DE102021112693A1 - Drive module with disc motor for an electrically operated vehicle and drive arrangement with the drive module - Google Patents

Abstract

A drive module 7 for an electrically operated vehicle 1 is provided, with a drive device 12 for generating an electric drive torque, with a wheel connection section 18 for drive-related connection of the drive module 7 to a wheel hub 51 of a drive wheel 4 of the vehicle 1, with a transmission device 13 for translating the drive torque to the wheel connection section 18, with the transmission device 13 having an input element connected to the drive device 12 and an output element connected to the wheel connection section 18, with a housing 14, the drive device 12 and the transmission device 13 being accommodated together in the housing 14, where the drive device 12 is designed as a pancake motor.

Description

The invention relates to a drive module for an electrically operated vehicle with the features of the preamble of claim 1. The invention also relates to a drive arrangement with the drive module.

There are electric drive modules for single or multi-track bicycles, such as cargo bikes, also known as biohybrids or biohybrid vehicles, in which the wheel is driven exclusively by human power or supported by an electric motor. Such bicycles are often designed either as serial biohybrid vehicles or as parallel biohybrid vehicles. In a serial biohybrid vehicle, the wheel is driven exclusively by an electric motor, for example a wheel hub motor. The energy required to operate the electric motor is provided both by a battery and by a pedal drive connected to an electric generator. In a parallel biohybrid vehicle, on the other hand, the electric motor and the pedal drive are both mechanically coupled to the drive wheel.

The pamphlet DE 102019108378 A1 discloses an electric bicycle drive with an electric drive unit which is connected to a drive end of a shaft, the driven end of the shaft having a receptacle for a hub. The mount for the hub is designed in such a way that a hub of a bicycle wheel to be mounted can be fixed to the mount for the hub by means of an assembly direction that is axial or helical in relation to the shaft, so that the hub of the bicycle wheel to be mounted can be the electric drive unit, the shaft and/or the brake unit can be assembled and/or disassembled on the receptacle.

The invention is based on the object of proposing a drive module for an electrically operated vehicle which is characterized by a compact design.

This object is achieved by a drive module having the features of claim 1 and a drive assembly having the features of claim 10. Preferred or advantageous embodiments of the invention result from the dependent claims, the following description and/or the attached figures.

The subject matter of the invention is a drive module which is designed and/or suitable for an electrically operated vehicle. In particular, the vehicle is designed as an electric bicycle, also known as an e-bike or pedelec. In principle, the bicycle can have exactly two wheels. Alternatively, however, the vehicle can also have more than two, in particular three or exactly four wheels. With more than two wheels, the vehicle is preferably designed as a cargo bike. The drive module is preferably arranged outside of the drive wheel, close to the wheel. Basically, the drive wheel is designed as a rear wheel of the vehicle. Alternatively, however, the drive wheel can also be designed as a front wheel of the vehicle.

The drive module has a drive device which is designed and/or suitable for generating an electrical drive torque. In particular, the drive device is designed as an electric motor, which converts electrical energy into an electrical drive torque. The drive device preferably has a rotor and a stator. The rotor defines a primary axis of rotation about which the rotor rotates in motor operation. Preferably, the drive module, in particular the drive device, can be and/or is connected in terms of drive technology to at least or precisely one drive wheel of the vehicle in order to transmit the drive torque to the drive wheel.

For this purpose, the drive module has a wheel connection section, which is designed and/or suitable for the drive connection of the drive module to a wheel hub of the drive wheel of the vehicle. In particular, the wheel connection section is and/or can be connected to the wheel hub in a torque-proof manner. The wheel connection section can be positively and/or non-positively connected to the wheel hub at least in the direction of rotation around the main axis of rotation. In particular, the wheel connection section is designed in the manner of a claw, with the wheel hub being designed in a complementary manner thereto.

The drive module has a transmission device which is designed and/or suitable for converting the drive torque to the wheel connection section. The drive device is geared to the wheel connection section or the drive wheel via the gear device. The transmission device has a transmission input, in particular an input element, and a transmission output, in particular an output element, with the drive motor being arranged on the input side and the wheel connection section on the output side. When driving, the drive torque is thus transmitted to the wheel connection section via the transmission device, so that the connection section is rotated. In particular, the input member with the rotor of the drive device and the output member with connected to the wheel connection section in a torque-proof manner. A power transmission path for transmission of the drive torque preferably runs from the drive device via the transmission device to the wheel connection section. In particular, the transmission device is used for stepping down (amount (i)>1), the speed at the transmission output being reduced and the torque transmitted to the wheel connection section being increased.

