Electric drive systems and vehicles having them

Abstract

This invention provides an electric drive system and a vehicle having the same. The electric drive system includes: a reducer, the reducer including a reducer housing with a first cavity inside the reducer housing; and a motor, the motor including a motor housing with a second cavity inside the motor housing, the motor including a rotor assembly at least partially located inside the motor housing, and a stator assembly at least partially located inside the motor housing. The first cavity and the second cavity communicate and together form a mounting cavity for mounting the rotor assembly and the stator assembly. A connecting portion is provided on the side of the reducer housing facing the motor. The rotor assembly includes a rotor shaft with a first sealing ring located in a sealing groove on the rotor shaft. A cooling space is formed between the sidewall of the connecting portion, the surface of the connection between the rotor shaft and the input shaft, and the first sealing ring. This application effectively solves the problem of large cabin space occupied by electric drive systems in the prior art.

Description

Technical Field

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

[0002] Existing electric drive system layouts are mainly divided into three types: Z-type, L-type, and T-type. Each layout has its own characteristics. For example, L-type and T-type electric drive systems have low Z-axis heights, making them suitable for rear-wheel drive configurations. However, L-type electric drive systems have long axial dimensions, and T-type electric drive systems have long distances between the drive controller and the three-phase wiring of the motor. Z-type electric drive systems have small axial dimensions, short distances between the drive controller and the motor's three-phase wiring, and good EMC performance, making them suitable for front engine compartment configurations. However, because the drive controller is located above the motor, the overall Z-axis dimension is relatively large. Existing Z-type drive system layouts often use an integrated housing for the reducer, motor, and drive controller. This reduces the overall Z-axis dimension but also brings disadvantages such as difficulties in manufacturing the integrated housing and low standardization. With the rapid development of new energy vehicles, high speed, miniaturization, and high efficiency have become the main development directions for electric drive systems. Further reducing the Y-axis dimension and Z-axis height, and improving the adaptability of electric drive systems, poses a greater challenge to the layout structure of electric drive systems.

[0003] Existing electric drive systems also suffer from poor cooling and lubrication at the connection points between the reducer and the motor output shaft, leading to reduced drive efficiency.

[0004] There is currently no effective solution to the aforementioned problems in the existing technology. Summary of the Invention

[0005] The main objective of this invention is to provide an electric drive system and a vehicle having the same, so as to solve the problem of the large cabin space occupied by the electric drive system in the prior art.

[0006] To achieve the above objectives, according to one aspect of the present invention, an electric drive system is provided, comprising: a reducer, the reducer including a reducer housing having a first cavity inside the reducer housing; a motor, the motor including a motor housing having a second cavity inside the motor housing, the motor including a rotor assembly at least partially located inside the motor housing, the motor including a stator assembly at least partially located inside the motor housing, the first cavity and the second cavity communicating and jointly forming a mounting cavity for mounting the rotor assembly and the stator assembly; wherein, a connecting portion is provided on the side of the reducer housing facing the motor, the connecting portion being located within the first cavity, the input shaft of the reducer being located within the connecting portion, the rotor assembly including a rotor shaft, a first sealing ring being provided on the rotor shaft within a sealing groove, a cooling space being formed between the sidewall of the connecting portion, the surface of the connection portion between the rotor shaft and the input shaft, and the first sealing ring, and coolant within the reducer can enter the cooling space to perform a cooling operation on the connection between the input shaft and the rotor shaft.

[0007] Furthermore, a rotor shaft spline is provided at the end of the rotor shaft near the reducer housing. A sealing groove is provided adjacent to the end of the rotor shaft spline away from the reducer housing. A support journal is also provided on the rotor shaft, which is located between the sealing groove and the rotor shaft spline. A spiral groove is provided on the support journal, which is connected to the cooling space. When the rotor shaft rotates, the coolant in the spiral groove is thrown out to cool the surface of the support journal. An oil return hole is also provided on the rotor shaft, which can guide part of the thrown-out coolant back into the spiral groove.

