Electric drive system assembly and vehicles having it

Abstract

This invention provides an electric drive system assembly and a vehicle having the same. The electric drive system assembly includes an inverter assembly, which includes a main housing and an upper housing, forming a first receiving space between the main housing and the upper housing. At least a portion of an AC connector assembly is disposed within the first receiving space. There are multiple AC connector assemblies, including a first AC connector assembly and a second AC connector assembly, which are arranged at an angle to each other. At least a portion of a drive motor and at least a portion of a generator are disposed within a receiving cavity of a motor housing, with the axis of the drive motor parallel to the axis of the generator. The inverter assembly is connected to the drive motor via the first AC connector assembly and to the generator via the second AC connector assembly. This invention solves the problem of insufficient flexibility in the vehicle's mounting bracket arrangement caused by traditional inverter-motor connection methods.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and more specifically, to an electric drive system assembly and a vehicle having the same. Background Technology

[0002] Compared to pure electric vehicles, hybrid vehicles have more stringent requirements for the size and weight of the electric drive system. Therefore, the integration of inverters and motors is a development trend. However, most integration solutions integrate the inverter and motor AC busbars axially. The inverter has a square shape, which cannot avoid the suspension brackets of some models. The inverter has not been developed from the perspective of the overall vehicle layout, resulting in insufficient flexibility in the overall vehicle layout and failure to make full use of the vehicle space.

[0003] Existing technology discloses a dual-motor controller and electric drive system. This patent uses a direct connection between the motor and the inverter's AC copper busbar, saving on wiring harness costs and providing high and low voltage separation for better EMC performance. However, this patent uses a traditional axial direct connection between the motor and the inverter's AC copper busbar, which cannot avoid the mounting brackets of some hybrid vehicles, making it unfriendly to the overall vehicle layout and failing to fully utilize the vehicle's space. Furthermore, the power modules used are double-sided water-cooled modules, with multiple modules connected to a cooling plate to form a small assembly. The module pins then connect to the main control board, resulting in a large number of pins. Additionally, the low-voltage signal connectors on the main control board are onboard connectors sealed to the enclosure, requiring high tolerances and strict manufacturing processes, making widespread adoption difficult. Moreover, the lack of an integrated magnetic ring on the AC busbar side leads to high motor shaft current, which can easily damage the motor bearings. Summary of the Invention

[0004] The main objective of this invention is to provide an electric drive system assembly and a vehicle having the same, so as to solve the problem that the traditional connection method between inverter and motor has insufficient flexibility in the arrangement of vehicle suspension brackets.

[0005] To achieve the above objectives, according to one aspect of the present invention, an electric drive system assembly is provided, comprising an inverter assembly, the inverter assembly including a main housing and an upper housing, a first receiving space being formed between the main housing and the upper housing, at least a portion of an AC connector assembly being disposed within the first receiving space, the AC connector assemblies being a plurality of such assemblies including a first AC connector assembly and a second AC connector assembly, and the first AC connector assembly and the second AC connector assembly being disposed at an angle to each other; a drive motor and a generator, at least a portion of the drive motor and at least a portion of the generator being disposed within a receiving cavity of a motor housing, and the axis of the drive motor being parallel to the axis of the generator; wherein, the inverter assembly is connected to the drive motor via the first AC connector assembly, and the inverter assembly is connected to the generator via the second AC connector assembly.

[0006] Furthermore, both the first AC connector assembly and the second AC connector assembly include AC connector copper busbars, the drive motor includes a drive motor AC copper busbar, and the generator includes a generator AC copper busbar. One end of the AC connector copper busbar in the first AC connector assembly is connected to the drive motor AC copper busbar, and one end of the AC connector copper busbar in the second AC connector assembly is connected to the generator AC copper busbar.

[0007] Furthermore, the inverter assembly also includes: a drive motor-side power module, which is disposed within the first accommodating space, and a first end of the drive motor-side power module is connected to a second end of the AC connection copper busbar in the first AC connection socket assembly; a generator-side power module, which is disposed within the first accommodating space, and a first end of the generator-side power module is connected to a second end of the AC connection copper busbar in the second AC connection socket assembly; a current sensor is provided between the drive motor-side power module and the first AC connection socket assembly, and between the generator-side power module and the second AC connection socket assembly; wherein, the first end of the drive motor-side power module extends along the length direction of the main housing, the first end of the generator-side power module extends along the width direction of the main housing, and the included angle between the drive motor-side power module and the generator-side power module is 90°.

[0008] Furthermore, the inverter assembly also includes: a bus capacitor, which has an L-shaped structure. The L-shaped structure includes a first bus capacitor and a second bus capacitor. The first bus capacitor is connected to the second end of the power module on the drive motor side, and the second bus capacitor is connected to the second end of the power module on the generator side. The first bus capacitor extends along the width direction of the main housing, and the second bus capacitor extends along the length direction of the main housing. The first bus capacitor and the second bus capacitor are integrally formed.

