A three-in-one electric drive axle

Abstract

The present invention relates to a three-in-one electric drive bridge, comprising a housing, a power cord, and a motor assembly installed in the housing, a reducer assembly, and a controller assembly installed at one end of the housing, an input shaft cavity, an intermediate shaft cavity, and an output shaft cavity are provided between the first housing and the second housing, a first oil guide flange and a second oil guide flange are provided between the outer wall of the output shaft cavity on the first housing and the second housing and the housing, respectively, an L-shaped reinforcing rib with a height lower than the housing plane is also provided on one side of the input shaft cavity and the intermediate shaft cavity, the L-shaped reinforcing rib and the housing form a chamber, and the chamber is divided into multiple chambers by multiple dividing ribs, wherein the height of the L-shaped reinforcing rib at the chamber away from one end of the output shaft cavity is flush with the housing plane, and a notch is provided on the dividing rib at the location, and an air hole is provided on the top of the chamber. The oil guide flange of the present invention can prevent the oil stirred by the large gear from flowing to the side, and the housing of the present invention is also provided with a ventilation structure that can effectively prevent the oil from overflowing.

Description

Technical Field

[0001] The invention relates to a new energy vehicle drive assembly, and in particular to a three-in-one electric drive axle. Background Art

[0002] The drive system of new energy vehicles is generally composed of an electric drive axle consisting of a motor, a reducer, a PEU, etc. The motor converts electrical energy into mechanical energy to provide power for the vehicle, and then reduces the motor speed through the reducer, while amplifying the motor's output torque to achieve the effect of deceleration and torque increase, so that the vehicle can run within a certain speed range and a certain driving force.

[0003] At present, the driving electric axle of new energy vehicles is composed of motors, reducers, controllers, etc. The overlapping installation of these three key components creates a large space and increases the difficulty of vehicle layout. It is difficult to coordinate the work of three suppliers (at least two) of the three components, resulting in multiple interfaces, large installation errors, low transmission efficiency, vibration and noise, and additional costs.

[0004] In addition, the existing drive axle has a compact structure. Due to its structural design, the lubrication system therein is often unable to fully lubricate the corresponding components, especially in the cavity of the reducer. The lubrication oil circuit is complex and it is difficult to fully lubricate the bearings, especially the bearings of the input shaft. Summary of the invention

[0005] In order to solve the above technical problems, the purpose of the present invention is to provide a three-in-one electric drive axle which is easy to install, has good component lubrication effect and is low in cost.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A three-in-one electric drive axle comprises a shell, a power cord, and a motor assembly, a reducer assembly, and a controller assembly installed in the shell. The power cord is electrically connected to the motor assembly and is arranged on the controller assembly through a harness integrated mounting structure. The shell comprises a first shell and a second shell. An input shaft cavity, an intermediate shaft cavity, and an output shaft cavity are arranged between the first shell and the second shell. A first oil guide flange and a second oil guide flange are respectively arranged between the outer wall of the output shaft cavity on the first shell and the second shell and the shell. An L-shaped reinforcing rib is also arranged on one side of the input shaft cavity and the intermediate shaft cavity. The height of the L-shaped reinforcing rib is lower than the shell plane. The L-shaped reinforcing rib and the shell form a chamber, and the chamber is divided into multiple chambers by a plurality of dividing ribs. The height of the L-shaped reinforcing rib at the chamber away from one end of the output shaft cavity is flush with the shell plane, and a notch is arranged on the dividing rib at that location. An air hole is arranged on the top of the chamber.

[0008] As a preferred solution, the wiring harness integrated installation structure includes a positive and negative fixing seat, a three-phase fixing seat, a positive and negative copper busbar and a three-phase copper busbar. The power line and the positive and negative copper busbar are respectively inserted into the positive and negative fixing seat and are fastened and connected by screws. The motor assembly includes a stator, a motor three-phase line is provided on the stator, and a three-phase copper nose is provided on the motor three-phase line. The three-phase copper nose and the three-phase copper busbar are respectively inserted into the three-phase fixing seat and are fastened and connected by screws. The positive and negative copper busbar and the three-phase copper busbar are respectively connected to the controller assembly. The power line and the three-phase line are installed through the positive and negative fixing seat and the three-phase fixing seat, so that the overall installation interface is less, and the three-phase fixing seat plays a role in isolating the motor and the controller cavity to a certain extent, so that the control accuracy is better.