[0008] Furthermore, the electric drive system also includes: a drive controller, the drive controller including a controller housing, the drive controller including an IGBT assembly disposed in the controller housing, the controller housing having a water inlet connected to the inlet end of the cooling channel of the IGBT assembly, the controller housing having a water outlet, the outlet end of the cooling channel of the IGBT assembly communicating with the water outlet, a second sealing ring being provided at the water outlet, the drive controller being located at the top of the motor housing, the top of the motor housing having a water inlet channel corresponding to the water outlet, and the water outlet extending into the water inlet channel.

[0009] Furthermore, the water inlet is integrally formed with the controller housing, and / or the water outlet is integrally formed with the controller housing.

[0010] Furthermore, the drive controller includes a three-phase wiring harness and a resolver signal harness. A three-phase wiring port is provided on the top of the motor housing. The three-phase wiring harness is electrically connected to the three-phase stator assembly through the three-phase wiring port so that the three-phase wiring harness can be stored inside the motor housing. The resolver signal harness is electrically connected to the resolver connector of the motor through the three-phase wiring port so that the resolver signal harness can be stored inside the motor housing.

[0011] Furthermore, the rotor assembly includes a rotor core connected to the rotor shaft. The rotor core includes multiple rotor core segments stacked along the axial direction of the rotor core. The number of rotor core segments is even. Two rotor core segments that are equidistant from the axial center of the rotor core are mounted on the rotor shaft using the same mounting method.

[0012] Furthermore, four keyways are evenly spaced along the circumference of the rotor shaft surface. The extension direction of the keyways is parallel to the axial direction of the rotor shaft. The inner ring of the rotor core segment is circumferentially spaced with a first convex key, a second convex key, a third convex key, and a fourth convex key. The first convex key and the third convex key are symmetrical about the central axis of the rotor shaft. The third convex key and the fourth convex key are also symmetrical about the central axis of the rotor shaft. There is a first preset angle between the first convex key and the second convex key, and there is a second preset angle between the third convex key and the second convex key. The structures of each rotor core segment are identically arranged.

[0013] Furthermore, the first preset included angle is R1, and the second preset included angle is R2, wherein 87.5°≤R1<90°, and the first preset included angle and the second preset included angle are set to be complementary.

[0014] Furthermore, the rotor core includes a first core segment, a second core segment, a third core segment, a fourth core segment, a fifth core segment, and a sixth core segment stacked along the axial direction of the rotor core. The first core segment and the sixth core segment are symmetrically arranged about the center position of the rotor core about the axial direction, the second core segment and the fifth core segment are symmetrically arranged about the center position of the rotor core about the axial direction, and the third core segment and the fourth core segment are symmetrically arranged about the center position of the rotor core about the axial direction. The first core segment and the second core segment are staggered on the rotor shaft, and the first core segment and the third core segment are staggered on the rotor shaft.

[0015] According to another aspect of the present invention, a vehicle is provided, including an electric drive system, wherein the electric drive system is the electric drive system described above.

[0016] By applying the technical solution of this invention, the reducer and motor housing together form a mounting cavity for mounting the rotor assembly and stator assembly. A cooling space is formed using the sidewalls of the connecting portion, the surface of the rotor shaft and input shaft connection, and the space between the first sealing ring to perform cooling at the connection between the input shaft and rotor shaft. This allows the reducer and motor housing to share a common housing, and the reducer integrates the function of the motor front cover, reducing the axial dimensions of the electric drive system and thus saving space occupied by the overall electric drive system. Simultaneously, cooling of the connection between the reducer and motor housing can be achieved within the shared housing, improving the operating efficiency of the electric drive system. The technical solution of this application effectively solves the problem of large cabin space occupied by the electric drive system in the prior art. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0018] Figure 1 A schematic diagram of the structure of a first embodiment of the electric drive system according to the present invention is shown;

[0019] Figure 2 A schematic diagram of a structure of an embodiment of a motor housing according to the present invention is shown;

[0020] Figure 3 A schematic diagram of an embodiment of the motor according to the present invention is shown;

[0021] Figure 4 A schematic diagram of a first embodiment of the rotor assembly according to the present invention is shown;

[0022] Figure 5 A schematic diagram of a second embodiment of the rotor assembly according to the present invention is shown;

[0023] Figure 6 A schematic diagram of a rotor core segment according to an embodiment of the present invention is shown;

[0024] Figure 7 A schematic diagram of the structure of a first embodiment of the drive controller according to the present invention is shown;

[0025] Figure 8 A schematic diagram of a second embodiment of the drive controller according to the present invention is shown;

[0026] Figure 9 A schematic diagram of a third embodiment of the drive controller according to the present invention is shown;

[0027] Figure 10 A schematic diagram of a second embodiment of the electric drive system according to the present invention is shown;

[0028] Figure 11 A schematic diagram of an embodiment of the cooling channel structure inside the motor housing according to the present invention is shown.

