An all-in-one electric drive assembly cooling system for new energy vehicles

Abstract

The present invention discloses a cooling system for an all-in-one electric drive assembly for a new energy vehicle, belonging to the technical field of new energy vehicles. The all-in-one electric drive assembly includes: a drive motor, a reducer and an electric control box, including: an oil storage cavity, an electronic oil pump, a heat exchanger and an oil cooling branch, and the oil storage cavity is arranged at the bottom of the shell of the all-in-one electric drive assembly. The present invention discloses a cooling system for an all-in-one electric drive assembly for a new energy vehicle. The coolant flows out from the water pump and contacts with the charger, the DC / DC converter and the motor controller shell to complete the cooling of the electric control box. The cooling oil enters the heat exchanger through the electronic oil pump to complete the heat exchange, and then enters multiple oil cooling branches to respectively cool the stator winding of the drive motor, the rotor of the drive motor, the spline of the reducer, the rear end bearing of the drive motor, the high-speed bearing at the end of the reducer I-stage shaft housing, the reducer I-stage shaft gear, and the bearing between the drive motor and the reducer, so as to ensure that different parts are cooled evenly, and the overall mechanism is simpler and more scientific, meeting the current design requirements.

Description

Technical Field

[0001] The invention discloses an all-in-one electric drive assembly cooling system for a new energy vehicle, belonging to the technical field of new energy vehicles. Background Art

[0002] With the rapid development of production technology, the new energy vehicle field has higher and higher requirements for electric drive performance, gradually developing towards high speed, high efficiency, and high power density. As the peak speed of the drive motor increases, more heat will be generated during the operation, affecting the performance of the electric drive, and in serious cases, the electric drive system may be burned. Therefore, having a good cooling system to effectively control the temperature of the electric drive assembly within a reasonable range is a prerequisite and important guarantee for improving the performance of the electric drive.

[0003] The traditional cooling system is cooling water circulation, or air cooling with fans, but fan air cooling is noisy. The water cooling with spiral water pipes has a good cooling effect at the water inlet pipe, but the cooling effect is limited at the water outlet pipe because the water temperature has increased, resulting in uneven cooling and poor device replaceability. Summary of the invention

[0004] The purpose of the present invention is to solve the problems of limited cooling effect, uneven cooling and poor device replaceability, and to propose an all-in-one electric drive assembly cooling system for new energy vehicles.

[0005] The problem to be solved by the present invention is achieved by the following technical solutions:

[0006] A cooling system for an all-in-one electric drive assembly for a new energy vehicle, the all-in-one electric drive assembly comprising: a drive motor, a reducer and an electronic control box, comprising: an oil storage cavity, an electronic oil pump, a heat exchanger and an oil cooling branch, the oil storage cavity is arranged at the bottom of a shell of the all-in-one electric drive assembly, the oil cooling branch is respectively arranged on the drive motor and the reducer, one end of the oil cooling branch is connected to the heat exchanger, and the other end is connected to the environment in the oil storage cavity, the outlet of the oil storage cavity is connected to the electronic oil pump, and the other end of the electronic oil pump is connected to the heat exchanger, the oil storage cavity is arranged at the front end of the drive motor and at the bottom of the reducer, and the heat exchanger is arranged at the top of the front end of the drive motor.

[0007] Preferably, the oil cooling branch includes: a first branch, a second branch, a third branch, a fourth branch and a fifth branch, the first branch is used to cool the front end winding and the rear end winding of the stator of the drive motor, the second branch is used to cool the rotor of the drive motor, the spline of the reducer, and the rear end bearing of the drive motor, the third branch is used to cool the high-speed bearing at the end of the stage I shaft housing of the reducer, the fourth branch is used to cool the stage I shaft gear of the reducer, and the fifth branch is used to cool the bearing between the drive motor and the reducer.

[0008] Preferably, the electric control box includes: an upper module, a middle module and a lower module, the upper module includes: a charger and a DC / DC converter, the middle module includes: a buried copper tube water cooling plate, and the lower module includes: a drive board and a control board.

[0009] Preferably, the buried copper tube water-cooled plate has a serpentine cooling water channel inside, with a water inlet and a water outlet respectively provided at both ends, the water inlet is connected to an external water pump, the water outlet is connected to one end of the coolant pipe of the heat exchanger, and the other end of the coolant pipe of the heat exchanger is connected to the external water pump.

[0010] The present invention has the following beneficial effects compared with the prior art:

[0011] The present invention discloses an all-in-one electric drive assembly cooling system for new energy vehicles. The coolant flows out from a water pump and contacts with a charger, a DC / DC converter and a motor controller housing to complete the cooling of an electronic control box. The cooling oil enters a heat exchanger through an electronic oil pump to complete heat exchange, and then enters multiple oil cooling branches to respectively cool the stator winding of a drive motor, a rotor of a drive motor, splines of a reducer, a rear end bearing of a drive motor, a high-speed bearing at the end of a first-stage shaft shell housing of the reducer, a first-stage shaft gear of the reducer, and a bearing between the drive motor and the reducer, so as to ensure uniform cooling of different parts. The overall structure is simpler and more scientific, and meets current design requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a front view of an all-in-one electric drive assembly cooling system for a new energy vehicle according to the present invention.

