A high-integration inverter and electric drive assembly device

Abstract

A high-integration inverter and electric drive assembly device, the main box assembly is connected with the upper cover, and the inside is provided with a power assembly, a bus capacitor and a control assembly; the power assembly is connected with the bus capacitor; the control assembly is fixed on the power assembly and the bus capacitor through bolts; the low-voltage connector passes through the upper cover and is interconnected with the vehicle wire harness plug; the rotary variable stator is installed at the bottom of the main box assembly through bolts; the motor housing is internally provided with a rotor assembly and a stator assembly; the electromagnetic filter and the direct current high-voltage wire harness are arranged in the independent cavity on the side of the motor housing; the rotor assembly passes through the rotary variable stator together with the wave spring, bearing and rotary variable rotor, the wave spring is attached to the L-shaped steel sleeve, the bearing is matched with the bearing chamber gap on the main box assembly, the rotary variable rotor is centered with the rotary variable stator, and the installation and cooperation of the inverter assembly and the electric drive assembly are completed.

Description

Technical Field

[0001] This invention relates to the field of inverter and electric drive assembly technology, and specifically to a highly integrated inverter and electric drive assembly device. Background Technology

[0002] As new energy vehicle technologies mature, the requirements for electric drive systems have consistently trended towards integration, lightweight design, high power density, and high volumetric density. To achieve higher power and torque, motor control technology increasingly favors high-voltage, high-speed, and high-torque operation. This leads to increased temperatures in the motor windings and bearings, necessitating oil cooling to directly cool these heat-generating components. The inverter, the motor controller, is designed for high voltage, high frequency, and high electromagnetic compatibility. Specific measures include using high-voltage SiC power devices, full-power component heat dissipation, and adding multi-stage filters to the DC front end. The entire electric drive assembly needs to achieve minimal size and optimized weight. Traditional oil-cooled electric drive systems typically place the inverter above the motor and reducer, with each assembly being a separate unit. This results in low integration, occupies significant vehicle height space, and the separate housing design of each assembly prevents a reduction in overall weight, leading to excessive vehicle weight and impacting efficiency and driving range.

[0003] In the prior art, patent document CN211151761U discloses "an axially integrated electric vehicle motor control system", which removes the connection structure between the traditional separate structure of the controller and the motor by installing the motor controller on the axial direction of the drive motor. This reduces the space occupied by the drive control system in the whole vehicle, reduces the weight of the drive control system, and realizes the requirements of lightweight, miniaturization and integration design.

[0004] In summary, existing technologies, due to the separate components of the inverter and electric drive assembly, not only fail to reduce the overall weight but also result in an excessively high vehicle weight, affecting efficiency and driving range. Summary of the Invention

[0005] This invention solves the problem that the existing technology, due to the separate components of the inverter and electric drive assembly, not only makes it impossible to reduce the overall weight, but also results in an excessively high vehicle weight, affecting efficiency and driving range.

[0006] The present invention discloses a highly integrated inverter and electric drive assembly device, the device comprising an inverter assembly and an electric drive assembly;

[0007] The inverter assembly includes a main housing assembly 1, a power assembly, a bus capacitor 3, a control assembly, a top cover 5, a vehicle wiring harness connector 6, and a resolver stator 7.

[0008] The main housing assembly 1 includes an L-shaped steel sleeve 1.3; the control assembly includes a low-voltage connector 4.2;

[0009] The electric drive assembly includes a motor housing 8, a rotor assembly 9, a stator assembly 10, an electromagnetic filter 11, and a DC high-voltage wiring harness 12;

[0010] The rotor assembly 9 includes a resolver rotor 9.1 and a bearing 9.2;

[0011] The main housing assembly 1 is fastened to the upper cover 5, and the power assembly, bus capacitor 3 and control assembly are installed inside.

[0012] The power assembly is connected to the bus capacitor 3;

[0013] The control assembly is fixed to the power assembly and bus capacitor 3 by bolts;

[0014] The low-voltage connector 4.2 passes through the upper cover 5 and is interconnected with the vehicle wiring harness plug 6;

[0015] The resolver stator 7 is bolted to the bottom of the main housing assembly 1;

[0016] The motor housing 8 is equipped with a rotor assembly 9 and a stator assembly 10.

