words, the rotor of each motor module is also supported by means of the rotary bearing when the motor modules are not connected to each other.

Preferably, the rotary bearing is a rolling bearing.

Preferably, at least two of the motor modules are permanently excited synchronous motors. Advantageously, all motor modules are permanently excited synchronous motors.

Preferably, the at least two motor modules are rated at between 25 and 75 kilowatts.

Preferably, the shaft coupling structure is arranged at the same axial height as the rotation bearing.

The rotor shafts of the motor modules (in the assembled state) extend collinearly.

According to a preferred embodiment, the rotary bearing has a first rotary bearing with a first set of rolling bodies arranged in a ring and a second rotary bearing with a second set of rolling bodies arranged in a ring and offset from the first set of rolling bodies. In this case, the shaft coupling is preferably at least partially, particularly preferably completely, surrounded by the first and second rotary bearings. The first and/or second rotary bearing is for example a rolling bearing, in particular a ball bearing.

The advantage of this embodiment is that the coupling structure of each individual motor module is supported on both sides of at least one rolling bearing. In order to join the two motor modules together, only the two coupling structures of the respective motor module have to be connected to one another in a form-fitting manner.

Advantageously, in this arrangement, the outermost rotary bearings of the motor modules in each case adjoin one another. In this way a particularly compact electric motor is obtained. Due to the modularity possibility of the electric motor, the electric motor is well suited for use in vehicles, in particular passenger vehicles. However, the motor can also be applied in other vehicles and in other fields.

Preferably, the first shaft coupling has a coupling structure, in particular a projection, which extends in the axial direction. Preferably, the first shaft coupling structure thus has a projection extending in the axial direction. The second shaft coupling structure preferably has a retraction which likewise extends in the axial direction, so that the first shaft coupling structure and the second shaft coupling structure bear against one another in the axial direction along the contact surface. Advantageously, the contact surface forms an angle of at most 5 ° with an angle measurement plane containing the rotational axis of the rotor. In this way, axial forces which would otherwise occur when a torque is applied to the connection of the electric motor module are reduced.

It is possible for the projection and the retraction to be configured asymmetrically. In this case, the first contact surface, along which the projection and the retraction lie against one another, extends at a different angle to the angle measurement plane than the second contact surface. It is possible in particular that one of these angles is zero. In this case, no axial force is generated when the rotor rotates in the first direction. Conversely, when the rotor is rotated in the opposite direction, a large force is generated.

Preferably, the electric motor has at least one additional component having an additional component coupling structure with a projection extending in the axial direction, wherein the additional component is connected in a form-fitting manner with one of the coupling structures of the motor module. Since the additional member has the same coupling structure as the motor modules, it can be arbitrarily placed between the two motor modules as required. The additional component is for example a rotary encoder (Drehgeber).

In this case, the electric motor accordingly has a rotary encoder with a rotary encoder coupling which has a projection extending in the axial direction, wherein the rotary encoder is connected in a form-fitting manner with one of the coupling structures of the motor module. Since the rotary encoder has the same coupling structure as the motor modules, the rotary encoder can be arbitrarily placed between the two motor modules as required.

It should be noted that the rotor shafts of all motor modules preferably have a coupling structure which can be coupled to one another in a form-fitting manner.

Alternatively or additionally, the additional component is a brake. According to this embodiment, the electric motor has a brake with a brake coupling having a projection extending in the axial direction, wherein the brake is connected in a form-locking manner with a coupling of a motor module or a coupling of a rotary encoder.

Alternatively or additionally again, the additional component is a clutch.

A second aspect of the invention relates to an electric motor comprising a stator with stator electromagnets and a rotor with permanent magnets, wherein the rotor shaft has cooling channels. An electric vehicle with a corresponding electric motor is also according to the invention. In other words, an electric vehicle having an electric motor having: (a) a stator having a stator electromagnet; and (b) a rotor having permanent magnets, wherein (c) the first rotor shaft and the second rotor shaft have cooling channels. It is possible, but not necessary, that the electric vehicle has the features according to claim 1. The preferred embodiments mentioned above are also preferred embodiments of the invention mentioned in this paragraph. The preferred embodiments mentioned below relate to both inventions.

