An integrated multi-speed electric drive axle assembly

Abstract

The present invention relates to an integrated multi-speed electric drive axle assembly, comprising a reducer assembly, a motor assembly, and an electronic control unit; the reducer assembly is connected to the motor assembly, and the motor assembly is controlled by the electronic control unit; the present invention implements a motor-controlled worm gear mechanism through sequential shifting to achieve simultaneous operation of the main / auxiliary speed change mechanisms, effectively reducing the shifting stroke and shifting time, thereby effectively increasing the shifting time interval and significantly improving the shifting efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy commercial vehicles, and in particular to an integrated multi-speed electric drive axle assembly. Background Art

[0002] As the most critical component of the vehicle's load-bearing system and transmission system, the axle's main function is to bear the vehicle's load while reducing the power generated by the engine and increasing the torque to drive the vehicle.

[0003] With the continuous development of new energy technologies, electric drive has become one of the main development directions in the field of commercial vehicle technology. The technical routes adopted by electric drive commercial vehicles in existing technologies mainly include: 1. Power is generated by a central motor, which is then increased in speed and torque by a mechanical gearbox, and finally input to the axle through a drive shaft to drive the vehicle; 2. Electric drive axle technology is used, in which power is generated by the motor, which is then reduced in speed and torque by a single-stage reduction gear or a multi-stage reduction gear to drive the vehicle;

[0004] The main problems with the above two technical routes are: the first technical route has a long power system transmission route, resulting in large losses, and is relatively poor in energy consumption and maintenance convenience; although the second technical route has achieved certain improvements in driving efficiency, the existence of multi-stage reduction gears causes the overall size structure of the axle to be large, making it difficult to meet the layout requirements of the vehicle suspension system. At the same time, there is no speed change system, and energy consumption remains high. Summary of the Invention

[0005] The purpose of the present invention is to address the deficiencies of the existing technology and thus provide an integrated multi-speed electric drive axle assembly. By integrating the motor assembly, electronic control assembly, reducer assembly, and drive axle housing assembly into an integrated design and adopting a sequential shifting structure, the axle output torque and transmission efficiency are effectively improved while ensuring the axle structure is compact and the volume is small, and the overall performance and energy consumption of the vehicle are significantly improved.

[0006] The present invention is achieved by adopting the following technical solutions:

[0007] An integrated multi-speed electric drive axle assembly includes a drive axle housing assembly, a reducer assembly, a motor assembly, and an electronic control unit. The reducer assembly, motor assembly, and electronic control unit are integrated into a single housing and connected to the drive axle housing assembly. The reducer assembly is connected to the motor assembly, which is controlled by the electronic control unit.

[0008] The speed reducer assembly includes: a motor shaft connected to the output end of the motor assembly, and a sequential shifting structure;

[0009] A first reduction gear shaft, transmission-connected to the motor shaft;

[0010] A main speed change gear shaft is transmission-connected to the first reduction gear shaft and is connected to the sequential shifting structure; the main speed change gear shaft is a segmented structure, and the main speed change gear shaft is used to achieve gear shifting under the action of the sequential shifting structure;

[0011] A secondary speed change gear shaft, drivingly connected to a side of the main speed change gear shaft away from the first reduction gear shaft;

[0012] The output shaft is transmission-connected to a side of the main speed change gear shaft away from the auxiliary speed change gear shaft.

[0013] Preferably, the motor assembly includes a drive motor and a sequential shift execution motor; the drive motor and the sequential shift execution motor are respectively controlled by an electronic control unit.

[0014] Preferably, the input end of the motor shaft is spline-connected to the output end of the drive motor, and an input gear is provided in the middle of the motor shaft.

[0015] Preferably, one end of the first reduction gear shaft is provided with a first reduction gear meshing with the input gear, and the other end is provided with a second reduction gear.

