A three-in-one electric drive system for electric vehicles

Abstract

The present invention relates to a three-in-one electric drive system for electric vehicles, including a controller, a motor and a reducer, the motor including a motor housing, an "8"-shaped opening cavity is provided at the tail end of the motor housing, the controller includes a mounting shell, an electrical control module and an end cover, the mounting shell includes an intermediate plate, the two sides of the intermediate plate are respectively a first box body and a second box body, the second box body is a cover plate of the "8"-shaped opening cavity, the second box body and the "8"-shaped opening cavity are closed to form a reducer housing, the electrical control module is installed in the first box body, the output end of the electrical control module passes through the intermediate plate to connect the motor, and the end cover is installed at the opening of the first box body. Compared with the prior art, the present invention has the advantages of realizing the deep integration of the controller, the reducer and the motor, improving the power density of the drive system, and meeting market demand.

Description

Technical Field

[0001] The present invention relates to the field of electric vehicles, and in particular to a three-in-one electric drive system for electric vehicles. Background Art

[0002] In recent years, with the increasing popularity of new energy vehicles, the motor controller has limited space in the vehicle and the internal components of the controller generate a lot of heat, so the controller has been required to have a compact structure, small mass and volume, and good heat dissipation. Since the space of electric vehicles is relatively small, the space inside the cabin is also relatively limited to a certain extent, so the electric drive system of the vehicle has been required to be lightweight, integrated, and miniaturized.

[0003] The electric drive system for traditional new energy vehicles usually adopts a two-in-one structure of motor and electronic control, or a two-in-one drive mode of motor and reducer, which are mechanically connected to each other through structural parts and electrically connected through adapter harnesses; the more integrated electric drive system integrates the motor, controller and reducer into a three-in-one. However, the above arrangement is generally a stacking of physical structures, such as the controller is arranged above the motor and reducer, which greatly increases the height of the entire three-in-one, and the space occupied will also increase accordingly. The integration is still relatively unsatisfactory and it is difficult to meet the requirements of the vehicle assembly space. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and provide a three-in-one electric drive system for electric vehicles, realize the deep integration of controller, reducer and motor, improve the power density of the drive system, and meet market demand.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A three-in-one electric drive system for an electric vehicle comprises a controller, a motor and a reducer, wherein the motor comprises a motor housing, and an "8"-shaped opening cavity is provided at the rear end of the motor housing, the controller comprises a mounting shell, an electrical control module and an end cover, the mounting shell comprises an intermediate plate, the two sides of the intermediate plate are respectively a first box body and a second box body, the second box body is a cover plate of the "8"-shaped opening cavity, and the second box body and the "8"-shaped opening cavity are closed to form a reducer housing, the electrical control module is installed in the first box body, the output end of the electrical control module passes through the intermediate plate to connect the motor, and the end cover is installed at the opening of the first box body.

[0007] Furthermore, the electrical control module includes a heat dissipation substrate, a power component, a filter, a current sensor and a three-phase output component. The filter is attached to the lower surface of the heat dissipation substrate, the power component is installed on the upper surface of the heat dissipation substrate, the output end of the filter is connected to the input end of the power component, and the three-phase output component is electrically connected to the output terminal of the power component through the current sensor. The three-phase output component is the output end of the electrical control module.

[0008] Furthermore, a rectangular heat sink is provided on the upper surface of the heat dissipation substrate, an oil inlet hole and an oil outlet hole are provided at the bottom of the rectangular heat sink, a first oil inlet channel and a first oil outlet channel are provided on the side wall of the first box body, and when the electrical control module is installed in the first box body, the first oil inlet channel is connected to the oil inlet hole, and the second oil outlet channel is connected to the oil outlet hole.

[0009] Furthermore, the first oil inlet channel and the first oil outlet channel are both L-shaped pipes, one end of the L-shaped pipe is inserted into the oil inlet hole or the oil outlet hole, and the other end is arranged along the middle plate and extends to the side wall of the first box body.

[0010] Furthermore, the end of the first oil inlet passage and the oil inlet hole are interlocked and connected to each other; the end of the first oil outlet passage and the oil outlet hole are interlocked and connected to each other.

[0011] Furthermore, a notch is provided at the top of the intermediate plate, and the three-phase output assembly passes through the notch to connect to the motor.