[0009] As a preferred solution, one end of the two power cords is respectively inserted into the two spaced bottom through holes of the positive and negative fixing seats, and the two positive and negative copper bars are respectively inserted into the positive and negative fixing seats through the two spaced first guide grooves on the upper part of the positive and negative fixing seats, the bottom through holes are connected to the first guide grooves, and one side of the positive and negative fixing seats is provided with mounting holes, and screws are inserted into the mounting holes to fasten the power cords to the positive and negative copper bars. The power cords are all arranged in the positive and negative fixing seats, which is not only highly integrated but also easy to install.

[0010] As a preferred solution, the three-phase wire copper nose is fixed to the three-phase fixing seat through a three-phase wire fixing plate, the three-phase copper busbar is inserted into the second guide groove on the three-phase fixing seat, and a mounting hole is provided on one side of the three-phase fixing seat, and screws are inserted into the mounting hole to fix the three-phase copper busbar and the three-phase wire copper nose.

[0011] As a preferred solution, a waterproof cap is also provided on the mounting hole, one end of the power cord is fastened to the positive and negative fixing seats through a locking joint, and the other end of the power cord is provided with a positive and negative plug. The above structure makes the joint highly integrated and has good dustproof and waterproof effects.

[0012] As a preferred embodiment, the first shell includes an integrally formed motor shell and a reducer half shell, a plurality of annular heat dissipation ribs are axially spaced apart on the outer wall of the motor shell, oblique shock-absorbing ribs are provided between the plurality of annular heat dissipation ribs, and a hollow transverse connecting block is provided between one side wall of the motor shell and the reducer half shell.

[0013] As a preferred solution, two of the multiple annular heat dissipation ribs extend outward to form mounting plates for mounting the wiring harness fixing seat.

[0014] As a preferred solution, the cross-sectional shape of the first oil guide flange is that the upper and lower parts are stepped, and the middle part is inclined.

[0015] As a preferred solution, the cross-sectional shape of the second oil guide flange is a step-shaped upper portion and an inclined lower portion. The provision of the oil guide flange allows the lubricating oil to circulate more smoothly.

[0016] As a preferred solution, the end surfaces of the intermediate shaft cavity and the output shaft cavity for mounting bearings are respectively provided with oil guide grooves, and the input shaft cavity portion located on the inner wall of the second housing is also provided with an oil guide groove.

[0017] The first oil guide flange and the second oil guide flange in the first housing and the second housing of the present invention can not only prevent the oil stirred by the large gear from flowing sideways and guide the oil to splash to the input shaft and the intermediate shaft in the tangential direction, but also help to increase the liquid level or save the amount of lubricating oil.

[0018] In addition, the shell of the present invention is also provided with a ventilation structure that can effectively prevent oil from overflowing. Most of the splashing oil is blocked outside the sealing cavity, and there is no direct splashing oil in the area near the vent hole, and the sealing effect is good. The present invention uses reinforcing ribs to form a sealing cavity, which is beneficial to improving material utilization and reducing shell weight and cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall structure of the three-in-one electric drive axle;

[0020] Figure 2 A schematic structural diagram of a first housing of a three-in-one electric drive axle at an angle;

[0021] Figure 3 A schematic structural diagram of the first housing of the three-in-one electric drive axle from another angle;

[0022] Figure 4 It is a schematic diagram of the internal structure of the second housing of the three-in-one electric drive axle;

[0023] Figure 5 It is a partial enlarged view of the ventilation structure of the second housing of the three-in-one electric drive axle;

[0024] Figure 6 It is an enlarged schematic cross-sectional view of a second oil guide flange of a second housing of a three-in-one electric drive axle;

[0025] Figure 7 It is an enlarged schematic cross-sectional view of a first oil guide flange of a first housing of a three-in-one electric drive axle;