The drive module has a housing, with the drive device and the transmission device being accommodated together in the housing. In particular, the drive device and the transmission device are completely accommodated in the housing. The wheel connection section is preferably guided in sections in the housing, with the wheel connection section being supported radially on the housing via at least one bearing device, preferably a roller bearing. The housing can be constructed in several parts, preferably in two parts. In particular, the housing has an accommodation space for accommodating the transmission device and the drive device, the transmission device and the drive device being accommodated in the housing in a form-fitting manner in the axial and/or radial direction in relation to the main axis of rotation. The stator is preferably firmly connected to the housing.

In the context of the invention, it is proposed that the drive device be designed as a pancake motor. In particular, the pancake motor is designed as an axial flux motor in which the magnetic field runs in the same direction as the axis of rotation or the magnetic flux in the air gap between the rotor and stator runs in the axial direction with respect to the main axis of rotation. The pancake motor is to be understood in particular as a permanently excited DC motor, in which the rotor is preferably designed in the form of a disk. In principle, the pancake motor can be designed as a one-sided arrangement (rotor - stator) or as a double-rotor arrangement (rotor - stator - rotor). However, the pancake motor is preferably designed as a double-stator arrangement (stator-rotor-stator). The disc rotor motor preferably has a diameter which is many times greater than its overall axial length. The drive module particularly preferably has a drive shaft which is non-rotatably connected to the rotor. The drive shaft can be positively and/or non-positively and/or cohesively connected to the rotor, preferably at least non-rotatably. Alternatively, the drive shaft and the rotor can also be formed from a common material section.

A drive device is thus proposed which is characterized by a small axial installation space. A drive module can thus be implemented which is characterized by a small axial design and low weight and can therefore be implemented in a particularly compact manner. Another advantage of using a disc motor is that the disc motor can accelerate and decelerate quickly. Furthermore, due to the relatively large diameter, the ratio of torque and speed is very high, so that the disk motor is characterized by a powerful drive. A drive module is thus proposed which is particularly suitable for pedelec drives in which the drive must be particularly powerful for a short time. Furthermore, disc motors can be cooled much better due to the large diameter and the waste heat, which mainly occurs in the stator, can be dissipated much better to the housing via conduction.

In a specific embodiment, it is provided that the pancake motor has a first and a second stator disk and a rotor disk arranged axially between the two stator disks. The rotor disk is preferably rotationally symmetrical, preferably in the form of a circular ring. The stator disks are spaced apart in the axial direction, with the rotor disk being arranged axially between the two stator disks. The rotor disk and the stator disks are preferably oriented parallel to one another and spaced apart from one another by an air gap. The stator disks are preferably each formed by a printed circuit board, also known as a printed circuit board (PCB), on which active areas are printed. In particular, the active areas are formed by stator windings, which are printed as electrical conductor tracks in the form of coils on the printed circuit board. In concrete terms, the commutator and stator winding are implemented as a printed circuit on the printed circuit board. In principle, the rotor disk can either be permanently excited by means of permanent magnets or have a rotor winding, so that the rotor disk can be excited electrically. Alternatively or additionally, the rotor disk can be formed by a circuit board printed with active areas. In particular, the active areas are formed by windings which are printed on the circuit board as electrical conductor tracks in the form of coils. Alternatively, however, the rotor disk can also have a large number of permanent magnets which are poled in the axial direction and which are arranged in a ring around the main axis of rotation. A pancake motor is thus proposed, which is characterized by a thin construction due to the printed windings. In addition, the printed windings are well cooled due to the large surface and can be operated with high electrical current densities.