[0017] The electromagnetic filter 11 and the DC high-voltage wiring harness 12 are arranged in an independent cavity on the side of the motor housing 8;

[0018] The rotor assembly 9, along with the wave spring, bearing 9.2, and resolver rotor 9.1, passes through the resolver stator 7. The wave spring fits against the L-shaped steel sleeve 1.3, the bearing 9.2 is clearance-fitted with the bearing chamber on the main housing assembly 1, and the resolver rotor 9.1 is aligned with the resolver stator 7, completing the installation and assembly of the inverter assembly and electric drive assembly.

[0019] Furthermore, in one embodiment of the present invention, the main housing assembly 1 further includes a main housing 1.1, a friction welding plate 1.2, a water inlet pipe 1.4, and a water outlet pipe 1.5;

[0020] The main housing 1.1 is equipped with a friction welding plate 1.2 inside;

[0021] The main body 1.1 has an inlet pipe 1.4 and an outlet pipe 1.5 respectively installed at both ends of the outer side.

[0022] Furthermore, in one embodiment of the present invention, the power assembly includes a power module 2, a DC terminal 2.1, an output terminal 2.2, and a current sensor through-hole 2.3;

[0023] The power assembly has a power module 2 in the middle, and a DC terminal 2.1 on one side and an output terminal 2.2 and a current sensor through hole 2.3 on the other side.

[0024] Furthermore, in one embodiment of the present invention, the current sensor through-hole 2.3 has a square hole on the lead-out copper busbar, and a Hall chip is disposed inside the hole.

[0025] Furthermore, in one embodiment of the present invention, the bus capacitor 3 includes a plastic shell 3.1, a large core 3.2, a small core 3.3, an AC terminal 3.4, and a DC terminal 3.5;

[0026] The plastic casing 3.1 of the bus capacitor 3 is designed in a semi-circular structure, and the large core 3.2 and small core 3.3 inside the bus capacitor 3 are arranged symmetrically on the left and right sides of the semi-circular plastic casing 3.1.

[0027] The plastic housing 3.1 is connected to the AC terminal 3.4 and the DC terminal 3.5 by welding.

[0028] Furthermore, in one embodiment of the present invention, the plastic shell 3.1 is perforated and ribs are extended along the periphery of the perforation to the capacitor potting surface, and a thin-walled steel tube is injected into its interior.

[0029] The AC terminal 3.4 is designed with a positive, negative, and positive structure, and it is laser-welded to the corresponding terminal of the power module 2.

[0030] The positive and negative DC copper output lines of the DC terminal 3.5 are integrally injection molded in a positive and negative stack and extended into the electromagnetic filter 11 of the electric drive assembly, where they are connected to the busbar of the electromagnetic filter 11.

[0031] Furthermore, in one embodiment of the present invention, the control assembly further includes a control and drive common PCB board 4, a current sensor 4.1, and a resolver pin guide bracket 4.3;

[0032] The current sensor 4.1 pin is soldered onto the control and drive common PCB board 4;

[0033] The control and drive PCB board 4 is equipped with a resolver pin guide bracket 4.3.

[0034] The current sensor 4.1 is a coreless current sensor.

[0035] Furthermore, in one embodiment of the present invention, the resolver stator 7 leads out signals to the control and drive common PCB board 4 and is designed as a direct-out pin structure. The pin structure is wrapped with a plastic protective shell, and the plastic protective shell has a radial annular sealing groove on its circumferential surface.

[0036] Furthermore, in one embodiment of the present invention, the inner diameter of the resolver stator 7 is larger than the outer diameter of the outer bearing ring of the electric drive assembly;

[0037] The bearing housing of the electric drive assembly is formed by the main housing assembly 1.

[0038] Furthermore, in one embodiment of the present invention, the stator assembly 10 includes a busbar 10.1 and two low-voltage pins 10.2;

[0039] The stator assembly 10 is internally provided with a busbar 10.1 and two low-voltage pins 10.2;

[0040] The busbar 10.1 is designed with an integrated injection-molded copper busbar. Inside the injection-molded copper busbar are two low-voltage pins 10.2. One side of the two low-voltage pins 10.2 is introduced into the busbar 10.1 to set an interface and connect to the stator temperature sensor. The other side is introduced into the inverter assembly cavity and connected to the control and drive common PCB board 4 through the wiring harness interface.