[0026] Figure 8 It is a connection diagram of the wiring harness integrated installation structure of the three-in-one electric drive axle;

[0027] Fig. 9 An exploded schematic diagram of the wiring harness integrated installation structure of the three-in-one electric drive axle;

[0028] Fig.10 It is an overall schematic diagram of the wiring harness integrated installation structure of the three-in-one electric drive axle;

[0029] Fig.11It is a schematic diagram of the structure of the three-phase fixing seat of the three-in-one electric drive axle;

[0030] Fig.12 It is a schematic diagram of the structure of the positive and negative fixing seats of the three-in-one electric drive axle;

[0031] Fig.13 Schematic diagram of the installation structure of the three-phase line fixing plate and the controller housing of the three-in-one electric drive axle Figure 1 ;

[0032] Fig.14 Schematic diagram of the installation structure of the three-phase line fixing plate and the controller housing of the three-in-one electric drive axle Figure 2 . DETAILED DESCRIPTION

[0033] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0034] like Figures 1 to 14 A three-in-one electric drive axle shown in the figure includes a shell, a power line 51, and a motor assembly 2 installed in the shell, a reducer assembly 1, and a controller assembly 3 installed at one end of the shell. The power line 51 is electrically connected to the motor assembly 2 and is arranged on the controller assembly 3 through a harness integrated mounting structure. The shell includes a first shell 21 and a second shell 47. An input shaft cavity 417, an intermediate shaft cavity 416 and an output shaft cavity 415 are arranged between the first shell 21 and the second shell 47. A first oil guide flange 43, a first oil guide flange 43, a second oil guide flange 43 are arranged between the outer wall of the output shaft cavity 415 on the first shell 21 and the second shell 47 and the shell. The second oil guide flange 48, the input shaft cavity 417, the intermediate shaft cavity 416 are further provided with L-shaped reinforcing ribs on one side, the height of the L-shaped reinforcing ribs is lower than the shell plane, the L-shaped reinforcing ribs and the shell form a chamber 46, and the chamber 46 is divided into multiple chambers by multiple dividing ribs 45, wherein the height of the L-shaped reinforcing ribs at the chamber 46 at one end away from the output shaft cavity 415 is flush with the shell plane, and the dividing ribs 45 at this location are provided with notches 49 and oil return ports 411, and the top of the chamber is provided with air holes 410. The top of the L-shaped reinforcing ribs and the matching surface of the box are reserved with the same processing allowance, and when processing the box surface, the matching surface of the oil guide ribs can be processed at the same time, and the matching is tight without additional processing costs.

[0035] Because the height of the L-shaped reinforcement rib at the chamber 46 at one end away from the output shaft cavity 415 is consistent with the installation surface, the L-shaped reinforcement ribs on both sides cooperate to form a sealed cavity after the box is assembled. One side of the sealed cavity is connected to the inside of the reducer through a notch, and the other side is connected to the outside through an air hole; when the internal pressure increases, the gas passes through the notch, the sealed cavity, and the air hole to the outside of the shell, and at the same time, most of the lubricating oil is blocked outside the sealed cavity, and a small part of the oil entering the sealed cavity flows back into the shell through the notch under the action of gravity.

[0036] The wiring harness integrated installation structure includes a positive and negative fixing seat 511, a three-phase fixing seat 512, a positive and negative copper busbar 54 and a three-phase copper busbar 55. The controller component 3 includes a controller housing 519. The positive and negative fixing seat 511 and the three-phase fixing seat 512 are both fixed on the controller housing 519.

[0037] The power cord 51 and the positive and negative copper busbars 54 are respectively inserted into the positive and negative fixing seats 511 and are fastened together by screws 53. The motor assembly 2 includes a stator 510, on which a motor three-phase line 57 is provided. The motor three-phase line 57 is provided with a three-phase copper nose 56. The three-phase copper nose 56 and the three-phase copper busbar 55 are respectively inserted into the three-phase fixing seat 512 and are fastened together by screws 53. The positive and negative copper busbars 54 and the three-phase copper busbar 55 are respectively connected to the controller assembly 3.

