TECHNICAL FIELD

This disclosure relates generally to a shaft assembly for a motor and, more particularly, to a shaft assembly incorporating an insert that provides a fluid conduit through the motor shaft assembly.

BACKGROUND

Electrified vehicles differ from conventional motor vehicles because, among other things, electrified vehicles are selectively driven using one or more electric machines powered by a traction battery. The electric machines can drive the electrified vehicles instead of, or in addition to, an internal combustion engine. Example electrified vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles (FCVs), and battery electric vehicles (BEVs).

The traction battery can be used to selectively power the electric machines and other electrical loads of the electrified vehicle. The traction battery includes a plurality of interconnected battery cells that store energy for powering these electrical loads. Components of the electrified machines contribute to the overall weight of the electrified vehicle. The electrified machines can require thermal management and lubrication.

SUMMARY

A shaft assembly according to an exemplary aspect of the present disclosure includes, among other things, an outer shaft rotatable about an axis, and a shaft insert that provides a flow conduit for a fluid and blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis.

In a further non-limiting embodiment of the foregoing assembly, the shaft insert is slideably received within the outer shaft.

In a further non-limiting embodiment of any of the foregoing assemblies, the shaft insert is formed within the outer shaft.

In a further non-limiting embodiment of any of the foregoing assemblies, portions of the shaft insert are radially spaced from the outer shaft to provide an annular cavity between the shaft insert and the outer shaft relative to the axis.

In a further non-limiting embodiment of any of the foregoing assemblies, the annular cavity comprises a first annular cavity and a second annular cavity separate from the first annular cavity.

In a further non-limiting embodiment of any of the foregoing assemblies, at least one radially extending rib of the shaft insert extends to the outer shaft. The at least one radially extending rib separates the first annular cavity from the second annular cavity.

In a further non-limiting embodiment of any of the foregoing assemblies, a radially outer perimeter of the shaft insert contacts the outer shaft along an entire axial length of the shaft insert.

In a further non-limiting embodiment of any of the foregoing assemblies, the outer shaft has a first material composition and the shaft insert has a second material composition having a lower density than a density of the first material composition.

In a further non-limiting embodiment of any of the foregoing assemblies, the first material composition comprises a metal or metal alloy, and the second material composition comprises a polymer-based material, a composite material, or both.

In a further non-limiting embodiment of any of the foregoing assemblies, the insert comprises a tube that is a metal or metal alloy, and the insert is sealed against the outer shaft.

In a further non-limiting embodiment of any of the foregoing assemblies, includes a transmission component of an electrified vehicle rotatably coupled to the outer shaft.

A shaft assembling method according to another exemplary aspect of the present disclosure includes, among other things, positioning a shaft insert within an outer shaft. The shaft insert has a fluid conduit and is configured to block fluid from communicating radially between the shaft insert and the outer shaft.

A further non-limiting embodiment of the foregoing method includes inserting the shaft insert as a molded component into the outer shaft.

A further non-limiting embodiment of the foregoing method includes molding the shaft insert within outer shaft.

A further non-limiting embodiment of the foregoing method includes radially spacing portions of the shaft insert from the outer shaft to provide an annular cavity between the shaft insert and the outer shaft relative to the axis.

A further non-limiting embodiment of the foregoing method includes separating the annular cavity into a first annular cavity and a separate, second annular using at least one rib extending radially from the shaft insert.

A further non-limiting embodiment of the foregoing method includes positioning the shaft insert such that a radially outer perimeter of the shaft insert contacts the outer shaft along an entire axial length of the shaft insert.

In a further non-limiting embodiment of the foregoing method, the outer shaft has a first material composition and the shaft insert has a second material composition having a lower density than a density of the first material composition.

In a further non-limiting embodiment of the foregoing method, the first material composition comprises a metal or metal alloy, and the second material composition comprises a polymer-based, a composite material, or both.

A further non-limiting embodiment of the foregoing method, includes rotating a transmission component of an electrified vehicle with the outer shaft.

BRIEF DESCRIPTION OF THE FIGURES

The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures that accompany the detailed description can be briefly described as follows:

FIG. 1 illustrates a schematic view of an example powertrain for an electrified vehicle.

FIG. 2 illustrates a perspective view of a motor from the powertrain of FIG. 1.