In a possible further development it is provided that the transmission device is designed as a planetary gear. In particular, the planetary gear is designed as a single-stage planetary gear. The planetary gear has a sun gear portion as an input member and a planetary carrier as an output member. In principle, the sun wheel section can be designed as a sun wheel which is connected in a torque-proof manner to the drive shaft. However, the sun wheel section is preferably formed by a sun wheel toothing integrated on an outer circumference of the drive shaft. The planetary carrier can be connected to the connection section in a torque-proof manner. Alternatively, however, the connection section and the planet carrier can also be made from a common material section, preferably in one piece. The planetary gear also has a planetary gearset rotatably mounted on the planetary gear carrier and a ring gear section, the planetary gears of the planetary gearset meshing with the sun gear section on the one hand and with the ring gear section on the other. The ring gear section can be designed as a separate ring gear, which is preferably arranged in the housing in a rotationally fixed manner. Alternatively, however, the ring gear section can also be designed as a ring gear toothing integrated into the housing. A transmission device is therefore proposed which is characterized by a small axial overall width.

In a further specification, it is provided that the planet gears of the planetary gear are designed as stepped planets. In particular, the graduated plans serve to increase the translation. In particular, the planetary gear can thus have a transmission ratio between the gear input and the gear output with an amount of more than 1:5, preferably more than 1:10, in particular more than 1:15. The planetary gear preferably has a transmission ratio with an amount of 1:7 to 1:14. The stepped planets can be designed in one or more parts. In particular, the stepped planets each have a first and a second planetary toothing with different tip circle diameters. The planet gears can be made in one piece, in particular made from a piece of material. Alternatively, the planet gears are formed by two separate gears which are non-rotatably connected to each other. A planetary gear is thus proposed which is characterized on the one hand by a compact design, in particular a small axial overall width, and at the same time by a high transmission ratio.

In a further concrete implementation it is provided that the transmission device and the drive device are arranged coaxially to one another in relation to a main axis of rotation in the housing. For this purpose, the drive shaft is arranged coaxially and/or concentrically to the rotor with respect to the main axis of rotation and guided through the transmission device in the axial direction with respect to the main axis of rotation and/or arranged coaxially with the transmission device. The connection section, the planetary gear, the drive shaft and the pancake motor are preferably arranged coaxially and/or concentrically in relation to the main axis of rotation. Particularly preferably, the drive module is and/or can be arranged coaxially to the drive wheel, in particular the wheel hub. A drive module with a coaxial design is therefore proposed, which is characterized by a particularly compact design.

In a possible further development it is provided that the housing has a partition which divides the housing into a drive space for accommodating the drive device and a gear space for accommodating the gear device. In particular, the gear compartment can be configured as a wet compartment, in particular provided with oil or grease lubrication, and the drive compartment as a dry compartment. The partition wall is preferably supported in the radial direction on the housing on the one hand and on the drive shaft on the other hand, preferably in a fluid-tight manner. In particular, the partition can be firmly connected to the housing and rest against the drive shaft via a seal, preferably a radial shaft sealing ring. A drive module is thus proposed which is characterized by a compact design and improved efficiency.

In a possible development it is provided that the drive module has a sensor device which is designed and/or suitable for detecting a motor parameter of the drive device. In particular, the sensor device is designed as a rotor position sensor, which is designed to detect a rotor position of the rotor. For this purpose, the sensor device is mounted on the partition wall opposite the drive device, in particular radially or axially opposite the rotor, with the sensor device remaining stationary when the rotor rotates. The sensor device can detect the position of the magnetic field inductively in order to draw conclusions about the rotor position. Alternatively or optionally in addition, a target can be provided on the rotor, which can be detected by the sensor device. In particular, the partition wall has a holding section, the sensor device being mounted on the holding section in a form-fitting and/or force-fitting and/or cohesive manner, preferably captively. For example, the holding section extends from the partition into the drive compartment, preferably at a distance from the rotor, in particular its outer circumference and/or end face. A particularly compact and space-saving arrangement of the sensor device within the housing is thus proposed.

In a further implementation, it is provided that the housing has an electronics space which is designed and/or suitable for accommodating power electronics of the drive device. In particular, the electronics space is separated from the gear space and/or the drive space, preferably in a fluid-tight manner. The electronics space is particularly preferably designed as a drying space. The electronics space is arranged in the radial direction with respect to the main axis of rotation on the outside of the drive device and/or adjacent to the drive space. The electronics space is particularly preferably designed as a housing section which is open radially outwards and which can preferably be closed by a cover. By integrating the power electronics into the housing, a drive module is proposed which is designed as a compact structural unit and includes all of the components in the housing in a particularly space-saving manner.