[0041] This invention solves the problem in existing technologies where the inverter and electric drive assembly are separate components, resulting in an inability to reduce overall weight and an excessively high vehicle weight, thus affecting efficiency and driving range. Specific beneficial effects include:

[0042] 1. This invention discloses a highly integrated inverter and electric drive assembly, adapted for oil-cooled electric drive systems. The motor and reducer share a common housing. This housing has a cavity for a filter and DC high-voltage wiring harness designed above the half-shaft, serving as the high-voltage input terminal of the inverter. The main inverter housing serves as the rear end cover of the motor, providing a bearing chamber and a mounting position for the resolver stator. The filter and high-voltage wiring harness at the front end of the inverter are arranged in an independent cavity within the shared housing of the motor and reducer, positioned above the half-shaft. This achieves a multi-stage filtering scheme without increasing the external boundary dimensions of the assembly, improving the EMC rating of the assembly, and reducing the size of the inverter body, ensuring that the inverter's outer boundary is limited to the maximum outer diameter of the motor housing. All internal components of the inverter that interact with the motor, including the resolver and motor bus, are sealed to the main housing to prevent internal motor oil from entering the inverter cavity. The inverter body volume is controlled at 4.2L, with an output power of 300kW, achieving a volumetric density of 71.4kW / L.

[0043] 2. The highly integrated inverter and electric drive assembly of this invention features pins that extend deep into the inverter and directly connect to the PCB board. Guide plugs are fixed on the board, and the pins are inserted into corresponding holes on the PCB using the guide holes on the plugs. Finally, the pins are soldered to the PCB to achieve resolver signal transmission. This design significantly improves the integration of the electric drive assembly and saves on connectors and wiring harnesses used for resolver signal transmission, reducing assembly design costs.

[0044] 3. The highly integrated inverter and electric drive assembly of the present invention has a capacitor core arranged with the semi-circular outer shell, which is mirror-symmetrical from left to right. The core with a different cross-section and height from the other cores is arranged in a position that avoids the resolver and bearing chamber, so as to make full use of the internal space of the capacitor.

[0045] 4. In the highly integrated inverter and electric drive assembly device described in this invention, the bus capacitor needs to be avoided at the pin lead-out part of the resolver. A hole is made in the plastic shell part of the capacitor and ribs are extended along the periphery of the hole to the potting surface of the capacitor. A thin-walled steel tube is injected into the inside, making the resolver pin independent into a cavity space, which can shield the interference of the alternating magnetic field inside the capacitor on the resolver signal.

[0046] 5. The highly integrated inverter and electric drive assembly of this invention features a power module design where the DC terminals and plastic housing are integrally injection molded. The plastic housing is supported by laser welding pressure and directly welded to the AC terminals of the capacitor. This replaces bolt tightening, does not occupy space above the module, maintains the same height as the upper surface of the capacitor, and facilitates the shared board arrangement of control and drive.

[0047] 6. The highly integrated inverter and electric drive assembly of this invention features a current sensor chip soldered onto an internal PCB, protected by a plastic casing. A pin extends upwards from the signal terminal and is soldered onto a shared PCB for both control and drive functions, directly transmitting the current value to the control board chip via the pin. Compared to ordinary magnetic core current sensors, this arrangement significantly improves space utilization and reduces cost, while also enhancing the spatial integration of the AC side.

[0048] 7. The highly integrated inverter and electric drive assembly of the present invention uses an oil-cooled motor, which does not require the introduction of coolant. The water inlet pipe and water outlet pipe are led out axially towards the motor, which does not occupy the outer boundary space of the electric drive assembly and facilitates connection with the heat exchanger of the reducer. Attached Figure Description

[0049] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0050] Figure 1 This is a diagram of a highly integrated inverter and electric drive assembly as described in the specific implementation. 7 is the resolver stator, 8 is the motor housing, 9 is the rotor assembly, 9.1 is the resolver rotor, 9.2 is the bearing, 10 is the stator assembly, 10.1 is the busbar, 11 is the electromagnetic filter, and 12 is the DC high-voltage wiring harness.

