High torque and power density drive system with shortened overall width

Patent metadata

Field	Value
Publication number	US-10797562-B2
Application number	US-201816181612-A
Country	US
Kind code	B2
Filing date	Nov 6, 2018
Priority date	Oct 23, 2018
Publication date	Oct 6, 2020
Grant date	Oct 6, 2020

Abstract

A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.

First claim

What is claimed is:

1. A powertrain assembly, comprising:
an electric motor, said electric motor comprising:
a hollow rotor shaft; and
a rotor lamination stack containing a plurality of permanent magnets, wherein said rotor lamination stack encircles said hollow rotor shaft, and wherein said rotor lamination stack is attached directly to said hollow rotor shaft;

a differential gear assembly mounted within said hollow rotor shaft, wherein a first output shaft coupled to said differential gear assembly exits said hollow rotor shaft from a first end of said hollow rotor shaft, wherein a second output shaft coupled to said differential gear assembly exits said hollow rotor shaft from a second end of said hollow rotor shaft, and wherein said second end of said hollow rotor shaft is distal from said first end of said hollow rotor shaft;
a first planetary gear assembly coupled to said first output shaft, wherein said first planetary gear assembly is coaxially aligned with said hollow rotor shaft, said first planetary gear assembly comprising a first planetary gear carrier;
a first constant velocity (CV) joint component, said first CV joint component further comprising a first CV joint housing member, wherein said first planetary gear carrier is integral to said first CV joint component;
a second planetary gear assembly coupled to said second output shaft, wherein said second planetary gear assembly is coaxially aligned with said hollow rotor shaft, said second planetary gear assembly comprising a second planetary gear carrier; and
a second CV joint component, said second CV joint component further comprising a second CV joint housing member, wherein said second planetary gear carrier is integral to said second CV joint component.

2. The powertrain assembly of claim 1 , further comprising:
a first CV joint carrier bearing assembly, wherein said first CV joint housing member is located within the plane defined by said first CV joint carrier bearing assembly; and
a second CV joint carrier bearing assembly, wherein said second CV joint housing member is located within the plane defined by said second CV joint carrier bearing assembly.

3. The powertrain assembly of claim 1 , said first planetary gear carrier comprising a first plurality of planetary gear carrier members extending from a rear surface of said first CV joint housing member, and said second planetary gear carrier comprising a second plurality of planetary gear carrier members extending from a rear surface of said second CV joint housing member.

4. The powertrain assembly of claim 1 , further comprising:
a first rotor carrier bearing mounted within a first portion of said hollow rotor shaft, wherein an outer bearing race of said first rotor carrier bearing is mounted to an inner rotor surface, wherein an inner bearing race of said first rotor carrier bearing is mounted to a first powertrain assembly housing member, and wherein said first powertrain assembly housing member extends into said hollow rotor shaft; and
a second rotor carrier bearing mounted within a second portion of said hollow rotor shaft, wherein an outer bearing race of said second rotor carrier bearing is mounted to said inner rotor surface, wherein an inner bearing race of said second rotor carrier bearing is mounted to a second powertrain assembly housing member, and wherein said second powertrain assembly housing member extends into said hollow rotor shaft.

5. The powertrain assembly of claim 1 , said electric motor further comprising a stator with a plurality of slots, wherein a plurality of windings occupy said plurality of slots, said plurality of windings comprised of stator wire with a rectangular cross-section.

6. The powertrain assembly of claim 1 , said rotor lamination stack further comprising:
a plurality of lamination layers; and
a plurality of rivets, said plurality of lamination layers clamped together with said plurality of rivets.

7. The powertrain assembly of claim 6 , said rotor lamination stack further comprising a first rotor assembly end plate and a second rotor assembly end plate, said plurality of lamination layers interposed between said first and second rotor assembly end plates, and wherein said plurality of rivets clamp together said first rotor assembly end plate, said plurality of lamination layers, and said second rotor assembly end plate.

8. A powertrain assembly, comprising:
an electric motor, said electric motor comprising:
a hollow rotor shaft;
a rotor lamination stack containing a plurality of permanent magnets, wherein said rotor lamination stack encircles said hollow rotor shaft, and wherein said rotor lamination stack is attached directly to said hollow rotor shaft; and
a stator with a plurality of slots, wherein a plurality of windings occupy said plurality of slots;

a differential gear assembly mounted within said hollow rotor shaft, wherein a first output shaft coupled to said differential gear assembly exits said hollow rotor shaft from a first end of said hollow rotor shaft, wherein a second output shaft coupled to said differential gear assembly exits said hollow rotor shaft from a second end of said hollow rotor shaft, and wherein said second end of said hollow rotor shaft is distal from said first end of said hollow rotor shaft;
a first planetary gear assembly coupled to said first output shaft, wherein said first planetary gear assembly is coaxially aligned with said hollow rotor shaft;
a first CV joint component, said first CV joint component further comprising a first CV joint housing member and a first plurality of planetary gear carrier members extending from a rear surface of said first CV joint housing member, wherein said first plurality of planetary gear carrier members correspond to said first planetary gear assembly;
a first CV joint carrier bearing assembly, wherein a portion of said first CV joint component is located within the plane defined by said first CV joint carrier bearing assembly;
a second planetary gear assembly coupled to said second output shaft, wherein said second planetary gear assembly is coaxially aligned with said hollow rotor shaft;
a second CV joint component, said second CV joint component further comprising a second CV joint housing member and a second plurality of planetary gear carrier members extending from a rear surface of said second CV joint housing member, wherein said second plurality of planetary gear carrier members correspond to said second planetary gear assembly; and
a second CV joint carrier bearing assembly, wherein a portion of said second CV joint component is located within the plane defined by said second CV joint carrier bearing assembly.

9. The powertrain assembly of claim 8 , further comprising:
a first rotor carrier bearing mounted within a first portion of said hollow rotor shaft, wherein an outer bearing race of said first rotor carrier bearing is coupled to an inner rotor surface, wherein an inner bearing race of said first rotor carrier bearing is coupled to a first powertrain assembly housing member, and wherein said first powertrain assembly housing member extends into said hollow rotor shaft; and
a second rotor carrier bearing mounted within a second portion of said hollow rotor shaft, wherein an outer bearing race of said second rotor carrier bearing is coupled to said inner rotor surface, wherein an inner bearing race of said second rotor carrier bearing is coupled to a second powertrain assembly housing member, and wherein said second powertrain assembly housing member extends into said hollow rotor shaft.

10. The powertrain assembly of claim 8 , said plurality of windings comprised of stator wire with a rectangular cross-section.

11. The

Assignees

• Atieva Inc

Inventors

• Dlala Emad
• Hung Shun-Cheng
• Mayer Jeremy
• Palfai Balazs
• Tebbe Michael

Classifications

• B60K17/24

  Arrangement of mountings for shafting · CPC title

• H02K7/116 Primary

  with gears · CPC title

• B60Y2200/91

  Electric vehicles · CPC title

• B60K17/06 Primary

  of change-speed gearing (B60K17/10 - B60K17/16 take precedence) · CPC title

• B60K17/16

  of differential gearing · CPC title