Electric vehicle drive motor

Claim 2

An electrically powered wheel for a vehicle comprising: a nonrotatable sleeve adapted to be secured to a vehicle suspension; a shaft journaled for rotation within said sleeve; an electric motor having a field assembly, said field assembly including an annular permanent magnet assembly including means providing a plurality of magnetic pole faces, said permaNent magnet assembly extending radially of said sleeve and nonrotatably secured thereto; an annular part formed of magnetic material axially spaced from said permanent magnet assembly to form an annular axially extending space located therebetween; means securing said annular part to said permanent magnet assembly whereby said annular part and permanent magnet assembly are nonrotatably secured to said sleeve; an armature for said motor, said armature comprising a disc of insulating material carrying armature conductor means; a radially extending flange formed integral with said shaft; means for clamping an inner portion of said armature between said flange and an annular clamping means to provide a driving connection between said armature and said shaft, the outer portion of said armature positioned in said axially extending space; a wheel drive member secured to said shaft, said wheel drive member including means for carrying and driving a vehicle wheel whereby said shaft forms an axle for a vehicle wheel and an output shaft for said motor; a first and a second pair of motor brushes engaging said armature conductor means; means supporting said first pair of motor brushes adjacent said armature conductor means and relative to said field pole faces to apply voltage across said armature conductor means which is effective to drive said wheel motor shaft in a given direction of rotation; means supporting said second pair of motor brushes adjacent said armature conductor means and relative to said field pole faces to apply a voltage across said armature conductor means which is effective to oppose the rotation of said motor shaft whereby the speed of a vehicle wheel connected to said wheel motor increased by applying increasing voltage across said first pair of motor brushes and the speed is decreased by applying increasing voltage to said second pair of motor brushes.

Claim 3

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal, said housing including end portions formed by first and second annular end plates made of a magnetic material; an annular field assembly secured to said first annular end plate including a plurality of permanently magnetized poles, said magnetized poles being of alternate opposite polarities which produce oppositely directed magnetic flux regions across an annular axial air gap space between said end plates; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system and supporting one of said first and second end plates; a shaft journaled within said cylindrical support sleeve, said shaft including an outer end having a driving flange for supporting a vehicle wheel and a portion intermediate the shaft ends including an armature support flange extending radially toward said annular air gap space between said first and second end plates; a disc armature including plural discs of insulating material having flat conductor segments secured on both sides of each of said discs said flat conductor segments being connected together to form an armature winding; means for clamping said disc armature to said armature support flange of said shaft so that said flat conductor segments are arranged for rotation within said annular air gap space including said magnetic field flux regions; plural brush elements circumferentially spaced apart and carried by one of said first and second annular end plates, said brush elements being spring biased into contact with the flat conductors carried by one of said nonconductive armature discs said brush elements being operative to conduct current to said armature winding in a given direction whereby torque is developed on the disc armature to rotate said shaft and said wheel driving flange of said shaft.

Claim 4

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal, said housing including end portions formed by first and second annular end plates made of a magnetic material; an annular field assembly secured to said first annular end plate including a plurality of permanently magnetized poles, said magnetized poles being of alternate opposite polarities which produce oppositely directed magnetic flux regions across an annular axial air gap space between said end plates; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system and supporting one of said first and second end plates; a shaft journaled within said cylindrical support sleeve, said shaft including an outer end having a driving flange for supporting a vehicle wheel and a portion intermediate the shaft ends including an armature support flange extending radially toward said annular air gap space between said first and second end plates; a disc armature including plural discs of insulating material having flat conductor segments secured on both sides of each of said discs said flat conductor segments being connected together to form an armature winding; means for clamping said disc armature to said armature support flange of said shaft so that said flat conductor segments are arranged for rotation within said annular air gap space including said magnetic field flux regions; plural brush elements circumferentially spaced apart and carried by one of said first and second annular end plates, said brush elements being spring biased into contact with the flat conductors carried by one of said nonconductive armature discs said brush elements being operative to conduct current to said armature winding in a given direction whereby torque is developed on the disc armature to rotate said shaft and said wheel driving flange of said shaft.

Claim 5

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal, said housing including an inner surface and an outer surface having integral fins extending radially outward to radiate heat to the ambient aiR surrounding said housing; motor end portions including first and second annular end plates formed of a magnetic material and carried in an axially spaced apart relationship by said inner surface of said housing; an annular field assembly formed by a plurality of circumferentially spaced permanent magnet pole sectors secured to said first annular end plate, said pole sectors having pole faces of alternate polarities which produce oppositely directed magnet flux regions across an air gap space between said pole faces and said second annular end plate; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system and including means for securing said first end plate intermediate the ends of said support sleeve; a shaft including a first end journaled within said cylindrical support sleeve and a second end extending outside of said second end plate, said second shaft end including a driving flange for receiving a vehicle wheel and a portion intermediate shaft ends including an armature support flange extending radially within the air gap space between said first and second end plates; an annular disc armature having flat conductors secured on both sides thereof; said flat conductors including connecting portions extending beyond the inner and outer boundaries of said annular disc armature in overlapping relationship; means connecting said conductor connecting portions together to form an armature circuit having wave shaped conductive paths; means including an insulating material sealing the overlapping connecting portions around the inner and outer disc boundaries; means for clamping said disc armature to said armature support flange of said shaft whereby the disc is rotatable within said magnetic field flux regions in said air gap space; and plural brushes each mounted on said first annular end plate between said permanent magnet sectors, said brushes making wiping contact with the flat conductors carried on one side of said disc armature to commutate current flow through said armature circuit when said brushes are connected to a source of electrical current.