[0051] Figure 2This is a diagram of the inverter assembly described in the specific implementation method. 1 is the main housing assembly, 2 is the power module, 3 is the bus capacitor, 4 is the control and drive common PCB board, 5 is the top cover, 6 is the vehicle wiring harness plug, and 7 is the resolver stator.

[0052] Figure 3 This is a diagram of the resolver stator as described in the specific implementation. 4 is the control and drive common PCB board, 4.3 is the resolver pin guide bracket, and 7 is the resolver stator.

[0053] Figure 4 This is a diagram of the bus capacitor as described in the specific implementation method. 3.1 is the plastic casing, and 3.5 is the DC terminal.

[0054] Figure 5 This is the bus capacitor diagram described in the specific implementation method. 3.2 is the large core, 3.3 is the small core, and 3.4 is the AC terminal.

[0055] Figure 6 This is a power assembly diagram as described in the specific implementation. 2 is the power module, 2.1 is the DC terminal, 2.2 is the output terminal, 2.3 is the current sensor through hole, 3.4 is the AC terminal, 4 is the control and drive common PCB board, and 4.1 is the current sensor.

[0056] Figure 7 This is a stator assembly diagram as described in the specific implementation, where 10.1 is the busbar and 10.2 is the low-voltage pin.

[0057] Figure 8 This is a control assembly diagram as described in the specific implementation. 4 is the control and drive PCB board, 4.1 is the current sensor, 4.2 is the low-voltage connector, and 4.3 is the resolver pin guide bracket.

[0058] Figure 9 This is a diagram of the main housing assembly as described in the specific implementation method. 1.1 is the main housing, 1.4 is the water inlet pipe, 1.5 is the water outlet pipe, 7 is the resolver stator, and 10.1 is the manifold.

[0059] Figure 10 This is a rotor assembly diagram as described in the specific implementation method. 1.2 is a friction welding plate, 1.3 is an L-shaped steel sleeve, 3.5 is a DC terminal, 9 is a rotor assembly, 9.1 is a resolver rotor, and 9.2 is a bearing. Detailed Implementation

[0060] Various embodiments of the present invention will now be clearly and completely described with reference to the accompanying drawings. The embodiments described with reference to the drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0061] This embodiment describes a highly integrated inverter and electric drive assembly device, the device comprising an inverter assembly and an electric drive assembly;

[0062] The inverter assembly includes a main housing assembly 1, a power assembly, a bus capacitor 3, a control assembly, a top cover 5, a vehicle wiring harness connector 6, and a resolver stator 7.

[0063] The main housing assembly 1 includes an L-shaped steel sleeve 1.3; the control assembly includes a low-voltage connector 4.2;

[0064] The electric drive assembly includes a motor housing 8, a rotor assembly 9, a stator assembly 10, an electromagnetic filter 11, and a DC high-voltage wiring harness 12;

[0065] The rotor assembly 9 includes a resolver rotor 9.1 and a bearing 9.2;

[0066] The main housing assembly 1 is fastened to the upper cover 5, and the power assembly, bus capacitor 3 and control assembly are installed inside.

[0067] The power assembly is connected to the bus capacitor 3;

[0068] The control assembly is fixed to the power assembly and bus capacitor 3 by bolts;

[0069] The low-voltage connector 4.2 passes through the upper cover 5 and is interconnected with the vehicle wiring harness plug 6;

[0070] The resolver stator 7 is bolted to the bottom of the main housing assembly 1;

[0071] The motor housing 8 is equipped with a rotor assembly 9 and a stator assembly 10.

[0072] The electromagnetic filter 11 and the DC high-voltage wiring harness 12 are arranged in an independent cavity on the side of the motor housing 8;

[0073] The rotor assembly 9, along with the wave spring, bearing 9.2, and resolver rotor 9.1, passes through the resolver stator 7. The wave spring fits against the L-shaped steel sleeve 1.3, the bearing 9.2 is clearance-fitted with the bearing chamber on the main housing assembly 1, and the resolver rotor 9.1 is aligned with the resolver stator 7, completing the installation and assembly of the inverter assembly and electric drive assembly.