[0038] One end of the two power cords 51 are respectively inserted into the two spaced-apart bottom through holes of the positive and negative fixing seat 511, and the two positive and negative copper busbars 54 are respectively inserted into the positive and negative fixing seat 511 through the two spaced-apart first guide grooves 518 on the upper part of the positive and negative fixing seat 511, the bottom through holes are connected to the first guide grooves 518, and a mounting hole is provided on one side of the positive and negative fixing seat 511, and a screw 53 is inserted into the mounting hole to fasten the power cord 51 and the positive and negative copper busbars 54.

[0039] The three-phase copper nose 56 is fixed on the three-phase fixing seat 512 through the three-phase wire fixing plate 516, and the three-phase copper busbar 55 is inserted into the second guide groove 517 on the three-phase fixing seat 512. A mounting hole is provided on one side of the three-phase fixing seat 512, and the screw 53 is inserted into the mounting hole to fix the three-phase copper busbar 55 and the three-phase copper nose 56.

[0040] The installation hole is also provided with a waterproof cap 514 , one end of the power cord 51 is fastened to the positive and negative fixing seats 511 through a locking joint 52 , and the other end of the power cord 51 is provided with a positive and negative plug 515 .

[0041] The first shell 21 includes an integrally formed motor shell and a reducer half shell, a plurality of annular heat dissipation ribs 22 are axially spaced apart on the outer wall of the motor shell, oblique shock-absorbing ribs 25 are arranged between the plurality of annular heat dissipation ribs 22, and a hollow transverse connecting block 23 is arranged between one side wall of the motor shell and the reducer half shell.

[0042] Two of the multiple annular heat dissipation ribs 22 extend outward to form mounting pieces 24 for mounting the harness fixing seat. Overall, the installation and fixing process of the harness and the clamp is simplified, while the weight of the drive axle is reduced and the strength requirements of the installation are met.

[0043] The cross-sectional shape of the first oil guide flange 43 is that the upper and lower parts are stepped and the middle part is inclined. The cross-sectional shape of the second oil guide flange 48 is that the upper part is stepped and the lower part is inclined.

[0044] The intermediate shaft cavity 416 and the output shaft cavity 415 are provided with oil guide grooves 42 on their end surfaces for mounting bearings, and the input shaft cavity 417 located on the inner wall of the second housing 47 is also provided with an oil guide groove 42. There are two oil guide grooves on each of the intermediate shaft cavity 416, the output shaft cavity 415 and the input shaft cavity 417 located on the inner wall of the second housing 47, and the two oil guide grooves are distributed at an interval of 180 degrees.

[0045] The annular heat dissipation ribs on the first shell are designed to take into account the flow-guiding characteristics of the shell to the air fluid when the vehicle is traveling in the direction of travel, that is, the shell faces the wind, and are arranged in combination with the shell casting process. The width of the annular heat dissipation ribs is 3mm-5mm, the height is 10mm-15mm, the interval between the ribs is 12mm-18mm, and the number of ribs on the shell is 10-15, which meets the heat dissipation requirements of the motor; the heat dissipation ribs are distributed throughout the circle without interruption, and there is no sudden change in height and thickness. The advantages are as follows: 1) The thermal expansion of the shell in the circumferential direction changes evenly, and the positioning accuracy of the motor stator and end cover is high; 2) It is conducive to the circumferential flow of air; 3) The stress distribution on the annular ribs is continuous, and the stiffness and strength are good; 4) It is easy to demold and has good processability;

[0046] The hollow transverse connection structure on the first shell is to extend the two annular ribs on the motor shell side close to the reducer half shell side to the reducer half shell side, and extend to the shell surface near the reducer mounting hole; at the same time, extend the parting ribs, and add an axial rib at the middle transition point. The newly extended reinforcing ribs in three directions are respectively perpendicular, and the rib width is 3mm-5mm. The advantages are: 1) The reinforcing ribs are arranged in three mutually perpendicular directions, and bear the loads from three mutually perpendicular directions respectively, which is beneficial to improve the overall stiffness and strength of the shell; 2) Make full use of the annular heat dissipation ribs on the surface of the motor shell, which is beneficial to improve material utilization and reduce shell weight on the one hand, and increase the heat dissipation area of ​​the heat dissipation ribs on the other hand; 3) The demolding direction is consistent with the demolding direction of the annular heat dissipation ribs, and the processability is strong;