[0009] Furthermore, the first bus capacitor is provided with multiple first copper busbars, and the first bus capacitor is connected to the second terminal of the power module on the drive motor side through the multiple first copper busbars. The second bus capacitor is provided with multiple second copper busbars, and the second bus capacitor is connected to the second terminal of the power module on the generator side through the second copper busbars.

[0010] Furthermore, the inverter assembly also includes: a first water channel for the main housing, which is die-cast with the main housing and has an inlet pipe at one end; a second water channel for the main housing, which is connected to the other end of the first water channel and is located at the bottom of the main housing; and a third water channel for the main housing, which is die-cast with the main housing and has an outlet pipe at one end.

[0011] Furthermore, the inverter assembly also includes: a water channel sealing cover, which is connected to the main housing and located at the bottom of the main housing, forming a second water channel for the main housing between the water channel sealing cover and the main housing.

[0012] Furthermore, the inverter assembly also includes: a top cover, with a second receiving space formed between the top cover and the upper housing, the second receiving space being divided into a high-voltage isolation zone and a low-voltage isolation zone by a partition; a control module, the control module being disposed in the low-voltage isolation zone, the control module being provided with onboard connectors; and a DC filter assembly, the DC filter assembly being disposed in the high-voltage isolation zone.

[0013] Furthermore, the partition includes: a first partition disposed within the second accommodating space, wherein a first stop step is provided at the end of the first end of the first partition; and a second partition disposed within the second accommodating space, wherein a second stop step is provided at the end of the first end of the second partition to cooperate with the first stop step, wherein the first end of the second partition is connected to the first end of the first partition through the second stop step and the first stop step, and the first partition and the second partition divide the second accommodating space into a high-pressure isolation zone and a low-pressure isolation zone.

[0014] Furthermore, a groove is provided on the top cover, a DC connector cover plate is provided on the groove wall, a sealing ring is provided inside the DC connector cover plate, and a DC high-voltage wire harness is provided on the top of the DC connector cover plate.

[0015] Furthermore, at least one of the first AC connector assembly and the second AC connector assembly includes: a plastic bracket with multiple fixing blocks on one side; a filter magnetic ring disposed within the plastic bracket; a pressure plate disposed above the filter magnetic ring, with slots on both sides of the pressure plate that mate with the fixing blocks, and a limiting groove on at least one side of the pressure plate; and foam disposed between the filter magnetic ring and the pressure plate; wherein the AC connection copper busbar includes a U-phase copper busbar, a V-phase copper busbar, and a W-phase copper busbar, with a portion of the U-phase copper busbar, a portion of the V-phase copper busbar, and a portion of the W-phase copper busbar passing through the plastic bracket, the filter magnetic ring, the foam, and the pressure plate.

[0016] According to another aspect of the present invention, a vehicle is provided, including an electric drive system assembly, the electric drive system assembly being the electric drive system assembly described above.

[0017] According to the technical solution of this invention, the inverter assembly includes a main housing and an upper housing, forming a first accommodating space between them. A first AC connector assembly and a second AC connector assembly are disposed within this first accommodating space, arranged at an angle. At least a portion of the drive motor and at least a portion of the generator are housed within the accommodating cavity of the motor housing. The drive motor and generator are arranged circumferentially along the motor housing, with the axis of the drive motor parallel to the axis of the generator. The inverter assembly is connected to the drive motor via the first AC connector assembly and to the generator via the second AC connector assembly. This achieves the technical effect of radial integration between the inverter assembly and the drive motor, and axial integration between the inverter assembly and the generator. It fully utilizes the vehicle space, making the arrangement of the vehicle's mounting brackets more flexible and solving the problem of insufficient flexibility in the arrangement of vehicle mounting brackets in traditional inverter-motor connection methods. The electric drive system assembly using the structure of this application saves vehicle space, and the inverter assembly can be installed in multiple vehicle models, realizing a platform-based design for the inverter assembly. Attached Figure Description

[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0019] Figure 1 A schematic diagram of the structure of a first embodiment of the inverter assembly according to the present invention is shown;

[0020] Figure 2 A schematic diagram of the structure of a first embodiment of the electric drive system assembly according to the present invention is shown;

[0021] Figure 3 A schematic diagram of a second embodiment of the electric drive system assembly according to the present invention is shown;

[0022] Figure 4 A schematic diagram of an embodiment of the main housing and waterway sealing cover according to the present invention is shown;

[0023] Figure 5 A schematic diagram of a structure of an embodiment of the main shell waterway according to the present invention is shown;

[0024] Figure 6 A schematic diagram of a second embodiment of the inverter assembly according to the present invention is shown;

[0025] Figure 7 A schematic diagram of an embodiment of the DC connector cover and top cover according to the present invention is shown;

[0026] Figure 8A schematic diagram of an embodiment of the cooperation between the first partition and the second partition according to the present invention is shown;

[0027] Figure 9 It shows Figure 8 Enlarged structural diagram of the embodiment at point I;

[0028] Figure 10 A schematic diagram of a bus capacitor according to an embodiment of the present invention is shown;

[0029] Figure 11 A schematic diagram of the structure of a first embodiment of the control module according to the present invention is shown;

[0030] Figure 12 A schematic diagram of the structure of a second embodiment of the control module according to the present invention is shown;

[0031] Figure 13 A schematic diagram of an embodiment of the AC connector assembly according to the present invention is shown.