In an optional refinement, it is provided that the housing has a frame connection section which is designed and/or suitable for fastening the drive module to a frame of the vehicle. In principle, the frame connection section can be formed by one or more fastening receptacles which are arranged on the housing and serve to receive a fastening means in order to connect the housing to the frame. Alternatively or optionally in addition, the frame connection section is formed by a receiving opening running coaxially to the main axis of rotation for receiving a wheel axle of the drive wheel, which passes through the housing coaxially to the main axis of rotation. For this purpose, in particular, the drive shaft is designed as a hollow shaft. In an intended installation situation, the wheel axle is preferably guided coaxially to the main axis of rotation through the housing, in particular the drive shaft. In particular, the drive module has a support sleeve which is inserted into a central opening of the housing to form or co-form the frame connection section. In an intended installation situation, the drive module is preferably mounted close to the wheel and fixed to the frame on the vehicle. A drive module is thus proposed which can be mounted in a simple manner near the drive wheel. In addition, due to the fact that the drive module is fixed to the frame, little or no wheel forces are transmitted to the drive module.

A further object of the invention relates to a drive arrangement with the drive module, as has already been described above. The drive arrangement has a generator module which can be driven by a vehicle user by pedaling and which is designed and/or suitable for generating electrical energy for the drive module. The generator module is in particular designed separately from the drive module. In particular, the generator module has a generator that can be driven via a pedal crankshaft, with electrical power resulting from the torques and speeds applied to the generator. Preferably, the vehicle user can vary the size of the electrical power depending on the pedaling force or pedaling frequency. The drive arrangement preferably has a control device which is designed to control the drive torque and/or a drive speed of the drive module as a function of the pedaling force and/or pedaling frequency. Particularly preferably, the generator is not designed to operate as a drive motor and/or can run exclusively in generator mode. Alternatively, the generator can be operated by an electric motor, e.g. to bring the cranks into a certain position.

In order to provide the electrical energy, the generator module is connected directly to the drive module via an electrical line. In particular, the drive device can thus be fed directly by the current generated by the generator. Alternatively or optionally in addition, the generator module is connected to the drive module indirectly via an energy storage module to provide the electrical energy. In particular, the energy storage module is designed as an accumulator which can be charged from an external power source. In particular, the electric motor can thus be fed by the current stored in the energy storage module.

Another subject matter of the invention relates to a vehicle with the generator module and/or the drive arrangement as already described above. In particular, the vehicle is an electric and/or human-powered vehicle, in particular a bicycle or cargo bike, which is driven by an electric motor. In particular, the vehicle is characterized in that the electrical energy required for the drive module is at least partially generated by the driver using the generator module. Alternatively, however, the vehicle can also be designed as an e-scooter or e-bike, with the electrical energy required for the drive module being provided exclusively by the energy storage module.

• 1 eine schematische Darstellung eines Fahrzeugs mit einer Antriebsanordnung als ein Ausführungsbeispiel der Erfindung;
• 2 eine Schnittdarstellung eines Antriebsmoduls der Antriebsanordnung;
• 3 eine Explosionsdarstellung des Antriebsmoduls gemäß 2;
• 4 eine Explosionsdarstellung einer Getriebeeinrichtung des Antriebsmoduls gemäß 2;
• 5 eine perspektivische Darstellung der Getriebeeinrichtung gemäß 4;
• 6 eine perspektivische Darstellung eines Antriebsrads mit dem Antriebsmodul für ein einspuriges Fahrzeug;
• 7 eine perspektivische Darstellung einer Antriebsachse mit dem Antriebsmodul für ein mehrspuriges Fahrzeug.

Further features, advantages and effects of the invention result from the following description of a preferred exemplary embodiment of the invention and the attached figures. show:

• 1 a schematic representation of a vehicle with a drive arrangement as an embodiment of the invention;
• 2 a sectional view of a drive module of the drive arrangement;
• 3 an exploded view of the drive module according to 2 ;
• 4 an exploded view of a transmission device of the drive module according to 2 ;
• 5 a perspective view of the transmission device according to FIG 4 ;
• 6 a perspective view of a drive wheel with the drive module for a single-track vehicle;
• 7 a perspective view of a drive axle with the drive module for a multi-track vehicle.