[0047] The oblique vibration damping ribs on the first housing are 2-8 low oblique ribs arranged at different angles with the annular ribs on the side of the motor housing, and the two sides extend to the vicinity of the end surface connection bolt holes. The demoulding direction of the oblique vibration damping ribs is consistent with the annular heat dissipation ribs, and the height of the oblique vibration damping ribs is controlled not to exceed one-third of the surrounding annular heat dissipation ribs. The advantages are: 1) It is conducive to improving the rigidity of the motor housing and reducing the vibration and noise of the motor housing; 2) It does not affect the air flow near the annular ribs; 3) It does not affect the air flow near the annular ribs; 4) It does not affect the air flow near the annular ribs.

[0048] The wiring harness fixing seat mounting plate on the first shell is to extend two appropriately positioned annular heat dissipation ribs radially, and the extension positions can be staggered at a certain angle in the circumferential direction to facilitate the installation of the wiring harness; its advantages are: directly opening holes on the extended sections of the heat dissipation ribs, using the heat dissipation ribs as supports, improving material utilization compared to the traditional mounting boss structure, and the extended sections are consistent with the annular ribs in the demolding direction, and have strong processability; the grooving direction is consistent with the end face processing direction, which can reduce the number of clamping times and save costs.

[0049] The first and second housings are designed with an annular oil guide flange structure on the housing side wall near the top of the reducer gear. The inner ring of the oil guide flange is located inside the root circle of the reducer gear. The distance between the top surface of the oil guide flange and the two end surfaces of the reducer gear is controlled to be no more than 15mm. The flange surface is as smooth as possible. The advantages are: 1) The oil guide flange can prevent the oil stirred by the gear from flowing to the side and guide the oil to splash to the input shaft and the intermediate shaft in the tangential direction; 2) It is conducive to increasing the liquid level or saving the amount of lubricating oil; The first and second housings are cast with L-shaped reinforcement ribs to block oil on the periphery of the input shaft bearing hole. The reinforcement rib is 3mm-5mm wide and is used to guide the lubricating oil into the input shaft cavity. The height difference between the reinforcement rib and the mounting plane is about 2mm-5mm, which is used for oil return and gas flow in the cavity.

[0050] The present invention proposes an integrated design of a motor, a reducer and a controller. The three-in-one electric drive axle also includes a motor shaft, a reducer input shaft, a secondary gear set, a radiator, etc. The power system adopts a parallel structure, the motor shaft and the reducer input shaft are an integrated structure, the reducer housing and the motor housing are an integrated structure, the motor end cover and the controller housing are an integrated structure, and a bevel gear structure reducer is adopted. This design can effectively reduce the installation space and installation difficulty, reduce the total weight of the product, and effectively reduce the manufacturing cost. In addition, a plurality of oil guide grooves are provided on the bearing mounting surface of the cavity formed between the motor reducer integrated housing and the second half shell of the reducer, which improves the lubrication effect of the components, especially the bearings.

[0051] It should be noted that the above embodiments are only representative examples of the present invention. The present invention can also have many variations. Any simple modification, equivalent changes and modifications made to the above embodiments based on the essence of the present invention should be considered to belong to the protection scope of the present invention.