[0074] In this embodiment, the main housing assembly 1 further includes a main housing 1.1, a friction welding plate 1.2, a water inlet pipe 1.4, and a water outlet pipe 1.5;

[0075] The main housing 1.1 is equipped with a friction welding plate 1.2 inside;

[0076] The main body 1.1 has an inlet pipe 1.4 and an outlet pipe 1.5 respectively installed at both ends of the outer side.

[0077] In this embodiment, the power assembly includes a power module 2, a DC terminal 2.1, an output terminal 2.2, and a current sensor through-hole 2.3;

[0078] The power assembly has a power module 2 in the middle, and a DC terminal 2.1 on one side and an output terminal 2.2 and a current sensor through hole 2.3 on the other side.

[0079] In this embodiment, the current sensor through-hole 2.3 has a square hole on the copper busbar, and a Hall chip is arranged inside the hole.

[0080] In this embodiment, the bus capacitor 3 includes a plastic shell 3.1, a large core 3.2, a small core 3.3, an AC terminal 3.4, and a DC terminal 3.5;

[0081] The plastic casing 3.1 of the bus capacitor 3 is designed in a semi-circular structure, and the large core 3.2 and small core 3.3 inside the bus capacitor 3 are arranged symmetrically on the left and right sides of the semi-circular plastic casing 3.1.

[0082] The plastic housing 3.1 is connected to the AC terminal 3.4 and the DC terminal 3.5 by welding.

[0083] In this embodiment, the plastic shell 3.1 is perforated and ribs are extended along the periphery of the perforation to the capacitor potting surface, and a thin-walled steel pipe is injected into its interior.

[0084] The AC terminal 3.4 is designed with a positive, negative, and positive structure, and it is laser-welded to the corresponding terminal of the power module 2.

[0085] The positive and negative DC copper output lines of the DC terminal 3.5 are integrally injection molded in a positive and negative stack and extended into the electromagnetic filter 11 of the electric drive assembly, where they are connected to the busbar of the electromagnetic filter 11.

[0086] In this embodiment, the control assembly further includes a control and drive common PCB board 4, a current sensor 4.1, and a resolver pin guide bracket 4.3;

[0087] The current sensor 4.1 pin is soldered onto the control and drive common PCB board 4;

[0088] The control and drive PCB board 4 is equipped with a resolver pin guide bracket 4.3;

[0089] The current sensor 4.1 is a coreless current sensor.

[0090] In this embodiment, the resolver stator 7 leads out signals to the control and drive common PCB board 4 and is designed as a direct-out pin structure. The pin structure is wrapped with a plastic protective shell, and the plastic protective shell has a radial annular sealing groove on its circumferential surface.

[0091] In this embodiment, the inner diameter of the resolver stator 7 is larger than the outer diameter of the outer bearing ring of the electric drive assembly;

[0092] The bearing housing of the electric drive assembly is formed by the main housing assembly 1.

[0093] In this embodiment, the stator assembly 10 includes a busbar 10.1 and two low-voltage pins 10.2;

[0094] The stator assembly 10 is internally provided with a busbar 10.1 and two low-voltage pins 10.2;

[0095] The busbar 10.1 is designed with an integrated injection-molded copper busbar. Inside the injection-molded copper busbar are two low-voltage pins 10.2. One side of the two low-voltage pins 10.2 is introduced into the busbar 10.1 to set an interface and connect to the stator temperature sensor. The other side is introduced into the inverter assembly cavity and connected to the control and drive common PCB board 4 through the wiring harness interface.

[0096] This embodiment is based on the highly integrated inverter and electric drive assembly device described in this invention, combined with... Figure 1 To better understand this implementation method, a practical implementation method is provided:

[0097] 1. A highly integrated inverter assembly, comprising a main housing 1.1, a power module 2, a DC bus capacitor 3, a current sensor 4.1, a control and drive shared PCB board 4, a top cover 5, and a resolver stator 7, as shown below. Figure 2 As shown.

[0098] 2. The electric drive assembly consists of a motor assembly, an inverter assembly, an electromagnetic filter 11, a DC high-voltage wiring harness 12, and a busbar 10.1.