[0016] Preferably, the main speed gear shaft includes a main speed gear shaft 1 and a main speed gear shaft 2 that rotate circumferentially;

[0017] The main speed gear shaft 1 is provided with a main speed gear 1, a main speed gear 2 and a main speed gear 3 that rotate in a circumferential direction; the main speed gear 1 is meshed with the second reduction gear;

[0018] A main speed change connecting ring fixedly connected to the main speed change gear shaft 1 is provided between the main speed change gear 1 and the main speed change gear 2, and a main speed change engaging sleeve is slidably provided on the outer side of the main speed change connecting ring;

[0019] The main speed gear 3 is provided with a main speed gear connecting ring 1 that matches the auxiliary speed gear connecting ring;

[0020] The main speed gear shaft 2 is a hollow structure, with the main speed gear 4 provided on one side close to the main speed gear shaft 1, and the main speed gear 5 fixedly provided on the other side;

[0021] The end of the main speed gear 4 close to the main speed gear shaft 1 is provided with a main speed gear connecting ring 2 that matches the auxiliary speed connecting ring, and an auxiliary speed engaging sleeve is slidably provided on the outside of the auxiliary speed connecting ring;

[0022] One end of the auxiliary speed gear shaft is provided with an auxiliary speed gear 2, which is engaged with the main speed gear 5, and the other end is fixedly provided with an auxiliary speed gear 1, which is engaged with the main speed gear 3.

[0023] Preferably, the output shaft includes a driven gear and a differential; the driven gear is meshed with the main speed gear four and is fixedly connected to the differential.

[0024] Preferably, the sequential shifting structure includes a worm, a worm wheel, a primary sequential shifting execution wheel, a primary speed shift fork, a secondary speed shift fork, a fork shaft, and a sequential shifting execution wheel shaft;

[0025] The sequential shifting execution motor is connected to a worm that meshes with a worm gear arranged at one end of a sequential shifting execution wheel shaft. A sequential shifting main execution wheel and a sequential shifting auxiliary execution wheel are provided on the sequential shifting execution wheel shaft. The sequential shifting main execution wheel and the sequential shifting auxiliary execution wheel are provided with a shift groove structure that allows the main speed shift fork and the auxiliary speed shift fork to slide on the fork shaft. The main speed shift fork and the auxiliary speed shift fork are respectively matched with the main speed shift engagement sleeve and the auxiliary speed shift engagement sleeve.

[0026] Preferably, the input gear, the first reduction gear, the second reduction gear, the auxiliary speed gear 1, the auxiliary speed gear 2, the main speed gear 1, the main speed gear 2, the main speed gear 3, the main speed gear 4, the main speed gear 5 and the driven gear are all helical cylindrical gears.

[0027] Preferably, the main speed gear 3 is positioned by a shaft shoulder on one side close to the main speed gear 2, and is positioned by a secondary speed connecting ring on the other side.

[0028] Compared with the prior art, the present invention has the following beneficial technical effects:

[0029] 1. Compact structure and high integration: The motor assembly, electronic control unit and reducer assembly are integrated into the same housing, thus achieving a high degree of integration of axle drive, control and speed change functions. At the same time, the main / auxiliary speed change gear shaft structure design effectively reduces the axial size of the axle reducer, making the axle structure more compact and smaller in size.

[0030] 2. Large output torque: According to the change of the axle gear position, the number of meshing gear pairs is changed in time. When large torque output is required under low-speed working conditions, multi-stage gear pair reduction is selected to achieve large torque output;

[0031] 3. High transmission efficiency: The main / sub-speed gear shaft structure is adopted to effectively reduce the number of meshing gear pairs and speed change mechanisms in the multi-speed transmission process, thereby effectively reducing transmission friction loss and improving transmission efficiency;

[0032] 4. High shifting efficiency: The sequential shifting structure is adopted. The worm gear mechanism is controlled by the sequential shifting execution motor to achieve simultaneous operation of the main and auxiliary speed change mechanisms, effectively reducing the shifting stroke and shifting time, thereby effectively increasing the shifting time interval and significantly improving the shifting efficiency.