Corresponding or identical parts are each provided with the same reference symbols in the figures.

1 shows a muscle-powered vehicle 1 in a greatly simplified representation. The vehicle 1 is designed as a bicycle, preferably as a single-track or multi-track cargo bike, which is essentially formed from a frame 2 and a front wheel 3 and a rear wheel 4 .

The vehicle 1 has a drive arrangement 5 which is used to drive the rear wheel 4 . The rear wheel 4 thus forms a drive wheel of the vehicle 1, with the front wheel 3 remaining unpowered. Optionally, however, it can also be provided that the front wheel 3 is driven.

The drive arrangement 5 includes a generator module 6, optionally a drive module 7 and an energy storage module 8. The generator module 6 is arranged in the area of the bottom bracket and can be driven by a vehicle user by pedaling power in order to generate electrical energy for the drive module 7. For this purpose, the generator module 6 has two pedal cranks 9 arranged diametrically opposite one another, which are set in rotation by pedaling force in order to generate electrical power in the generator module 6 .

The bicycle has no mechanical drive connection between the pedal cranks 9 and the drive wheel 4 . The generator module 6 is only electrically connected to the drive module 6 and/or the energy storage module 8 via an electrical line 10 in order to provide the electrical energy required for the drive module 7 . The drive module 7 can be designed, for example, as a wheel hub motor that is integrated into the rear wheel 4 and transmits an electrical drive torque to the rear wheel 4 . The drive module 7 can be supplied directly by the electrical energy generated by the generator module 6 or indirectly by the electrical energy stored in the energy storage module 8 . The energy storage module 8 can be fed by the generator module 6 while driving and can also be charged from an external power source. Optionally, the electrical energy provided by the generator module 6 can be made available to a consumer 11, e.g. light.

the 2 shows the drive module 7 in a longitudinal section along a main axis of rotation 100. The drive module 7 has a drive device 12 and a transmission device 13, which are accommodated together in a housing 14.

The drive module 7 has a drive shaft 15 which defines the main axis of rotation 100 with its axis of rotation. The drive shaft 15 is, on the one hand, drive-wise connected to the drive device 12 and, on the other hand, gear-wise connected to a gear input of the gear device 13 .

The drive device 12 is designed as an electrical machine, preferably an electric motor, with the drive module 7 having a stator 16 and a rotor 17 . The rotor 17 is connected to the drive shaft 15 in a rotationally fixed manner. The stator 16, on the other hand, is fixed to the housing 15 and thus remains stationary. The transmission device 13 is used to transfer a drive torque introduced into the drive shaft 15 to a wheel connection section 18 , the wheel connection section 18 being used for the drive-related connection to the drive wheel 4 of the vehicle 1 . For this purpose, the drive shaft 15 is connected to a transmission input and the wheel connection section 18 is connected to a transmission output of the transmission device 13 . The transmission device 13, the drive device 12 and the wheel connection section 18 are arranged coaxially to one another in relation to the main axis of rotation 100.

The transmission device 13 is designed as a planetary gear, the transmission device 13 having a sun wheel section 19 as an input member, a plurality of planet wheels 20, one Planet carrier 21 has as an output member and a ring gear section 22. The sun wheel section 19 is designed, for example, as a sun wheel toothing integrated into the drive shaft 15 , which engages with a planetary wheel toothing of the planetary wheels 22 . The planet gears 20 are each rotatably mounted on the planet carrier 21 via a carrier bolt 23, the planet carrier 21 in turn being coupled to the wheel connection section 18 in a rotationally fixed manner, for example via a spline. The ring gear section 22 is designed as a separate ring gear which is connected to the housing 14 in a torque-proof manner.

The housing 14 has a multi-part design, with the housing 14 having a housing base body 24 which is closed off in the axial direction by a housing cover 25 . The housing base body 24 and the housing cover 25 each have a central through-opening 26, 27, which is used for the passage of a wheel axle 52, as in 6 shown, serve through the housing 15. In particular, the through openings 26, 27 form a frame connection section 28, via which the drive module 7 can be firmly connected to the frame 2.

