Motor/generator

• US 20060283642A1
• Filed: 06/01/2005
• Published: 12/21/2006
• Est. Priority Date: 06/01/2005
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Hickam, Christopher Dale
• Granted Patent: US 7,370,716 B2
• Time in Patent Office: Days
• US Class Current: 180/65.100
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/36 characterised by the transmission gearings
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 2220/50 Structural details of electrical machines
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: F02N 15/00 Other power-operated starting apparatus; Component parts, details, or accessories, not provided for in, or of interest apart from groups F02N5/00 - F02N13/00
• CPC Class Codes: F02N 15/006 Assembling or mounting of starting devices
• CPC Class Codes: F16D 1/02 for connecting two abutting shafts or the like
• CPC Class Codes: H02K 7/006 Structural association of a motor or generator with the drive train of a motor vehicle
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

Abstract

A motor/generator is provided for connecting between a transmission input shaft and an output shaft of a prime mover. The motor/generator may include a motor/generator housing, a stator mounted to the motor/generator housing, a rotor mounted at least partially within the motor/generator housing and rotatable about a rotor rotation axis, and a transmission-shaft coupler drivingly coupled to the rotor. The transmission-shaft coupler may include a clamp, which may include a base attached to the rotor and a plurality of adjustable jaws.

Claims

1. A motor/generator for connecting between a transmission input shaft and an output shaft of a prime mover, the motor/generator comprising:

a motor/generator housing;

a stator mounted to the motor/generator housing;

a rotor mounted at least partially within the motor/generator housing and rotatable about a rotor rotation axis;

a transmission-shaft coupler drivingly coupled to the rotor, wherein the transmission-shaft coupler includes a transmission-shaft recess, and wherein a surface of the transmission-shaft recess is configured to engage the input shaft of the transmission in such a manner to drivingly couple the transmission-shaft coupler and the transmission input shaft.

2. The motor/generator of claim 1, further including:

a motor/generator input shaft drivingly coupled to the rotor; and

wherein a circumference of the surface of the transmission-shaft recess and a circumference of the motor/generator input shaft have mating shapes and sizes.

3. The motor/generator of claim 1, wherein the surface of the transmission-shaft recess includes a plurality of splines distributed around an axis along which the transmission-shaft recess extends.

4. The motor/generator of claim 1, wherein the transmission-shaft coupler is fixedly engaged to the rotor and the transmission-shaft recess extends along the rotor rotation axis.

5. The motor/generator of claim 1, further including:

a motor/generator input shaft drivingly coupled to the rotor, wherein the motor/generator input shaft is configured to engage an interior surface of a variable-slip drive-train coupler.

6. The motor/generator of claim 1, further including:

a motor/generator input shaft drivingly coupled to the rotor, wherein the motor/generator input shaft includes a plurality of splines that extend axially along and that are distributed around the motor/generator input shaft.

7. The motor/generator of claim 6, wherein the motor/generator input shaft is fixedly engaged to the rotor and extends along the rotor rotation axis.

8. The motor/generator of claim 1, wherein the transmission-shaft coupler further includes a clamp with a base that is fixedly engaged to the rotor and a plurality of adjustable jaws that are disposed at different angular positions about the rotor rotation axis.

9. The motor/generator of claim 1, wherein the motor/generator housing further includes prime-mover-mounting features that are in accordance with at least one of SAE standards and ISO standards for mounting transmissions to prime movers.

10. The motor/generator of claim 9, wherein the motor/generator housing further includes transmission-mounting features that are in accordance with at least one of SAE standards and ISO standards for mounting transmissions to prime movers.

11. The motor/generator of claim 1, wherein the motor/generator housing further includes prime-mover-mounting features that are in accordance with at least one of SAE®

standard J617, SAE®

standard J1172, and ISO standard ISO 7649.

12. The motor/generator of claim 1, wherein the rotor is configured and associated with the motor/generator housing and the transmission-shaft coupler in such a manner to facilitate drivingly coupling the rotor to the transmission input shaft with the transmission input shaft supporting a substantial portion of the weight of the rotor.

13. A method of assembling a drive train, which drive train includes a transmission with a transmission housing and a transmission input shaft, a prime mover with an output shaft, and a motor/generator with a motor/generator housing and a rotor mounted at least partially within the motor/generator housing, which rotor is rotatable about a rotor rotation axis, the method comprising:

connecting the rotor to the transmission input shaft;

connecting the rotor to the output shaft of the prime mover; and

mounting the motor/generator housing to the transmission housing by mounting an adapter component to the motor/generator housing and mounting the adapter component to the transmission housing.

14. The method of claim 13, wherein mounting the motor/generator housing to the transmission housing includes:

mounting the adapter component to a mounting surface of the motor/generator housing such that the adapter component extends across at least a portion of an opening in the motor/generator housing; and

inserting the transmission input shaft through a portion of the opening in the motor/generator housing that the adapter component leaves exposed.

15. The method of claim 14, wherein inserting the transmission input shaft through a portion of the opening in the motor/generator housing that the adapter component leaves exposed includes inserting the transmission input shaft through a transmission-shaft opening of the adapter component.