Advantageously, the electric motor is formed by a first electric motor module and a second electric motor module, wherein the electric motor modules have the above-described characteristics. The first rotor shaft and the second rotor shaft are coupled to one another in a form-fitting manner by means of a shaft coupling, wherein the cooling channel preferably extends through the first rotor and the second rotor. Furthermore, it is advantageous if these coupling structures are at least partially surrounded by the rotary bearing. In this way, an electric motor is obtained which is modular with a cooled rotor.

Advantageously, the rotor shaft has a central cooling channel extending in the axial direction, an inlet branch channel extending radially outward and connected to the central cooling channel, and also has an outlet branch channel extending outward and connected to the central cooling channel. In this way, the cooling fluid can be fed to the stator via the inlet branch channel. The stator preferably has a cooling fluid inlet for supplying a cooling fluid, in particular a cooling liquid, to the inlet branch channel and a cooling fluid outlet for discharging the cooling fluid from the outlet branch channel.

Particularly preferably, the cooling fluid inlet has a first shaft seal and a second shaft seal forming an annular channel. Preferably, the cooling fluid inlet also has an inlet line configured for conveying the cooling fluid to the annular channel. The annular channel is arranged to flow cooling fluid into the input branch channel. In other words, the input branch channel is disposed between the first shaft seal and the second shaft seal over an axial length along the longitudinal axis of the rotor.

Advantageously, the two motor modules are of identical construction. If there are more than two motor modules, it is preferred that most of the motor modules are of the same construction, and it is particularly advantageous that all of the motor modules are of the same construction. The feature of the motor module being structurally identical is to be understood in particular that the motor modules consist of at least 90% by weight of identical parts. In particular, the at least two electric motor modules are preferably identical, in particular completely identical, over at least 95 weight percent in the part required for the technical function. It is possible, but not necessary, that the motor modules differ in parts that are not relevant for their function, for example in colour or of course in the possible signs with serial numbers. It is particularly preferred that all motor modules are of identical construction.

Preferably, the electric motor of at least one of the motor modules has a magnet carrier and a plurality of permanent magnets fixed to the magnet carrier. Advantageously, the rotor has a bypass channel which extends at least also in the axial direction through the magnet carrier and is connected to the central cooling channel. In this way the magnet carrier can be cooled effectively.

Permanent magnets lose their magnetization above the curie temperature. Since electric motors, in particular such motors installed in electric vehicles, must also function properly in relatively warm environments and, furthermore, heating of the permanent magnets and the magnet carriers cannot be avoided, in particular due to eddy current losses, it must be ensured that the permanent magnets do not heat up too strongly. This is achieved up to now by detecting the temperature and switching off the respective electric motor when a predefined threshold temperature has been exceeded, which lies below the cooling temperature of the permanent magnet. This process, while still possible and preferred, is no longer necessary due to the cooling of the magnet carrier.

It is particularly advantageous if the permanent magnets are arranged radially outside the stator electromagnet. The motor may then be referred to as an outer rotor. It is particularly advantageous if the rotor shaft has a first sleeve section extending in a first axial direction and a second sleeve section extending in a direction opposite to the first axial direction, wherein the sleeve sections are preferably symmetrical to one another and preferably contain cooling channels. These cooling channels are preferably connected to a cooling channel, in particular a central cooling channel. By actively cooling the sleeve section, the electric motor can be operated with high continuous power.

The sleeve section is preferably formed on a tubular component which is fixed to a web (stem). The web preferably has radially outwardly extending connecting channels connecting the central cooling channel with the outer channels in the tubular member. This type of construction makes it relatively simple to manufacture the sleeve section with the passage.

It should be noted that here, as throughout the description, the presence of a feature determining an object is understood to mean in particular the presence of at least one of these objects. In the present case, this means that the web has at least one connecting channel extending radially outwards.