FIG. 3 illustrates a side view of a portion of the motor of FIG. 3 with a stator of the motor sectioned to show a rotor of the motor.

FIG. 4 illustrates a section view at Line 4-4 in FIG. 3 of a shaft assembly of the motor.

FIG. 5 illustrates a section view at line 5-5 in FIG. 4 of the shaft assembly of the motor.

FIG. 6 illustrates a step in an assembling method for the shaft assembly of FIG. 4.

FIG. 7 illustrates a section view of a shaft for the motor of FIG. 2 according to another exemplary embodiment.

FIG. 8 illustrates a step in an assembling method for the shaft assembly of FIG. 7.

FIG. 9 illustrates a shaft assembly for use in the motor of FIG. 2 according to yet another exemplary embodiment.

FIG. 10 illustrates a shaft assembly for use in the motor of FIG. 2 according to yet another exemplary embodiment.

DETAILED DESCRIPTION

This disclosure is directed toward a shaft assembly for a motor. The shaft assembly incorporates an insert. The insert reduces an overall weight of the shaft assembly. The insert includes a conduit used to communicate a fluid through the shaft assembly. These and other features are discussed in greater detail in the following paragraphs of this detailed description.

FIG. 1 schematically illustrates a powertrain 10 for an electrified vehicle. Although depicted as a hybrid electric vehicle (HEV), it should be understood that the concepts described herein are not limited to HEVs and could extend to any other types of conventional vehicles and electrified vehicle, including, but not limited to, plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), etc.

The powertrain 10 of the example electrified vehicle includes a battery pack 14 having a plurality of battery arrays 18, an internal combustion engine 20, a motor 22, and a generator 24. The motor 22 and the generator 24 are types of electric machines. The motor 22 and generator 24 may be separate or have the form of a combined motor-generator. This motor 22, the generator 24, or both, can be part of a transmission for the electrified vehicle. Passageways for communicating a fluid through portions of the motor 22, the generator 24, or both, can facilitate meeting lubrication and thermal management requirements for the motor 22, the generator 24, bearings of the motor 22 and the generator 24, and other components associated with the transmission.

In this embodiment, the powertrain 10 is a power-split powertrain that employs a first drive system and a second drive system. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 28. The first drive system includes a combination of the engine 20 and the generator 24. The second drive system includes at least the motor 22, the generator 24, and the battery pack 14. The motor 22 and the generator 24 are portions of an electric drive system of the powertrain 10.

The engine 20 and the generator 24 can be connected through a power transfer unit 30, such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, can be used to connect the engine 20 to the generator 24. In one non-limiting embodiment, the power transfer unit 30 is a planetary gear set that includes a ring gear 32, a sun gear 34, and a carrier assembly 36.

The generator 24 can be driven by the engine 20 through the power transfer unit 30 to convert kinetic energy to electrical energy. The generator 24 can alternatively function as a motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft 38 connected to the power transfer unit 30.

The ring gear 32 of the power transfer unit 30 is connected to a shaft 40, which is connected to the vehicle drive wheels 28 through a second power transfer unit 44. The second power transfer unit 44 may include a gear set having a plurality of gears 46. Other power transfer units could be used in other examples.

The gears 46 transfer torque from the engine 20 to a differential 48 to ultimately provide traction to the vehicle drive wheels 28. The differential 48 may include a plurality of gears that enable the transfer of torque to the vehicle drive wheels 28. In this example, the second power transfer unit 44 is mechanically coupled to an axle 50 through the differential 48 to distribute torque to the vehicle drive wheels 28.

The motor 22 can be selectively employed to drive the vehicle drive wheels 28 by outputting torque to a power transfer unit shaft 52 that is connected to the second power transfer unit 44. In this embodiment, the motor 22 and the generator 24 cooperate as part of a regenerative braking system in which both the motor 22 and the generator 24 can be employed as motors to output torque. For example, the motor 22 and the generator 24 can each output electrical power to recharge cells of the battery pack 14.

Referring now to FIGS. 2 to 5 with continuing reference to FIG. 1, the motor 22 includes a motor shaft assembly 60, a rotor 64, a stator 68, and a housing 70. The motor shaft assembly 60 is connected to the power transfer unit shaft 52. The rotor 64 is disposed within the stator 68. Portions of the motor shaft assembly 60, the rotor 64, and the stator 68 are housed within the housing 70.

