Electric drive system housing for a vehicle and vehicle

Abstract

This invention provides an electric drive system housing for a vehicle and a vehicle. The electric drive system housing includes: an upper housing comprising a controller upper housing and an end cover for covering the controller upper housing, the end cover being detachably fixedly connected to the controller upper housing, and a partition provided within the controller upper housing; and a lower housing located below the upper housing, the lower housing comprising at least an integrally formed controller lower housing, a motor housing, and a reducer housing, the controller lower housing being detachably fixedly connected to the controller upper housing to form the controller housing, the partition dividing the controller housing into at least two chambers for mounting various power electronic modules of the vehicle. This invention solves the problem of low integration in existing multi-functional electric drive system housings.

Description

Technical Field

[0001] This invention relates to the automotive field, specifically providing an electric drive system housing and a vehicle. Background Technology

[0002] The electric drive system is a core component of new energy vehicles, functioning similarly to the engine and transmission in a gasoline vehicle. It primarily comprises three parts: the motor, the controller, and the transmission assembly. The controller, following instructions from the vehicle controller, inverts the high-voltage direct current from the battery pack into three-phase alternating current to drive the motor. A reducer then decelerates the motor and increases the output torque to rotate the wheels. Following the trend of integration, the electric drive system is undergoing system upgrades and transformations to achieve multi-component integration. This integration is gradually progressing from hardware to electrical and chip integration, ultimately forming a more comprehensive, all-in-one powertrain system.

[0003] Chinese utility model patent CN208754130U discloses a three-in-one housing structure for a controller, reducer, and motor. This three-in-one housing structure includes a controller housing, a reducer housing, and a motor housing, all integrally cast. Specifically, the controller housing, reducer half-shell, motor end cover, and motor housing are integrally cast; the water channels and high / low pressure interfaces are also integrally cast; the motor water channels are designed as radial M-shaped channels, so that cooling water exiting from the controller first cools the common water channels of the housing, preventing the high temperature of the motor from adversely affecting the controller. This three-in-one housing structure adopts an integrated design, with shared housing components, reducing material usage and the need for fixing, sealing, and the use of multiple parts. However, the structure of this controller housing results in a low degree of integration of its components.

[0004] Therefore, a new technical solution is needed in this field to solve the above problems. Summary of the Invention

[0005] To address the issue of low integration in existing electric drive system housings, this invention provides an electric drive system housing for vehicles. The electric drive system housing of this invention includes: an upper housing comprising a controller upper housing and an end cover for covering the controller upper housing, the end cover being detachably and fixedly connected to the controller upper housing, and a partition provided within the controller upper housing; and a lower housing located below the upper housing, the lower housing comprising at least an integrally formed controller lower housing, a motor housing, and a reducer housing, the controller lower housing being detachably and fixedly connected to the controller upper housing to form the controller housing, and the partition dividing the controller housing into at least two chambers for mounting various power electronic modules of the vehicle.

[0006] The controller housing of this invention is divided into an upper controller housing and a lower controller housing, with a partition inside the upper controller housing. When the upper and lower controller housings are combined, the partition divides the controller housing into at least two chambers, thus fully utilizing the space within the controller housing and improving the integration of the internal power electronic modules. The end caps facilitate the installation and maintenance of the power electronic modules in the upper chamber of the controller. The lower controller housing, motor housing, and reducer housing are integrally cast, eliminating the need for connecting parts between them. This reduces the difficulty of the processing and assembly of the electric drive housing; furthermore, the integration of the three into one unit reduces the overall size and minimizes the space encroached upon by the electric drive system housing within the vehicle's interior. Furthermore, integrating the controller housing with the motor housing allows the external wiring harnesses for the controller and motor to be moved inside the housing, optimizing the vehicle's interior space and improving aesthetics.