[0099] 3. The inverter is located at the end of the motor, axially aligned with the motor. The inverter main housing 1.1 serves as the end cover for the motor assembly, with the motor and reducer sharing the same housing. The internal components of the inverter are arranged to fully utilize the space within the maximum outer diameter range of the motor. The front-end DC electromagnetic filter 11 and DC high-voltage harness 12 are located in independent cavities on the side of the shared housing between the motor and reducer, making full use of the space above the half-shaft. The resolver stator 7 of the rotary transformer, which measures the motor speed, is bolted to the bottom of the inverter main housing; this area also serves as a bearing housing to support the motor rotor end bearings.

[0100] 4. The resolver stator 7 needs to output signals to the inverter control board. A direct-output pin structure is designed here, installed on the main housing 1.1 along with the resolver stator 7. The pin is encased in a plastic shell with a radial annular sealing groove on its circumferential surface. A sealing ring seals the pin with the perforated portion of the main housing, preventing motor-side oil from entering the inverter cavity. The pin extends deep into the inverter and directly to the control and drive common PCB board 4. Guide inserts are fixed on the board. Using the corresponding guide holes on the inserts, the pins are inserted into the corresponding holes on the control and drive common PCB board 4, and finally soldered to the control and drive common PCB board 4 to achieve resolver signal transmission. This design significantly improves the integration of the electric drive assembly and saves on connectors and wiring harnesses used for resolver signal transmission, reducing assembly design costs. Figure 3 As shown.

[0101] 5. The outer shell of bus capacitor 3 is designed as a semi-circular structure, placed in the upper semi-circle of the motor, with the motor busbar arranged in the lower semi-circle. This allows the capacitor to extend axially into the motor section, increasing the capacitor height and capacitance without altering the axial dimensions of the electric drive assembly. The internal core of the capacitor is arranged symmetrically with the semi-circular outer shell, with cores of different cross-sections and heights to avoid the resolver and bearing housing, fully utilizing the internal space of the capacitor. The bus capacitor needs to avoid the resolver pinout section. An opening is made in the capacitor's plastic shell, with ribs extending around the opening to the capacitor's potting surface. A thin-walled steel tube is then injection-molded inside, creating an independent cavity for the resolver pins, shielding the alternating magnetic field inside the capacitor from interference with the resolver signal. The DC terminals 3.5, positive and negative, are integrally injection-molded with positive and negative layers and extend to the motor-side filter cavity, connecting to the filter busbar. The AC terminals 3.4 are designed with positive, negative, and positive structures for each phase, and are laser-welded to the corresponding terminals on the power module. The positive and negative leads create a capacitive effect, reducing the parasitic inductance of the circuit. Figure 4-5 As shown.

[0102] 6. The design of power module 2 features a single injection-molded DC terminal 2.1 and a plastic housing 3.1. The plastic housing 3.1 supports the pressure from laser welding and is directly welded to the AC terminal 3.4 of the capacitor. This replaces bolt tightening, does not occupy space above the module, and maintains the same height as the upper surface of the capacitor, facilitating the shared board layout for control and drive. The positive-negative-positive structure of the copper busbars on each phase DC terminal creates a multi-capacitor effect in horizontal space, reducing the module's parasitic inductance. It also increases the cross-sectional area of ​​the copper busbars, improving the conduction current and increasing the module's output power. The AC terminal 3.4 has square holes on its copper busbar leads, housing Hall effect chips. A coreless current sensor chip is used, capturing the electromagnetic field induced by the current flowing through the copper busbar to detect the current. The current sensor chip is soldered onto the shared control and drive PCB 4, protected by a plastic housing. Pins extend upwards from the signal end and are soldered onto the shared control and drive PCB 4, transmitting the current value directly to the control board chip via these pins. Compared to ordinary magnetic core current sensors, this arrangement significantly improves space utilization and reduces cost, while also increasing the spatial integration of the AC side. The power module's output end is designed with a side mounting nut for connecting the busbar 10.1 from the motor side to the inverter's internal circuitry, enabling current transmission. Figure 6 As shown.