Power from the battery pack 14, or from some other source, energizes the stator 68, which rotates the rotor 64 to rotate the shaft assembly 60 about an axis A. Rotation of the shaft assembly 60 rotates the power transfer unit shaft 52 to drive the second power transfer unit 44.

The rotor 64, in this example, comprises stacks of individual laminations secured to the shaft assembly 60. The laminations are steel in this example. The laminations could be compressed axially between a nut 72 and a radial flange 74 of the shaft assembly 60.

Increasing an outer diameter D_Rof the rotor 64 can increase a torque generated by the rotor 64 and the shaft assembly 60. Increasing the diameter D_Rof the rotor 64 can require increasing a diameter D_sof the shaft assembly 60. Packaging requirements could also require decreasing an axial length of the shaft, which can lead to an increase in the diameter D_R.

In an exemplary non-limiting embodiment, the shaft assembly 60 includes an insert 76, an outer shaft 80, and a retention ring 82. The insert 76 is made of a material weighing less than a material of the outer shaft 80. The insert provides a fluid conduit 84. The insert 76 reduces an overall weight of the shaft assembly 60 when compared to a similarly sized shaft assembly that lacks any insert and provides a similarly sized fluid conduit with an outer shaft. Notably, density of the insert 76 is less than a density of the outer shaft 80.

The insert 76 is received within the outer shaft 80 of the shaft assembly 60. The retention ring 82 can prevent movement of the insert 76 relative to the outer shaft 80 and, as will be explained, provide an opening 90 and a support surface.

The insert 76 provides a fluid conduit 84. Thus, the shaft assembly 60 is considered a hollow shaft assembly. Notably, the fluid conduit 84 has a perimeter 86 provided entirely by the insert 76. That is, the fluid conduit 84 does not extend radially between the insert 76 and the outer shaft 80 such that a portion of the perimeter 86 would be provided by the outer shaft 80.

Fluid, such as a cooling fluid, a lubricating fluid, or both, can move from a fluid supply 88 to the fluid conduit 84 of the insert 76. The fluid, for example, can be used to control thermal energy levels of the motor 22 and, optionally, other components. The fluid could instead or additionally be used to lubricate components of the motor 22 and, optionally, other components.

In this exemplary embodiment, fluid moves along a path P through the opening port 90 in the retention ring 82 to the fluid conduit 84. The retention ring 82 provides a sealing interface with the fluid supply 88. The rejection ring 82 can, for example, seal against a fluid input port from the fluid supply with an o-ring type seal.

The retention ring 82 can be a metal, or metal alloy. In a specific embodiment, the retention ring 82 is an aluminum. The retention ring 82 can be press-fit into the outer shaft 80.

A first portion of the fluid that has entered the fluid conduit 84 flows through a portion of the fluid conduit 84 and then flows radially along paths P_Rfrom the fluid conduit 84. The fluid exiting the fluid conduit 84 along the radial paths P_Rflows along radial passageways 92 extending through the insert 76 and the outer shaft 80. Fluid flowing along the paths P_Rcan be used to, for example, cool the laminations of the rotor 64, to cool the stator 68, or to lubricate components that move relative to each other. The example shaft assembly 60 includes two radial passageways 92 circumferentially distributed about the axis A.

A second, remaining, portion of the fluid that has entered the fluid conduit 84 flows along the entire axial length of the fluid conduit 84 and then flows along an axial path P_Afrom the fluid conduit 84. The fluid exiting the fluid conduit 84 along the axial path P_Aflows along an axial passageway 94 in the power transfer unit shaft 52. The fluid exiting the fluid conduit 84 along the axial path P_Acould also flow along an interface between the outer shaft 80 of the shaft assembly 60 and the power transfer unit shaft 52. Fluid exiting the fluid conduit 84 along the axial path P_Acould, for example, cool the power transfer unit shaft 52 and support structure associated with the shaft assembly 60 or the power transfer unit shaft 52, such as bearings. Fluid exiting the fluid conduit 84 along the axial path P_Acould instead, or additionally be used to lubricate components that move relative to each other.