[0032] The above figures include the following reference numerals:

[0033] 1. Main housing; 2. Upper housing; 3. Top cover; 4. DC connector cover; 5. Sealing ring; 6. Water channel sealing cover; 7. Inlet pipe; 8. Outlet pipe; 9. Bus capacitor; 10. Drive motor side power module; 11. Drive motor side drive board; 12. Generator side power module; 13. Generator side drive board; 14. Control module; 15. DC filter assembly; 16. DC connector; 17. AC connector assembly; 171. First AC connector assembly; 172. Second AC connector assembly; 18. Current sensor; 181. First current sensor; 182. Second current sensor; 19. Discharge resistor;

[0034] 20. Pressure balancing element; 21. Threaded plug; 22. First current sensor signal harness; 23. Drive motor resolver and temperature signal harness; 24. Cable between control module and generator-side power module; 25. Second current sensor signal harness; 26. Generator resolver and temperature signal harness; 27. Interlock harness; 28. Drive motor; 29. ​​Generator;

[0035] 30. Other components of the vehicle; 31. DC high-voltage wiring harness;

[0036] 40. Motor housing; 41. Receiving cavity;

[0037] 50. First accommodation space;

[0038] 60. Secondary storage space;

[0039] 101. First water passage of the main hull; 102. Second water passage of the main hull; 103. Third water passage of the main hull;

[0040] 201. First partition; 2010. High-voltage isolation zone; 2011. First stop step;

[0041] 301, Second partition; 3010, Low-pressure isolation zone; 3011, Second stop step; 302, Groove;

[0042] 901. First busbar capacitor; 902. Second busbar capacitor; 903. First copper busbar; 904. Second copper busbar; 905. Third copper busbar; 906. Discharge resistor harness; 907. Barb;

[0043] 1401. Drive motor side current sensor signal connector; 1402. Drive motor resolver and temperature signal connector; 1403. 50-pin board-to-board connector; 1404. 50-pin ribbon cable connector; 1405. Second current sensor signal connector; 1406. Generator resolver and temperature signal connector; 1407. Interlock connector; 1408. Onboard connector;

[0044] 170. AC connection copper busbar; 1701. U-phase copper busbar; 1702. V-phase copper busbar; 1703. W-phase copper busbar; 1704. Plastic bracket; 17041. Fixing block; 1705. Filter magnetic ring; 1706. Foam; 1707. Pressure plate; 17071. Card slot; 17072. Limiting slot;

[0045] 2801. AC copper busbar for drive motor; 2802. Suspension bracket fixing part;

[0046] 2901. Generator AC busbar. Detailed Implementation

[0047] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0048] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0049] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0050] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0051] Combination Figures 1 to 13 As shown, according to a specific embodiment of this application, an electric drive system assembly is provided.

[0052] Specifically, the electric drive assembly includes an inverter assembly, a drive motor 28, and a generator 29. The inverter assembly includes a main housing 1 and an upper housing 2, forming a first receiving space 50. At least a portion of the AC connector assembly 17 is disposed within the first receiving space 50. There are multiple AC connector assemblies 17, including a first AC connector assembly 171 and a second AC connector assembly 172, which are arranged at an angle. At least a portion of the drive motor 28 and at least a portion of the generator 29 are disposed within the receiving cavity 41 of the motor housing 40, with the axis of the drive motor 28 parallel to the axis of the generator 29. The inverter assembly is connected to the drive motor 28 via the first AC connector assembly 171, and to the generator 29 via the second AC connector assembly 172.

[0053] Applying the technical solution of this embodiment, the inverter assembly includes a main housing 1 and an upper housing 2, forming a first accommodating space 50. A first AC connector assembly 171 and a second AC connector assembly 172 are disposed within the first accommodating space 50, with the first AC connector assembly 171 and the second AC connector assembly 172 arranged at an angle. At least a portion of the drive motor 28 and at least a portion of the generator 29 are disposed within the accommodating cavity 41 of the motor housing 40, with the axis of the drive motor 28 parallel to the axis of the generator 29. The inverter assembly is connected to the drive motor 28 via the first AC connector assembly 171 and to the generator 29 via the second AC connector assembly 172. This achieves the technical effect of radial integration of the inverter assembly and the drive motor 28, and axial integration of the inverter assembly and the generator 29. It fully utilizes the vehicle space, making the arrangement of the suspension brackets more flexible, and solves the problem of insufficient flexibility in the arrangement of the vehicle suspension brackets in traditional inverter-motor connection methods. The electric drive system assembly using the structure of this application saves vehicle space, and the inverter assembly can be installed in multiple models, realizing the platform design of the inverter assembly.

