Integrated powertrain

Abstract

An integrated power system integrates a motor and a driver into one unit. The structure comprises a front cover, a rotor assembly, a stator assembly, a motor housing, and a rear cover. The rotor assembly and stator assembly are assembled inside the motor housing and fixed to it by the front cover. A plurality of busbars extend from the rear end of the stator assembly, passing through the motor housing, and are then fixed to the back side of the motor housing by the rear cover. Finally, the plurality of busbars are connected to a printed circuit board by fixing elements to form an integrated power system. By integrating the motor and driver into one unit, the internal space layout is simplified, solving the drawbacks of conventional separate installation and wiring of the motor and driver. Furthermore, this integrated power system achieves structural enhancement, cost reduction, and improved range.

Description

Technical Field

[0001] This invention relates to an integrated power system, and more particularly to an integrated power system for electric locomotives that integrates the motor and the drive unit. Prior Technology

[0002] In recent years, with the vigorous development of environmental awareness, electric vehicles are taking away market share from traditional internal combustion engine vehicles with unstoppable momentum. From leading experts in academia to government agencies and corporate groups, everyone is investing all their efforts in research, innovation and promotion, painting a bright future for green travel.

[0003] Please refer to Figures 1 and 1A, which are perspective views of the overall structure of a conventional power system and schematic diagrams of a power system implementation in the conventional patent (CN215817761). As shown in the figures, the motor assembly 10 provides power to the electric vehicle and is controlled and driven by the external drive assembly 20. The motor assembly 10 and the drive assembly 20 are connected by a power transmission line 25 for the transmission of power and signals. As seen in Figure 1A, the complex wiring between the motor 30 and the drive 50 will inevitably create difficulties in the wiring layout and structural space arrangement during structural design. Please also refer to Figures 2 and 3. In the conventional motor assembly 10, the drive assembly 20 is a single unit. The cross-sectional view of the motor assembly 10 shows the stator assembly. The rotor assembly 16 and the stator assembly 14 are located inside the motor housing 11, with the bracket 12 and the outer cover 13 sequentially mounted on the upper end. Inside the stator assembly 14, there are a plurality of annular busbars 15 on the upper end of the core 141 and coil 142. A busbar contact is formed by axially extending from each busbar 15, so that it can be connected to the power transmission line 25 by means of the terminal 26 and the fixing element 27. The driver assembly 20 is composed of a base 21 and an outer cover 24. A printed circuit board 22 is housed inside the drive assembly 20. A busbar 23 is connected to the side of the printed circuit board 22. The busbar 23, the terminal 26, and the fixing element 27 are connected to the power transmission line 25 to output power and signals to drive the motor assembly 10. However, in practice, the drive assembly 20 and the motor assembly 10 are connected by power transmission lines. During assembly, the insulation layer of the power transmission lines may be damaged due to interference or careless handling, making protection difficult. Furthermore, the internal layout of the vehicle's structure, in order to accommodate their respective installation positions, has resulted in an enlarged vehicle body, leading to increased weight and significantly increasing the overall size and weight of the vehicle. This will further reduce the driving range significantly. To ensure the driving range, it is necessary to design a larger capacity battery, which increases costs. In addition, due to the aforementioned internal structural design, enlarged vehicle body (frame), and larger battery, the supporting strength of the frame body needs to be carefully confirmed and evaluated. Common practices include adding peripheral reinforcing brackets to improve strength, or using stronger materials and increasing material thickness to enhance the rigidity of the original frame. However, this increases manufacturing costs and is not ideal, requiring improvement.

[0004] For the reasons mentioned above, there is still room for improvement in the existing technology. In view of this, the inventor actively researched and, with years of experience in the development of related products, and through continuous experimentation and improvement, finally developed this invention. Summary of the Invention

[0005] The main objective of this invention is to provide an integrated powertrain system that overcomes the shortcomings of separate motors and drives in conventional technologies. This system integrates the motor and drive into one unit, thereby achieving smaller size and lighter weight, and offering advantages and functions such as reduced structural strength requirements, lower vehicle manufacturing costs, and improved vehicle range.

[0006] To achieve the above objectives, the present invention provides an integrated power system, the structure of which is It comprises a front cover, a rotor assembly, a stator assembly, a motor housing, and a rear cover; the rotor assembly and the stator assembly are assembled inside the motor housing and fixed to the motor housing by the front cover; a plurality of busbars extend from the rear end of the stator assembly through the motor housing and are then assembled and fixed to the back side of the motor housing by the rear cover; finally, the plurality of busbars are connected to a printed circuit board by a fixing element to form an integrated power system.