[0013] Figure 2 It is a top view of an all-in-one electric drive assembly cooling system for a new energy vehicle of the present invention.

[0014] Figure 3 The invention discloses an oil circuit cooling principle diagram of an all-in-one electric drive assembly cooling system for a new energy vehicle.

[0015] Figure 4 The present invention is a water circuit cooling principle diagram of an all-in-one electric drive assembly cooling system for new energy vehicles.

[0016] Figure 5 The present invention is a schematic diagram of a buried copper tube water cooling plate of an all-in-one electric drive assembly cooling system for new energy vehicles.

[0017] Among them, 1. All-in-one electric drive assembly; 11. Drive motor; 12. Reducer; 13. Electronic control box; 14. Heat exchanger; 15. Electronic oil pump; 16. Oil storage chamber; 17. Water inlet; 18. Water outlet; 19. Buried copper tube water cooling plate. DETAILED DESCRIPTION

[0018] The following is based on the attached Figure 1-5 The present invention is further described:

[0019] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0021] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0022] like Figure 1 As shown, the first embodiment of the present invention provides an all-in-one electric drive assembly cooling system for new energy vehicles based on the prior art. The all-in-one electric drive assembly 1 includes: a drive motor 11, a reducer 12 and an electric control box 13, including: an oil storage cavity 16, an electronic oil pump 15, a heat exchanger 14 and an oil cooling branch. The structures of the above components and the connection relationship between them will be described in detail below.

[0023] The oil storage cavity 16 is arranged at the bottom of the housing of the all-in-one electric drive assembly 1, and the oil cooling branch is arranged on the drive motor 11 and the reducer 12 respectively. One end of the oil cooling branch is connected to the heat exchanger 14, and the other end is connected to the environment in the oil storage cavity 16. The outlet of the oil storage cavity 16 is connected to the electronic oil pump 15, and the other end of the electronic oil pump 15 is connected to the heat exchanger 14. The drive motor 11 and the reducer 12 share a common electric drive housing, and a filter is installed between the oil storage cavity 16 and the electronic oil pump 15. The oil storage cavity 16 is arranged at the front end of the drive motor 11 and the bottom of the reducer 12. The heat exchanger 14 is installed at the top of the front end of the drive motor 11, and the heat exchanger 14 is a water-oil heat exchanger.

[0024] The electronic oil pump 15 adopts a gear pump structure, sucking the cooling oil in the oil storage cavity 16 and injecting it into the all-in-one electric drive assembly 1 under pressure. The cooling oil directly enters the heat exchanger 14 through the inside of the shell for cooling, and after being cooled by the heat exchanger 14, it is divided into five branches.

[0025] Among them, the first branch cools the front and rear windings of the stator of the drive motor 11. The first branch starts from the output end of the heat exchanger 14, extends from the top of the drive motor 11 to the middle position of the stator winding of the drive motor 11, then wraps the outside of the stator winding and splits to the front and rear ends of the stator winding of the drive motor 11, and reaches the two ends of the stator of the drive motor 11. Oil spray rings are set at both ends of the stator winding. After the cooling oil reaches the oil spray ring, it is sprayed on the stator winding of the drive motor 11 under the action of pressure to achieve a cooling effect.

[0026] Among them, the second branch cools the rotor of the drive motor 11, the spline of the reducer, and the rear-end bearing of the drive motor 11. The second branch starts from the output end of the heat exchanger 14, extends along the shell of the all-in-one electric drive assembly 1 to the bearing seat at the end of the reducer's first-level hollow shaft shell, and then splits. A part of it reaches the central groove of the bearing seat through the oil channel in the shell, and reaches the rear-end bearing through the hollow shaft of the drive motor 11 rotor. A groove is set in the center of the bearing seat, and the groove is directly connected to the first-level hollow shaft of the reducer. The first-level hollow shaft of the reducer is connected to the hollow shaft of the drive motor 11 rotor through a spline, and the cooling oil cools it when it flows through the spline of the reducer.

[0027] The hollow shaft of the first stage of the reducer and the hollow shaft of the rotor of the drive motor 11 are connected. There is a specific oil path between the rotor axis of the drive motor 11 and the rotor matching gap. When the cooling oil flows through the center of the rotor shaft, part of it enters the specific oil path to cool the rotor, especially the magnetic steel, and the other part reaches the rear end bearing. The outlet of the rotor specific oil path is set at the maximum diameter at both ends of the rotor, and is evenly distributed in the form of small holes. After the cooling oil reaches both ends of the rotor, it is ejected due to the centrifugal force to cool the windings at both ends of the drive motor 11 and the rear end bearing.