The example insert 76 is a polymer-based material, such as a resin material or a plastic material. The insert 76 could, for example, be a thermoset resin or a molded plastic, like nylon. In some examples, the insert 76 is a composite material, which could include a fibrous material. A composite material could instead, or additionally, be a material filled with additives, such as microballoons, or including pockets of injected air to facilitate decreasing a density of the insert 76. The example outer shaft 80 is a metal or metal alloy. The example retention ring 82 is aluminum or steel. The insert 76 effectively takes the place of heavier, metallic-based material. Utilizing the insert 76 can thus reduce an overall weight of the shaft assembly when compared to shaft assemblies without an insert.

Notably, a radially outer perimeter of the insert 76 contacts the outer shaft 80 along an entire axial length of the insert 76. While the insert 76 could be completely removed, and the area occupied by the insert 76 left open to reduce a weight of the shaft assembly 60, this approach would not provide the fluid conduit 84 having a relatively small cross-sectional diameter. That is, if the insert 76 were completely removed from the shaft assembly 60, fluid would need to additionally fill the area occupied by the insert 76. Much more fluid would then be required and fluid pressure could not be as closely controlled. Further, the fluid would be inhibited from flowing smoothly through the shaft assembly 60 since the relatively small cross-sectional diameter of the fluid conduit 84 within the insert 76 promotes a smooth flow of the fluid.

The retention ring 82 can provide a support surface for the shaft assembly 60. The support surface could interface with supportive bearings, for example. Providing the support surface with the retention ring 82 makes the support surface less prone to wear than if the insert 76 provided the support surface.

Further, the retention ring 82, which is made of a harder material than the insert 76 will avoid at least some wearing of a seal associated with the fluid inlet port from the fluid supply 88. That is, the seal could wear more quickly if the seal were interfacing with the insert 76 rather than the retention ring 82

Referring to FIG. 6, with continuing reference to FIG. 5, the insert 76 can be formed within the outer shaft 80 of the shaft assembly 60. In the examples of this disclosure, the insert 76 is shown as a single monolithic structure. The insert 76 could instead be provided by a plurality of separate insert portions.

When forming the insert 76 within the outer shaft 80, molten material from a material supply 89 is injected into a cavity C provided between the outer shaft 80 of the shaft assembly 60 and a die pin 96. The molten material within the cavity C cures to provide the insert 76.

Once cured, the die pin 96 is withdrawn axially along a direction W. The area formerly occupied by the die pin 96 establishes the fluid conduit 84 within the insert 76.

The radial passageways 92 can be formed with a drilling process, for example. Alternatively, the radial passageways 92 could be provided by forming the molten material around pins extending radially through the outer shaft 80 into the cavity C.

After the insert 76 is formed, the retention ring 82 is inserted into the outer shaft 80 of the shaft assembly 60.

In this disclosure, like reference numbers designate like elements where appropriate and reference numerals with the addition of 100 of multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements.

Referring now to FIGS. 7 and 8, a shaft assembly 160 according to another exemplary embodiment includes an insert 176 held within an outer shaft 180. The insert 176 provides a fluid conduit 184.

Assembling the shaft assembly 160 involves sliding the insert 176 along the rotational axis A of the shaft assembly 160 into the outer shaft 180 from the position of FIG. 8 to the position of FIG. 7. A retention ring 182 is then inserted into the outer shaft 180 to hold the insert 176 within the outer shaft 180 and to, optionally, provide a support surface for the shaft assembly 160.

Notably, the insert 176 can be formed independently from the outer shaft 180 and formed prior to insertion within the outer shaft 180. Forming the insert 176 independently from the outer shaft 180 can permit the insert 176 to incorporate more varied geometries as the final geometry is not constrained to the shape of the cavity C (FIG. 6). A density of the insert 176 is less than a density of the outer shaft 180.

Like the insert 76 of the embodiment of FIGS. 4 to 6, the insert 176 can be formed from a polymer-based material, such as a resin material or a plastic material. The insert 176 could, for example, be a thermoset resin or a molded plastic, like nylon. In some examples, the insert 176 is a composite material, which could include a fibrous material. A composite material could instead, or additionally, be a material filled with additives, such as microballoons, or including pockets of injected air to facilitate decreasing a density of the insert 176. The insert 176 reduces an overall weight of the shaft assembly 160 when compared to a shaft assembly occupying the area of the insert 176 with a metal or metal alloy.

