Integrated oil-cooled e-axle

Abstract

The prevent invention relates to the technical field of new energy automobile power devices, and specifically relates to an integrated oil-cooled e-axle, comprising: an integrated housing, and a motor, a controller, and a speed reducer that are installed on the integrated housing. The motor is in transmission fit with the speed reducer. The motor is electrically connected to the controller. The integrated housing is provided with an oil cooling flow channel. The oil cooling flow channel comprises a first main flow channel and a second main flow channel. The motor and the speed reducer are provided with corresponding oil paths that are connected to the first main flow channel and the second main flow channel respectively, so that cooling oil cools a rotor and a stator of the motor along the oil paths, and lubricates bearings on the speed reducer. Oil cooling advantages are fully utilized in the present invention. On the basis of an oil cooling design of a conventional stator and rotor, the cooling design is optimized, so that the motor, the speed reducer, and a differential are cooled, all bearings on the motor, the speed reducer, and the differential are lubricated, thereby improving the output performance of the e-axle, prolonging the service life of the e-axle, and achieving higher reliability and practicability.

Description

An integrated oil-cooled electric bridge Technical Field

[0001] The present invention belongs to the technical field of new energy vehicle power devices, and particularly relates to an integrated oil-cooled electric bridge. Background Art

[0002] The electric bridge (also known as the electric drive system) is the power system of an electric vehicle, used to drive the vehicle. The electric bridge generally consists of three parts: the motor, the reducer, and the motor controller. During operation, the motor controller converts the DC power provided by the battery into three-phase AC power to supply the motor. The motor converts the three-phase electrical energy into mechanical energy of the motor rotor through electromagnetic action. The reducer converts the mechanical energy of the motor rotor into the required speed and torque to drive the vehicle through an appropriate speed ratio. Currently, mainstream electric bridges tend to design the three parts independently. After they are assembled separately or partially, they are then mechanically assembled into an assembly using bolts. This traditional solution results in a large weight and volume for the electric bridge assembly. At the same time, this type of electric bridge mainly uses a water-cooled motor cooling method, which is not very efficient and the motor performance is not outstanding.

[0003] Summary of the Invention

[0004] In view of the shortcomings of the prior art mentioned above, the purpose of the present invention is to provide an integrated oil-cooled electric bridge with a three-in-one highly integrated design, which optimizes the oil cooling flow channel inside the electric bridge, cools the motor, reducer and differential while also lubricating their corresponding bearing systems to improve the output performance of the electric bridge.

[0005] To achieve the above-mentioned objectives and other related objectives, the present invention provides an integrated oil-cooled electric bridge, comprising: an integrated housing, and a motor, a controller, and a reducer installed on the integrated housing, and the motor and the reducer are transmission-matched, and the motor and the controller are electrically connected; wherein, an oil-cooling flow channel is provided on the integrated housing, and the oil-cooling flow channel includes a first main flow channel and a second main flow channel, and corresponding oil circuits are provided on the motor and the reducer, respectively connected to the first main flow channel and the second main flow channel, so that the cooling oil cools the rotor and stator of the motor along the oil circuit and lubricates the bearings on the reducer.

[0006] According to a specific embodiment of the present invention, the motor includes: a stator, fixed in the integrated shell, and the stator includes: a stator core, fixed to the inner wall of the integrated shell, and a first oil injection ring and a second oil injection ring are respectively provided at both ends of the stator core; a first through hole is circumferentially provided in the stator core for connecting the first oil injection ring and the second oil injection ring; a stator winding is fixed on the stator core, and the two ends of the stator winding are respectively provided corresponding to the first oil injection ring and the second oil injection ring; and a rotor is rotatably matched with the stator.

[0007] According to a specific embodiment of the present invention, the first main flow channel is formed on the outer wall of the integrated shell and is arranged corresponding to the stator core; a first oil outlet hole is provided on the first main flow channel, which is connected to the second oil spray ring; wherein the cooling oil flows from the first oil outlet hole along the first main flow channel into the second oil spray ring.

[0008] According to a specific embodiment of the present invention, the first oil injection ring and the second oil injection ring adopt a completely sealless structure or a partially sealless structure; the first oil injection ring and the second oil injection ring form a quasi-sealed fit with the first through hole.

[0009] According to a specific embodiment of the present invention, the rotor includes: a rotating shaft, a first end of which is equipped with a first rotating bearing, a second end of which is equipped with a second rotating bearing, and a third rotating bearing on the shaft body; and a first oil pipeline is formed inside the rotating shaft along the first end; a rotor core is coaxially fixedly connected to the rotating shaft; and a rotating disk is fixed at both ends of the rotor core; wherein a second through hole is circumferentially provided on the core, and a first connecting hole is provided between the rotating shaft and the rotating disk, passing through one side where the rotating shaft and the rotating disk are fitted to connect the first oil pipeline and the second through hole.

[0010] According to a specific embodiment of the present invention, a second connecting hole is provided on the rotating shaft at a position corresponding to the third bearing, passing through one side of the first oil passage, so that cooling oil can flow out along the second connecting hole to the third bearing.

[0011] According to a specific embodiment of the present invention, the first main flow channel further extends in a direction close to the second end of the rotating shaft.

[0012] According to a specific embodiment of the present invention, a second oil outlet hole is further provided on the first main flow channel, and the second oil outlet hole is located above the second rotating bearing; wherein, a plug is provided at the outlet of the second oil outlet hole, and the cooling oil flows out from the second oil outlet hole along the first main flow channel and drips onto the second rotating bearing.