The frame connection section 28 comprises a first and a second support sleeve 29, 30, which serves to guide the wheel axle 52 through. The drive shaft 15 and the wheel connection section 18 are hollow-cylindrical for this purpose, the first support sleeve 29 being guided coaxially through the drive shaft 15 with respect to the main axis of rotation 100 and the second support sleeve 30 being guided coaxially through the wheel connection section 18 .

The drive shaft 15 is rotatably supported via a first bearing device 31 in the first through opening 26 in the radial direction and via a second bearing device 32 in the radial direction on the wheel connection section 18 . The wheel connection section 18 is in turn rotatably supported or can be supported via a third bearing device 33 in the radial direction in the second passage opening 27 and via a fourth bearing device 34 on the wheel axle 52 . For this purpose, the fourth bearing device 34 is arranged coaxially between the first and the second support sleeve 29, 30, the two support sleeves 29, 30 being supported on the fourth bearing device 34 in the axial direction. For example, the bearing devices 31, 32, 33, 34 are designed as roller bearings, in particular as ball bearings.

Furthermore, the drive module 7 has a partition 35 which divides the housing 14 into a drive space 36 for accommodating the drive device 12 and a gear space 37 for accommodating the gear device 13 . To further reduce the friction losses in the drive module 7, in particular in the transmission device 13, the transmission space 37 can be provided with oil or grease lubrication. The drive space 36 preferably forms a dry space, with the gear space 37 being separated from the dry space by the partition 35, preferably in a fluid-tight manner.

The drive module 7 also includes power electronics 38 for the drive device 12, which are arranged in an electronics space 39 of the housing 14 in the radial direction adjacent to the drive space 36. The electronics space 39 is separated from the drive space 36 and the gear space 37 and is accessible from the outside in the radial direction via a further housing cover 40, the further housing cover 40 sealing the electronics space 39 in a fluid-tight manner in the assembled state.

The partition wall 35 has a holding section 41, a sensor device 42 for detecting an engine parameter being captively mounted on the holding section 41. For example, the sensor device 42 is designed as a rotor position sensor, the rotor position sensor being designed to detect a rotor position of the rotor 17 . For this purpose, a rotating target element can be placed on the rotor 17, with the rotor position sensor remaining stationary on the partition wall 35, for example at an axial distance from the rotor 17.

Conventional central motors are particularly unsuitable for heavy cargo bikes and lead to increased chain wear. Conventional wheel hub drives are significantly weaker in terms of torque and usually have poor thermal properties. With higher power requirements and, in particular, lower speeds, the efficiencies deteriorate and thermal losses increase. In the case of the external rotor motors that are generally used, this waste heat, which is mainly generated in the stator, does not reach the outer housing via convection and the motors have to degrade in terms of performance. This makes robust operation, e.g. on a long mountain, unfavorable or even impossible. In addition, wheel hub drives, which are designed in particular for single-track pedelecs, are relatively unsuitable for use in multi-track pedelecs and for cantilever installation (one-sided connection in contrast to two-wheelers). The higher lateral forces present here overwhelm such drives. In addition, the rotating motor housings are annoying if they are not spoked directly as a hub, but also rotate somewhat independently of the wheel.

It is therefore provided that the drive device 12 as a pancake motor, too known as a double axial flux machine. For this purpose, the drive device 12 has a rotor disk 43 as the rotor 17, which is arranged axially between two stator disks 44, 45 as the stator 16 in a narrow air gap. The pancake motor is preferably designed as a printed circuit board motor, also known as a PCB machine (PCB=Printed Circuit Board). For example, the stator disks 44 , 45 can essentially each be formed by at least one printed circuit board 46 with conductor tracks that are not shown in detail, the conductor tracks forming stator coils of the stator 17 . The circuit board 46 can be formed, for example, from non-magnetic and non-conductive material, for example by a thin plastic or ceramic disk. The stator windings and a commutator can be printed with copper, for example, on both sides of the circuit board. The magnetic fields of the current-carrying conductor tracks on the stator disc are superimposed with the rotor field of the rotor 17 and generate a force effect that causes the drive torque. In principle, the rotor disk 43 can be formed by a plurality of permanent magnets arranged in the circumferential direction. Alternatively, however, the rotor disk 43 can also be formed by a printed circuit board with conductor tracks that are not shown in detail, the conductor tracks forming rotor coils of the rotor 17 .