[0054] Both the first AC connector assembly 171 and the second AC connector assembly 172 include AC connector copper busbars 170. The drive motor 28 includes a drive motor AC busbar 2801, and the generator 29 includes a generator AC busbar 2901. One end of the AC connector copper busbar 170 in the first AC connector assembly 171 is connected to the drive motor AC busbar 2801, and one end of the AC connector copper busbar 170 in the second AC connector assembly 172 is connected to the generator AC busbar 2901. This saves two high-voltage AC wiring harnesses, reducing size and effectively lowering the overall vehicle cost. Figure 1 , Figure 4 As shown, the main housing 1 has an L-shaped shell. The length of the first AC connector assembly 171 is arranged along the width of the main housing 1, with a portion of the first AC connector assembly 171 located within the first receiving space 50 and the other portion passing through the first end of the main housing 1. The length of the second AC connector assembly 172 is arranged along the length of the main housing 1, with a portion of the second AC connector assembly 172 located within the first receiving space 50 and the other portion passing through the second end of the main housing 1. Thus, there is a 90° angle between the length of the first AC connector assembly 171 and the length of the second AC connector assembly 172. Figure 2As shown, the main housing 1 has an L-shaped housing. When the inverter assembly is mounted on the motor housing 40, the AC connection copper busbar 170 in the first AC connection assembly 171 is directly connected to the AC busbar 2801 of the drive motor, realizing the radial integration of the inverter assembly and the drive motor 28. The AC connection copper busbar 170 in the second AC connection assembly 172 is directly connected to the AC busbar 2901 of the generator, realizing the axial integration of the inverter assembly and the generator 29. This allows the suspension bracket fixing part 2802 to extend from the motor housing 40, achieving the purpose of avoiding the vehicle's suspension bracket.

[0055] like Figure 3 As shown, the drive motor 28 and generator 29 are housed in the receiving cavity 41 of the motor housing 40, and the axis of the drive motor 28 is parallel to the axis of the generator 29. The inverter assembly is placed at an angle on the drive motor 28 and generator 29 along with the motor housing 40, thereby reducing the height of the inverter assembly in the vertical direction. This conformal arrangement makes the vertical direction of the vehicle more space-saving, and other vehicle components 30 can be placed on top of the inverter. For hybrid vehicles, the arrangement is more flexible, and the inverter assembly can meet the needs of multiple models, thereby realizing the platform design of the inverter assembly.

[0056] like Figure 1As shown, the inverter assembly also includes a drive motor-side power module 10 and a generator-side power module 12. The drive motor-side power module 10 is disposed within the first accommodating space 50, and its first end is connected to the second end of the AC connection copper busbar 170 in the first AC connection socket assembly 171. The generator-side power module 12 is disposed within the first accommodating space 50, and its first end is connected to the second end of the AC connection copper busbar 170 in the second AC connection socket assembly 172. A current sensor 18 is provided between the drive motor-side power module 10 and the first AC connection socket assembly 171, and between the generator-side power module 12 and the second AC connection socket assembly 172. The current sensor 18 includes a first current sensor 181 and a second current sensor 182. The second end of the AC connection copper busbar 170 in the first AC connector assembly 171 passes through the first current sensor 181 and is then connected to the first end of the drive motor side power module 10. The second end of the AC connection copper busbar 170 in the second AC connector assembly 172 passes through the second current sensor 182 and is then connected to the first end of the generator side power module 12. The first current sensor 181 is located on the AC side of the drive motor side power module 10, and the second current sensor 182 is located on the AC side of the generator side power module 12. The first end of the drive motor side power module 10 extends along the length direction of the main housing 1, and the first end of the generator side power module 12 extends along the width direction of the main housing 1. The angle between the drive motor side power module 10 and the generator side power module 12 is 90°. Specifically, the length direction of the drive motor-side power module 10 is arranged along the width direction of the main housing 1, and the drive motor-side power module 10 is disposed at the first end of the main housing 1. The length direction of the generator-side power module 12 is arranged along the length direction of the main housing 1, and the generator-side power module 12 is disposed at the second end of the main housing 1, so that the angle between the length direction of the drive motor-side power module 10 and the length direction of the generator-side power module 12 is 90°. A drive motor-side drive plate 11 is disposed on the drive motor-side power module 10, and a generator-side drive plate 13 is disposed on the generator-side power module 12.