[0013] According to a specific embodiment of the present invention, a third oil outlet is further provided on the first main channel; wherein, a spray device is provided at the outlet of the third oil outlet, and the cooling oil flows out from the third oil outlet along the first main channel and is sprayed onto the high-voltage line electrically connecting the motor and the controller.

[0014] According to a specific embodiment of the present invention, the reducer includes: a driving gear, which is arranged to rotate coaxially with the rotating shaft; a driven gear, which is in transmission cooperation with the driving gear; an intermediate shaft, which is equipped with a first intermediate bearing at the first end and a second intermediate bearing at the second end; and the intermediate shaft is arranged to rotate coaxially with the driven gear; a reducer housing, which is provided with a first oil passage, a second oil passage, and a third oil passage; wherein the outlet of the first oil passage is connected to the first oil passage, and the outlet of the second oil passage is provided corresponding to the matching position of the driving gear and the driven gear; a second oil passage is formed inside the intermediate shaft along the direction from the first end to the second end, and the outlet of the third oil passage is connected to the second oil passage.

[0015] According to a specific embodiment of the present invention, the second main flow channel is respectively provided with a first outlet, a second outlet, and a third outlet, which are correspondingly connected to the inlet of the first oil channel, the inlet of the second oil channel, and the inlet of the third oil channel.

[0016] According to a specific embodiment of the present invention, a first gap is formed between the outlet of the first oil channel and the first oil passage, and the position of the first gap corresponds to the first rotating bearing; wherein the cooling oil flows out from the first gap along the first oil channel to the first rotating bearing.

[0017] According to a specific embodiment of the present invention, a second gap is formed between the outlet of the third oil channel and the second oil passage, and the position of the second gap corresponds to the first intermediate bearing; wherein the cooling oil flows out from the second gap along the third oil channel to the first intermediate bearing.

[0018] According to a specific embodiment of the present invention, it further includes: a differential, which is in transmission cooperation with the intermediate shaft; wherein, the differential includes a gear assembly, an output shaft and a differential housing, the gear assembly is respectively in transmission cooperation with the intermediate shaft and the output shaft, and the output shaft is used to connect to an external device.

[0019] According to a specific embodiment of the present invention, the first end of the output shaft is equipped with a first differential bearing; wherein, the third oil channel forms a sub-oil channel at the first end of the intermediate shaft along the cross-sectional direction of the intermediate shaft, and a first oil hole is formed on the differential housing, which is arranged corresponding to the first differential bearing and is connected to the sub-oil channel, so that the cooling oil drips along the first oil hole onto the first differential bearing.

[0020] According to a specific embodiment of the present invention, the second end of the output shaft is equipped with a second differential bearing; wherein, a second oil hole is provided in the integrated housing, which is respectively arranged corresponding to the first oil spray ring and the second differential bearing, so that the cooling oil flows from the second oil hole along the first oil spray ring to the second differential bearing.

[0021] According to a specific embodiment of the present invention, an oil pool is provided at the bottom of the integrated housing for collecting the cooling oil; wherein, the bottom of the integrated housing is inclined along the direction in which the two ends of the motor converge toward the center, and in the direction in which the motor approaches the reducer, to form the oil pool.

[0022] According to a specific embodiment of the present invention, an oil return hole or an oil return channel is correspondingly provided on the bottom of the integrated housing along the path in the direction where the two ends of the motor converge toward the center, and / or on the path in the direction where the motor approaches the reducer, so that the cooling oil can flow into the oil pool.

[0023] According to a specific embodiment of the present invention, a heat exchanger and an oil pump are further included, and the oil pump extracts oil from the oil pool and inputs the oil into the heat exchanger for cooling to form the cooling oil.

[0024] According to a specific embodiment of the present invention, an oil suction port is provided at the center of both ends of the motor at the bottom of the integrated housing, and an oil suction channel is extended and connected to the oil suction port; wherein the other end of the oil suction channel is connected to the oil pump.

[0025] According to a specific embodiment of the present invention, a water cooling channel is further provided on the integrated housing; wherein cooling water flows along the water cooling channel through the controller, the second rotating bearing and the heat exchanger, and flows out of the heat exchanger.

[0026] According to a specific embodiment of the present invention, the controller includes a cooling plate, and the cooling plate is provided with a water inlet and a water outlet; the integrated shell is provided with a water inlet hole and a water outlet hole corresponding to the water inlet and the water outlet respectively; wherein, cooling water flows into the cold plate from the water inlet hole and flows out from the water outlet hole.

[0027] According to a specific embodiment of the present invention, a cover shell is further provided on the side of the integrated shell close to the second rotating bearing, and a first channel is provided on the cover shell to cooperate with the water outlet so that cooling water flows into the first channel; and the first channel is arranged on the outside of the second rotating bearing.

[0028] According to a specific embodiment of the present invention, the first channel is arranged around the circumference of the second rotating bearing.

[0029] According to a specific embodiment of the present invention, a second channel is further provided on the integrated housing, connecting the first channel and the heat exchanger, and the second channel is arranged outside the stator key of the motor.