16. The method of claim 15, wherein the adapter component is a plate.

17. The method of claim 13, wherein:

the motor/generator includes a transmission-shaft coupler that is drivingly coupled to the rotor;

the transmission-shaft coupler includes a clamp with a plurality of adjustable jaws; and

connecting the rotor to the transmission input shaft includes clamping the transmission-shaft coupler to the transmission input shaft by;

positioning the transmission input shaft between the jaws of the clamp; and

adjusting the jaws of the clamp toward the transmission input shaft until the transmission input shaft is clamped between the jaws of the clamp.

18. The method of claim 17, wherein the transmission-shaft coupler and a base of the clamp are fixedly attached to the rotor prior to clamping the transmission-shaft coupler to the transmission input shaft.

19. The method of claim 17, wherein:

a base of the clamp is fixedly attached to the rotor with the jaws of the clamp disposed at different angular positions about the rotor rotation axis; and

the method further includes;

adjusting the jaws of the clamp in such a manner to reduce the run-out of the rotor with respect to the rotor rotation axis.

20. The method of claim 13, wherein:

the motor/generator includes a motor/generator input shaft that is drivingly coupled to the rotor; and

connecting the rotor to the output shaft of the prime mover includes engaging the motor/generator input shaft to an interior surface of a variable-slip drive-train coupler, such that the motor/generator input shaft is drivingly coupled to the variable-slip drive-train coupler.

21. The method of claim 13, further including:

attaching the motor/generator housing to a prime-mover housing of the prime mover.

22. A drive train, comprising:

a prime mover;

a variable-slip drive-train coupler engaged to an output shaft of the prime mover;

a transmission with an input shaft;

a motor/generator, including;

a motor/generator housing;

a stator mounted to the motor/generator housing;

a rotor mounted to the motor/generator housing and rotatable about a rotor rotation axis;

a motor/generator input shaft that is drivingly coupled to the rotor and that is engaged to an interior surface of the variable-slip drive-train coupler in such a manner to drivingly couple the motor/generator input shaft and the variable-slip drive-train coupler; and

wherein the rotor is drivingly coupled to the transmission input shaft.

23. The drive train of claim 22, wherein:

the motor/generator further includes a transmission-shaft coupler that is drivingly coupled to the rotor; and

the transmission-shaft coupler includes a transmission-shaft recess with a surface that engages the transmission input shaft, such that the transmission-shaft coupler is drivingly coupled to the transmission input shaft.

24. The drive train of claim 23, wherein the surface of the transmission-shaft recess and the interior surface of the variable-slip drive-train coupler are configured such that each could drivingly engage the transmission input shaft.

25. The drive train of claim 24, wherein the transmission-shaft recess extends along a transmission-shaft axis that is substantially aligned with the rotor rotation axis.

26. The drive train of claim 23, wherein the transmission-shaft coupler is fixedly attached to the rotor and the transmission-shaft recess extends along a transmission-shaft axis that is substantially aligned with the rotor rotation axis.

27. The drive train of claim 23, wherein a circumference of the surface of the transmission-shaft recess that engages the transmission input shaft has substantially the same shape and size as a circumference of the interior surface of the variable-slip drive-train coupler that engages the motor/generator input shaft.

28. The drive train of claim 22, wherein the motor/generator input shaft and the transmission input shaft are configured such that each could drivingly engage the interior surface of the variable-slip drive-train coupler.

29. The drive train of claim 28, wherein the motor/generator input shaft is fixedly engaged to the rotor and extends along the rotor rotation axis.

30. The drive train of claim 22, wherein a circumference of the transmission input shaft has substantially the same shape and size as a circumference of the motor/generator input shaft that engages the interior surface of the variable-slip drive-train coupler.

31. The drive train of claim 22, wherein:

the motor/generator housing includes prime-mover-mounting features, through which the motor/generator housing is attached to a prime-mover housing of the prime mover; and

the motor/generator housing includes transmission-mounting features through which the motor/generator is mounted to a transmission housing of the transmission.

32. The drive train of claim 22, wherein:

the motor/generator housing includes prime-mover-mounting features, through which the motor/generator housing is mounted to a prime-mover housing of the prime mover; and

the prime-mover-mounting features are in accordance with at least one of SAE®

standards and ISO standards for mounting transmissions to prime movers.

33. The drive train of claim 32, wherein the prime-mover-mounting features are in accordance with at least one of SAE®

standard J617, SAE®

standard J1172, and ISO standard ISO 7649.

34. The drive train of claim 22, wherein:

the motor/generator housing further includes transmission-mounting features, through which the motor/generator housing is mounted to a transmission housing of the transmission; and

the transmission-mounting features are in accordance with at least one of SAE®

standards and ISO standards for mounting transmissions to prime movers.

35. The drive train of claim 22, further including:

an adapter component connected between the motor/generator housing and a transmission housing of the transmission.

36. The drive train of claim 22, wherein the interior surface of the variable-slip drive-train coupler that the motor/generator input shaft is engaged to is an interior surface of an output hub of the variable-slip drive-train coupler.

37. The drive train of claim 22, wherein:

the motor/generator further includes a transmission-shaft coupler that is drivingly coupled to the rotor;

the transmission-shaft coupler includes a clamp with a plurality of jaws; and

the transmission input shaft is clamped between the jaws of the clamp.

38. The drive train of claim 22, wherein the transmission-shaft coupler is fixedly engaged to the rotor and the transmission input shaft supports a substantial portion of the weight of the rotor.