[0029] The above figures include the following reference numerals:

[0030] 10. Reducer; 11. Reducer housing; 111. Connecting part; 12. First cavity;

[0031] 20. Motor; 21. Motor housing; 211. Water inlet channel; 212. Three-phase terminal; 22. Second cavity; 23. Rotor assembly; 231. Rotor shaft; 2311. Sealing groove; 232. Rotor shaft spline; 233. Support journal; 234. Helical groove; 235. Rotor core section; 2351. First key; 2352. Second key; 2353. Third key; 2354. Fourth key; 236. Keyway; 24. Stator assembly; 240. First core section; 241. Second core section; 242. Third core section; 243. Fourth core section; 244. Fifth core section; 245. Sixth core section;

[0032] 30. Drive controller; 31. Controller housing; 32. IGBT assembly; 33. Water inlet; 34. Water outlet; 35. Second sealing ring.

[0033] 40. Sealing steel gasket; 41. Positioning pin; 42. Drive controller positioning pin;

[0034] 50. Stator positioning stop; 51. Stator positioning keyway;

[0035] 60. DC capacitor; 61. Control board; 62. Driver board; 63. Current sensor; 64. AC component; 65. Shielding board; 66. DC component; 67. High and low voltage shielding board;

[0036] 70. Axial positioning stop; 71. Front dynamic balancing deweight plate; 72. Rear dynamic balancing deweight plate; 73. Rear end pressure ring; 74. Bearing;

[0037] 80. Rotor core; 81. Permanent magnet. Detailed Implementation

[0038] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0039] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0040] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0041] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0042] Combination Figures 1 to 11 As shown, according to a specific embodiment of this application, an electric drive system is provided.

[0043] like Figures 1 to 3 As shown, the electric drive system includes a reducer 10 and a motor 20. The reducer 10 includes a reducer housing 11. The reducer housing 11 has a first cavity 12 inside. The motor 20 includes a motor housing 21, with a second cavity 22 inside the motor housing 21. The motor 20 includes a rotor assembly 23 located at least partially inside the motor housing 21 and a stator assembly 24 located at least partially inside the motor housing 21. The first cavity 12 and the second cavity 22 communicate and together form a mounting cavity for mounting the rotor assembly 23 and the stator assembly 24. The reducer housing 11 has a connecting portion 111 on the side facing the motor 20. The connecting portion 111 is located inside the first cavity 12, and the input shaft of the reducer 10 is located inside the connecting portion 111. The rotor assembly 23 includes a rotor shaft 231, and a first sealing ring is provided on the rotor shaft 231 within a sealing groove 2311. A cooling space is formed between the side wall of the connecting portion 111, the surface of the connection between the rotor shaft 231 and the input shaft, and the first sealing ring. Coolant in the reducer 10 can enter the cooling space to perform cooling operations at the connection between the input shaft and the rotor shaft 231.

[0044] By applying the technical solution of this invention, the reducer 10 and the motor housing 21 together form a mounting cavity for mounting the rotor assembly 23 and the stator assembly 24. A cooling space is formed by the side wall of the connecting part 111, the surface of the connection between the rotor shaft 231 and the input shaft, and the space between the first sealing ring. This cools the connection between the input shaft and the rotor shaft 231, allowing the reducer 10 and the motor housing 21 to share a housing, reducing the axial dimension of the electric drive system and saving overall space. Simultaneously, cooling of the connection between the reducer 10 and the motor housing 21 can be achieved within the shared housing, improving the operating efficiency of the electric drive system. The technical solution of this application effectively solves the problem of large cabin space occupied by the electric drive system in the prior art.