[0028] Among them, the third branch cools the high-speed bearing at the end of the reducer's shaft housing at level I. The third branch starts from the output end of the heat exchanger 14, extends along the housing of the all-in-one electric drive assembly 1 to the bearing seat at the end of the hollow shaft housing at level I of the reducer, and then splits and passes through the outer ring of the bearing at the end of the shaft housing at level I of the reducer to reach the high-speed bearing at the end of the shaft housing at level I of the reducer for cooling. The third branch shares the oil channel in the housing with the second branch. The outer ring of the bearing is grooved, and the cooling oil flows through the high-speed bearing.

[0029] The fourth branch cools the reducer I-stage shaft gear. The fourth branch starts from the output end of the heat exchanger 14, extends along the housing of the all-in-one electric drive assembly 1 to the top of the reducer I-stage shaft gear for spray cooling.

[0030] The fifth branch cools the bearings between the drive motor 11 and the reducer 12. The fifth branch starts from the output end of the heat exchanger 14, extends along the housing of the all-in-one electric drive assembly 1 to the output end bearing seat of the reducer I hollow shaft drive motor 11, and cools the bearings between the drive motor 11 and the reducer 12.

[0031] The cooling oil in each branch flows downward due to gravity, enters the oil storage cavity 16, and enters the oil pump 15, completing an oil cooling and heat dissipation cycle.

[0032] The electric control box 13 includes: an upper module, a middle module and a lower module. The upper module includes: a charger and a DC / DC converter. The electronic components are connected to the housing through silicone grease. The middle module includes: a buried copper tube water cooling plate 19, which has a serpentine cooling water channel inside. An inlet 17 and an outlet 18 are set outside, and the two are on the same horizontal plane. The lower module includes: a drive board and a control board. There is a serpentine cooling water channel inside. An inlet 17 and an outlet 18 are set outside, and the two are on the same horizontal plane.

[0033] The buried copper tube water cooling plate 19 has a serpentine cooling water channel inside, with a water inlet 17 and a water outlet 18 at both ends. The water inlet 17 is connected to an external water pump, and the water outlet 18 is connected to one end of the coolant pipe of the heat exchanger 14, and the other end of the coolant pipe of the heat exchanger 14 is connected to an external water pump. The coolant flows out from the water pump, flows into the water inlet 17 of the electric control box through the external water pipe, enters the copper pipe, and contacts the charger, DC / DC converter and motor controller housing through the buried copper tube water cooling plate 19 to complete the cooling of the electric control box 13, and then flows out through the water outlet 18. It reaches the heat exchanger 14 through the connecting pipe and is cooled by the cooling oil. After leaving the heat exchanger 14, it enters the water pump through the external water pipe to complete a water cooling heat dissipation cycle. The turning point of the pipeline is set to be an arc shape to achieve the effect of increasing the flow rate of the coolant and improving the cooling capacity.

[0034] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and the embodiments. It can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily realized. Therefore, without departing from the general concept defined by the claims and equivalent scope, the present invention is not limited to the specific details and the illustrations shown and described here.

Claims

1. A cooling system for an all-in-one electric drive assembly for a new energy vehicle, the all-in-one electric drive assembly (1) comprising: A drive motor (11), a reducer (12) and an electric control box (13), characterized in that they include: an oil storage cavity (16), an electronic oil pump (15), a heat exchanger (14) and an oil cooling branch, wherein the oil storage cavity (16) is arranged at the bottom of the housing of the all-in-one electric drive assembly (1), and the oil cooling branch is arranged on the drive motor (11) and the reducer (12) respectively, one end of the oil cooling branch is connected to the heat exchanger (14), and the other end is connected to the environment in the oil storage cavity (16), the outlet of the oil storage cavity (16) is connected to the electronic oil pump (15), and the other end of the electronic oil pump (15) is connected to the heat exchanger (14), the oil storage cavity (16) is arranged at the front end of the drive motor (11) and at the bottom of the reducer (12), and the heat exchanger (14) is arranged at the top of the front end of the drive motor (11); The oil cooling branch comprises: a first branch, a second branch, a third branch, a fourth branch and a fifth branch, the first branch being used to cool the stator front-end winding and the rear-end winding of the drive motor (11), the second branch being used to cool the rotor of the drive motor (11), the speed reducer spline and the rear-end bearing of the drive motor (11), the third branch being used to cool the high-speed bearing at the end of the first-stage shaft housing of the speed reducer (12), the fourth branch being used to cool the first-stage shaft gear of the speed reducer (12), and the fifth branch being used to cool the bearing between the drive motor (11) and the speed reducer (12); The electric control box (13) comprises an upper module, a middle module and a lower module, the upper module comprises a charger and a DC / DC converter, the middle module comprises a copper tube water cooling plate (19), and the lower module comprises a drive board and a control board; The buried copper tube water cooling plate (19) has a serpentine cooling water channel inside, and a water inlet (17) and a water outlet (18) are respectively provided at two ends thereof, the water inlet (17) is connected to an external water pump, the water outlet (18) is connected to one end of a coolant pipe of a heat exchanger (14), and the other end of the coolant pipe of the heat exchanger (14) is connected to an external water pump.

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