[0007] In the preferred embodiment of the electric drive system housing for vehicles described above, at least two chambers are included, comprising a first chamber and a second chamber. The first chamber is enclosed by an end cover, the side wall of the upper controller housing, and a partition; the second chamber is enclosed by a lower controller housing and a partition. The arrangement of these two chambers divides the space within the controller housing into upper and lower layers. The removable end cover facilitates the maintenance and replacement of the power electronic modules within the first chamber; the detachable fixed connection between the upper and lower controller housings facilitates the maintenance and replacement of the power electronic modules within the second chamber, thus improving space utilization.

[0008] In the preferred embodiment of the electric drive system housing for a vehicle described above, a vertical baffle perpendicular to the partition is provided on the partition, dividing at least one of the first and second chambers into multiple sub-chambers. The vertical baffle further improves the utilization rate of the internal space of the first and second chambers, allowing each power electronic module to be more stably fixed in a sub-chamber that matches its shape. Furthermore, the vertical baffle also mitigates electromagnetic interference between power electronic modules.

[0009] In the preferred embodiment of the electric drive system housing for a vehicle described above, the multiple sub-chambers include a first sub-chamber located within a first chamber, a second sub-chamber located within a second chamber, and a third sub-chamber extending from the first chamber to the second chamber. The first sub-chamber is used to install an inverter, the second sub-chamber is used to install a DC / DC converter, and the third sub-chamber is used to install a high-voltage power distribution module. By integrating the inverter, DC / DC converter, and high-voltage power distribution module, the external wiring harnesses of the electric drive housing are reduced, the integration of the electric drive system housing is improved, and the encroachment on the vehicle's interior space is further reduced.

[0010] In the preferred embodiment of the above-described housing for an electric drive system of a vehicle, a controller coolant inlet is formed on the side wall of the upper controller housing for introducing coolant into the upper controller housing; a partition is integrally formed with the side wall, and a cooling channel is formed thereon, which is interconnected with the controller coolant inlet. With this configuration, the cooling channel on the partition can cool the power electronic modules inside the controller housing, and the integrally formed partition and cooling channel improve the sealing performance of the coolant flow path and reduce the manufacturing difficulty of the cooling channel.

[0011] In the preferred embodiment of the electric drive system housing for a vehicle described above, the cooling channel includes a first channel and a second channel connected in series. The first channel is formed on the lower surface of the partition, and the second channel is formed on the upper surface of the partition. With this configuration, the first and second channels constitute a single coolant flow path, allowing for the simultaneous cooling of the power electronic modules in both the first and second sub-chambers using a single coolant flow path, thereby improving the thermal management capability of the controller housing.

[0012] In the preferred embodiment of the electric drive system housing for a vehicle described above, the first flow channel includes a first inlet and a first outlet, with the first inlet connected to the controller coolant inlet; the second flow channel includes a second inlet and a second outlet, with the second inlet connected to the first outlet, allowing coolant to flow into the first flow channel from the first inlet and out of the first flow channel from the first outlet into the second flow channel, and then out of the second flow channel via the second outlet. Since the second flow channel is used to cool the inverter module, and the inverter module typically employs a finned heat dissipation structure to match the second flow channel, this configuration prevents the coolant from directly impacting the easily damaged inverter module heat dissipation structure. Furthermore, the flow path from the first flow channel located on the lower surface of the partition to the second flow channel located on the upper surface has low flow resistance, thus improving the cooling effect.

[0013] In the preferred embodiment of the electric drive system housing for a vehicle described above, a controller coolant outlet for introducing coolant into the motor housing is formed at the bottom of the lower controller housing. This controller coolant outlet is interconnected with a second outlet and with a motor coolant inlet formed on the motor housing. This configuration achieves series connection of the coolant flow paths for the controller and motor, reduces the number of cooling pipes, and further improves the integration of the electric drive system housing.

[0014] In the preferred embodiment of the electric drive system housing for a vehicle described above, the second outlet extends to the lower surface of the partition via a tubular member. The configuration of the tubular member facilitates a sealed connection between the second outlet and the controller coolant outlet when the upper and lower housings are fixedly assembled.