[0030] The present invention provides an integrated oil-cooled electric bridge, which fully utilizes the advantages of oil cooling. On the basis of the traditional stator and rotor oil cooling design, the cooling design is optimized to cool the motor, reducer and differential, thereby extending the service life of the electric bridge and improving reliability. It also lubricates all bearings on the motor, reducer and differential, which correspondingly improves the output performance of the electric bridge. The amount of lubricating oil is actively adjustable through an oil pump and is decoupled from the assembly speed, making it highly adaptable. At the same time, water cooling channels are added accordingly to optimize the cooling design, cool the controller, i.e., the stator punch keys, and promote oil circulation in the electric bridge through a heat exchanger to improve oil cooling efficiency. The integrated oil-cooled electric bridge of the present invention has a three-in-one highly integrated design and adopts an integrated housing, which can reduce the number of mating surfaces and the number of connectors, and reduce the size and weight of the assembly. The oil cooling channel and the water cooling channel are all integrated inside the housing, without the need for integrated external piping. The outer boundary is neat and compact, with good reliability and high practicality. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG1 is a perspective view of a specific embodiment of an integrated oil-cooled bridge provided by the present invention;

[0032] FIG2 is a perspective view of a specific embodiment of the integrated housing provided by the present invention;

[0033] FIG3 is a schematic diagram showing the distribution of an oil cooling channel according to a specific embodiment of the present invention;

[0034] FIG4 is a partial schematic diagram of another specific embodiment of the oil cooling channel provided by the present invention;

[0035] FIG5 is a partial cross-sectional view of a specific embodiment of a motor provided by the present invention;

[0036] FIG6 is a partial cross-sectional view of another specific embodiment of an electrode provided by the present invention;

[0037] FIG7 is a partial cross-sectional view of a specific embodiment of a reducer provided by the present invention;

[0038] FIG8 is a partial cross-sectional view of a specific embodiment of a speed reducer and a differential provided by the present invention;

[0039] FIG9 is a perspective view of another specific embodiment of the integrated housing provided by the present invention;

[0040] FIG10 is a schematic diagram showing the distribution of a specific embodiment of the water cooling channel provided by the present invention;

[0041] FIG11 is a schematic diagram showing the distribution of another specific embodiment of the water cooling channel provided by the present invention. DETAILED DESCRIPTION

[0042] The following describes the embodiments of the present invention through specific examples. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. The details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other unless they conflict.

[0043] It should be noted that the illustrations provided in the following embodiments are merely schematic illustrations of the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape, and size of components in actual implementation. In actual implementation, the type, quantity, and proportion of each component may be changed arbitrarily, and the component layout may also be more complex.

[0044] Please refer to Figures 1-11, which show an integrated oil-cooled electric bridge, comprising: a motor 10, a controller 20, a reducer 30, and an integrated housing 40, and the integrated housing 40 is formed with corresponding mounting positions for mounting the motor 10, the controller 20, and the reducer 30. As shown in Figure 2, the interior of the integrated housing 40 is hollow, and the motor 10 and the reducer 30 are respectively embedded in the integrated housing 40 from both sides to form a transmission fit. A groove is also formed on the top of the integrated housing 40 for mounting the controller 20, and the controller 20 is electrically connected to the motor 10 to control the start and stop and the rotation speed of the motor 10 according to the control signal. The electric bridge in this embodiment greatly simplifies the overall structure, reduces system components, and reduces the volume and weight of the electric bridge through an integrated setting.

[0045] Furthermore, an oil cooling channel 41 is provided inside the integrated housing 40, extending along the positions of the stator 11 and the rotor 12 of the motor 10, and oil circuits that cooperate with the oil cooling channel 41 are formed on the stator 11 and the rotor 12, so that the cooling oil can cool the motor 10. At the same time, the cooling oil can also lubricate the bearings on the rotor 12 along the oil circuit, thereby improving the rotation performance of the motor 10. Specifically, as shown in Figure 3, the oil cooling channel 41 includes a first main channel 411 and a second main channel 412, which are respectively provided corresponding to the oil circuits on the stator 11 and the rotor 12, and the cooling oil can act on the stator 11 and the rotor 12 from different channels. This embodiment integrates the oil cooling channel 41 on and inside the housing of the electric bridge, thereby avoiding the need for a large number of pipes, which results in a complex overall structure of the electric bridge and crisscrossed cooling paths.

[0046] In one specific embodiment, as shown in FIG6 , the stator 11 of the motor 10 is fixed within an integrated housing 40 and includes a stator core 111 and a stator winding 112. The stator core 111 is fixed to the integrated housing 40, being fixedly attached to the inner wall of the integrated housing 40. A first oil injection ring 113 and a second oil injection ring 114 are provided at either end of the stator core 111, respectively. A first through-hole 1111 is provided circumferentially around the stator core 111 to connect the first and second oil injection rings 113, 114, forming an oil circuit. The stator winding 112 is fixed to the stator core 111, with the first and second oil injection rings 113, 114 provided at either end.

[0047] Specifically, the first main channel 411 is formed on the outer wall of the integrated housing 40 and is positioned to correspond to, and preferably parallel to, the stator core 111. Furthermore, a first oil outlet hole 4111 is formed in the first main channel 411, extending through the integrated housing 40 to connect the first main channel 411 with the second oil spray ring 114. Cooling oil can flow from the first oil outlet hole 4111 along the first main channel 411 into the second oil spray ring 114. Under the influence of oil pressure, the second oil spray ring 114 sprays the cooling oil onto the ends of the stator winding 112. Simultaneously, the cooling oil can flow along the first through-hole 1111 in the stator core 111 to the first oil spray ring 113, where it is sprayed onto the other end of the stator winding 112, thereby cooling the stator winding 112.