[0033] 5. Low noise, stable and reliable operation: The final reducer adopts a full helical gear structure, which effectively reduces the transmission noise and vibration amplitude of the axle, thereby improving the transmission efficiency and significantly improving the operating reliability of the axle. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention will be further described below with reference to the accompanying drawings:

[0035] Figure 1 This is a schematic structural diagram of an integrated multi-speed electric drive axle assembly according to an embodiment of the present invention;

[0036] Figure 2 Schematic diagram of the sequential shifting structure and transmission shaft arrangement structure according to an embodiment of the present invention;

[0037] Figure 3 This is a schematic diagram of the transmission shafting arrangement structure according to an embodiment of the present invention;

[0038] Figure 4 This is a structural diagram of a sequential shifting device according to an embodiment of the present invention;

[0039] Figure 5 This is a schematic diagram of power transmission of a gear shaft system during a power-off working condition according to an embodiment of the present invention;

[0040] Figure 6 This is a schematic diagram of power transmission of the gear shaft system in the first gear position according to an embodiment of the present invention;

[0041] Figure 7 This is a schematic diagram of power transmission of the gear shaft system in the second gear position according to an embodiment of the present invention;

[0042] Figure 8 This is a schematic diagram of power transmission of a gear shaft system in the third gear according to an embodiment of the present invention;

[0043] Figure 9 This is a schematic diagram of power transmission of a gear shaft system in the fourth gear according to an embodiment of the present invention;

[0044] Figure 10 A schematic diagram of the motion trajectory of the sequential shifting structure of the transmission according to an embodiment of the present invention when arranged in three gears;

[0045] Figure 11 Schematic diagram of the motion trajectory of the sequential shifting structure of the transmission according to an embodiment of the present invention when arranged in four gears.

[0046] Description of reference numerals:

[0047] 1. Reducer assembly; 2. Motor assembly; 3. Drive axle housing assembly; 4. Electronic control unit;

[0048] 11. Motor shaft; 12. First reduction gear shaft; 13. Auxiliary speed gear shaft; 14. Main speed gear shaft; 14a. Main speed gear shaft 1; 14b. Main speed gear shaft 2; 15. Output shaft; 16. Sequential shift mechanism;

[0049] 11-1, motor connection spline; 11-2, input gear;

[0050] 12-1, first reduction gear; 12-2, second reduction gear;

[0051] 13-1, auxiliary speed gear 1; 13-2, auxiliary speed gear 2;

[0052] 14-1, Main speed gear 1; 14-2, Main speed gear sleeve; 14-3, Main speed gear connecting ring; 14-4, Main speed gear 2; 14-5, Main speed gear 3; 14-6, Auxiliary speed gear sleeve; 14-7, Main speed gear 4; 14-8, Main speed gear 5; 14-9, Main speed gear connecting ring 2; 14-10, Main speed gear connecting ring 1; 14-11, Auxiliary speed gear connecting ring;

[0053] 15-1, driven gear; 15-2, differential;

[0054] 16-1, sequential shift actuator motor; 16-2, worm; 16-3, worm gear; 16-4, sequential shift main actuator wheel; 16-5, main speed shift fork; 16-6, auxiliary speed shift fork; 16-7, fork shaft; 16-8, sequential shift actuator wheel shaft; 16-9, sequential shift auxiliary actuator wheel. DETAILED DESCRIPTION

[0055] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other. In the description of the present invention, it should also be noted that, unless otherwise clearly specified and limited, the terms "setting", "installation" and "connection" 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 directly connected, or indirectly connected through an intermediate medium, or it can be internal communication between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0056] Example 1:

[0057] like Figure 1-11As shown, an integrated multi-speed electric drive axle assembly includes a reducer assembly 1, a motor assembly 2, and an electronic control unit 4, which are integrated into the same housing and connected to the drive axle housing assembly 3; the reducer assembly 1 is connected to the motor assembly 2, and the motor assembly 2 is controlled by the electronic control unit 4;

[0058] The reducer assembly 1 includes: a motor shaft 11 connected to the output end of the motor assembly 2, and a sequential shifting structure 16;