Advantageously, the stator has a cooling socket which is arranged for cooling the electromagnet. Most of the lost heat accumulates in the electromagnet. At the same time, electromagnets are generally less temperature sensitive than permanent magnets. It is thus possible to guide the cooling fluid in the cooling circuit and, after the cooler in the flow direction, first cool the permanent magnets, in particular the magnet carriers, and then the stator electromagnets. Alternatively, there may also be two cooling circuits, wherein one cooling circuit cools the permanent magnet and the second cooling circuit cools the electromagnet.

The electric motor is advantageously formed as described above from at least two electric motor modules, wherein the electric motors of the respective electric motor modules each have a cooling channel, wherein the two cooling channels are connected to one another such that a cooling fluid can flow from the first cooling channel into the second cooling channel.

Preferably, the first electric motor module has a first module housing with a first housing coupling structure, wherein the second electric motor module has a second module housing with a second housing coupling structure, wherein the electric motor modules are connected to one another by means of their housing coupling structures in a form-fitting manner. This forms a particularly simple form of motor module coupling.

The housing coupling structure is preferably connectable in an externally releasable manner. In other words, two coupled motor modules can be connected from the outside and released from each other, while the other motor modules do not have to be forcibly connected or released from each other.

It is particularly advantageous if the housing coupling structures are each formed at least in part by a conical housing ring. Advantageously, the motor module has a connector for connecting the housing coupling structures to one another in a form-fitting manner. The connector is preferably constructed in such a way that it can be fitted from the outside. In other words, the motor modules can be separated from each other only by loosening the connectors. The connector can be externally fitted.

The connectors are preferably clips, so that the housing coupling structures are connected to one another by means of the clips. The clamping band preferably has an at least partially conical inner surface, wherein the conical inner surface is usually designed in such a way that no line contact, but rather a surface contact, occurs between the housing ring on the one hand and the clamping band on the other hand.

Preferably, the first rotor shaft and the second rotor shaft and, if appropriate, further components of the electric motor that are coupled by means of the shaft coupling are coupled with an axial play. Axial length variations at the rotor due to manufacturing tolerances or thermally induced length variations during operation are compensated by defined axial clearances in the shaft coupling.

Drawings

The invention is explained in detail below with reference to the drawings. All the figures show the invention in one of the different motor construction types presenting the preferred embodiment of the invention, i.e. as a permanent magnet excited synchronous motor. However, other motor construction types may be used, such as asynchronous motors or brushless dc motors. Shown in the drawings are:

figure 1a an electric vehicle according to the invention with an electric motor according to the invention,

figure 1b is a rear view of an electric vehicle according to the invention,

fig. 1c is a perspective view of an electric vehicle according to a second embodiment, with two switching clutches and two driven axles,

fig. 1d is a perspective view of an electric vehicle according to a third embodiment, with two electric motors according to the invention, the rotors of which extend parallel to one another,

fig. 2a is a perspective view, to scale, of a motor module which is configured as an inner rotor and can be part of a motor according to the invention,

figure 2b is a perspective view of the rotor of the motor module according to figure 2a in the form of an inner rotor,

fig. 3a cross section of an electric motor according to the invention in the form of a rotor, which consists of two motor modules according to fig. 2a and 2b,

figure 3b is a detailed view of the motor module according to figure 3a,

fig. 4 shows a perspective view, to scale, of an electric motor according to the invention according to a fourth embodiment, which comprises three motor modules, in the sub-drawing of fig. 4a, and a partially exploded view of the electric motor according to the sub-drawing of fig. 4a in the sub-drawing of fig. 4b,

fig. 5 cross section of a motor module, which is a motor in the form of an inner rotor,

fig. 6a cross section of a motor module of a motor according to the invention or of a motor according to the invention, said motor module being an external rotor motor,

fig. 7 shows in sub-fig. 7a the rotor of the motor module according to fig. 6 in an isometric view, and in sub-fig. 7b the rotor shaft and the web of the rotor according to sub-fig. 7a,

fig. 8 shows a cross section of an electric motor according to the invention with two motor modules, which are designed as an external rotor motor,

fig. 9 shows in an isometric view in sub-fig. 9a cooling nozzle of an electric motor according to the invention, and fig. 9b shows a cross-section of a stator cover 50 of the cooling nozzle according to sub-fig. 9a, an

Fig. 10 shows another embodiment of the motor module 38.