A drive device 12 is thus proposed which has rapid acceleration and deceleration, since the inertia of the pancake motor is very low and the ratio of torque and inertia is therefore very high. In addition, the stator 16 has no iron, so that the armature inductance is low. Furthermore, the printed circuit board motor has a high overload current capacity and can therefore also deliver high torque and power for short periods. In addition, the motor speed torque curve is nearly linear due to negligible armature response and flux distortion. Another advantage is that the drive module is very small (max. 70 wide and max. 180 mm diameter) and light (max. 5 kg), making it suitable for light electric vehicles. Due to the narrow, disk-like configuration, the drive module 7 is particularly suitable for two-wheel and multi-wheel pedelecs. Disc motors are also characterized by a high drive torque (approx. 140 Nm). The drive module 7 is therefore suitable for pedelec drives in which a high-torque drive moment must be provided for a short time.

3 shows the drive module 7 of FIG 2 in an exploded view. As already in 2 described, the drive module 7 has the drive device 12 and the transmission device 13 which are arranged next to one another in the housing 14 in the axial direction. For this purpose, the housing base body 24 is open in the axial direction in relation to the main axis of rotation 100, with the drive device 12 and the transmission device 13 being mounted one after the other in the housing base body 24 and then being sealed off from the environment by the housing cover 25.

The drive shaft 15 extends in the axial direction via a central opening in the partition 35 from the drive chamber 36 into the gear chamber 37, with the drive shaft 15 having a driving section 47 on the drive side for driving the rotor 17 in a rotationally fixed manner and having the sun wheel section 19 on the transmission side. A particularly compact configuration of the drive shaft 15 is thus proposed.

the 4 and 5 each show the transmission device 13 of the drive module 7. The transmission device 13 in 4 in an exploded view and in 5 shown in a perspective view. The transmission device 13 designed as a planetary gear has three planet gears 20 which are each designed as stepped planets. For this purpose, the planetary gears 20 each have a first and a second planetary gearing 48, 49 with different tip circle diameters, with the first planetary gearing 48 engaging with the sun gear section 19 and the second planetary gearing 49 with the ring gear section 22 in an installation situation. The two planet gears 48, 49 are each formed by a separate gear, the two gears of each planet wheel 20 are non-rotatably connected to each other.

By configuring the planet gears 20 as stepped planets, the transmission device 13 can be realized with a gear ratio of 1:7 to 1:14. Thus, a high drive torque introduced at a low speed can be converted by the transmission device 13 into a small output torque at a high speed. In other words, a rotational movement of the drive shaft 15 is accelerated via the transmission device 13 .

The connection section 18 is designed as a drive hub, which has a connection contour 50 on the face side for the non-rotatable, in particular form-fitting, connection of the drive module 7 . For example, the connection section 18 is designed in the form of a claw, which can be brought into engagement with a corresponding counter-claw of the drive wheel 4 in the axial direction.

6 shows a three-dimensional representation of an exemplary integration of the drive module 7 in a single-track pedelec or two-wheeler. For this purpose, the drive module 7 is arranged close to the wheel on the drive wheel 4 , the drive module 7 being connected to a wheel hub 51 of the drive wheel 4 via the wheel connection section 18 . Instead of the chain together with the pinion, the drive module 7 is electrically connected to the generator module 6 via the line 10 so that a serial drive is formed without mechanically connecting the pedal crank to the drive wheel 4 . The drive module 7 close to the wheel is fixed to the frame 2 via the frame connection section 28, for which purpose a wheel axle 52, eg a quick-release axle or quick-release axle, is pushed through the through-openings 26, 27 or the support sleeves 29, 30. Furthermore, the housing 14 can be fixed to the frame 2 via at least one fastening means 53 so that the drive module 7 is firmly connected to the frame 2 .