[0015] To address the issue of low integration levels in existing electric drive system housings, the present invention also provides a vehicle that uses the electric drive system housing described in any of the preceding claims. By employing the electric drive system housing described in any of the preceding claims, the space utilization and overall NVH performance of the vehicle of the present invention are improved. Attached Figure Description

[0016] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, in which:

[0017] Figure 1 This is an assembly schematic diagram of an embodiment of the present invention for a vehicle electric drive system housing;

[0018] Figure 2 This is an exploded view of an embodiment of the housing for an electric drive system of a vehicle according to the present invention;

[0019] Figure 3 This is a schematic diagram of the controller housing of an embodiment of the present invention for an electric drive system housing for a vehicle;

[0020] Figure 4 This is a schematic diagram of the first chamber of an embodiment of the housing for an electric drive system of a vehicle according to the present invention;

[0021] Figure 5 This is a schematic diagram of the second chamber of an embodiment of the housing for an electric drive system of a vehicle according to the present invention;

[0022] Figure 6 This is a schematic diagram of the first flow channel of an embodiment of the present invention for a housing of an electric drive system for a vehicle;

[0023] Figure 7 This is a schematic diagram of the lower housing of the controller in an embodiment of the electric drive system housing for a vehicle according to the present invention;

[0024] Figure 8 This is a cross-sectional view of an embodiment of the present invention for a housing of an electric drive system for a vehicle;

[0025] Figure 9 This is an embodiment of the present invention for a housing of an electric drive system for a vehicle. Figure 8 A magnified view of point A in the image.

[0026] List of reference numerals in the attached diagram:

[0027] 1. Electric drive system housing; 10. Upper housing; 11. Controller housing; 11a. Upper controller housing; 11b. Lower controller housing; 111. First vertical wall; 112. Mounting hole; 113. Controller coolant inlet; 114. Controller coolant outlet; 115. Bottom surface; 116. Second vertical wall; 117. Support platform; 118. Through hole; 12. End cap; 13. Partition; 131. Fixing post; 132. First vertical baffle; 133. Copper busbar through hole; 134. Second vertical baffle; 135. First wiring hole; 136. Third vertical baffle; 137. Second wiring hole; 138. First flow channel; 138a. First flow section; 138b. Second flow section; 1381. Water channel; 1382. Cover plate; 13821. Outlet Water nozzle; 13822, Annular groove; 1383, Separating rib; 1384, First inlet; 1385, First outlet; 1386, Guide rib; 13861, Drainage opening; 139, Boss; 1391, Second flow channel; 13911, Second inlet; 13912, Second outlet; 1392, Edge; 14, First chamber; 141, First sub-chamber; 142, Third sub-chamber; 143, Fourth sub-chamber; 15, Second chamber; 151, Second sub-chamber; 20, Lower housing; 21, Motor housing; 211, Outer water jacket; 212, Inner water jacket; 213, Motor cooling flow channel; 2131, Motor coolant inlet; 2132, Motor coolant outlet; 22, Reducer housing; 23, Motor end cover; 24, Reducer end cover. Detailed Implementation

[0028] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0029] It should be noted that in the description of this invention, terms such as "upper," "lower," "left," "right," "inner," and "outer," indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection, an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0031] To address the issue of low integration in existing electric drive system housings, this invention provides an electric drive system housing 1 for vehicles. The electric drive system housing of this invention includes: an upper housing 10, comprising a controller upper housing 11a and an end cover 12 for covering the controller upper housing, the end cover 12 being detachably fixedly connected to the controller upper housing 11a, and a partition 13 disposed within the controller upper housing 11a; and a lower housing 20 located below the upper housing 10, the lower housing 20 comprising at least an integrally formed controller lower housing 11b, a motor housing 21, and a reducer housing 22, the controller lower housing 11b being detachably fixedly connected to the controller upper housing 11a to form the controller housing 11, and the partition 13 dividing the controller housing 11 into at least two chambers for installing various power electronic modules of the vehicle.