[0048] The spray hole angles on the first and second oil spray rings 113, 114 are adjustable to evenly spray cooling oil onto the stator winding 112, enhancing cooling efficiency. The first and second oil spray rings 113, 114 can employ a fully or partially sealless structure. A quasi-sealed fit is formed between the first and second oil spray rings 113, 114 and the first through-holes 1111 in the stator core 111, enhancing cooling oil delivery. Furthermore, as cooling oil flows through the first through-holes 1111, the stator core 111 is cooled accordingly. Furthermore, the circumferential arrangement of the first through-holes 1111 ensures sufficient contact between the cooling oil and the stator core 111, significantly enhancing cooling efficiency.

[0049] Furthermore, the rotor 12 rotates in conjunction with the stator 11. When the controller 20 outputs current, the magnetic field causes the rotor 12 to rotate and output power. The rotor 12 includes a rotating shaft 121, a rotor core 122, and a rotating disk 123. The first end of the rotating shaft 121 is fitted with a first rotating bearing 1211, the second end is fitted with a second rotating bearing 1212, and the shaft body is fitted with a third rotating bearing 1213. A first oil passage 1214 is formed within the rotating shaft 121, extending from the first end toward the second end.

[0050] Furthermore, the rotor core 122 is coaxially fixed to the rotating shaft 121, and is circumferentially provided with second through-holes 1221. The rotating disk 123 is fixed to both ends of the rotor core 122. Furthermore, to cool the rotor core 122, a first connecting hole 1215 is provided between the rotating shaft 121 and the rotating disk 123. This hole 1215 penetrates the side where the rotating shaft 121 and the rotating disk 123 meet, connecting the first oil passage 1214 with the second through-hole 1221, allowing cooling oil to flow into the rotor core 122 through the first oil passage 1214.

[0051] In one embodiment, the first main channel 411 extends toward the second end of the rotating shaft 121, and the extended portion of the first main channel 411 is provided with a second oil outlet 4112 and a third oil outlet 4113. As shown in FIG5 , the second oil outlet 4112 is located above the second rotating bearing 1212, and a plug is provided at the outlet to prevent cooling oil from spraying out of the second oil outlet 1212. Due to the plug and gravity, the cooling oil can slowly flow out of the second oil outlet 4112 and drip onto the second rotating bearing 1212 for lubrication. In this embodiment, the controller 20 and the motor 10 are connected via a UVWN high-voltage line, and the third oil outlet 4113 is positioned directly opposite the high-voltage line. As shown in FIG4 , the third oil outlet 4113 can preferably be formed as four spray holes or equipped with a spray device, so that cooling oil is sprayed through the third oil outlet 4113 to cool the high-voltage line. It should be noted that the connection between the controller 20 and the motor 10 via a high-voltage line is only a preferred embodiment. The third oil outlet 4113 can be adjusted according to actual needs. For example, if there is no N phase, three nozzles can be set to correspond to the UVW high-voltage line.

[0052] In one specific embodiment, as shown in FIG7 , the reducer 30 includes: a driving gear 31, which is coaxially rotatable with the rotating shaft 121 of the rotor 12 and can be fixed to the first end of the rotating shaft 121. A driven gear 32, which meshes with the driving gear 31 to form a transmission fit, and the radius of the driven gear 32 is larger than that of the driving gear 31, so as to reduce the speed obtained from the rotating shaft 121 and achieve a reduction effect. An intermediate shaft 33, which is coaxially rotatable with the driven gear 32, is provided with a first intermediate bearing 331 and a second intermediate bearing 332 at its first and second ends, respectively. A second oil passage 333 is formed internally along the first and second ends of the intermediate shaft 33.

[0053] Preferably, the driven gear 32 is disposed on the first end of the intermediate shaft 33. In this embodiment, the direction from the first end to the second end of the intermediate shaft 33 is consistent with the direction from the first end to the second end of the rotating shaft 121. Furthermore, a reducer housing 34 is provided between the various components of the reducer 30. A portion of the reducer housing 34 is disposed outside the driven gear 32 and is assembled and mated with the integrated housing 40. This portion of the reducer housing is provided with a first oil passage 341, a second oil passage 342, and a third oil passage 343, respectively, which are connected to the second main flow channel 412. Cooling oil can flow along the first oil passage 341, the second oil passage 342, and the third oil passage 343 to various locations within the reducer 30 for cooling and lubrication.

[0054] The first oil passage 341 is used to direct cooling oil into the first oil passage 1214 of the rotating shaft 121. Therefore, the outlet of the first oil passage 341 is connected to the first oil passage 1214. The second oil passage 342 is used to introduce cooling oil to the meshing area between the driving gear 31 and the driven gear 32 for lubrication to improve rotational performance. Therefore, the outlet of the second oil passage 342 is located directly opposite the driving gear 31 and / or the driven gear 32. The third oil passage 343 is used to direct cooling oil into the second oil passage 333 of the intermediate shaft 33. Therefore, the outlet of the third oil passage 343 is connected to the second oil passage 333.

[0055] Specifically, the second main flow channel 412 is located on the outer wall of the integrated housing 40 and extends toward the first end of the rotating shaft 121. Furthermore, the second main flow channel 412 is provided with a first outlet, a second outlet, and a third outlet (not shown) corresponding to the first oil passage 341, the second oil passage 342, and the third oil passage 343, respectively, on the reducer housing 34. In this embodiment, the first outlet and the first oil passage 341, the second outlet and the second oil passage 342, and the third outlet and the third oil passage 343 are sealed by press-fitting, allowing cooling oil to flow into the reducer 30.

[0056] It should be noted that in this embodiment, the second main flow channel 412 is illustrated as an outlet in order to connect to the oil circuit on the reducer housing 34. However, this arrangement is not limited to this and can be adjusted according to actual needs. For example, to avoid devices or circuits on the bridge, the second main flow channel 412 can branch into multiple branches to avoid these devices and then connect to the oil circuit on the reducer housing 34.