Claim 6

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal, said housing including an inner surface and an outer surface having integral fins extending radially outward to radiate heat to the ambient aiR surrounding said housing; motor end portions including first and second annular end plates formed of a magnetic material and carried in an axially spaced apart relationship by said inner surface of said housing; an annular field assembly formed by a plurality of circumferentially spaced permanent magnet pole sectors secured to said first annular end plate, said pole sectors having pole faces of alternate polarities which produce oppositely directed magnet flux regions across an air gap space between said pole faces and said second annular end plate; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system and including means for securing said first end plate intermediate the ends of said support sleeve; a shaft including a first end journaled within said cylindrical support sleeve and a second end extending outside of said second end plate, said second shaft end including a driving flange for receiving a vehicle wheel and a portion intermediate shaft ends including an armature support flange extending radially within the air gap space between said first and second end plates; an annular disc armature having flat conductors secured on both sides thereof; said flat conductors including connecting portions extending beyond the inner and outer boundaries of said annular disc armature in overlapping relationship; means connecting said conductor connecting portions together to form an armature circuit having wave shaped conductive paths; means including an insulating material sealing the overlapping connecting portions around the inner and outer disc boundaries; means for clamping said disc armature to said armature support flange of said shaft whereby the disc is rotatable within said magnetic field flux regions in said air gap space; and plural brushes each mounted on said first annular end plate between said permanent magnet sectors, said brushes making wiping contact with the flat conductors carried on one side of said disc armature to commutate current flow through said armature circuit when said brushes are connected to a source of electrical current.

Claim 7

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal including an inner cylindrical surface; motor end portions including first and second annular end plates formed of a magnetic material and carried in an axially spaced apart relationship by said inner surface of said housing; an annular field assembly formed by a plurality of circumferentially spaced permanently magnetized pole sectors secured to said first annular end plate, said pole sectors providing magnetized pole faces of alternating polarities which produce oppositely directed magnetic flux regions across an annular air gap space between said pole faces and said second end plate; a shaft including a first end extending through the annular portion of said first annular end plate and the second end extending through the annular portion of said second annular end plate; a wheel drive means connected to said second shaft end for supporting and driving a vehicle wheel, an armature for said motor, said armature including a disc of insulating material carrying armature conductors extending radially on both sides thereof; means for mounting said armature to said shaft whereby said armature conductors extend into said annular air gap space; a plurality of brushes engaging one side of said armature; means supporting said brushes engaging one side of said armature; means supporting said brushes adjacent said one side of said armature; a cylindrical support sleeve including a radially outwardly extending plate formed integral with said support sleeve; means for mounting said first motor end plate to said last named outwardly extending plate so that a first end of said sleeve is exposed for mounting to a vehicle suspension system and the other sleeve end extends within said cylindrical motor housing; means for rotatably supporting said first shaft end within said support sleeve; an end closure Means sealing said first end of said support sleeve; a first annular sealing means for sealing the other end of said support sleeve about said shaft; and a second annular sealing means for sealing the annular space between said second annular motor end plate and said shaft whereby the ends of said motor housing are enclosed to seal the internal portion of said wheel motor.

Claim 8

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic metal including an inner cylindrical surface; motor end portions including first and second annular end plates formed of a magnetic material and carried in an axially spaced apart relationship by said inner surface of said housing; an annular field assembly formed by a plurality of circumferentially spaced permanently magnetized pole sectors secured to said first annular end plate, said pole sectors providing magnetized pole faces of alternating polarities which produce oppositely directed magnetic flux regions across an annular air gap space between said pole faces and said second end plate; a shaft including a first end extending through the annular portion of said first annular end plate and the second end extending through the annular portion of said second annular end plate; a wheel drive means connected to said second shaft end for supporting and driving a vehicle wheel, an armature for said motor, said armature including a disc of insulating material carrying armature conductors extending radially on both sides thereof; means for mounting said armature to said shaft whereby said armature conductors extend into said annular air gap space; a plurality of brushes engaging one side of said armature; means supporting said brushes engaging one side of said armature; means supporting said brushes adjacent said one side of said armature; a cylindrical support sleeve including a radially outwardly extending plate formed integral with said support sleeve; means for mounting said first motor end plate to said last named outwardly extending plate so that a first end of said sleeve is exposed for mounting to a vehicle suspension system and the other sleeve end extends within said cylindrical motor housing; means for rotatably supporting said first shaft end within said support sleeve; an end closure Means sealing said first end of said support sleeve; a first annular sealing means for sealing the other end of said support sleeve about said shaft; and a second annular sealing means for sealing the annular space between said second annular motor end plate and said shaft whereby the ends of said motor housing are enclosed to seal the internal portion of said wheel motor.