[0059] A first reduction gear shaft 12 is transmission-connected to the motor shaft 11;

[0060] The main speed change gear shaft 14 is transmission-connected to the first reduction gear shaft 12 and is connected to the sequential shifting structure 16; the main speed change gear shaft 14 is a segmented structure, and the main speed change gear shaft 14 is used to achieve gear shifting under the action of the sequential shifting structure 16;

[0061] The auxiliary speed change gear shaft 13 is transmission-connected to the side of the main speed change gear shaft 14 away from the first reduction gear shaft 12;

[0062] The output shaft 15 is transmission-connected to a side of the main transmission gear shaft 14 away from the auxiliary transmission gear shaft 13 .

[0063] In one embodiment of the present invention, the motor assembly 2 includes a drive motor and a sequential shift execution motor 16 - 1 ; the drive motor and the sequential shift execution motor 16 - 1 are controlled and connected by an electronic control unit 4 ;

[0064] In one embodiment of the present invention, a motor connecting spline 11 - 1 is provided at one end of the motor shaft 11 and is connected to the drive motor, and an input gear 11 - 2 is provided in the middle of the motor shaft 11 ;

[0065] In one embodiment of the present invention, one end of the first reduction gear shaft 12 is provided with a first reduction gear 12-1 meshing with the input gear 11-2, and the other end is provided with a second reduction gear 12-2 meshing with the main speed change gear 14-1;

[0066] In one embodiment of the present invention, the main speed change gear shaft 14 includes a main speed change gear shaft 14a and a main speed change gear shaft 2 14b that can rotate freely in the circumferential direction; the main speed change gear shaft 14a is provided with a main speed change gear 1 14-1, a main speed change gear 2 14-4 and a main speed change gear 3 14-5 that can rotate freely in the circumferential direction; a main speed change connecting ring 14-3 fixedly connected to the main speed change gear shaft 14a is provided between the main speed change gear 1 14-1 and the main speed change gear 2 14-4, and a meshing spline structure with the same specifications as the main speed change connecting ring 14-3 is provided on the opposite side thereof; a main speed change meshing sleeve 14-2 that can slide left and right is provided on the outer side of the main speed change connecting ring 14-3 by means of a spline connection; the main speed change gear 3 14-5 is close to the main speed change gear 2 14- 4 is positioned by a shaft shoulder on one side and by a secondary speed-changing connecting ring 14-11 on the other side, and a main speed-changing gear connecting ring 1 14-10 with the same specifications as the secondary speed-changing connecting ring 14-11 is provided on the main speed-changing gear 3 14-5; the main speed-changing gear shaft 2 14b is a hollow structure, and a main speed-changing gear 4 14-7 integrally formed therewith is provided on the side close to the main speed-changing gear shaft 1 14a, and a main speed-changing gear 5 14-8 is fixedly provided on the other side; a main speed-changing gear connecting ring 2 14-9 with the same specifications as the secondary speed-changing connecting ring 14-11 is provided on the end portion of the main speed-changing gear 4 14-7 close to the side of the main speed-changing gear shaft 1 14a, and a secondary speed-changing engaging sleeve 14-6 that can slide left and right is provided on the outer side of the secondary speed-changing connecting ring 14-11 by means of a spline connection;

[0067] In one embodiment of the present invention, one end of the auxiliary speed gear shaft 13 is provided with an auxiliary speed gear 2 13-2 integrally formed therewith and meshing with the main speed gear 5 14-8, and the other end is fixedly provided with an auxiliary speed gear 1 13-1 and meshing with the main speed gear 3 14-5;

[0068] In one embodiment of the present invention, the output shaft 15 includes a driven gear 15-1 and a differential 15-2. The driven gear 15-1 is engaged with the main speed gear 14-7 and is fixedly connected to the differential 15-2.