The insert 176 is formed to provide an annular channel 98 about a periphery of the insert 176. When the insert 176 is positioned within the outer shaft 180 as shown in FIG. 7, the annular channel 98 is positioned radially between a portion of the insert 176 and a portion of the outer shaft 180. The annular channel 98 is an open area where the radially outer perimeter of the insert 176 is spaced from the outer shaft 280. The open area of the annular channel 98 is separated from the fluid conduit 184 by portions of the insert 176 such that fluid flowing in the fluid conduit 184 does not enter the open area of the annular channel 98.

The annular channel 98 can reduce an amount of material required to provide the shaft assembly 160, and additionally reduce an overall weight of the shaft assembly 160 when compared to a shaft assembly that fills the area of the annular channel 98 with a material.

Referring now to FIG. 9, yet another example shaft assembly 260 includes an insert 276 received within an outer shaft 280 of the shaft assembly 260. A density of the insert 276 is less than a density of the outer shaft 280. Like the insert 76 of the embodiment of FIGS. 4 to 6, the insert 276 can be formed from a polymer-based material, such as a resin material or a plastic material. The insert 276 could, for example, be a thermoset resin or a molded plastic, like nylon. In some examples, the insert 276 is a composite material, which could include a fibrous material. A composite material could instead, or additionally, be a material filled with additives, such as microballoons, or including pockets of injected air to facilitate decreasing a density of the insert 276. The insert 276 reduces an overall weight of the shaft assembly 260 when compared to a shaft assembly occupying the area of the insert 276 with a metal or metal alloy. The insert 276 provides a fluid conduit 284.

The shaft assembly 260 includes two annular channels 298a and 298b separated by a radially extending rib 99 of the insert 276. The rib 99 directly contacts the outer shaft 280 of the shaft assembly 260. The rib 99 is a single rib in this example. In other examples, the rib 99 could be one of a series of one or more separate ribs. The annular channels 298a and 298b are open areas where the radially outer perimeter of the insert 276 is spaced from the outer shaft 280. The open area of the annular channels 298a and 298b are separated from the fluid conduit 184 by portions of the insert 276 such that fluid flowing in the fluid conduit 284 does not enter the open area of the annular channels 298a and 298b.

The rib 99 can facilitate supporting the insert 276 within the outer shaft 280 such that the areas of the insert 276 providing the annular channels 298a and 298b do not flex radially relative to the outer shaft 280. The rib 99, or ribs, can prevent significant radially outward deflections of the insert 276 under high centrifugal forces when the shaft assembly 260 is rotating at relatively high speeds.

Referring now to FIG. 10, yet another example shaft assembly 360 includes an insert 376 received within an outer shaft 380 of a shaft assembly 360. The insert 376, in this exemplary embodiment, is a tube of a metal or metal alloy. The insert 376 provides a fluid conduit 384.

The insert 376 is formed to provide an annular channel 398 about a periphery of the insert 376. When the insert 376 is positioned within the outer shaft 380 as shown in FIG. 10, the annular channel 398 is positioned radially between a portion of the insert 376 and a portion of the outer shaft 380. The annular channel 398 is an open area where the radially outer perimeter of the insert 376 is spaced from the outer shaft 380. The open area of the annular channel 398 is separated from the fluid conduit 384 by portions of the insert 376 such that fluid flowing in the fluid conduit 384 does not enter the open area of the annular channel 398.

The annular channel 398 can reduce an amount of material required to provide the shaft assembly 360, and additionally reduce an overall weight of the shaft assembly 360 when compared to a shaft assembly that fills the area of the annular channel 398 with a material.

Areas B where the insert 376 contacts the outer shaft 380 can include an adhesive to bond the insert 376 to the outer shaft 380 and to seal the annular channel 398 from fluid moved through the fluid conduit 384 provided by the insert 376. The insert 376 could instead, or additionally, be crimped or mechanically secured to the outer shaft 380. In such cases a seal, like an o-rings or a polymer/adhesive seal, could be used to seal the annular channel 398 from fluid moved through the fluid conduit 384.

A feature of the disclosed embodiments can include incorporating an insert into a shaft assembly to provide a fluid conduit and to reduce an overall weight of the shaft assembly. In some examples, the insert can reduce a weight of a shaft assembly by up to 25 percent when compared to a shaft assembly lacks an insert and provides a fluid conduit with an outer shaft.

The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Thus, the scope of legal protection given to this disclosure can only be determined by studying the following claims.