Claim 9

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic material, said housing including an inner surface having a pair of annular grooves and an outer surface having integral fins extending radially outward to radiate heat to the ambient air surrounding said housing; motor end portions including first and second annular end plates formed of a magnetic material, said first and second end plates carried in an axially spaced apart relationship by said inner surface of said housing and held in place by a pair of snap rings resiliently engaging said annular grooves; an annular field assembly including circumferentially spaced permanent magnet pole sectors providing magnetized poles of alternating polarities which produce oppositely directed magnetic fluxes, the paths of said magnetic fluxes including an air gap space between said permanent magnet pole sectors and said second end plate; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system including means for securing the annular portion of said first end plate intermediate the ends of said support sleeve; a shaft including a rearward end journaled within said cylindrical support sleeve and an outer end extending through the annular portion of said second end plate, said outer shaft end including a driving flange for receiving and supporting a vehicle wheel; an intermediate shaft portion having an increased diameter; said intermediate shaft portion including an integral armature support flange extending radially between said first and second end plates; an annular sealing means for enclosing the outer end of said motor and extending between said second end plate and said shaft; a disc armature including plural nonconductive annular discs made of an insulating sheet material; a plurality of armature conductors secured on both sides of each of said nonconductive discs said armature conductors including connecting portions extending beyond the inner and outer boundaries of said nonconductive discs in overlapping relationship; means connecting said conductor connecting portions together at the outer boundaries and at the inner boundaries so as to form an armature circuit having a continuous wave winding pattern; means for clamping said disc armature to said armature support flange of said shaft whereby the armature circuit pattern extends into said magnetic field flux paths produced by said annular field assembly; a plurality of brush holders circumferentially spaced from each other and carried by said first annular end plate between said magnetic pole sectors, first and second groups of motor brushes included in said brush holders and engaging said armature conductors which are carried by said disc armature; conductor means for connecting said first group of brushes to a source of electrical power to apply a voltage across said first group of brushes that supplies current in said armature conductors so that torque is developed which rotates said disc armature in a predetermined direction; and means connected between said second group of brushes and the electrical source for selectively applying a voltage across said second group of brushes which is effective to oppose the torque producing effect of the voltage applied across said first group of brushes thereby opposing the rotation of said armature to decrease the speed of a vehicle wheel being driven by said motor shaft.

Claim 10

An axial air gap electric wheel motor comprising: a cylindrical motor housing formed of a nonmagnetic material, said housing including an inner surface having a pair of annular grooves and an outer surface having integral fins extending radially outward to radiate heat to the ambient air surrounding said housing; motor end portions including first and second annular end plates formed of a magnetic material, said first and second end plates carried in an axially spaced apart relationship by said inner surface of said housing and held in place by a pair of snap rings resiliently engaging said annular grooves; an annular field assembly including circumferentially spaced permanent magnet pole sectors providing magnetized poles of alternating polarities which produce oppositely directed magnetic fluxes, the paths of said magnetic fluxes including an air gap space between said permanent magnet pole sectors and said second end plate; a cylindrical support sleeve for mounting said wheel motor to a vehicle suspension system including means for securing the annular portion of said first end plate intermediate the ends of said support sleeve; a shaft including a rearward end journaled within said cylindrical support sleeve and an outer end extending through the annular portion of said second end plate, said outer shaft end including a driving flange for receiving and supporting a vehicle wheel; an intermediate shaft portion having an increased diameter; said intermediate shaft portion including an integral armature support flange extending radially between said first and second end plates; an annular sealing means for enclosing the outer end of said motor and extending between said second end plate and said shaft; a disc armature including plural nonconductive annular discs made of an insulating sheet material; a plurality of armature conductors secured on both sides of each of said nonconductive discs said armature conductors including connecting portions extending beyond the inner and outer boundaries of said nonconductive discs in overlapping relationship; means connecting said conductor connecting portions together at the outer boundaries and at the inner boundaries so as to form an armature circuit having a continuous wave winding pattern; means for clamping said disc armature to said armature support flange of said shaft whereby the armature circuit pattern extends into said magnetic field flux paths produced by said annular field assembly; a plurality of brush holders circumferentially spaced from each other and carried by said first annular end plate between said magnetic pole sectors, first and second groups of motor brushes included in said brush holders and engaging said armature conductors which are carried by said disc armature; conductor means for connecting said first group of brushes to a source of electrical power to apply a voltage across said first group of brushes that supplies current in said armature conductors so that torque is developed which rotates said disc armature in a predetermined direction; and means connected between said second group of brushes and the electrical source for selectively applying a voltage across said second group of brushes which is effective to oppose the torque producing effect of the voltage applied across said first group of brushes thereby opposing the rotation of said armature to decrease the speed of a vehicle wheel being driven by said motor shaft.