Detailed Description

Fig. 1a shows an electric vehicle 10 according to the invention in the form of an electric vehicle having a first axle 12 in the form of a front axle and a second axle 14 in the form of a rear axle. The wheels 16.1, 16.2 are fixed to the first axle 12 and the wheels 16.3, 16.4 are fixed to the second axle 14. The electric motor 18 drives the wheels 16.1, 16.2 of the first axle 12 via a differential gear 20, which may also be referred to as a differential.

The motor 18 is powered by a battery 22. The battery 22 comprises at least two, in the present case eight battery cells 24.1, 24.2. A battery is understood here to mean any type of assembly consisting of an electrical current (galvanosh) element for storing electrical energy or for converting it into electrical energy for supplying the electric motor 18.

It can be seen that the motor axis of rotation D₁₈Extending between one side of the battery cells 24.1, 24.3, 24.5, 24.7 and the other side of the battery cells 24.2, 24.4, 24.6, 24.8. Arranged at the motor rotation axis D₁₈The mass m of the battery cells 24.1, 24.3, 24.5 and 24.7 on the right_rCorresponding to the motor rotation axis D₁₈The mass m of the left-hand cell elements (i.e. in the present case the cell elements 24.2, 24.4, 24.6 and 24.8)₁。

Two masses m_r、m₁Features which correspond to one another are understood in particular to mean that the two masses deviate from one another by at most 20%, preferably by at most 15%.

The electric vehicle 10 has a vehicle floor 26. In the present embodiment, the battery 22 and the motor 18 are both mounted on the vehicle floor 26. Furthermore, the electric vehicle 10 comprises components not shown, such as a housing, in particular made of sheet metal, as well as a seat and a steering device.

Fig. 1b shows the electric vehicle 10 in a rear view. It can be seen that the motor has a structural height h_MCorresponding to the height h of the battery_B. Height h of motor structure_MAn imaginary rectangular parallelepiped Q which is the smallest volume of 90% of the mass of the cell 22₁Of (c) is measured. Fig. 1b also shows a body 28 of the electric vehicle 10. Furthermore, a driver's seat 30 and a co-driver's seat 32 are depicted, each arranged on a flat floor 34 of a passenger compartment 36.

In the embodiment shown in fig. 1a, the electric motor 18 is formed by three motor modules 38.1, 38.2, 38.3 coupled one behind the other. All three motor modules 38.1, 38.2, 38.3 are identical in construction and have rotor shafts 40.1, 40.2, 40.3 coupled to one another. The motor modules 38.i (i ═ 1.. N; N: number of motor modules) are identical in construction.

Fig. 1c shows a perspective view without the body, to scale, of an electric vehicle 10 according to the invention, which has a first switching clutch 77.1 and a second switching clutch 77.2. The first shifting clutch is located in the torque path between the electric motor 18 and the wheels 16.1, 16.2 of the first axle 12. The second switching clutch 72 is located in the torque path between the electric motor 18 and the wheels 16.3 and 16.4 of the second axle 14. The shifting clutches 77.1, 77.2 are preferably electrically switchable. In this manner, the electric vehicle 10 can have either pure front wheel drive or pure rear wheel drive or all-wheel drive.

Fig. 1d shows a scaled-down perspective view of an electric vehicle according to the invention having two electric motors 18.1, 18.2, according to a further embodiment. Both motors 18.1, 18.2 consist of at least two modules, the respective axes of rotation of which extend parallel to each other.