[0032] Figure 1 This is an assembly schematic diagram of an embodiment of the present invention for a vehicle electric drive system housing; Figure 2 This is an exploded view of an embodiment of the housing for an electric drive system of a vehicle according to the present invention. Figure 1 and Figure 2 As shown, the electric drive system housing 1 for a vehicle of the present invention includes an upper housing 10 and a lower housing 20 located below the upper housing 10. In one or more embodiments, both the upper housing 10 and the lower housing 20 are made of aluminum alloy, which ensures the strength of the electric drive system housing 1 while also being lightweight. Alternatively, at least one of the upper housing 10 and the lower housing 20 may be made of steel to improve the rigidity of the housing. The upper housing 10 includes a controller upper housing 11a and an end cover 12. The lower housing 20 includes a controller lower housing 11b integrally cast, a motor housing 21, and a reducer housing 22. The motor housing 21 and the reducer housing 22 are arranged side by side, and the controller lower housing 11b is located above the motor housing 21 and the reducer housing 22. The controller upper housing 11a and the controller lower housing 11b can be combined to form the controller housing 11 through a detachable fixed connection between the upper housing 10 and the lower housing 20. A sealing strip is provided on the contact surface between the upper housing 11a and the lower housing 11b of the controller, which, together with the fasteners, serves to provide waterproofing, dustproofing, and shock absorption.

[0033] Figure 3This is a schematic diagram of the controller housing of an embodiment of the present invention for an electric drive system housing for a vehicle; Figure 4 This is a schematic diagram of the first chamber of an embodiment of the housing for an electric drive system of a vehicle according to the present invention; Figure 5 This is a schematic diagram of the second chamber of an embodiment of the present invention for a vehicle electric drive system housing. (See diagram below.) Figure 2 and Figure 3 As shown, the upper housing 10 includes a controller upper housing 11a, an end cap 12, and a partition 13.

[0034] like Figure 2 and Figure 3 As shown, in one or more embodiments, the controller housing 11a is configured as a generally rectangular frame consisting of four first vertical walls 111, each with a plurality of mounting holes 112. The mounting holes 112 are used to mount terminals (not shown) that mate with external wiring harnesses. The external wiring harnesses are used to connect the power electronic module within the controller housing 11 to other external components. In one or more embodiments, these other external components include, but are not limited to, a battery pack, a low-voltage battery, a PTC heater, an air conditioning compressor, an air pump, an oil pump, and a CAN communication network. In alternative embodiments, the other external components may be one or more of the aforementioned components. Additionally, a controller coolant inlet 113 is formed on the first vertical wall 111.

[0035] Continue reading Figure 2 and Figure 3 The end cap 12 is located at the upper opening of the controller upper housing 11a and forms a detachable fixed connection with the controller upper housing 11a. The fixed connection method includes, but is not limited to, screw connection, snap connection, etc. A sealing strip is arranged on the contact surface between the end cap 12 and the controller upper housing 11a, which, together with the fasteners, plays a role in waterproofing, dustproofing, and shock absorption.

[0036] Continue reading Figure 2 and Figure 3 In one or more embodiments, the partition 13 is disposed within the upper housing 11a of the controller, integrally cast with the upper housing 11a, and configured to be substantially parallel to the end cap 12. The space above the partition 13 forms a first chamber 14, and the space below the partition 13 forms a second chamber 15 (see [link to documentation]). Figure 5The use of two chambers improves the space utilization within the controller housing 11. Alternatively, the partition 13 can be configured to be substantially perpendicular to the end cover 12, forming chambers on both sides of the partition 13. Fixing posts 131 are provided on both the upper and lower surfaces of the partition 13. The power electronic module can be fixedly connected to the fixing posts 131 by means of screwing, snap-fitting, or other methods. In an alternative embodiment, fixing posts 131 are provided only on the upper surface of the partition 13 to mount the power electronic module disposed in the first chamber 14. The electronic module disposed in the second chamber 15 can be mounted via fixing posts or other fixing structures within the lower housing 11b of the controller.