[0057] like Figure 1 , Figure 10As shown, the inverter assembly also includes a bus capacitor 9, which has an L-shaped structure. The L-shaped structure includes a first bus capacitor 901 and a second bus capacitor 902. The first bus capacitor 901 is connected to the second terminal of the drive motor-side power module 10 and is located on the DC side of the drive motor-side power module 10. The second bus capacitor 902 is connected to the second terminal of the generator-side power module 12 and is located on the DC side of the generator-side power module 12. The first bus capacitor 901 extends along the width direction of the main housing 1, and the second bus capacitor 902 extends along the length direction of the main housing 1, and the first bus capacitor 901 and the second bus capacitor 902 are integrally formed. This configuration allows for direct electrical connections between the drive motor-side power module 10, the generator-side power module 12, and the bus capacitor 9, eliminating the need for busbar adapters. This effectively reduces parasitic inductance, lowers peak voltage, extends the service life of the power modules, and improves the reliability of the inverter assembly. Furthermore, the first bus capacitor 901 and the second bus capacitor 902 are integrated into one unit, sharing a single housing, which saves space and reduces production costs. In addition, the capacitor cores corresponding to the drive motor-side power module 10 and the generator-side power module 12 are symmetrically arranged, avoiding uneven use of capacitor cores. A discharge resistor 19 is also provided on the main housing 1, and the discharge resistor 19 is positioned close to the bus capacitor 9.

[0058] like Figure 10 As shown, the first bus capacitor 901 is provided with multiple first copper busbars 903, which are connected to the second terminal of the drive motor-side power module 10. Specifically, six first copper busbars 903 are provided on the potting surface of the upper surface of the first bus capacitor 901, directly connected to the copper busbars of the drive motor-side power module 10. The second bus capacitor 902 is provided with multiple second copper busbars 904, which are connected to the second terminal of the generator-side power module 12. Specifically, six second copper busbars 904 are provided on the potting surface of the upper surface of the second bus capacitor 902, directly connected to the copper busbars of the generator-side power module 12. Two third copper busbars 905 are also provided on the potting surface of the second bus capacitor 902. If the parasitic inductance is high, the copper busbars (first copper busbars 903, second copper busbars 904, and third copper busbars 905) of the bus capacitor 9 can be stacked to reduce the parasitic inductance. Two discharge resistor bundles 906 extend from the inside of the bus capacitor 9. The top of the discharge resistor bundles 906 is designed with barbs 907 for connecting with the slot of the discharge resistor 19. This connection method does not require screwing in bolts, which can improve the production cycle.

[0059] like Figure 4As shown, the inverter assembly also includes a first water channel 101, a second water channel 102, and a third water channel 103 in the main housing. The first water channel 101 is die-cast into the main housing 1, and a water inlet pipe 7 is provided at one end of the first water channel 101. The second water channel 102 is connected to the other end of the first water channel 101 and is located at the bottom of the main housing 1. The third water channel 103 is die-cast into the main housing 1, and one end of the third water channel 103 is connected to the second water channel 102. A water outlet pipe 8 is provided at the other end of the third water channel 103. Specifically, the water inlet pipe 7 and the water outlet pipe 8 are connected to the first water channel 101 and the third water channel 103 in the main housing respectively by interference fit or by bolt fixing, thereby fixing the water inlet pipe 7 and the water outlet pipe 8 to the main housing 1. Coolant enters the first water channel 101 of the main housing through the inlet pipe 7, then flows into the water channel of the drive motor-side power module 10, exits from the outlet of the drive motor-side power module 10, enters the middle of the second water channel 102 of the main housing, then enters the third water channel 103 of the main housing, and finally flows out through the outlet pipe 8, completing the heat dissipation of the inverter assembly. The second water channel 102 of the main housing passes over the bottom surface of the bus capacitor 9, providing heat dissipation for the bus capacitor 9 and improving its reliability. By incorporating multiple water channels within the inverter assembly, the heat dissipation performance of the inverter assembly is excellent.

[0060] like Figure 4 As shown, the inverter assembly also includes a water channel sealing cover 6, which is connected to the main housing 1. Specifically, the water channel sealing cover 6 is connected to the main housing 1 by friction stir welding, which improves the production cycle time. The water channel sealing cover 6 is located at the bottom of the main housing 1, and a second water channel 102 is formed between the water channel sealing cover 6 and the main housing 1. In this embodiment, the water channel sealing cover 6 has multiple bends, and the structure of the second water channel 102 of the main housing is adapted to the water channel sealing cover 6. This arrangement avoids bolts in the inverter assembly and increases the flow area of ​​coolant in the second water channel 102 of the main housing, thereby enhancing the heat dissipation performance of the inverter assembly.