[0012] Furthermore, the second box body and the four sides of the "8"-shaped opening cavity are connected by bolts.

[0013] Furthermore, the motor is provided with a second oil inlet channel, and the first oil outlet channel is connected to the second oil inlet channel via an interface and a hose.

[0014] Furthermore, a plurality of pillars are vertically arranged on the middle plate of the first box body, the edge of the heat dissipation substrate is fixed in the first box body through the pillars, and the heat dissipation substrate is parallel to the middle plate.

[0015] Furthermore, a busbar socket is provided on the first box body, and the input end of the electrical control module is connected to the busbar socket.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. The present invention adopts an integrated design of the motor, reducer and controller. Half of the reducer housing is integrated with the motor housing and the rear end cover by die-casting, and the other half of the reducer housing is integrated with the controller housing by die-casting. While reducing the number of parts in the system, it improves the integration of the electric drive system and reduces the volume, making it easier to install the three-in-one assembly in the vehicle cabin.

[0018] 2. An integrated modular electrical control module is used in the controller, including these parts that can be assembled into a highly integrated control device based on the heat dissipation substrate. It has a simple structure and high integration, which makes it easy to assemble the control device as a whole directly into the box after the motor and reducer are assembled, simplifying the assembly and facilitating installation.

[0019] 3. The electrical control module realizes cooling of power components and filters through the heat dissipation substrate, and adopts a three-dimensional heat dissipation structure with upper and lower layers, which has good heat dissipation effect and avoids the risk of damage to electronic power devices due to excessive temperature rise.

[0020] 4. The motor and controller each have independent oil cooling channels. Connecting the motor's oil cooling channel and the controller's oil cooling channel through a hose can effectively reduce the temperature rise of the entire system assembly, making it easier to further improve the power density of the electric drive system. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the structure of the present invention.

[0022] Figure 2 It is a schematic diagram of the explosion structure of the present invention.

[0023] Figure 3 Schematic diagram of the structure of the installation shell.

[0024] Figure 4 It is a schematic diagram of the structure of the installation shell from another angle.

[0025] Figure 5 It is a structural diagram of the electrical control module.

[0026] Figure 6 It is a schematic diagram of the structure of the heat dissipation substrate.

[0027] Figure 7 It is a schematic diagram of the structure of the power component.

[0028] Figure numerals: 1. controller, 11. mounting shell, 111. first housing, 112. second housing, 113. middle plate, 113a. notch, 113b. support, 113c. boss, 114. first oil inlet channel, 115. first oil outlet channel, 12. electrical control module, 121. heat dissipation substrate, 121-1. first mounting column, 121-2. second mounting column, 21a. heat dissipation pool, 121b. oil inlet hole, 121c. oil outlet hole, 13. end cover, 14. busbar socket, 122. power component, 123. filter, 124. current sensor, 125. three-phase output component, 2. motor, 21. motor housing, 21a. second oil inlet channel, 21b. second oil outlet channel, 22. "8" shaped opening, 3. reducer, 4. hose. DETAILED DESCRIPTION

[0029] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0030] like Figure 1 As shown, this embodiment provides a three-in-one electric drive system for an electric vehicle, including a controller 1, a motor 2 and a reducer 3, and the overall appearance is a T-shaped structure.

[0031] like Figure 2 to Figure 4 As shown, the motor 2 includes a motor housing 21, and an "8"-shaped opening cavity 22 is provided at the rear end of the motor housing 21. The controller 1 includes a mounting shell 11, an electrical control module 12 and an end cover 13. The mounting shell 11 includes an intermediate plate 113, and the two sides of the intermediate plate 113 are respectively a first box body 111 and a second box body 112, and the second box body 112 is a cover plate of the "8"-shaped opening cavity 22. The second box body 112 and the "8"-shaped opening cavity 22 are connected by bolts around, and the second box body 112 and the "8"-shaped opening cavity 22 are closed to form a reducer housing. The internal parts of the reducer 3 are installed in the reducer housing. The electrical control module 12 is installed in the first box body 111, and the output end of the electrical control module 12 is connected to the motor 2 through the intermediate plate 113, and the end cover 13 is installed at the opening of the first box body 111. A bus socket 14 is also provided on the first box body 111, and the input end of the electrical control module 12 is connected to the bus socket 14.