[0103] 7. The motor busbar 10.1 features an integrated injection-molded copper busbar. The contact area with the inverter housing has a radial sealing groove on the plastic part, using a rubber ring to achieve a seal with the inverter housing, isolating the motor cavity from the inverter cavity and preventing oil from entering the inverter cavity. Two low-voltage pins 10.2 are arranged inside the injection-molded part. One side of the pin leads to the motor busbar interface for connecting to the stator temperature sensor signal; the other side leads to the inverter cavity and connects to the control and drive common PCB board 4 via a wiring harness interface, completing the transmission of the motor stator temperature signal to the control chip. The inverter's power module three-phase output copper busbar has an embedded nut. The motor busbar is led into the inverter and directly connected to the three-phase output copper busbar of the power module with screws. Holes are opened on the upper side of the main housing for tightening the screws at the three-phase connection and for inserting and removing the stator temperature signal wiring harness connector. Figure 7 As shown.

[0104] 8. Control and Drive Shared PCB Board 4: This board integrates the drive and control circuits. Its interfaces include vehicle signal connectors, resolver signal pin interfaces, motor stator temperature signal interfaces, and power module pin interfaces. It also integrates and solders a current sensor chip. The vehicle signal connectors are soldered to the board end and are secured to the threaded holes extending from the capacitor housing directly below the busbar with three bolts. The connectors pass through the top cover and are radially sealed to it, interconnecting with the outer vehicle wiring harness connectors. The control and drive shared PCB board 4 has numerous solder joints, and the positions of the current sensor chip and module's lead-out copper busbars are precise. Precision positioning pins are placed on the power module to ensure the positional accuracy between the current sensor and the through-holes on the output copper busbars. Figure 8 As shown.

[0105] 9. Main Housing Design: Besides housing and protecting internal components, the inverter main housing also serves as the motor end cover, providing a bearing housing for the motor rotor and acting as a floating support for the bearing. An L-shaped steel sleeve 1.3 is integrally cast with the aluminum alloy housing on the inner wall of the bearing housing. The inner wall of the steel sleeve has a clearance fit with the outer ring of the bearing. Steel with higher strength than aluminum is used as the bearing support component, increasing the strength, rigidity, and wear resistance of the bearing housing. The inner diameter of the resolver stator 7 is larger than the outer diameter of the bearing outer ring and is mounted on the inverter main housing 1.1. The resolver signal terminal is directly led to the control and drive common PCB board 4 via a plastic-coated shell and pins, forming a radial seal with the main housing 1.1. During assembly with the motor, the motor rotor assembly 9, along with the wave spring, bearing, and resolver rotor 9.1, passes through the resolver stator 7. The wave spring fits against the L-shaped steel sleeve 1.3, and the bearing has a clearance fit with the bearing housing on the main housing. The resolver rotor 9.1 is aligned with the resolver stator 7, completing the electric drive assembly installation. The main housing 1.1 has an opening at the DC copper busbar lead-out end of the bus capacitor 3, and a similar opening is made at the motor housing, allowing the bus capacitor copper busbar to pass through the two housing layers and enter the filter cavity to complete the connection with the filter copper busbar. The inverter main housing 1.1 and the motor housing require a perimeter press-fit seal at this point, isolating the main housing from the motor body cavity to prevent oil from entering the inverter cavity and filter cavity. The inverter main housing 1.1 uses a ring of flange bolts to press-fit a steel gasket to achieve a seal with the motor housing. The main housing 1.1 has a cooling and sealing cavity below the capacitors created using friction welding to achieve capacitor cooling. The friction-welded water channel extends to the bottom of the power module, connecting with the water channel of power module 2. The motor is oil-cooled and does not require coolant. The inlet pipe 1.4 and outlet pipe 1.5 are led out axially inwards towards the motor, not occupying the outer boundary space of the electric drive assembly, and facilitating connection to the reducer's heat exchanger. Figure 9-10 As shown.