[0007] This integrated power system features a split-type motor housing, consisting of a hollow motor housing and a central bracket. During motor assembly, a jig is used to sequentially install the stator and rotor assemblies into the motor housing, followed by assembly with the central bracket to complete the motor assembly. Finally, the drive unit at the rear of the central bracket is installed. This structural design reduces the manufacturing cost of the motor housing while improving the ease of motor assembly.

[0008] To further understand the features and technical content of the present invention, please refer to the following detailed description and accompanying drawings. However, the accompanying drawings are for reference and illustration only and are not intended to limit the present invention in any way. Simple Explanation of the Diagram

[0009] [Figure 1] is a three-dimensional diagram of the overall structure of a known dynamic system; [Figure 1A] is a schematic diagram of the power system implementation in the prior art (CN215817761); [Figure 2] is a longitudinal sectional view of a motor used in a conventional power system; [Figure 2A] is a magnified view of the portion marked A in Figure 2; [Figure 2B] is a three-dimensional schematic diagram of the wiring components of a conventionally used motor; [Figure 3] is a three-dimensional sectional view of a conventional power system application actuator; [Figure 3A] is a three-dimensional schematic diagram of the wiring components of a conventional application driver; [Figure 4] is a perspective view of the integrated power system of the present invention; [Figure 4A] is an exploded perspective view of the integrated power system of the present invention; [Figure 4B] is another perspective view of the stator assembly and busbar of the integrated power system of the present invention; [Figure 5] is a cross-sectional view of the integrated power system of the present invention; [Figure 5A] is a magnified view of the portion marked B in Figure 5; [Figure 6] is a three-dimensional schematic diagram of the motor tail-end busbar of the integrated power system of the present invention; [Figure 7A] is an exploded perspective view of another embodiment of the integrated power system of the present invention; [Figure 7B] is a perspective view of the motor tail end of another embodiment of the integrated power system of the present invention. Implementation

[0010] Please refer to Figures 4 to 6. This invention relates to an integrated power system comprising a front cover 37, a rotor assembly 34, a stator assembly 32, a motor housing 31, a rear cover 35, and a plurality of printed circuit boards 40. The front end of the motor housing 31 is an annular metal shell, while the rear end is a base plate. The stator assembly 32 and the rotor assembly 34 are sequentially assembled into the front end of the motor housing 31, and then the front cover 37 is used to fix the aforementioned assemblies into the motor housing 31. The front cover 37 has a through hole in the middle for the spindle of the rotor assembly 34 to pass through, and a plurality of fixing holes symmetrically arranged on the front face of the motor housing 31 are provided axially on the front cover 37. The base plate on the other side of the motor housing 31 serves as a substrate for mounting the plurality of printed circuit boards 40 at the rear end and for mounting the rear cover 35, thereby forming an integrated power system that integrates the motor and the driver.

[0011] In the cross-sectional view of Figure 5, we can clearly see the simplicity and rationality of the structure of the present invention. In particular, the stator assembly 32 has a plurality of busbars 33 with annular portions and columnar portions extending from the annular portions. The columnar portions axially pass through the power through holes 332 on the base plate of the motor housing 31 and are connected to the corresponding printed circuit board 40. With the holes 331 on the columnar portions of the busbars 33, the fixing element 38 is combined with the insulating pad 39 that passes through the rear end cover 35 to form a covering and fixation.

[0012] In Figure 6, we can clearly see the busbar 33 mounted on the upper part of the stator assembly 32, stator core 321 and coil 322. The annular part of the busbar 33 is provided with the columnar part corresponding to the needs of the printed circuit board at the upper end, so that the assembled integrated power system 30 can reliably integrate the motor and drive into one unit. In addition to helping to facilitate the design of the internal space of the frame, it also has good benefits and performance in terms of reducing parts, reducing weight, reducing vehicle manufacturing costs and battery range.