[0032] like Figure 5 and Figure 6As shown, the electrical control module 12 includes a heat dissipation substrate 121, a power component 122, a filter 123, a current sensor 124 and a three-phase output component 125. The filter 123 is attached to the lower surface of the heat dissipation substrate 121; the power component 122 is installed on the upper surface of the heat dissipation substrate 121. The output end of the filter 123 is connected to the input end of the power component 122. The three-phase output component 125 is electrically connected to the output terminal of the power component 122 through the current sensor 124, and the three-phase output component 125 is the output end of the electrical control module 12. A notch 113a is provided at the top of the middle plate 113 of the mounting shell 11, and the three-phase output component 125 passes through the notch 113a to connect the internal electronic parts of the motor 2. A rectangular heat dissipation pool 121a is provided on the upper surface of the heat dissipation substrate 121, and an oil inlet hole 121b and an oil outlet hole 121c are provided at the bottom of the rectangular heat dissipation pool 121a. A first oil inlet channel 114 and a first oil outlet channel 115 are provided on the side wall of the first housing 111. When the electrical control module 12 is installed in the first housing 111, the first oil inlet channel 114 is connected to the oil inlet hole 121b, and the first oil outlet channel 115 is connected to the oil outlet hole 121c. Specifically, a plurality of pillars 113b are vertically provided on the middle plate 113 of the first housing 111, and the edge of the heat dissipation substrate 121 is fixed in the first housing 111 through the pillars 113b, and the heat dissipation substrate 121 is parallel to the middle plate 113. The first oil inlet channel 114 and the first oil outlet channel 115 are both L-shaped pipes, one end of the L-shaped pipe is inserted into the oil inlet hole 121b or the oil outlet hole 121c, and the other end of the L-shaped pipe is arranged along the middle plate 113 and extends to the side wall of the first housing 111. The connection mode between the L-shaped pipe and the oil inlet hole 121b or the oil outlet hole 121c is a chimeric sealed connection.

[0033] The motor 2 is provided with a second oil outlet channel 21b and a second oil inlet channel 21a, and the first oil outlet channel 115 is connected to the second oil inlet channel 21a through an interface and a hose 4. During operation, cooling oil enters from the first oil inlet channel 114 and exits from the first oil outlet channel 115, thereby cooling the electrical control module 12 of the controller 1; the cooling oil then enters from the second oil inlet channel 21a through the hose 4 and exits from the second oil outlet channel 21b, thereby cooling the motor 2.

[0034] like Figure 7 As shown, the filter 123 is in the shape of a square as a whole, and the side of the filter 123 is filled with an input copper bar and an output copper bar. The input copper bar is a T-shaped combination of positive and negative copper bars, and the output copper bar is a stacked copper bar. One end of the output copper bar is provided with six output terminals arranged side by side. The output terminal is electrically connected to the input terminal of the power component 122, and the input end copper bar is connected to the bus socket 14, which is the input end of the electrical control module 12.

[0035] The specific assembly process of this embodiment is as follows:

[0036] First, pre-install the electrical control module 12. Place a sealing ring around the heat sink 121a of the heat sink substrate 121, and then lock the power component 122 above the heat sink 121a with bolts. Then, fix the PCB circuit board of the power component 122 to the first mounting column 121-1 of the heat sink substrate 121 with bolts. Next, fix the three-phase output component 125 on the second mounting column 121-2 of the heat sink substrate 121, and electrically connect its input end to the output terminal of the power component 122 through the current sensor 124. Next, place a thermal pad on the mounting surface of the filter 123, fix the filter 123 to the lower end surface of the heat sink substrate 121 with bolts, and then electrically connect its output terminal to the input end of the power component 122.

[0037] Secondly, assemble the three-in-one electric drive system. Install the reduction gear mechanism of the reducer 3 into the "8"-shaped opening cavity 22 of the rear end cover 13 of the motor 2. Then the second box body 112 is installed to the opening of the "8"-shaped opening cavity 22 to achieve the sealing of the reducer. Next, place the electrical control module 12 at the bottom of the first box body 111, and fix the heat dissipation substrate 121 of the electrical control module 12 to the pillar 113b in the first box body 111 by bolts. Next, fix the three-phase output assembly 125 to the boss 113c in the first box body 111 by bolts. Then, install the busbar socket 14 on the side wall of the first box body 111, and electrically connect its terminal to the input copper busbar of the filter 123.