However, this relates to parallelism in the technical sense, i.e. the two axles extend parallel to each other in the mathematical sense, although this may, but need not, be. The axes of rotation may in particular enclose an angle of less than 3 ° with one another, for example.

Fig. 2a shows a motor module 38 in the form of an inner rotor, which has a first rotor 42 (see fig. 2b) and a module housing 44. A first coupling structure 46a is formed on the rotor shaft 40 of the rotor 42. The module housing 44 includes a housing ring 48, which may also be referred to as a coupling ring. In the present case, the housing ring 48 is formed on the stator cover 50 a. Furthermore, the module housing 44 comprises a second stator cover 50b and a stator carrier 52, which is connected to the two stator covers 50a, 50b and is arranged between them in the illustrated embodiment in the form of an inner rotor.

It can be seen that the shaft coupling structure 46 projects partially axially beyond the module housing 44 and is partially retracted behind the module housing 44.

Fig. 2b shows a rotor 42 having a shaft coupling structure 46a.1 and a second shaft coupling structure 46b.1 arranged opposite the first coupling structure 46a. The rotor 42 has a magnet carrier 54, by means of which permanent magnets 56.1, 56.2 are arranged. Permanent magnets 56.j (j ═ 1, 2.·) are arranged such that north and south poles, respectively, are alternately directed outward.

Fig. 2b also shows that the first coupling structure 46a has a projection 58.1 extending in the axial direction. In the assembled state, the projection 58.1 bears along the two contact surfaces K1, K2 against complementary coupling structures of adjacent motor modules. The contact surfaces K1, K2 form an angle between 0 ° and 1 ° with an angle measuring plane E in the present case. The angle measurement plane E is a plane that contains the rotational axis D of the rotor 42 and that is in contact with or intersects the respective contact surface K at least one location.

Furthermore, the rotor 42 has a first bearing surface 60.1 and a second bearing surface 60.2.

Fig. 3a shows a cross section of an embodiment of the electric motor 18 according to the invention, which is formed by motor modules 38.1, 38.2, which are each identical in construction.

The first motor module 38.1 has a first rotary bearing 62a.1 and a second rotary bearing 62b.1 in the form of ball bearings. The second motor module 38.2 has a rotary bearing 62a.2 and a second rotary bearing 62 b.2. The first rotary bearing 62a.1 has a first set of rolling elements 64.1, 64.2, which are arranged in a ring. The second rotary bearing 62b.2 also has rolling bodies 66.1, 66.2 arranged along a second ring offset from the first ring. The two rotary bearings 62a.1 and 62b.2 form a rotary bearing 68. It can be seen that the coupling structure 46a of the first motor module 38.1 forms a form-fit with the coupling structure 46b.2 of the second motor module 38.2, and the coupling structures 46a.1, 46b.2 are surrounded by the rotary bearing 68.

Fig. 3a shows that the coupling structure 46a.1 of the first motor module 38.1 extends below the rotary bearing 62b.2 of the second motor module 38.2. This forms a generally preferred embodiment, regardless of other features of the embodiments described herein. Furthermore, the coupling structure 46b.2 extends below the rotary bearing 62 a.1.

When in this description reference is made to an axial length, this then relates to a position along a schematically depicted x-axis, which extends in the direction of the rotation axis D. Therefore, the coupling structures 46a.1 and 46b.2 are arranged in particular at the same axial level as the rotary bearing 38.

Fig. 3b shows a detail of fig. 3 a. It can be seen that the module housing 44.1 has a first housing coupling structure 70a.1 forming a first conical housing ring. The second module housing 44.2 has a second housing coupling structure 70b.2 which likewise forms a second conical housing ring. The two housing coupling structures 70a.1, 70b.2 are connected in a form-fitting manner by means of a connector in the form of a coupling clip 72. The coupling clip 72 has a conical inner surface 74 which has a corresponding surface contact with the housing coupling structures 70a.1, 70b.2 and thus brings about a form-locking.