[0037] like Figure 4 and Figure 5 As shown, a first vertical baffle 132 is provided on the upper surface of the partition 13. Based on Figure 4 As shown, a first sub-chamber 141 is formed on the right side of the first vertical baffle 132 for mounting the inverter. Within the area of ​​the first sub-chamber 141, the partition 13 also has copper busbar through holes 133 to allow a copper busbar extending from the inverter capable of conducting three-phase AC power to pass through and connect to the motor mounted in the lower housing 20. A second vertical baffle 134 is also provided on the lower surface of the partition 13. The second vertical baffle 134 has the same shape as the first vertical baffle 132 and is symmetrical about the plane containing the partition 13. Figure 5 As shown, a second sub-chamber 151 is formed on the right side of the second vertical baffle 134 for mounting a DC / DC converter.

[0038] Continue reading Figure 4 and Figure 5 In one or more embodiments, a plurality of first wiring holes 135 are also provided on the partition 13. The first wiring holes 135 connect the first chamber 14 and the second chamber 15, so the symmetrically arranged first vertical baffles 132 and second vertical baffles 134 together with the upper housing 11a of the controller form a third sub-chamber 142 extending from the first chamber 14 to the second chamber 15. A portion of the high-voltage power distribution module (i.e., the high-voltage power distribution module is installed in the third sub-chamber 142) is installed on the upper and lower surfaces of the partition 13, and the connecting wires of the high-voltage power distribution module pass through the first wiring holes 135. Since the high-voltage power distribution module is relatively large, the above configuration not only makes full use of the space inside the controller housing 11, but also ensures the secure installation of the high-voltage power distribution module. In alternative embodiments, a larger through hole can be provided on the partition 13 or the partition 13 can be omitted in the third sub-chamber to accommodate the installation of the high-voltage power distribution module.

[0039] Continue reading Figure 4 and Figure 5In one or more embodiments, a third vertical baffle 136 and a second wiring hole 137 are further provided on the upper surface of the partition 13. The third vertical baffle 136 divides a portion of the space of the first sub-chamber 132 to form a fourth sub-chamber 143. Wires on the inverter, DC / DC converter, and high-voltage power distribution module that need to be connected to external wiring harnesses through the side wall 111 of the area where the fourth sub-chamber 143 is located can extend from the second wiring hole 137 into the fourth sub-chamber 143 and then connect to predetermined terminals. This configuration not only improves the space utilization within the controller housing 11 but also facilitates later inspection and maintenance. Alternatively, the fourth sub-chamber 143 can be arranged in other suitable locations or the fourth sub-chamber 143 can be omitted to accommodate the connection lines of the power electronic modules.

[0040] It should be noted that the aforementioned partition 13 and the vertical baffles on the partition can also be configured in other suitable shapes, positions, and numbers to divide the controller housing 11 into more sub-chambers, accommodating more power electronic modules, thereby improving the integration of the electric drive system housing 1 of the present invention. Other power electronic modules include, but are not limited to, on-board chargers, DC / AC converters, etc.

[0041] A cooling channel communicating with the controller coolant inlet 113 is also formed on the partition 13, so that coolant flows through the controller coolant inlet 113 and along the cooling channel within the controller housing 11 to cool the power electronic modules therein. In one or more embodiments, the cooling channel includes a first channel 138 and a second channel 1391 connected in series. The first channel 138 is formed on the lower surface of the partition 13, while the second channel 1391 is formed on the upper surface of the partition 13.