[0045] In an optional embodiment, the reducer 10 includes a reducer housing, an input shaft disposed within the reducer housing, an intermediate shaft system, and a differential assembly, with the input shaft, intermediate shaft system, and differential assembly being drive-connected. The motor 20 includes a motor housing 21, a stator assembly 24, and a rotor assembly 23.

[0046] In another preferred embodiment, the motor housing 21 is disposed on one side of the reducer 10, and is positioned and fixed by two locating pins 41 and eight connecting bolts. A sealing steel gasket 40 is provided between the motor housing and the reducer housing to seal the inner cavity of the motor housing. The sealing steel gasket is more suitable for disassembly and reassembly than sealant. Figure 1 The image also shows the drive controller positioning pin 42. (For example...) Figure 2 The stator positioning stop 50 and stator positioning keyway 51 are also shown.

[0047] like Figure 4 As shown, a rotor shaft spline 232 is provided at the end of the rotor shaft 231 near the reducer housing 11. A sealing groove 2311 is adjacent to the end of the rotor shaft spline 232 facing away from the reducer housing 11. A support journal 233 is also provided on the rotor shaft 231, located between the sealing groove 2311 and the rotor shaft spline 232. A helical groove 234 is provided on the support journal 233, which communicates with the cooling space. When the rotor shaft 231 rotates, the coolant in the helical groove 234 is thrown out to cool the surface of the support journal 233. An oil return hole is also provided on the rotor shaft 231, which can guide some of the thrown-out coolant back into the helical groove 234. This arrangement can efficiently cool the rotor shaft 231, and by using the support journal 233 to replace the original support bearing, the overall size can be reduced. To avoid the high heat problem caused by eliminating the bearing, the oil from inside the reducer can fully lubricate and cool this area.

[0048] Preferably, the rotor assembly 23 is coaxially arranged inside the stator assembly 24. The front end of the rotor assembly 23 is connected to the input shaft of the reducer via a spline to transmit power. The front end of the rotor assembly 23 is provided with an axial positioning stop 70 and a support journal 233. The support journal 233 has a helical groove 234 to guide the lubricating oil transmitted from the reducer input shaft into the support journal 233, preventing overheating and wear during operation. An O-ring seal is provided at the end of the helical groove 234 to seal the lubricating oil. The axial positioning stop 70 is subjected to sulfurizing heat treatment to improve wear caused by spline clearance during operation. A support bearing is provided at the rear end of the rotor assembly, arranged in a bearing chamber corresponding to the motor housing assembly, and the rotor assembly is axially preloaded by a wave-shaped elastic washer at the end of the support bearing.

[0049] like Figure 11 The diagram shows the built-in cooling water circuit within the motor housing, which integrates a spiral cooling water circuit for heat dissipation of the stator assembly. This built-in embedded water circuit helps reduce the size of the motor housing.

[0050] Furthermore, the electric drive system also includes a drive controller 30, which includes a controller housing 31 and an IGBT assembly 32 disposed on the controller housing 31. The controller housing 31 has a water inlet 33 connected to the inlet end of the cooling channel of the IGBT assembly 32. The controller housing 31 also has a water outlet 34, the outlet end of the cooling channel of the IGBT assembly 32 communicating with the water outlet 34. A second sealing ring 35 is provided at the water outlet 34. The drive controller 30 is located on the top of the motor housing 21. A water inlet channel 211 is provided on the top of the motor housing 21 corresponding to the water outlet 34, and the water outlet 34 extends into the water inlet channel 211. The drive controller 30 is disposed on the side of the motor and reducer, and is positioned and fixed by one locating pin and six connecting bolts. The second sealing ring 35 is preferably an O-ring. By integrally molding the water outlet pipe (i.e., water outlet 34) with the housing of the drive controller, and inserting the water outlet pipe directly into the water inlet (i.e., water inlet channel 211) of the motor housing, the Z-axis distance of the electric drive system can be shortened to the greatest extent.

[0051] like Figure 7 and Figure 8 The document also shows a DC capacitor 60, a control board 61, a drive board 62, a current sensor 63, an AC component 64, a shielding plate 65, a DC component 66, and high and low voltage shielding plates 67. Shielding plate 65 and high and low voltage shielding plates 67 can be the same or have different separate structures.