[0057] The cooling oil flows along the first oil passage 341 into the first oil passage 1214 to cool the rotating shaft 121 from the inside, and then flows along the first connecting hole 1215 into the second through hole 1221 of the rotor core 122. The cooling oil, passing through the second through hole 1221, is able to effectively contact the rotor core 122, enhancing the cooling effect. When the rotating shaft 121 drives the rotor core 122 to rotate, the cooling oil splashes along the ends of the second through hole 1221 under the action of centrifugal force to the ends of the stator winding 112, further enhancing the cooling of the stator winding 112.

[0058] The cooling oil passes through the second oil passage 342 and is sprayed onto the driving gear 31 from the outlet, thereby improving the transmission performance of the driving gear 31 and the driven gear 32. Preferably, a spray device can be provided at the outlet of the second oil passage 342 to improve the splashing effect of the cooling oil.

[0059] Furthermore, in this embodiment, the connection between the first oil passage 341 and the first oil conduit 1214 is not sealed, and a first gap is formed at the connection. This allows cooling oil to partially flow out of the first gap when it flows into the first oil conduit 1214 and lubricate the first rotating bearing 1211, thereby improving the rotational performance of the rotor 12. Furthermore, a second connecting hole 1216 is provided on the rotating shaft 121 at the location of the third rotating bearing 1213. This hole connects to the first oil conduit 1214 and extends through one side of the first oil conduit 1214. This allows cooling oil in the first oil conduit 1214 to flow out of the second connecting hole 1216 and lubricate the third rotating bearing 1213, further improving the rotational performance of the rotor 12.

[0060] In this embodiment, as shown in Figure 8 , the third oil passage 343 on the reducer housing 34 communicates with the second oil conduit 333 within the intermediate shaft 33. A second gap is formed at the connection, corresponding to the position of the first intermediate bearing 331. When cooling oil flows into the third oil passage 343, most of it enters the second oil conduit 333, cooling the intermediate shaft 33. A small amount drips along the second gap onto the first intermediate bearing 331, lubricating the rotational fit between the first intermediate bearing 331 and the intermediate shaft 33, thereby improving the power output performance of the electric axle.

[0061] Furthermore, the second oil passage 333 runs through the first and second ends of the intermediate shaft 33. Cooling oil flows in from the first end of the intermediate shaft 33 and sprays out from the second end onto the inner wall of the integrated housing 40. A shoulder is provided at a corresponding position on the inner wall of the integrated housing to allow the cooling oil to drip along the shoulder onto the second intermediate bearing 332, thereby lubricating the second intermediate bearing 332. Alternatively, the connection angle between the third oil passage 343 and the second oil passage 333 can be adjusted so that the cooling oil sprays along the third oil passage 343 onto the inner wall of the second oil passage 333 and then flows to the first and second intermediate bearings 331, 332 at either end.

[0062] It can be seen that the cooling oil flows along the second main flow channel 412 on the integrated housing 40 and the oil circuit in the reducer 30, which effectively cools and lubricates the bearing system in the reducer 30, greatly improving the power output performance of the reducer 30, reducing the friction loss between the gears, and avoiding overheating of the shaft that affects its service life.

[0063] In a specific embodiment, the integrated oil-cooled electric bridge provided in this embodiment is applied to a vehicle. Therefore, the electric bridge also includes a differential 50 to output different torques. The differential cooperates with the intermediate shaft of the reducer 30 to obtain power input, and the differential 50 includes a gear assembly, an output shaft, and a matching differential housing. Among them, the intermediate shaft 33, the gear assembly and the output shaft are matched with each other to adjust the power of the reducer 30 and output it through the output shaft. In application, the first end and the second end of the output shaft are respectively matched with a first differential bearing and a second differential bearing to achieve transmission and power output. In order to improve the output performance of the differential, a corresponding oil circuit is also provided on the differential.

[0064] Specifically, the third oil passage 343 forms a sub-oil passage 3431 at the first end of the intermediate shaft along the cross-sectional direction of the intermediate shaft 33, into which a portion of the cooling oil can flow. Accordingly, a corresponding first oil hole is provided in the differential housing, directly opposite the first differential bearing and connected to the sub-oil passage 3431, allowing the cooling oil to lubricate the first differential bearing. Furthermore, due to the transmission coordination between the motor 10, the reducer 30, and the differential 50, they are interconnected within the integrated housing 40. Therefore, second oil holes are provided within the integrated housing 40, corresponding to the positions of the first oil spray ring 113 and the second differential bearing, respectively. Cooling oil sprayed from the first oil spray ring 113 splashes onto the second oil hole and flows along the second oil hole to lubricate the second differential bearing.

[0065] The cooling oil in this embodiment cools and lubricates the motor 10, the reducer 30 and the differential 50 along the oil cooling channel 41 and the corresponding oil circuit, thereby improving the power output performance of the electric bridge and extending the service life of the electric bridge.

[0066] It should be noted that the above-mentioned cooling oil oil cooling channel 41 and the set oil circuit for cooling and lubricating the motor 10, reducer 20 and differential 50 are not limited to the structural forms such as the holes and pipelines mentioned in this embodiment. For example, the cooling oil can also be delivered to the various bearing systems of the motor 10, reducer 30 and differential 50 by grooving or drilling oil channel holes, and structures with similar oil delivery methods are within the scope of protection of this application.