[0069] In one embodiment of the present invention, the sequential shifting structure 16 includes a sequential shifting execution motor 16-1, which is connected to a worm 16-2 that meshes with a worm gear 16-3 provided at one end of a sequential shifting execution wheel shaft 16-8. The sequential shifting execution wheel shaft 16-8 is provided with a sequential shifting main execution wheel 16-4 and a sequential shifting auxiliary execution wheel 16-9 that are integrally formed therewith. The sequential shifting main execution wheel 16-4 and the sequential shifting auxiliary execution wheel 16-9 are provided with a shifting groove structure that allows a main speed shift fork 16-5 and an auxiliary speed shift fork 16-6 to slide left and right on the fork shaft 16-7. The main speed shift fork 16-5 and the auxiliary speed shift fork 16-6 cooperate with the main speed shifting engagement sleeve 14-2 and the auxiliary speed shifting engagement sleeve 14-6, respectively.

[0070] In one embodiment of the present invention, the input gear 11-2, the first reduction gear 12-1, the second reduction gear 12-2, the auxiliary speed gear 1 13-1, the auxiliary speed gear 2 13-2, the main speed gear 1 14-1, the main speed gear 2 14-4, the main speed gear 3 14-5, the main speed gear 4 14-7, the main speed gear 5 14-8 and the driven gear 15-1 are all helical cylindrical gears;

[0071] The multi-speed shifting principle of the electric drive axle assembly is as follows: when the axle needs to shift gears, the sequential shift execution motor 16-1 in the sequential shift structure 16 rotates the worm 16-2 under the control of the electronic control unit 4, and at the same time, the worm wheel 16-3 arranged on the sequential shift execution wheel shaft 16-8 and meshing with the worm 16-2 drives the sequential shift main execution wheel 16-4 and the sequential shift auxiliary execution wheel 16-9 to rotate a certain angle, thereby driving at least one of the main speed shift fork 16-5 and the auxiliary speed shift fork 16-6 arranged on the shift fork shaft 16-7 to slide left and right, realizing selective connection between the various speed gears, thereby completing the change of the axle gear position; the sequential shift structure 16 can achieve three-speed or four-speed shifting by adjusting the expansion trajectory of the speed slot structure of the sequential shift main execution wheel 16-4 and the sequential shift auxiliary execution wheel 16-9.

[0072] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and it is intended that all variations within the meaning and scope of the appended claims be encompassed. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

[0073] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features thereof can be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated multi-speed electric drive axle assembly, characterized in that: The invention comprises a drive axle housing assembly (3), a reducer assembly (1), a motor assembly (2), and an electronic control unit (4); the reducer assembly (1), the motor assembly (2), and the electronic control unit (4) are integrated in the same housing and connected to the drive axle housing assembly (3); the reducer assembly (1) is connected to the motor assembly (2), and the motor assembly (2) is controlled by the electronic control unit (4); The speed reducer assembly (1) comprises: a motor shaft (11) connected to the output end of the motor assembly (2), and a sequential shifting structure (16); A first reduction gear shaft (12) is transmission-connected to the motor shaft (11); A main speed change gear shaft (14) is transmission-connected to the first reduction gear shaft (12) and is connected to a sequential shifting structure (16); the main speed change gear shaft (14) is a segmented structure, and the main speed change gear shaft (14) is used to achieve gear shifting under the action of the sequential shifting structure (16); A secondary speed change gear shaft (13) is transmission-connected to a side of the main speed change gear shaft (14) away from the first reduction gear shaft (12); An output shaft (15) is drivingly connected to a side of the main speed change gear shaft (14) away from the auxiliary speed change gear shaft (13); The motor assembly (2) includes a drive motor and a sequential shift execution motor (16-1); the drive motor and the sequential shift execution motor (16-1) are respectively controlled by an electronic control unit (4); The sequential shifting structure (16) comprises a worm (16-2), a worm wheel (16-3), a sequential shifting main execution wheel (16-4), a main speed shift fork (16-5), an auxiliary speed shift fork (16-6), a fork shaft (16-7), and a sequential shifting execution wheel shaft (16-8); The sequential shift execution motor (16-1) is connected to a worm (16-2) meshing with a worm wheel (16-3) provided at one end of a sequential shift execution wheel shaft (16-8); the sequential shift execution wheel shaft (16-8) is provided with a sequential shift main execution wheel (16-4) and a sequential shift auxiliary execution wheel (16-9) integrally formed therewith. The sequential shift main execution wheel (16-4) and the sequential shift auxiliary execution wheel (16-9) are provided with a shift groove structure that enables the main speed shift fork (16-5) and the auxiliary speed shift fork (16-6) to slide on the fork shaft (16-7); the main speed shift fork (16-5) and the auxiliary speed shift fork (16-6) respectively cooperate with the main speed shift engagement sleeve (14-2) and the auxiliary speed shift engagement sleeve (14-6).