[0042] Continue reading Figure 3 and Figure 4 In one or more embodiments, a boss 139 integrally formed with the partition 13 is provided on the upper surface of the partition 13 in the region of the first sub-chamber 141. An open water tank is provided in the middle of the boss 139, which is the second flow channel 1391. When the inverter is installed in the first sub-chamber 141, the finned heat dissipation structure for the IGBT in the inverter is inserted into the second flow channel 1391, and the sealing ring on the heat dissipation structure can abut against the edge 1392 of the boss 139, so that the heat dissipation structure and the second flow channel 1391 form a sealed connection. Alternatively, the second flow channel can also be provided in other shapes to match the IGBT heat dissipation structure.

[0043] Figure 6 This is a schematic diagram of the first flow channel of an embodiment of the present invention for a vehicle electric drive system housing. (See diagram below.) Figure 5 and Figure 6As shown, in one or more embodiments, on the lower surface of the partition 13 in the region where the second sub-chamber 151 is located, a first flow channel 138 is integrally formed with the partition 13 for cooling the DC / DC converter and for fluid communication with the controller coolant inlet 113. Figure 5 and Figure 6 As shown, the first flow channel 138 includes a water channel 1381 integrally formed with the partition 13 and a cover plate 1382 forming a sealed connection with the water channel 1381, so that the coolant flows in the first flow channel 138 without leaking into the controller housing 11. The connection between the cover plate 1382 and the water channel 1381 can be, but is not limited to, screwing or welding. The cover plate 1382 can be made of copper to improve heat dissipation efficiency, or it can be made of aluminum to reduce manufacturing costs. Figure 4 As shown, the second flow channel 1391 has a second inlet 13911 and a second outlet 13912.

[0044] Continue reading Figure 6In one or more embodiments, the first flow channel 138 is divided into a first flow segment 138a and a second flow segment 138b by a partition rib 1383. In one or more embodiments, the first flow segment 138a is configured as a "U"-shaped flow channel, and the second flow segment 138b is configured as a "J"-shaped flow channel to reduce flow resistance. Alternatively, the first flow segment 138a and the second flow segment 138b may also be configured in other suitable shapes. The first flow segment 138a has a first inlet 1384, a first outlet 1385, and a guide rib 1386. A flow-guiding opening 13861 is provided on the guide rib 1386 to reduce the flow resistance of the coolant at the first outlet 1385. The first outlet 1385 of the first flow segment 138a connects to the second inlet 13911 of the second flow channel 1391, and the second flow segment 138b connects to the second outlet 13912 of the second flow channel 1391. Therefore, along the flow direction of the coolant, the second flow channel 1391 is located between the first flow section 138a and the second flow section 138b, and they are connected in series. The coolant flows from the controller coolant inlet 113 into the controller housing 11, then through the first inlet 1384 into the first flow section 138a of the first flow channel 138, and then out of the first flow section 138a from the first outlet 1385. The coolant leaving the first flow section 138a enters the second flow channel 1391 through the second inlet 13911, and then flows out of the second flow channel 1391 from the second outlet 13912 before flowing into the second flow section 138b. The coolant then flows out of the controller housing 11 via the second flow section 138b. Alternatively, the first flow channel 138 can also be configured to have only a first flow section, where the coolant flows through the second flow channel and does not flow back into the first flow channel. With the above configuration, the coolant first enters the first flow channel 138 located on the lower surface of the partition 13, then flows into the second flow channel 1391 located on the upper surface of the partition 13, and finally flows back to the first flow channel 138. The advantage of this configuration is that it avoids the coolant directly entering the second flow channel 1391 and impacting the easily damaged IGBT heat dissipation structure. The area of ​​the first flow channel 138 used to cool the DC / DC converter is usually larger than the area of ​​the second flow channel 1391 used to cool the inverter. If the coolant adopts a "top-to-bottom" flow path (i.e., the coolant first enters from the second flow channel and then flows into the first flow channel), the coolant is prone to collision and turbulence when entering the first flow channel 138 from the second flow channel 1391, which increases the flow resistance and thus affects the heat exchange efficiency. In an alternative embodiment, the coolant can also be supplied "from top to bottom", but the coolant should be prevented from directly impacting the IGBT cooling structure. For example, the flow direction of the coolant inlet can be configured to face the baffle 13, and guide ribs can be provided in the first flow channel 138 by integral molding or welding to reduce the impact and turbulence of the coolant.