[0067] Furthermore, the cooling oil in this embodiment forms an oil circulation system. The cooling oil is delivered to the bearing systems of the motor 10, the reducer 30, and the differential 50 through the oil cooling channel 41 and the provided oil circuit. Furthermore, the bottom of the integrated housing 40 is centered on the location of the reducer 30, with the periphery inclined toward the center to form an oil pool (not shown). Under the action of gravity, the cooling oil eventually drips or flows into the oil pool. Specifically, the oil pool is located along the longitudinal axis of the motor 10 and below the reducer 30 to better collect the cooling oil within the integrated housing. Corresponding oil return holes or oil return channels are provided in the oil return path at the bottom of the integrated housing 40 to allow the cooling oil to pass through. The cooling oil at both ends of the rotor is collected through the oil return holes or oil return channels and flows into the oil pool. Furthermore, as shown in Figure 9, the bottom of the integrated housing 40 is also provided with an oil suction port 43 and an oil suction channel 44. The oil suction port 43 can be located at the center of each end of the motor 10, thereby connecting to the oil return path at both ends of the rotor, allowing the cooling oil to pass through the oil suction port 43. At the same time, the oil suction channel 44 extends the oil suction port 43, with the other end connected to the oil pump. Under the negative pressure of the oil pump, cooling oil can be directly drawn by the oil pump through the oil suction port 43 and the oil suction channel 44, thereby achieving oil circulation. Furthermore, the oil pump can also vacuum the oil to create negative pressure, accelerating the return of cooling oil from both ends of the motor, reducing oil accumulation at the ends and lowering the risk of oil accumulation entering the motor air gap. In addition, negative pressure accelerates the return oil flow rate and can also reduce the cross-section of the return oil channel to a certain extent, which is conducive to reducing the envelope size. Accelerating the return oil flow rate and speeding up oil circulation can reduce the amount of cooling oil added.

[0068] An oil pump and a heat exchanger 60 are also located within the integrated housing 40. The oil pump draws oil from the oil sump, cools it down through the heat exchanger 60, and regenerates it into cool oil. This oil is then transported along the oil cooling channel to the motor 10, the reducer 30, and the differential 50, thus forming an oil cycle. Preferably, a filter is provided between the oil sump and the oil pump to filter out impurities and components within the oil sump.

[0069] In one embodiment, as shown in FIG10 , the integrated housing 40 is further provided with a water cooling channel 42. Cooling water is drawn from the vehicle and flows along the cooling channel 42 through the controller 20, the second rotating bearing 1212, and the heat exchanger 60 before returning to the vehicle, forming a water cycle. The cooling water, while flowing through the heat exchanger 60, cools the oil input into the heat exchanger 60, thereby forming cooling oil.

[0070] The controller 20 assembly includes a cold plate, and the cold plate is provided with a water inlet and a water outlet. A water inlet hole 421 and a water outlet hole are provided at the mounting position of the controller 20, corresponding to the water inlet and water outlet. Cooling water can flow into the cold plate along the water inlet hole 421 and the water outlet hole to cool the controller 20. In this embodiment, the water inlet and water outlet on the cold plate are connected to the water inlet hole 421 and the water outlet hole on the integrated housing via a press-fit seal. Alternatively, other connections may be used, such as providing a water inlet pipe and a water outlet pipe on the integrated housing 40 that can be inserted into the water inlet and water outlet of the controller 20 cold plate. The actual connection structure is not subject to excessive restrictions.

[0071] Furthermore, as shown in Figure 4 , a cover 45 is provided on the side of the integrated housing 40 near the second rotating bearing 1212, i.e., the side where the motor 10 is mounted. A first channel is provided on the cover 45, cooperating with a water outlet. This allows cooling water to flow from the cold plate and then into the first channel to cool the second rotating bearing 1212. Preferably, the first channel is circumferentially arranged around the second rotating bearing 1212 for more efficient cooling. The first channel can also be configured in other configurations.

[0072] As shown in Figure 11, a second channel 422 is formed on the integrated shell 40 along the direction of the stator key of the motor 10, and is connected to the first channel and the heat exchanger 60. The cooling water can cool the stator key well through the second channel 422 to avoid the risk of the stator key loosening under high temperature conditions.

[0073] The water-cooling channel in this embodiment can not only cool the control board, but also cool the second rotating bearing and the electronic punch key along the water channel. Finally, it can also cool the oil in the heat exchanger, promote oil circulation in the electric bridge, and correspondingly improve the power output performance of the electric bridge and extend its service life.

[0074] In summary, the present invention provides an integrated oil-cooled electric bridge, which fully utilizes the advantages of oil cooling. On the basis of the traditional stator and rotor oil cooling design, the cooling design is optimized to cool the motor, reducer and differential, thereby extending the service life of the electric bridge and improving reliability. It also lubricates all bearings on the motor, reducer and differential, which correspondingly improves the output performance of the electric bridge. The amount of lubricating oil is actively adjustable through an oil pump and is decoupled from the assembly speed, making it highly adaptable. At the same time, water cooling channels are added accordingly to optimize the cooling design, cool the controller, i.e., the stator punch key, and promote oil circulation in the electric bridge through a heat exchanger to improve oil cooling efficiency. The integrated oil-cooled electric bridge of the present invention has a three-in-one highly integrated design and adopts an integrated housing, which can reduce the number of mating surfaces and the number of connectors, and reduce the size and weight of the assembly. The oil cooling channel and the water cooling channel are all integrated inside the housing, without the need for integrated external piping. The outer boundary is neat and compact, with good reliability and high practicality.