[0061] like Figure 1 , Figure 8As shown, the inverter assembly also includes a top cover 3, a control module 14, and a DC filter assembly 15. A second receiving space 60 is formed between the top cover 3 and the upper housing 2. The second receiving space 60 is divided into a high-voltage isolation zone 2010 and a low-voltage isolation zone 3010 by a partition, realizing high and low voltage zoning. The control module 14 is located in the low-voltage isolation zone 3010. The control module 14 is equipped with an onboard connector 1408, which saves the wiring harness between the control module 14 and the connector, reduces costs, and improves production cycle time. The onboard connector 1408 is also equipped with a sealing part, including a sealing ring. The top cover 3 presses on the sealing ring of the onboard connector 1408 to form a seal between the inside and outside of the top cover 3. The DC filter assembly 15 is located in the high-voltage isolation zone 2010 and is mounted on the upper housing 2. A DC connector 16 is located on the upper surface of the top cover 3. One end of the copper busbar of the DC filter assembly 15 is connected to the copper busbar of the DC connector 16 by bolts. An opening is made on the side of the top cover 3 for bolt tightening tools; after the bolts are tightened, the opening is sealed with adhesive using a threaded plug 21. The other end of the copper busbar of the DC filter assembly 15 is connected to the third copper busbar 905 of the bus capacitor 9.

[0062] The partition includes a first partition 201 and a second partition 301. The first partition 201 is disposed within the second accommodating space 60, and a first stop step 2011 is provided at its first end. The second partition 301 is disposed within the second accommodating space 60, and a second stop step 3011 is provided at its first end to cooperate with the first stop step 2011. The first end of the second partition 301 is connected to the first end of the first partition 201 via the second stop step 3011 and the first stop step 2011. The first partition 201 and the second partition 301 divide the second accommodating space 60 into a high-pressure isolation zone 2010 and a low-pressure isolation zone 3010. Figure 9 As shown, the first stop step 2011 and the second stop step 3011 have an L-shaped structure with opposite directions. Through the cooperation of the first stop step 2011 and the second stop step 3011, the shielding effect between the high voltage isolation zone 2010 and the low voltage isolation zone 3010 can be better, thereby making the EMC performance of the inverter assembly better.

[0063] like Figure 7As shown, a groove 302 is provided on the top cover 3, and a DC connector cover plate 4 is provided on the groove wall of the groove 302. A sealing ring 5 is provided inside the DC connector cover plate 4, and a DC high-voltage wire harness 31 is provided on the top of the DC connector cover plate 4. The sealing ring 5 achieves the sealing of the internal structure of the inverter assembly. The sealing ring 5 can be installed independently in the sealing groove of the top cover 3, or it can be vulcanized into one piece with the DC connector cover plate 4. In this embodiment, the DC connector cover plate 4 is pressed down by the DC high-voltage wire harness 31. This design ensures that the DC connector cover plate 4 cannot be disassembled before the DC high-voltage wire harness 31 is disassembled, eliminating the need for additional interlocking components and reducing costs. When the DC high-voltage wire harness 31 is disassembled, the voltage inside the inverter assembly can drop to a safe range in a short time, thereby reducing the risk of electric shock to operators and improving the safety performance of the inverter assembly.

[0064] like Figure 13 As shown, at least one of the first AC connector assembly 171 and the second AC connector assembly 172 includes a plastic bracket 1704, a filter magnetic ring 1705, a pressure plate 1707, and foam 1706. Multiple fixing blocks 17041 are provided on both sides of the plastic bracket 1704. The filter magnetic ring 1705 is disposed within the plastic bracket 1704. The pressure plate 1707 is disposed above the filter magnetic ring 1705. The pressure plate 1707 has slots 17071 on both sides that mate with the fixing blocks 17041. At least one side of the pressure plate 1707 also has a limiting groove 17072. The drive motor resolver and temperature signal harness 23 and the generator resolver and temperature signal harness 26 are limited within the limiting groove 17072 of the pressure plate 1707, preventing the harnesses from being scratched. Foam 1706 is disposed between the filter magnetic ring 1705 and the pressure plate 1707. The positions of the fixing block 17041 and the slot 17071 determine the height of the space where the foam 1706 is placed, thereby determining the pressure that the foam 1706 can provide. The pressure generated by the compression of the foam 1706 is used to fix the filter magnetic ring 1705. The filter magnetic ring 1705 can reduce the current of the motor shaft, thereby reducing the risk of bearing damage. The AC connection copper busbar 170 includes a U-phase copper busbar 1701, a V-phase copper busbar 1702, and a W-phase copper busbar 1703. Part of the U-phase copper busbar 1701, part of the V-phase copper busbar 1702, and part of the W-phase copper busbar 1703 are disposed within the plastic bracket 1704, the filter magnetic ring 1705, the foam 1706, and the pressure plate 1707. In this embodiment, the foam 1706 can be adhered to the pressure plate 1707, and then the pressure plate 1707 can be pressed onto the filter magnetic ring 1705. The fixing method of the fixing block 17041 and the slot 17071 is used to fix the plastic bracket 1704, the filter magnetic ring 1705, the pressure plate 1707 and the foam 1706. This method is simple and convenient, and achieves the technical effect of good assemblability of the AC connector assembly 17.