[0052] The drive controller comprises an IPU module, a control board, and a housing. The IPU module includes an AC component 64, a current sensor 63, an IGBT component 32, a drive board, a DC capacitor 60, and a DC component 66. The AC component is bolted to the drive controller body. The output terminal of the AC component 64 passes through the current sensor 63 and is electrically connected to the IGBT via bolts. The input terminal of the IGBT is electrically connected to the DC capacitor via bolts, and the input terminal of the DC capacitor is electrically connected to the DC component via bolts. The drive board is bolted to the upper part of the IGBT and electrically connected via soldered pins. The control board 61 is stacked on top of the shielding plate 65 and bolted to it. The shielding plate 65 and the DC capacitor 60 are bolted to the housing. The drive controller housing integrates a cooling water circuit, and O-rings are used at the interface with the IGBT water circuit for sealing. The drive controller housing has a shielding structure to physically isolate high-voltage and low-voltage components, improving EMC performance. The internal components of the drive controller are arranged in a flat layout to minimize the height of the drive controller.

[0053] Furthermore, the inlet 33 is integrally formed with the controller housing 31, and / or the outlet 34 is integrally formed with the controller housing 31.

[0054] Furthermore, the drive controller 30 includes a three-phase wiring harness and a resolver signal harness. A three-phase wiring port 212 is provided on the top of the motor housing 21. The three-phase wiring harness is electrically connected to the three phases of the stator assembly through the three-phase wiring port 212, allowing the three-phase wiring harness to be housed within the motor housing 21. The resolver signal harness is electrically connected to the resolver connector of the motor 20 through the three-phase wiring port 212, allowing the resolver signal harness to be housed within the motor housing 21. The three-phase wiring harness of the drive controller 30 is directly inserted into the three-phase wiring port 212 of the motor housing 21 and directly connected to the stator assembly using three bolts. The low-voltage harness is directly connected to the resolver connector inside the motor housing through the three-phase wiring port 212. Both the three-phase high-voltage lines and the resolver low-voltage harness are located inside the motor housing, maximizing the EMC performance of the electric drive system.

[0055] Preferably, the stator assembly 24 is interference-fitted with the motor housing 21, and a stator positioning stop 50 is provided at the bottom of the motor housing 21 to limit the stator assembly in the axial direction. A flat key is provided on the surface of the stator assembly to limit the circumferential direction.

[0056] Furthermore, the rotor assembly 23 includes a rotor core connected to the rotor shaft 231. The rotor core includes multiple rotor core segments 235 stacked along the axial direction of the rotor core. The number of rotor core segments 235 is even. Two rotor core segments 235 that are equidistant from the axial center of the rotor core are mounted on the rotor shaft 231 using the same mounting method. "Using the same mounting method" means that they are mounted on the rotor shaft 231 at the same mounting angle. The projections of two rotor core segments 235 that are equidistant from the axial center of the rotor core along the axial direction of the rotor shaft 231 coincide.

[0057] like Figure 4 The image also shows an axial locating stop 70. (For example...) Figure 5 The diagram also shows the front dynamic balancing deweight plate 71, the rear dynamic balancing deweight plate 72, the rear end pressure ring 73, and the bearing 74. (For example...) Figure 6 The rotor core 80 and permanent magnet 81 are also shown.

[0058] like Figure 6 As shown, four keyways 236 are evenly spaced along the circumference of the rotor shaft 231. The extension direction of the keyways 236 is parallel to the axial direction of the rotor shaft 231. A first key 2351, a second key 2352, a third key 2353, and a fourth key 2354 are circumferentially spaced along the inner ring of the rotor core segment 235. The first key 2351 and the third key 2353 are symmetrical about the central axis of the rotor shaft 231, and the third key 2353 and the fourth key 2354 are also symmetrical about the central axis of the rotor shaft 231. A first preset angle is formed between the first key 2351 and the second key 2352, and a second preset angle is formed between the third key 2353 and the second key 2352. All rotor core segments 235 have the same structure. The rotor shaft surface has four keyways 236 parallel to the axis, with each keyway 236 having an included angle of 90°. The diagonal keyways 236 have equal widths.

[0059] Preferably, the rotor shaft has a hollow internal structure and a stepped external diameter to minimize its weight. A shoulder is provided at the splined end of the rotor shaft for axial positioning of the dynamic balancing plate before press-fitting.