[0075] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

[0076] In the description herein, numerous specific details, such as examples of components and / or methods, are provided to provide a complete understanding of the embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention may be practiced without one or more of the specific details or with other devices, systems, assemblies, methods, components, materials, parts, etc. In other cases, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of the embodiments of the present invention.

[0077] Reference throughout this specification to "one embodiment," "an embodiment," or "a specific embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention, and not necessarily in all embodiments. Thus, various appearances of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the invention may be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments of the invention described and illustrated herein are possible in light of the teachings herein and are considered part of the spirit and scope of the invention.

[0078] It should also be understood that one or more of the elements shown in the figures may also be implemented in a more separate or more integrated manner, or even removed because they are inoperable in certain circumstances or provided because they may be useful depending on the application.

[0079] In addition, unless otherwise expressly indicated, any marking arrows in the drawings should be regarded as illustrative only and not limiting. Furthermore, unless otherwise indicated, the term "or" as used herein is generally intended to mean "and / or." Where a term is unclear in providing separation or combination capabilities, the combination of components or steps will also be considered as indicated.

[0080] As used in the description herein and throughout the claims that follow, “a,” “an,” and “the” include plural references unless otherwise indicated. Likewise, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless otherwise indicated.

[0081] The above description of the illustrated embodiments of the present invention (including that described in the Abstract) is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. Although specific embodiments of the present invention and examples of the present invention are described herein for illustrative purposes only, as those skilled in the art will recognize and appreciate, various equivalent modifications are possible within the spirit and scope of the present invention. As noted, modifications may be made to the present invention in light of the above description of the illustrated embodiments of the present invention, and such modifications will be within the spirit and scope of the present invention.

[0082] Systems and methods have been generally described herein in detail to facilitate understanding of the present invention. In addition, various specific details have been given to provide an overall understanding of embodiments of the present invention. However, those skilled in the relevant art will recognize that embodiments of the present invention may be practiced without one or more of these specific details, or with other devices, systems, accessories, methods, components, materials, parts, etc. In other cases, well-known structures, materials, and / or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

[0083] Thus, although the invention has been described herein with reference to specific embodiments thereof, freedom of modification, various changes and substitutions are contemplated within the foregoing disclosure, and it should be understood that in some cases, some features of the invention will be employed without the corresponding use of other features without departing from the scope and spirit of the claimed invention. Thus, many modifications may be made to adapt a particular environment or material to the true scope and spirit of the invention. The invention is not intended to be limited to the specific terminology used in the claims below and / or to the specific embodiments disclosed as the best mode contemplated for carrying out the invention, but the invention is intended to include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention will be determined solely by the appended claims.

Claims

1. An integrated oil-cooled bridge, characterized in that: It comprises: an integrated housing, and a motor, a controller, and a reducer installed on the integrated housing, wherein the motor and the reducer are in transmission cooperation, and the motor and the controller are electrically connected; Among them, the integrated shell is provided with an oil cooling channel, and the oil cooling channel includes a first main channel and a second main channel. The motor and the reducer are provided with corresponding oil circuits respectively connected to the first main channel and the second main channel, so that the cooling oil can cool the rotor and stator of the motor along the oil circuit and lubricate the bearings on the reducer.

2. The integrated oil-cooled bridge according to claim 1, characterized in that: The motor comprises: A stator is fixed in the integrated housing, and the stator comprises: The stator core is fixedly attached to the inner wall of the integrated shell, and the two ends of the stator core are respectively provided with a first oil injection ring and a second oil injection ring; The stator core is provided with a first through hole in the circumferential direction for connecting the first oil injection ring and the second oil injection ring; A stator winding is fixed on the stator core, and two ends of the stator winding are respectively arranged corresponding to the first oil injection ring and the second oil injection ring; The rotor is rotatably matched with the stator.

3. The integrated oil-cooled bridge according to claim 2, characterized in that: The first main flow channel is formed on the outer wall of the integrated shell and is arranged corresponding to the stator core; a first oil outlet hole is provided on the first main flow channel, which is connected to the second oil injection ring; wherein the cooling oil flows from the first oil outlet hole into the second oil injection ring along the first main flow channel.

4. The integrated oil-cooled bridge according to claim 2, characterized in that: The first oil injection ring and the second oil injection ring adopt a completely seal-free structure or a partially seal-free structure; the first oil injection ring and the second oil injection ring form a quasi-sealed fit with the first through hole.

5. The integrated oil-cooled bridge according to claim 2, characterized in that: The rotor comprises: A rotating shaft, wherein the first end is matched with a first rotating bearing, the second end is matched with a second rotating bearing, and the shaft body is matched with a third rotating bearing; and a first oil passage is formed inside the rotating shaft along the first end; A rotor core, coaxially and fixedly connected to the rotating shaft; A rotating disk is fixed at both ends of the rotor core; The core is provided with a second through hole in its circumference, and a first connecting hole is provided between the rotating shaft and the rotating disk, penetrating through one side where the rotating shaft and the rotating disk are attached, so as to connect the first oil passage and the second through hole.

6. The integrated oil-cooled bridge according to claim 5, characterized in that: A second connecting hole is provided on the rotating shaft at a position corresponding to the third bearing and passes through one side of the first oil passage, so that cooling oil can flow out along the second connecting hole to the third bearing.

7. The integrated oil-cooled bridge according to claim 5, characterized in that: The first main flow channel also extends toward a direction close to the second end of the rotating shaft.

8. The integrated oil-cooled bridge according to claim 7, characterized in that: A second oil outlet hole is also provided on the first main flow channel, and the second oil outlet hole is located above the second rotating bearing; wherein a plug is provided at the outlet of the second oil outlet hole, and the cooling oil flows out from the second oil outlet hole along the first main flow channel and drips onto the second rotating bearing.