[0065] like Figure 1 , Figure 11 , Figure 12 As shown, the control module 14 has seven low-voltage signal connectors, namely, drive motor side current sensor signal connector 1401, drive motor resolver and temperature signal connector 1402, 50-pin board-to-board connector 1403 between control module 14 and drive motor side power module 10, 50-pin ribbon cable connector 1404 between control module 14 and generator side power module 12, second current sensor signal connector 1405, generator resolver and temperature signal connector 1406, and interlock connector 1407. The seven low-voltage signal connectors on the control module 14 are connected to the mating connector through six low-voltage wire harnesses and one board-to-board connector, respectively. The six low-voltage wire harnesses are: first current sensor signal harness 22, drive motor resolver and temperature signal harness 23, ribbon cable 24 between control module and generator side power module, second current sensor signal harness 25, generator resolver and temperature signal harness 26, and interlock harness 27. This design ensures that the wiring harness is routed neatly, achieving the technical effects of preventing damage to the harness, reducing electromagnetic interference, and improving the reliability of the inverter assembly.

[0066] In another specific embodiment of this application, a pressure balancing element 20 is also provided on one side of the main housing 1 to maintain the internal and external pressure difference balance of the inverter assembly.

[0067] The electric drive system assembly in the above embodiments can also be applied to the field of vehicle technology. Specifically, according to another specific embodiment of this application, a vehicle is provided, including an electric drive system assembly, which is the electric drive system assembly described in the above embodiments. In this embodiment, because the vehicle uses the electric drive system assembly described in the above embodiments, it can significantly save vehicle space and make the vehicle's suspension bracket arrangement more flexible.

[0068] As can be seen from the above description, the embodiments of the present invention achieve the following technical effects:

[0069] By applying the technical solution of this application, the inverter assembly and generator 29 are integrated in the axial direction, and the drive motor 28 is integrated in the radial direction. This avoids interference with the vehicle's mounting brackets, making full use of the vehicle's space. The inverter assembly has a flexible layout and can adapt to multiple vehicle models. Furthermore, the inverter assembly features internal high and low voltage partitioning, and the resolver and temperature signal harnesses are located within the inverter assembly and connected internally to the drive motor 28 and generator 29, resulting in good EMC performance. Both the drive motor 28 and generator 29 are connected to the inverter assembly via the AC connector assembly 17. Since the AC connector assembly 17 includes a filter magnetic ring 1705, the risk of bearing damage caused by current in the motor shaft can be reduced. Additionally, the use of board-to-board connectors and onboard connectors 1408 enables a fewer-parts and integrated design, reducing the production cost of the electric drive system assembly.

[0070] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0071] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0072] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0073] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric drive system assembly, characterized by, The application relates to an inverter assembly, which comprises a main shell (1) and an upper shell (2), a first containing space (50) is formed between the main shell (1) and the upper shell (2), and at least part of an alternating current connector assembly (17) is arranged in the first containing space (50); the alternating current connector assembly (17) is multiple, the multiple alternating current connector assemblies (17) comprise a first alternating current connector assembly (171) and a second alternating current connector assembly (172), and the first alternating current connector assembly (171) and the second alternating current connector assembly (172) are arranged at an included angle; a driving motor (28) and a generator (29) are arranged in a containing cavity (41) of a motor shell (40), and the axis of the driving motor (28) is parallel to the axis of the generator (29); the inverter assembly is connected with the driving motor (28) through the first alternating current connector assembly (171) and is connected with the generator (29) through the second alternating current connector assembly (172); the first alternating current connector assembly (171) and the second alternating current connector assembly (172) each comprise an alternating current connecting copper bar (170), the driving motor (28) comprises a driving motor alternating current copper bar (2801), the generator (29) comprises a generator alternating current copper bar (2901), one end of the alternating current connecting copper bar (170) in the first alternating current connector assembly (171) is connected with the driving motor alternating current copper bar (2801), and one end of the alternating current connecting copper bar (170) in the second alternating current connector assembly (172) is connected with the generator alternating current copper bar (2901); at least one of the first alternating current connector assembly (171) and the second alternating current connector assembly (172) comprises a plastic support (1704), both sides of the plastic support (1704) are provided with a plurality of fixing blocks (17041); a filter magnetic ring (1705) is arranged in the plastic support (1704); a pressing plate (1707) is arranged above the filter magnetic ring (1705), both sides of the pressing plate (1707) are provided with clamping grooves (17071) matched with the fixing blocks (17041), and at least one side of the pressing plate (1707) is further provided with a limiting groove (17072); and a foam (1706) is arranged between the filter magnetic ring (1705) and the pressing plate (1707). ​ ​ ​ ​ ​ ​ ​ ​ ​ The alternating current connecting copper bar (170) includes a U-phase copper bar (1701), a V-phase copper bar (1702) and a W-phase copper bar (1703), and part of the U-phase copper bar (1701), part of the V-phase copper bar (1702) and part of the W-phase copper bar (1703) are arranged in the plastic support (1704), the filter magnetic ring (1705), the foam (1706) and the pressing plate (1707).