[0060] like Figure 6 As shown, the first preset included angle is R1, and the second preset included angle is R2, where 87.5°≤R1<90°, and the first and second preset included angles are complementary. That is to say, the inner ring of the rotor core section 235 is provided with four protruding keys, and the included angles formed by adjacent protruding keys between the four protruding keys are 87.5°, 92.5°, 87.5° and 92.5° respectively.

[0061] Furthermore, the rotor core includes a first core segment 240, a second core segment 241, a third core segment 242, a fourth core segment 243, a fifth core segment 244, and a sixth core segment 245 stacked along the axial direction of the rotor core. The first core segment 240 and the sixth core segment 245 are symmetrically arranged about the center position of the rotor core along the axial direction; the second core segment 241 and the fifth core segment 244 are symmetrically arranged about the center position of the rotor core along the axial direction; and the third core segment 242 and the fourth core segment 243 are symmetrically arranged about the center position of the rotor core along the axial direction. The first core segment 240 and the second core segment 241 are offset from each other on the rotor shaft 231, and the first core segment 240 and the third core segment 242 are also offset from each other on the rotor shaft 231. It should be noted that the structures of each rotor core segment 235 are identical, differing only in their installation angle when connected to the rotor shaft 231. The first core segment 240 and the sixth core segment 245 are arranged with a first convex key (that is, the first convex key is used as the initial installation position and the initial installation keyway set on the rotor shaft 231. For example, the keyway at the top of the rotor shaft 231 is determined as the initial installation keyway, and the first convex key is installed in the initial installation keyway). The second core segment 241 and the fifth core segment 244 are arranged with a second convex key (that is, the second convex key is used as the initial installation position and the initial installation keyway set on the rotor shaft 231. For example, the keyway at the top of the rotor shaft 231 is determined as the initial installation keyway, and the second convex key is installed in the initial installation keyway. At this time, the first core segment 240 and the second core segment 241 will be angularly misaligned). The third core segment 242 and the fourth core segment 243 are arranged with a second convex key after being flipped back and forth.

[0062] The rotor core and permanent magnet adopt a six-segment integral injection molding scheme. In order to ensure the fluidity of the injection molding material, in addition to paying attention to the staggered arrangement of the injection filling positions, the axial length of the rotor core is 0.3mm longer than that of the permanent magnet. A certain height of glue cap is left at the end of the integral injection molding, and the dynamic balancing de-weighting plate is set with annular glue grooves at the corresponding positions to achieve glue avoidance.

[0063] According to another specific embodiment of the present invention, a vehicle is provided, including an electric drive system, wherein the electric drive system is the electric drive system of the above embodiment.

[0064] As can be seen from the above description, the above embodiments of the present invention achieve the following technical effects: while taking into account the integration of the housing, the electric drive system reduces the overall size of the electric drive system by adopting solutions such as a shared housing, embedded cooling water circuit, and three-phase direct connection.

[0065] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0066] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0067] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0068] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric drive system, characterized in that, include: The reducer (10) includes a reducer housing (11) and the reducer housing (11) has a first cavity (12) inside. The motor (20) includes a motor housing (21) having a second cavity (22) inside the motor housing (21), the motor (20) including a rotor assembly (23) at least partially located inside the motor housing (21), and a stator assembly (24) at least partially located inside the motor housing (21). The first cavity (12) and the second cavity (22) are connected and together form a mounting cavity for mounting the rotor assembly (23) and the stator assembly (24). The reducer housing (11) has a connecting part (111) on the side facing the motor (20). The connecting part (111) is located in the first cavity (12). The input shaft of the reducer (10) is located in the connecting part (111). The rotor assembly (23) includes a rotor shaft (231). A first sealing ring is provided on the rotor shaft (231) and located in the sealing groove (2311). A cooling space is formed between the side wall of the connecting part (111), the surface of the connecting part between the rotor shaft (231) and the input shaft, and the first sealing ring. The coolant in the reducer (10) can enter the cooling space to perform a cooling operation on the connection between the input shaft and the rotor shaft (231). The rotor shaft (231) is provided with a rotor shaft spline (232) at one end near the reducer housing (11). The sealing groove (2311) and the rotor shaft spline (232) are arranged adjacent to each other at the end away from the reducer housing (11). The rotor shaft (231) is also provided with a support journal (233), which is located between the sealing groove (2311) and the rotor shaft spline (232). The support journal (233) is provided with a spiral groove (234), which is connected to the cooling space. When the rotor shaft (231) rotates, the coolant in the spiral groove (234) is thrown out to cool the surface of the support journal (233). The rotor shaft (231) is also provided with an oil return hole, which can guide part of the thrown-out coolant back into the spiral groove (234).