7 shows in a three-dimensional representation an alternative integration of the drive module 7 in a multi-track pedelec or two-wheeler, in particular a cargo bike. For this is in 7 a drive axle 54, for example a rear axle or swing arm, is shown with two drive wheels 4, which for the vehicle 1, as in 1 described is suitable. The drive axle 54 has two drive modules 7 , each drive module 7 being connected in terms of drive technology to the respectively associated drive wheel 4 in order to drive a drive wheel 4 . In the case of a serial drive using the generator module 6, the chain and the differential are omitted, so that the installation space between the wheels 4 can be used freely. The two drive modules 7 are each arranged close to the associated drive wheel 4 and are connected to the frame 2 in a fixed manner.

Reference List

1

vehicle

2

frame

3

front wheel

4

rear wheel

5

drive arrangement

6

generator module

7

drive module

8th

energy storage module

9

crank

10

Management

11

consumer

12

drive device

13

gear mechanism

14

Housing

15

drive shaft

16

stator

17

rotor

18

bike connection section

19

sun gear section

20

planet gears

21

planet carrier

22

ring gear section

23

support bolts

24

housing body

25

housing cover

26

first passage opening

27

second passage opening

28

frame connection section

29

first support sleeve

30

second support sleeve

31

first storage facility

32

second storage facility

33

third storage facility

34

fourth storage facility

35

partition wall

36

drive room

37

gear room

38

power electronics

39

electronics room

40

another housing cover

41

holding section

42

sensor device

43

rotor disc

44

first stator disc

45

second stator disc

46

circuit board

47

takeaway section

48

first planetary gearing

49

second planetary gearing

50

connection contour

51

wheel hub

52

wheel axle

53

fasteners

54

drive axle

100

main axis of rotation

QUOTES INCLUDED IN DESCRIPTION

This list of the documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102019108378 A1 [0003]

Claims (10)

Drive module (7) for an electrically operated vehicle (1), with a drive device (12) for generating an electric drive torque, with a wheel connection section (18) for drive-related connection of the drive module (7) to a wheel hub (51) of a drive wheel (4) of the vehicle (1), with a transmission device (13) for converting the drive torque to the wheel connection section (18), the transmission device (13) having an input element connected to the drive device (12) and an output element connected to the wheel connection section (18), with a housing (14), the drive device (12) and the gear device (13) being accommodated together in the housing (14), characterized in that the drive device (12) is designed as a pancake motor. Drive module (7) after claim 1 , characterized in that the pancake motor has a first and a second stator disk (44, 45) and a rotor disk (43) arranged axially between the two stator disks (44, 45), the rotor disk (43) and/or the two stator disks ( 44, 45) are formed by at least one circuit board (46) printed with one or more active areas. Drive module (7) after claim 1 or 2 , characterized in that the transmission device (13) is designed as a planetary gear, the input member being formed by a sun wheel section (19) and the output member being formed by a planet carrier (21) of the planetary gear. Drive module (7) after claim 3 , characterized in that the planet gears (20) of the planetary gear are designed as stepped planets. Drive module (7) according to one of the preceding claims, characterized in that the drive device (12) and the gear device (13) are arranged coaxially to one another in relation to a main axis of rotation (100) in the housing (14). Drive module (7) according to one of the preceding claims, characterized in that the housing (14) has a partition (35) which divides the housing (14) into a drive space (36) for receiving the drive device (12) and a gear space (37 ) divided to accommodate the transmission device (37). Drive module (7) after claim 6 , characterized by a sensor device (42) for detecting a motor parameter of the drive device (12), wherein the sensor device (42) is mounted opposite the drive device (12) on the partition (35). Drive module (7) according to one of the preceding claims, characterized in that the housing (14) has an electronics space (39) for accommodating power electronics (38), the electronics space (39) in the radial direction in relation to a main axis of rotation (100) is arranged to the drive device (12). Drive module (7) according to one of the preceding claims, characterized in that the housing (14) has a frame connection section (28) for fastening the housing (14) to a frame (2) of the vehicle (1). Drive arrangement (5) with the drive module (7) according to one of the preceding claims, characterized by a generator module (6) which can be driven by a vehicle user by pedaling power for generating electrical energy for the drive module (7) and an energy storage module (8), the generator module ( 6) is connected directly to the drive module (7) via an electric line (10) and/or indirectly via an energy storage module (8) to the drive module (7) in order to provide the electrical energy.

Images