[0045] Figure 7 This is a schematic diagram of the lower housing of the controller in an embodiment of the electric drive system housing for a vehicle according to the present invention; Figure 8This is a cross-sectional view of an embodiment of the present invention for a housing of an electric drive system for a vehicle; Figure 9 This is an embodiment of the present invention for a vehicle electric drive system housing. Figure 8 A magnified view of a portion at point A. (See image below.) Figure 5 and Figure 9 As shown, the cover plate 1382 has a water outlet 13821, which can be integrally formed with the cover plate 1382 or welded to the cover plate 1382. The water outlet 13821 is disposed on the second flow section 138b of the first flow channel 138 so that the coolant can enter the next flow channel from the second flow section 138b.

[0046] like Figure 7 and Figure 8 As shown, a controller coolant outlet 114 is provided on the lower housing 11b of the controller. The controller coolant outlet 114 is interconnected with the water outlet 13821 so that coolant can flow out from the controller housing 11. Figure 9 As shown, in one or more embodiments, both the water outlet 13821 and the controller coolant outlet 114 are configured as tubular components, and the water outlet 13821 has a small diameter, suitable for insertion into the controller coolant outlet 114. An annular groove 13822 is provided on the outer wall of the water outlet 13821 to accommodate a sealing ring. In alternative embodiments, other sealing methods, such as packing seals or mechanical seals, may also be used between the water outlet 13821 and the controller outlet 114.

[0047] Continue reading Figure 7 The controller lower housing 11b also includes a bottom surface 115 and a second vertical wall 116 with the same cross-sectional shape as the first vertical wall 111. Since the controller lower housing 11b is integrated with the motor housing 21 and the reducer housing 22, the bottom surface 115 has an irregular shape to reduce manufacturing difficulty. Multiple support platforms 117 are provided on the bottom surface 115. The support platforms 117 are suitable for mounting pads and abutting against the power electronic modules installed in the second chamber, providing support and cushioning. A through hole 118 is also provided on the bottom surface 115. The through hole 118 is located above the motor housing 21. The three-phase copper busbar extending from the inverter passes through the copper busbar through hole 133 and then through the through hole 118 to finally connect to the motor in the motor housing 21.

[0048] Continue reading Figure 2 and Figure 8In one or more embodiments, the motor housing 21, configured to mount the drive motor, is generally cylindrical. The motor housing 21 has an outer water jacket 211, an inner water jacket 212, and a motor cooling channel 213 formed between the outer and inner water jackets 211 and 212. Alternatively, the motor housing 21 may employ other suitable cooling structures. In one or more embodiments, the motor cooling channel 213 has a motor coolant inlet 2131 and a motor coolant outlet 2132. Since the controller lower housing 11b is integrated with the motor housing 21, the motor coolant inlet 2131 extends to and fluidly communicates with the controller coolant outlet 114, thereby connecting the controller's cooling path in series with the motor's cooling path, reducing the number of pipes and sealing surfaces, and improving the housing's integration. Alternatively, the motor cooling path and the controller cooling path may not be integrated; instead, two different cooling paths may be used, resulting in fewer coolant cooling components and better cooling performance.

[0049] Continue reading Figure 1 and Figure 2 The motor coolant outlet 2132 is formed on the outer wall of the motor housing 21. Therefore, when the electric drive system housing 1 of the present invention for a vehicle is assembled (e.g. Figure 1 (As a result of the state), the coolant can flow from the controller coolant inlet 114 into the electric drive system housing 1 and out from the motor coolant outlet 2132, cooling the entire electric drive system housing 1 through a flow path, which greatly improves the integration of the housing.