Fig. 3b also shows that the axial structural length L1 is less than twice the axial structural length L2 of the coupling section, in this case less than 1.5 times. The axial structural length L2 corresponds to the axial length of the shaft coupling. The axial structural length L3 of the coupling clip 72 is smaller than the axial structural length L2 by a certain amount.

The coupling clip 72 is configured such that it can be released and slipped on from the outside. The two electric motor modules 38.1, 38.2 can thus be connected in the following manner: the rotor shafts are first connected to one another by means of their respective shaft coupling structures. The housings are then connected to one another by means of a connector, here a connector clip 72. In order to release the connection between the two motor modules 38.1, 38.2, the coupling clip 72 must only be removed, and the rotor shafts can then be pulled axially away from one another.

Fig. 4a shows an electric motor according to the invention, which comprises three motor modules 38.1, 38.2 and 38.3 as well as a rotary encoder 76, a clutch 77 and a brake 78. The rotary encoder 76 and the brake 78 each have a shaft extending coaxially with the rotor shaft of the motor module 38. i.

Fig. 4b shows a partially exploded view of the electric motor 18 according to fig. 4 a. It can be seen that the rotary encoder 76 has a rotary encoder coupling structure 80a, 80b which corresponds to the coupling structure 46 of the motor module 38.

The brake 78 has at least one brake coupling 82a, which is also designed like another coupling, so that the brake 78 can thus be connected in a form-fitting manner both to the rotary encoder 76 and to each motor module 38. The clutch 77 has the same coupling structure as the brake 78 so that it can be coupled with each motor module like the brake 78.

Fig. 5 shows a cross section of a motor module 38.1, which at the same time can be regarded as a separate electric motor. It can be seen that a cooling channel 84 is disposed in the rotor shaft 40. The cooling fluid 86 in the form of a cooling liquid is conveyed in the present form axially through a cooling fluid input 88. The seal sleeve 90 rotates with the rotor shaft and is connected to the rotor shaft 40 by a seal.

At least one, preferably two, partition walls 92a, 92b are arranged in the rotor shaft 40, which partition walls cause the cooling fluid 86 to flow through a first bypass channel 94a, a second bypass channel 94b or further bypass channels not shown. The bypass channels 94a, 94b extend not only in the axial direction but also in the radial direction and thus extend largely parallel to the cooling channel 84. The cooling fluid in the bypass channel 94 cools the magnet carrier 54 and thus the permanent magnets 56.

Radially outside the permanent magnets 56, stator sheet packs 96 are arranged. Stator plate stack 96 is cooled by cooling fluid in stator cooling channels 98. The stator cooling channels 98 cannot extend over the entire width of the stator plate package, in particular the winding heads 100a, 100b do not have to be located over the axial length over which the stator cooling channels 98 also extend.

Fig. 6 shows a further embodiment of an electric motor module 38 according to the invention, which at the same time forms a separate embodiment of an electric motor according to the invention. Since the electric motor according to fig. 5 is an inner rotor, the electric motor 38 according to fig. 6 is an outer rotor in which the permanent magnets 56 are arranged radially outside the stator plate packs 96. The stator plate groups 96a, 96b are inserted into the space between the rotor shaft 40 and a tubular member 102 having a first sleeve section 104 and a second sleeve section 106. Tubular member 102 is secured to a web 108, which may also be referred to as a rotor hub. The tubular member 102 and the web 108 form a T-shaped rotor element.

The rotor shaft 40 has an inlet branch channel 110, by means of which the cooling fluid 86 can be guided into the cooling channel 84. The separating walls 92a, 92b, 92c result in the cooling fluid from the branch channel 110 first passing through a part of the cooling duct 84 and then flowing into the first web channel 112, from where it can flow into a channel, not shown, in the tubular component 102. There, the cooling fluid heats up and flows back into the channels 84 through the second web channels 114 in the web 108. Via the discharge branch channel 115, the cooling fluid flows from the rotor 42 into the collar-shaped channel 129 between the stator housing 121 and the rotor shaft 40 and from there into the cooling fluid discharge 118.