[0013] As shown in Figure 7, this is another embodiment of the integrated power system of the present invention. The integrally manufactured motor housing 31 can be separated into a motor housing 31a and a middle bracket 36, and integrated with the front cover 37. The rear end of the middle bracket 36 is a base plate, which also has power through holes 332. Although the original design of the motor housing 31 has the advantage of simplifying integration with the other side base plate and has better joint strength with the rear cover 35 of the driver, and the assembly connection dimensional accuracy requirements of the busbar 33 and the printed circuit board 40 are smaller, the radial force generated by the spindle of the rotor assembly 34 during operation of the integrated power system 30 causes a large radial force on the front cover 37, requiring the use of high-strength fixing components to fasten the front cover 37 to the motor housing 31. After transforming it into a combination of the motor housing 31a and the middle bracket 36 and integrating the front cover 37, the single Although the intermediate bracket 36 of the pure conversion rear end has high requirements for the dimensional accuracy of the assembly connection between the busbar 33 and the printed circuit board 40 (cumulative tolerance factor), it can be used with different driver structures (different drivers are matched with different rear end cover 35 shapes). At the same time, the motor housing 31a is axially annular and has a hollow metal shell with an opening at the front end for the spindle of the rotor assembly 34 to pass through. After the front end cover 37 is integrated, the spindle of the rotor assembly 34 generates radial force, which has little impact on the front end strength of the motor housing 31a.

[0014] In summary, the integrated power system of this invention improves upon the conventional technology by connecting the motor and its driver via a power transmission line. It integrates them into a single unit with a simple structure, which not only reduces the difficulties of separate design of the frame mechanism caused by the driver, but also reduces the overall size of the power system, which helps to make the design more flexible and reasonable. Furthermore, it has the advantages of fewer parts, easier maintenance, and lower material costs, which can significantly improve the vehicle's range and achieve the effect of energy saving and carbon reduction.

[0015] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Anyone skilled in this art may make some modifications and refinements without departing from the spirit and scope of this invention. Therefore, the scope of protection of this invention shall be determined by the appended claims.

[0016] 10: Motor Assembly 11: Motor housing 12: Bracket 13: Outer cover 14: Stator assembly 141: Iron Heart 142: Coil 15: Busbar 16: Rotor assembly 20: Drive assembly 21: Base 22: Printed Circuit Board 23: Busbar 24: Outer Cover 25: Power transmission lines 26:Terminal 27: Fixed components 30: Integrated Powertrain 31: Motor housing 31a: Motor housing 32: Stator assembly 321: Stator core 322: Coil 33: Busbar 331: Kong 332: Power Through Hole 34: Rotor assembly 35: Rear end cover 36: Middle bracket 37: Front cover 38: Fixed components 39: Insulating mat 40: Printed Circuit Board

Claims

1. An integrated power system, comprising: A rotor assembly consists of a spindle; a stator assembly includes a stator core and coils. A plurality of busbars are disposed on the upper end of the stator assembly, each having an annular portion and a columnar portion extending from the annular portion, the columnar portion having a connection hole; a motor housing, the front end of which is an annular metal shell, and the rear end of which is a base plate; a rear end cover, having a printed circuit board locked inside the rear end cover, the overall structure being assembled and fixed to the motor housing; a front end cover, having a through hole in the middle for the rotor assembly spindle to pass through, and having a plurality of fixing holes symmetrically arranged on the front end face of the motor housing along the axial direction of the front end cover; the rotor assembly and the stator assembly are sequentially assembled into the motor housing and fixed to the motor housing by the front end cover; the columnar portion of the busbar passes axially through the motor housing and is assembled and fixed to the base plate of the motor housing by the rear end cover; finally, the busbar is connected to a printed circuit board by a fixing element to form an integrated power system.

2. An integrated power system, comprising: A rotor assembly consists of a spindle; a stator assembly includes a stator core and coils. A plurality of busbars are disposed on the upper end of the stator assembly, each having an annular portion and a columnar portion extending from the annular portion, the columnar portion having a hole for engagement; a motor housing, which is an axially annular hollow metal shell with an opening at the front end for the spindle of the rotor assembly to pass through; a middle bracket, one end of which is fixed to the motor housing, the rear end of which is a base plate; a rear end cover, having a printed circuit board locked inside the rear end cover, the overall structure being assembled and fixed to the motor housing and the middle bracket; the rotor assembly and the stator assembly are sequentially assembled into the motor housing and fixed to the motor housing by the middle bracket; the columnar portion of the busbar passes axially through the middle bracket and is assembled and fixed by the rear end cover and the base plate of the middle bracket; finally, the busbar is connected to a printed circuit board by a fixing element to form an integrated power system.

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