9. The integrated oil-cooled bridge according to claim 7, characterized in that: A third oil outlet hole is also provided on the first main flow channel; wherein a spray device is provided at the outlet of the third oil outlet hole, and the cooling oil flows out from the third oil outlet hole along the first main flow channel and is sprayed onto the high-voltage line electrically connecting the motor and the controller.

10. The integrated oil-cooled bridge according to claim 3, characterized in that: The reducer comprises: A driving gear, coaxially rotatably arranged with the rotating shaft; A driven gear, drivingly matched with the driving gear; An intermediate shaft, a first end of which is matched with a first intermediate bearing, and a second end of which is matched with a second intermediate bearing; and the intermediate shaft and the driven wheel are arranged to rotate coaxially; The reducer housing is provided with a first oil passage, a second oil passage, and a third oil passage; Among them, the outlet of the first oil passage is communicated with the first oil pipeline, and the outlet of the second oil passage is arranged corresponding to the matching position of the driving gear and the driven gear; a second oil pipeline is formed inside the intermediate shaft along the direction from the first end to the second end, and the outlet of the third oil passage is communicated with the second oil pipeline.

11. The integrated oil-cooled bridge according to claim 10, characterized in that: The second main flow channel is respectively provided with a first outlet, a second outlet, and a third outlet, and is correspondingly connected to the inlet of the first oil channel, the inlet of the second oil channel, and the inlet of the third oil channel.

12. The integrated oil-cooled bridge according to claim 11, characterized in that: A first gap is formed between the outlet of the first oil passage and the first oil passage, and the position of the first gap corresponds to the first rotating bearing; wherein the cooling oil flows out from the first gap along the first oil passage to the first rotating bearing.

13. The integrated oil-cooled bridge according to claim 11, characterized in that: A second gap is formed between the outlet of the third oil passage and the second oil passage, and the position of the second gap corresponds to the first intermediate bearing; wherein the cooling oil flows out from the second gap along the third oil passage to the first intermediate bearing.

14. The integrated oil-cooled bridge according to claim 13, characterized in that: Also includes: A differential, drivingly matched with the intermediate shaft; The differential comprises a gear assembly, an output shaft and a differential housing. The gear assembly is respectively in driving cooperation with the intermediate shaft and the output shaft. The output shaft is used to connect with an external device.

15. The integrated oil-cooled bridge according to claim 14, characterized in that: The first end of the output shaft is matched with a first differential bearing; Among them, the third oil channel forms a sub-oil channel at the first end of the intermediate shaft along the cross-sectional direction of the intermediate shaft, and a first oil hole is formed on the differential housing, which is arranged corresponding to the first differential bearing and is connected to the sub-oil channel so that the cooling oil drips along the first oil hole onto the first differential bearing.

16. The integrated oil-cooled bridge according to claim 14, characterized in that: The second end of the output shaft is matched with a second differential bearing; Wherein, a second oil hole is provided in the integrated housing, which is respectively arranged corresponding to the first oil spray ring and the second differential bearing, so that the cooling oil flows from the second oil hole along the first oil spray ring to the second differential bearing.

17. The integrated oil-cooled bridge according to claim 1, characterized in that: An oil pool is provided at the bottom of the integrated housing for collecting the cooling oil; wherein the bottom of the integrated housing is inclined along the direction in which the two ends of the motor converge toward the center and the direction in which the motor approaches the reducer, thereby forming the oil pool.

18. The integrated oil-cooled bridge according to claim 17, characterized in that: The bottom of the integrated housing is provided with oil return holes or oil return channels along the path where the two ends of the motor converge toward the center and / or along the path where the motor approaches the reducer, so that the cooling oil can flow into the oil pool.

19. The integrated oil-cooled bridge according to claim 17, characterized in that: It also includes a heat exchanger and an oil pump, and the oil pump draws oil from the oil pool and inputs the oil into the heat exchanger for cooling to form the cooling oil.

20. The integrated oil-cooled bridge according to claim 19, characterized in that: The bottom of the integrated housing is provided with an oil suction port at the center of both ends of the motor, and an oil suction passage is extended and connected to the oil suction port; wherein the other end of the oil suction passage is connected to the oil pump.

21. The integrated oil-cooled bridge according to claim 19, characterized in that: The integrated housing is also provided with a water cooling channel, wherein cooling water flows along the water cooling channel through the controller, the second rotating bearing and the heat exchanger, and flows out from the heat exchanger.

22. The integrated oil-cooled bridge according to claim 21, characterized in that: The controller includes a cooling plate, and the cooling plate is provided with a water inlet and a water outlet; the integrated shell is provided with a water inlet hole and a water outlet hole corresponding to the water inlet and the water outlet respectively; wherein cooling water flows into the cold plate from the water inlet hole and flows out from the water outlet hole.

23. The integrated oil-cooled bridge according to claim 22, characterized in that: A cover shell is further provided on one side of the integrated housing close to the second rotating bearing. A first channel is provided on the cover shell to cooperate with the water outlet so that cooling water flows into the first channel. The first channel is arranged on the outside of the second rotating bearing.

24. The integrated oil-cooled bridge according to claim 23, characterized in that: The first channel is disposed around the circumference of the second rotating bearing.

25. The integrated oil-cooled bridge according to claim 23, characterized in that: The integrated housing is also provided with a second channel, which connects the first channel and the heat exchanger, and the second channel is arranged on the outside of the stator key of the motor.

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