2. The electric drive system assembly of claim 1, wherein, The inverter assembly further comprises: a drive motor side power module (10) arranged in the first accommodating space (50), and a first end of the drive motor side power module (10) is connected with a second end of an alternating current connecting copper bar (170) in the first alternating current connecting seat assembly (171); a generator side power module (12) arranged in the first accommodating space (50), and a first end of the generator side power module (12) is connected with a second end of an alternating current connecting copper bar (170) in the second alternating current connecting seat assembly (172), and a current sensor (18) is arranged between the drive motor side power module (10) and the first alternating current connecting seat assembly (171) and between the generator side power module (12) and the second alternating current connecting seat assembly (172). The first end of the drive motor side power module (10) is arranged in the length direction of the main shell (1), the first end of the generator side power module (12) is arranged in the width direction of the main shell (1), and the included angle between the drive motor side power module (10) and the generator side power module (12) is 90°.

3. The electric drive system assembly of claim 2, wherein, The inverter assembly further comprises: a bus capacitor (9) in an L-shaped structure, the L-shaped structure comprising a first bus capacitor (901) and a second bus capacitor (902), the first bus capacitor (901) being connected with a second end of the drive motor side power module (10), and the second bus capacitor (902) being connected with a second end of the generator side power module (12); The first bus capacitor (901) is arranged in the width direction of the main shell (1), and the second bus capacitor (902) is arranged in the length direction of the main shell (1), and the first bus capacitor (901) and the second bus capacitor (902) are arranged integrally.

4. The electric drive system assembly of claim 3, wherein, The first bus capacitor (901) is provided with a plurality of first copper bars (903), the first bus capacitor (901) is connected with the second end of the drive motor side power module (10) through the plurality of first copper bars (903), the second bus capacitor (902) is provided with a plurality of second copper bars (904), and the second bus capacitor (902) is connected with the second end of the generator side power module (12) through the second copper bars (904).

5. The electric drive system assembly of claim 3, wherein, The inverter assembly further comprises: A main shell first water channel (101) is die-cast with the main shell (1), one end of the main shell first water channel (101) is provided with a water inlet pipe (7); A main shell second water channel (102) is provided in communication with the other end of the main shell first water channel (101), and the main shell second water channel (102) is arranged at the bottom of the main shell (1); A main shell third water channel (103) is die-cast with the main shell (1), one end of the main shell third water channel (103) is provided in communication with the main shell second water channel (102), and the other end of the main shell third water channel (103) is provided with a water outlet pipe (8).

6. The electric drive system assembly of claim 5, wherein, The inverter assembly further comprises: A water channel sealing cover (6) is connected with the main shell (1), the water channel sealing cover (6) is located at the bottom of the main shell (1), and the main shell second water channel (102) is formed between the water channel sealing cover (6) and the main shell (1).

7. The electric drive system assembly of claim 1, wherein, The inverter assembly further comprises: A top cover (3) is formed with a second containing space (60) between the top cover (3) and the upper shell (2), the second containing space (60) is divided into a high-voltage isolation area (2010) and a low-voltage isolation area (3010) by a partition plate; A control module (14) is arranged in the low-voltage isolation area (3010), and the control module (14) is provided with a board-mounted connector (1408); A direct-current filter assembly (15) is arranged in the high-voltage isolation area (2010).

8. The electric drive system assembly of claim 7, wherein, The partition plate comprises: A first partition plate (201) is arranged in the second containing space (60), and an end of a first end of the first partition plate (201) is provided with a first stop step (2011); A second partition plate (301) is arranged in the second containing space (60), an end of a first end of the second partition plate (301) is provided with a second stop step (3011) matched with the first stop step (2011), the first end of the second partition plate (301) is connected with the first end of the first partition plate (201) through the second stop step (3011) and the first stop step (2011), and the first partition plate (201) and the second partition plate (301) divide the second containing space (60) into the high-voltage isolation area (2010) and the low-voltage isolation area (3010).

9. The electric drive system assembly according to claim 7, wherein A groove (302) is formed in the top cover (3), a direct-current connector cover plate (4) is arranged on the groove wall of the groove (302), a sealing ring (5) is arranged in the direct-current connector cover plate (4), and a direct-current high-voltage wire harness (31) is arranged on the top of the direct-current connector cover plate (4).

10. A vehicle characterized by comprising: The electric drive system assembly as claimed in any one of claims 1-9. The electric drive system assembly as claimed in any one of claims 1-9.

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