2. The electric drive system according to claim 1, characterized in that, The electric drive system also includes: A drive controller (30) includes a controller housing (31) and an IGBT assembly (32) disposed on the controller housing (31). The controller housing (31) is provided with a water inlet (33) connected to the inlet end of the cooling channel of the IGBT assembly (32). The controller housing (31) is provided with a water outlet (34) connected to the outlet end of the cooling channel of the IGBT assembly (32). A second sealing ring (35) is provided at the water outlet (34). The drive controller (30) is located at the top of the motor housing (21). A water inlet channel (211) is provided at the top of the motor housing (21) corresponding to the water outlet (34). The water outlet (34) extends into the water inlet channel (211).

3. The electric drive system according to claim 2, characterized in that, The inlet (33) is integrally formed with the controller housing (31), and / or the outlet (34) is integrally formed with the controller housing (31).

4. The electric drive system according to claim 2, characterized in that, The drive controller (30) includes a three-phase wiring harness and a resolver signal harness. The top of the motor housing (21) is provided with a three-phase wiring port (212). The three-phase wiring harness is electrically connected to the three-phase stator assembly through the three-phase wiring port (212) so that the three-phase wiring harness is housed in the motor housing (21). The resolver signal harness is electrically connected to the resolver connector of the motor (20) through the three-phase wiring port (212) so that the resolver signal harness is housed in the motor housing (21).

5. The electric drive system according to claim 1, characterized in that, The rotor assembly (23) includes a rotor core connected to the rotor shaft (231). The rotor core includes a plurality of rotor core segments (235) stacked along the axial direction of the rotor core. The number of rotor core segments (235) is even. Two rotor core segments (235) that are equidistant from the center position of the axial direction of the rotor core are mounted on the rotor shaft (231) in the same mounting manner.

6. The electric drive system according to claim 5, characterized in that, The surface of the rotor shaft (231) is provided with four keyways (236) evenly spaced along its circumference. The extension direction of the keyways (236) is parallel to the axial direction of the rotor shaft (231). The inner ring of the rotor core segment (235) is provided with a first convex key (2351), a second convex key (2352), a third convex key (2353), and a fourth convex key (2354) spaced along its circumference. The first convex key (2351) and the third convex key (2353) are symmetrical about the central axis of the rotor shaft (231). The third convex key (2353) and the fourth convex key (2354) are symmetrical about the central axis of the rotor shaft (231). The first convex key (2351) and the second convex key (2352) have a first preset angle, and the third convex key (2353) and the second convex key (2352) have a second preset angle. The rotor core segments (235) are arranged with the same structure.

7. The electric drive system according to claim 6, characterized in that, The first preset included angle is R1, and the second preset included angle is R2, wherein 87.5°≤R1<90°, and the first preset included angle and the second preset included angle are complementary.

8. The electric drive system according to any one of claims 6 to 7, characterized in that, The rotor core includes a first core segment (240), a second core segment (241), a third core segment (242), a fourth core segment (243), a fifth core segment (244), and a sixth core segment (245) stacked along the axial direction of the rotor core. The first core segment (240) and the sixth core segment (245) are symmetrically arranged about the center position of the rotor core about the axial direction. The second core segment (241) and the fifth core segment (244) are symmetrically arranged about the center position of the rotor core about the axial direction. The third core segment (242) and the fourth core segment (243) are symmetrically arranged about the center position of the rotor core about the axial direction. The first core segment (240) and the second core segment (241) are offset from each other on the rotor shaft (231). The first core segment (240) and the third core segment (242) are offset from each other on the rotor shaft (231).

9. A vehicle comprising an electric drive system, characterized in that, The electric drive system is the electric drive system according to any one of claims 1 to 8.

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