Claims

1. A three-in-one electric drive axle, characterized in that: The invention comprises a housing, a power line (51), a motor assembly (2) installed in the housing, a reducer assembly (1), and a controller assembly (3) installed at one end of the housing, wherein the power line (51) is electrically connected to the motor assembly (2) and is arranged on the controller assembly (3) via a harness integrated mounting structure, wherein the housing comprises a first housing (21) and a second housing (47), wherein an input shaft cavity (417), an intermediate shaft cavity (416), and an output shaft cavity (415) are arranged between the first housing (21) and the second housing (47), and a first oil guide flange (43) and an intermediate shaft cavity (416) are arranged between the outer walls of the output shaft cavity (415) on the first housing (21) and the second housing (47) and the housing, respectively. A second oil guide flange (48), wherein one side of the input shaft cavity (417) and the intermediate shaft cavity (416) is further provided with an L-shaped reinforcing rib, the height of the L-shaped reinforcing rib being lower than the shell plane, the L-shaped reinforcing rib and the shell forming a chamber (46), and the chamber (46) is divided into a plurality of chambers by a plurality of dividing ribs (45), wherein the height of the L-shaped reinforcing rib at the chamber (46) at one end away from the output shaft cavity (415) is flush with the shell plane, and a notch (49) is provided on the dividing rib (45) at that location, and an air hole (410) is provided at the top of the chamber; The cross-sectional shape of the first oil guide flange (43) is that the upper and lower parts are stepped, and the middle part is inclined; The cross-sectional shape of the second oil guide flange (48) is a step-shaped upper portion and an inclined lower portion; The intermediate shaft cavity (416) and the output shaft cavity (415) are respectively provided with oil guide grooves (42) on their end surfaces for mounting bearings, and the input shaft cavity (417) portion located on the inner wall of the second housing (47) is also provided with an oil guide groove (42).

2. The three-in-one electric drive axle according to claim 1, characterized in that: The wire harness integrated installation structure comprises a positive and negative fixing seat (511), a three-phase fixing seat (512), a positive and negative copper busbar (54) and a three-phase copper busbar (55); the power line (51) and the positive and negative copper busbar (54) are respectively inserted into the positive and negative fixing seat (511) and are fastened and connected by screws (53); the motor assembly (2) comprises a stator (510); a motor three-phase line (57) is provided on the stator (510); a three-phase line copper nose (56) is provided on the motor three-phase line (57); the three-phase line copper nose (56) and the three-phase copper busbar (55) are respectively inserted into the three-phase fixing seat (512) and are fastened and connected by screws (53); the positive and negative copper busbar (54) and the three-phase copper busbar (55) are respectively connected to the controller assembly (3).

3. The three-in-one electric drive axle according to claim 2, characterized in that: One end of the two power lines (51) is respectively inserted into two spaced-apart bottom through holes of the positive and negative fixing seat (511); the two positive and negative copper bars (54) are respectively inserted into the positive and negative fixing seat (511) through two spaced-apart first guide grooves (518) on the upper part of the positive and negative fixing seat (511); the bottom through holes are communicated with the first guide grooves (518); and a mounting hole is provided on one side of the positive and negative fixing seat (511); a screw (53) is inserted into the mounting hole to fasten the power lines (51) and the positive and negative copper bars (54).

4. The three-in-one electric drive axle according to claim 2, characterized in that: The three-phase copper nose (56) is fixed to the three-phase fixing seat (512) via a three-phase fixing plate (516); the three-phase copper busbar (55) is inserted into a second guide groove (517) on the three-phase fixing seat (512); a mounting hole is provided on one side of the three-phase fixing seat (512); a screw (53) is inserted into the mounting hole to fix the three-phase copper busbar (55) and the three-phase copper nose (56).

5. A three-in-one electric drive axle according to claim 3 or 4, characterized in that: A waterproof cap (514) is also provided on the mounting hole, one end of the power cord (51) is fastened to the positive and negative fixing seats (511) via a locking joint (52), and the other end of the power cord (51) is provided with a positive and negative plug (515).

6. The three-in-one electric drive axle according to claim 1, characterized in that: The first housing (21) comprises an integrally formed motor housing and a reducer half housing, a plurality of ring-shaped heat dissipation ribs (22) are provided on the outer wall of the motor housing at intervals along the axial direction, oblique shock-absorbing ribs (25) are provided between the plurality of ring-shaped heat dissipation ribs (22), and a hollow transverse connecting block (23) is provided between a side wall of the motor housing and the reducer half housing.

7. The three-in-one electric drive axle according to claim 6, characterized in that: Two of the multiple annular heat dissipation ribs (22) extend outward to form mounting plates (24) for mounting a wiring harness fixing seat.

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