[0038] Finally, the end cover 13 is installed to the opening of the first box body 111. Then, the first oil outlet channel 115 and the second oil inlet channel 21a are connected through the hose 4, and the hose 4 is locked with a clamp.

[0039] At this point, the assembly of the highly integrated three-in-one electric drive system of this embodiment is completed.

[0040] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A three-in-one electric drive system for an electric vehicle, comprising a controller (1), a motor (2) and a reducer (3), characterized in that: The motor (2) comprises a motor housing (21), and an "8"-shaped opening cavity (22) is provided at the rear end of the motor housing (21). The controller (1) comprises a mounting housing (11), an electrical control module (12), and an end cover (13). The mounting housing (11) comprises an intermediate plate (113), and the two sides of the intermediate plate (113) are respectively a first box body (111) and a second box body (112). The second box body (112) is a cover plate of the "8"-shaped opening cavity (22). The second box body (112) and the "8"-shaped opening cavity (22) are closed to form a reducer housing. The electrical control module (12) is mounted in the first box body (111), and the output end of the electrical control module (12) passes through the intermediate plate (113) to connect to the motor (2). The end cover (13) is mounted at the opening of the first box body (111).

2. A three-in-one electric drive system for electric vehicles according to claim 1, characterized in that: The electrical control module (12) comprises a heat dissipation substrate (121), a power component (122), a filter (123), a current sensor (124) and a three-phase output component (125); the filter (123) is attached to the lower surface of the heat dissipation substrate (121); the power component (122) is mounted on the upper surface of the heat dissipation substrate (121); the output end of the filter (123) is connected to the input end of the power component (122); the three-phase output component (125) is electrically connected to the output terminal of the power component (122) through the current sensor (124); and the three-phase output component (125) is the output end of the electrical control module (12).

3. A three-in-one electric drive system for electric vehicles according to claim 2, characterized in that: The upper surface of the heat dissipation substrate (121) is provided with a rectangular heat dissipation pool (121a), the bottom of the rectangular heat dissipation pool (121a) is provided with an oil inlet hole (121b) and an oil outlet hole (121c), and the side wall of the first box body (111) is provided with a first oil inlet channel (114) and a first oil outlet channel (115); when the electrical control module (12) is installed in the first box body (111), the first oil inlet channel (114) is connected to the oil inlet hole (121b), and the first oil outlet channel (115) is connected to the oil outlet hole (121c).

4. A three-in-one electric drive system for electric vehicles according to claim 3, characterized in that: The first oil inlet channel (114) and the first oil outlet channel (115) are both L-shaped pipes, one end of the L-shaped pipe is inserted into the oil inlet hole (121b) or the oil outlet hole (121c), and the other end is arranged along the middle plate (113) and extends to the side wall of the first box body (111).

5. The three-in-one electric drive system for electric vehicles according to claim 3, characterized in that: The end of the first oil inlet channel (114) and the oil inlet hole (121b) are interlocked and connected to each other; the end of the first oil outlet channel (115) and the oil outlet hole (121c) are interlocked and connected to each other.

6. A three-in-one electric drive system for electric vehicles according to claim 2, characterized in that: A notch (113a) is provided at the top end of the intermediate plate (113), and the three-phase output component (125) passes through the notch (113a) to connect to the motor (2).

7. The three-in-one electric drive system for electric vehicles according to claim 1, characterized in that: The second box body (112) and the "8"-shaped opening cavity (22) are connected around by bolts.

8. The three-in-one electric drive system for electric vehicles according to claim 3, characterized in that: The motor (2) is provided with a second oil inlet channel (21a), and the first oil outlet channel (115) is connected to the second oil inlet channel (21a) via an interface and a hose (4).

9. The three-in-one electric drive system for electric vehicles according to claim 2, characterized in that: A plurality of pillars (113b) are vertically arranged on the middle plate (113) of the first box body (111); the edge of the heat dissipation substrate (121) is fixed in the first box body (111) via the pillars (113b); and the heat dissipation substrate (121) is parallel to the middle plate (113).

10. The three-in-one electric drive system for electric vehicles according to claim 1, characterized in that: The first box body (111) is provided with a busbar socket (14), and the input end of the electrical control module (12) is connected to the busbar socket (14).

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