2. The integrated multi-speed electric drive axle assembly according to claim 1, characterized in that: The input end of the motor shaft (11) is spline-connected to the output end of the drive motor, and an input gear (11-2) is provided in the middle of the motor shaft (11).

3. The integrated multi-speed electric drive axle assembly according to claim 2, characterized in that: One end of the first reduction gear shaft (12) is provided with a first reduction gear (12-1) meshing with the input gear (11-2), and the other end is provided with a second reduction gear (12-2).

4. The integrated multi-speed electric drive axle assembly according to claim 3, characterized in that: The main speed change gear shaft (14) comprises a main speed change gear shaft 1 (14a) and a main speed change gear shaft 2 (14b) that rotate in the circumferential direction; The main speed change gear shaft 1 (14a) is provided with a main speed change gear 1 (14-1), a main speed change gear 2 (14-4) and a main speed change gear 3 (14-5) that rotate in a circumferential direction; the main speed change gear 1 (14-1) is meshed with the second reduction gear (12-2); A main speed change connecting ring (14-3) fixedly connected to the main speed change gear shaft (14a) is provided between the main speed change gear 1 (14-1) and the main speed change gear 2 (14-4), and a main speed change engagement sleeve (14-2) is slidably provided on the outer side of the main speed change connecting ring (14-3); The main speed change gear three (14-5) is provided with a main speed change gear connecting ring one (14-10) that matches the auxiliary speed change connecting ring (14-11); The main speed change gear shaft 2 (14b) is a hollow structure, with a main speed change gear 4 (14-7) provided on one side close to the main speed change gear shaft 1 (14a), and a main speed change gear 5 (14-8) fixedly provided on the other side; The end portion of the main speed change gear 4 (14-7) close to the main speed change gear shaft 1 (14a) is provided with a main speed change gear connecting ring 2 (14-9) that matches the auxiliary speed change connecting ring (14-11), and an auxiliary speed change engagement sleeve (14-6) is slidably provided on the outside of the auxiliary speed change connecting ring (14-11); One end of the auxiliary speed gear shaft (13) is provided with an auxiliary speed gear 2 (13-2) and meshes with the main speed gear 5 (14-8), and the other end is fixedly provided with an auxiliary speed gear 1 (13-1) and meshes with the main speed gear 3 (14-5).

5. The integrated multi-speed electric drive axle assembly according to claim 4, characterized in that: The output shaft (15) comprises a driven gear (15-1) and a differential (15-2); the driven gear (15-1) is meshed with a main speed change gear four (14-7) and is fixedly connected to the differential (15-2).

6. The integrated multi-speed electric drive axle assembly according to claim 5, characterized in that: The input gear (11-2), the first reduction gear (12-1), the second reduction gear (12-2), the auxiliary speed gear 1 (13-1), the auxiliary speed gear 2 (13-2), the main speed gear 1 (14-1), the main speed gear 2 (14-4), the main speed gear 3 (14-5), the main speed gear 4 (14-7), the main speed gear 5 (14-8) and the driven gear (15-1) are all helical cylindrical gears.

7. The integrated multi-speed electric drive axle assembly according to claim 4, characterized in that: The main speed change gear 3 (14-5) is positioned by a shaft shoulder on one side close to the main speed change gear 2 (14-4), and is positioned by a secondary speed change connecting ring (14-11) on the other side.

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