[0106] The above provides a detailed description of a highly integrated inverter and electric drive assembly proposed in this invention. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this invention. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A highly integrated inverter and electric drive assembly, characterized in that, The device includes an inverter assembly and an electric drive assembly; The inverter assembly includes a main housing assembly (1), a power assembly, a bus capacitor (3), a control assembly, a top cover (5), a vehicle wiring harness connector (6), and a resolver stator (7). The main housing assembly (1) includes an L-shaped steel sleeve (1.3); the control assembly includes a low-voltage connector (4.2). The electric drive assembly includes a motor housing (8), a rotor assembly (9), a stator assembly (10), an electromagnetic filter (11), and a DC high-voltage wiring harness (12). The rotor assembly (9) includes a resolver rotor (9.1) and a bearing (9.2). The main housing assembly (1) is fastened to the top cover (5), and is equipped with a power assembly, bus capacitor (3) and control assembly inside; The power assembly is connected to the bus capacitor (3); The control assembly is fixed to the power assembly and bus capacitor (3) by bolts; The low-voltage connector (4.2) passes through the top cover (5) and interconnects with the vehicle wiring harness plug (6); The resolver stator (7) is bolted to the bottom of the main housing assembly (1); The motor housing (8) is provided with a rotor assembly (9) and a stator assembly (10). The electromagnetic filter (11) and the DC high voltage harness (12) are arranged in an independent cavity on the side of the motor housing (8); The rotor assembly (9), along with the wave spring, bearing (9.2), and resolver rotor (9.1), passes through the resolver stator (7). The wave spring fits against the L-shaped steel sleeve (1.3), the bearing (9.2) is clearance-fitted with the bearing chamber on the main housing assembly (1), and the resolver rotor (9.1) is aligned with the resolver stator (7), thus completing the installation and assembly of the inverter assembly and the electric drive assembly. The main housing assembly (1) also includes a main housing (1.1), a friction welding plate (1.2), a water inlet pipe (1.4), and a water outlet pipe (1.5). The main housing (1.1) is equipped with a friction welding plate (1.2). The main body (1.1) has an inlet pipe (1.4) and an outlet pipe (1.5) respectively installed at both ends of the outer side. The power assembly includes a power module (2), a DC terminal (2.1), an output terminal (2.2), and a current sensor through hole (2.3). The power assembly has a power module (2) in the middle, a DC terminal (2.1) on one side, and an output terminal (2.2) and a current sensor through hole (2.3) on the other side. The current sensor through hole (2.3) has a square hole on the copper busbar, and a Hall chip is arranged inside the hole; The bus capacitor (3) includes a plastic shell (3.1), a large core (3.2), a small core (3.3), an AC terminal (3.4), and a DC terminal (3.5). The plastic shell (3.1) of the bus capacitor (3) is designed as a semi-circular structure, and the large core (3.2) and small core (3.3) inside the bus capacitor (3) are arranged symmetrically on the left and right sides of the semi-circular plastic shell (3.1); The plastic housing (3.1) is connected to the AC terminal (3.4) and the DC terminal (3.5) by welding; The plastic shell (3.1) is perforated and ribs are extended along the periphery of the perforation to the capacitor potting surface, and a thin-walled steel pipe is injected into its interior. The AC terminal (3.4) is designed with a positive, negative, and positive structure, and it is laser-welded to the corresponding terminal of the power module (2); The positive and negative DC copper output lines of the DC terminal (3.5) are integrally injection molded in a positive and negative stack and extended into the electromagnetic filter (11) of the electric drive assembly, which is connected to the busbar of the electromagnetic filter (11). The control assembly also includes a control and drive common PCB board (4), a current sensor (4.1), and a resolver pin guide (4.3). The pins of the current sensor (4.1) are soldered onto the control and drive common PCB board (4); The control and drive common PCB board (4) is provided with a resolver pin guide bracket (4.3). The current sensor (4.1) is a coreless current sensor; The resolver stator (7) leads out signals to the control and drive common PCB board (4) and is designed as a direct-out pin structure. The pin structure is wrapped with a plastic protective shell, and the plastic protective shell has a radial annular sealing groove on its ring surface. The inner diameter of the resolver stator (7) is larger than the outer diameter of the outer bearing ring of the electric drive assembly; The bearing chamber of the electric drive assembly is formed by the main housing assembly (1); The stator assembly (10) includes a busbar (10.1) and two low-voltage pins (10.2). The stator assembly (10) is internally provided with a busbar (10.1) and two low-voltage pins (10.2). The busbar (10.1) is designed with an integrated injection-molded copper busbar. Two low-voltage pins (10.2) are arranged inside the injection-molded copper busbar. One side of the two low-voltage pins (10.2) is introduced into the busbar (10.1) to set an interface and connect to the stator temperature sensor. The other side is introduced into the inverter assembly cavity and connected to the control and drive common PCB board (4) through the wiring harness interface.

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