[0050] Continue reading Figure 2 The reducer housing 22 is located at one end of the motor rotor spindle along its axial direction and is formed together with the motor housing 22 for mounting the reducer and its corresponding differential. In an alternative embodiment, the lower housing 20 may also integrate further transmission mechanisms, such as half-shaft assemblies. In addition, the motor housing 21 has a motor end cover 23, and the reducer housing 22 has a reducer end cover 24.

[0051] The vehicle of the present invention uses the above-described electric drive system housing 1 for a vehicle. This vehicle can be any suitable electric vehicle, hybrid electric vehicle, etc.

[0052] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. An electric drive system housing for a vehicle, characterized by, The electric drive system housing includes: The upper housing includes a controller upper housing and an end cap for covering the controller upper housing, the end cap being detachably fixedly connected to the controller upper housing, and a partition being provided inside the controller upper housing; and The lower housing is located below the upper housing. The lower housing includes at least an integrally formed lower controller housing, a motor housing, and a reducer housing. The lower controller housing is detachably fixedly connected to the upper controller housing to form the controller housing. The partition divides the controller housing into at least two chambers for installing various power electronic modules of the vehicle. The controller coolant inlet is formed on the side wall of the controller housing for introducing coolant into the controller housing, and a cooling flow channel communicating with the controller coolant inlet is formed on the partition plate; The cooling channel includes a first channel and a second channel connected in series, wherein the first channel is formed on the lower surface of the partition and the second channel is formed on the upper surface of the partition. The second flow channel is configured as an open water tank with a protrusion integrally formed with the partition plate, allowing the needle-fin heat dissipation mechanism for the IGBT of the inverter in the various power electronic modules to be inserted therein.

2. The electric drive system housing for a vehicle according to claim 1, characterized by, The at least two chambers include a first chamber and a second chamber, wherein the first chamber is enclosed by the end cap, the side wall of the upper housing of the controller, and the partition; and the second chamber is enclosed by the lower housing of the controller and the partition.

3. The electric drive system housing for a vehicle according to claim 2, characterized by, A vertical baffle perpendicular to the partition is provided on the partition, and the vertical baffle divides at least one of the first chamber and the second chamber into a plurality of sub-chambers.

4. The electric drive system housing for a vehicle according to claim 3, characterized by, The plurality of sub-chambers includes a first sub-chamber located within the first chamber, a second sub-chamber located within the second chamber, and a third sub-chamber extending from the first chamber to the second chamber; The first sub-chamber is used to install an inverter, the second sub-chamber is used to install a DC / DC converter, and the third sub-chamber is used to install a high-voltage power distribution module.

5. The housing for an electric drive system of a vehicle according to any one of claims 1-4, characterized in that, The partition is integrally formed with the sidewall.

6. The housing for an electric drive system of a vehicle according to claim 1, characterized in that, The first flow channel includes a first inlet and a first outlet, and the first inlet is connected to the controller coolant inlet; The second flow channel includes a second inlet and a second outlet. The two inlets are interconnected with the first outlet, so that the coolant flows into the first flow channel from the first inlet and flows out of the first flow channel from the first outlet and into the second flow channel, and then flows out of the second flow channel through the second outlet.

7. The housing for an electric drive system of a vehicle according to claim 6, characterized in that, A controller coolant outlet is formed at the bottom of the lower housing of the controller for introducing coolant into the motor housing. The controller outlet is interconnected with the second outlet and with the motor coolant inlet formed on the motor housing.

8. The electric drive system housing for a vehicle of claim 7, wherein, The second outlet extends to the lower surface of the partition via a tubular member.

9. A vehicle characterized by comprising: The vehicle includes an electric drive system housing for a vehicle as described in any one of claims 1-8.

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