The cooling fluid 86 reaches the input branch channel 110 via the cooling fluid input 120. The cooling fluid feed 120 is also formed in the stator housing 121, in the present case in the stator cover 50 b.1. The cooling fluid input 120 includes a first shaft seal 122 and a second shaft seal 124. In the present embodiment, the second shaft seal 124 also serves to seal the slew bearing 62 b.1. Of course, the second shaft seal may be arranged at other positions.

Fig. 7a shows an isometric view of the rotor 42 of the module 38.1. It can be seen that the tubular member 102 is fixed to the web 108 by means of screws 126.1, 126.2 (see fig. 7 b).

Fig. 7b shows the web channels 112, 114, between which web annular channels 128 are arranged. The cooling fluid flows from the web annular channel 128 into the open component 102 and back therefrom so that it reaches the second web channel 114.

Fig. 8 shows a cross section of an electric motor 18 according to the invention, which is formed by two motor modules 38.1, 38.2 in the form of outer rotors.

Fig. 9a shows a part of a stator housing 121, which is composed of a stator cover 50 and a stator carrier 52, having an inlet 132 for a cooling fluid and an outlet 133 for the cooling fluid and having a cooling socket 130. The cooling connections of the electric motor 18 are also depicted in fig. 9 and are marked here (also as are other multiply present components) with the numerical suffixes "a" and "b" and ". 1" and ". 2". This count should be used to name multiple existing objects as homogeneous as simple as possible. The stator electromagnets 134 of the electric motor (outer rotor) are cooled by means of the cooling socket 130 (see fig. 7 and 9).

Fig. 9b shows a cross section of the stator cover 50 and the rotor shaft 40 for illustrating the collar-shaped channel 129.

Fig. 10 shows a further embodiment of the motor module 38, in which the shaft coupling structure 46 is designed with multiple teeth.

List of reference numerals

10 electric vehicle

12 first axle

14 second axle

16 wheels

18 electric motor

20 differential mechanism

22 cell

24 cell unit

26 vehicle floor

28 vehicle body

30 driver's seat

32 co-pilot seat

34 bottom plate

36 passenger compartment

38 electric motor module

40 rotor shaft

42 rotor

44 module housing

46-axis coupling structure

48 casing ring

50 stator cover

52 stator carrier

54 magnet carrier

56 permanent magnet

58 projection

60 bearing seat surface

62 swivel bearing

64 rolling element

66 rolling elements

68 swivel support

70 casing coupling structure

72 coupling clamp

74 inner surface

76 rotary encoder

77 switching clutch

78 brake

79 coupling transmission device

80 rotary encoder coupling structure

81 clutch coupling structure

82 brake coupling structure

84 cooling channel

86 cooling fluid

88 cooling fluid input

90 sealing sleeve

92 partition wall

94 side channel

96 stator sheet group

98 stator cooling channels

100 winding head

102 tubular member

104 first sleeve section

106 second sleeve section

108 web

110 input branch channel

112 web channel

114 second web channel

115 discharge branch channel

116 stator

118 cooling fluid discharge

120 cooling fluid input

121 stator housing (composed of stator cover 50 and stator carrier 52)

122 first shaft seal

124 second shaft seal

126 screw

128 web annular channel

129 shaft annular channel

130 cooling connection pipe

132 inflow part

133 outflow part

134 stator electromagnet

Distance between A and B

D axis of rotation

D₁₈Motor rotation axis

E angle measuring plane

i. j corner mark

K_iContact surface

Axial construction length of L1 rotary bearing

Axial structural length of L2 shaft coupling structure

Axial structural length of L3 housing coupling structure

m₁Left side battery quality

m_rRight side battery mass

Central percentile of Q

Cuboid Q1 and Q2

S₁₀Vehicle mass center of gravity

S₁₈The motor is heavyHeart with heart-shaped

S₂₂Center of mass of battery