Distributed Electric Drive System

Abstract

The present invention discloses a distributed electric drive system, which includes an electric control motor assembly and a reducer assembly. Two electric control motor assemblies are symmetrically installed on both sides of the reducer assembly. The electric control motor assembly includes an electric control housing, a motor housing, a motor, and a motor controller. The motor is installed in the motor housing, and the motor controller is installed in the electric control housing. The reducer assembly includes a reducer housing and a reducer body. There are two reducer bodies and they are symmetrically installed in the reducer housing. The motor housing is in the shape of a hollow cylinder, and the motor housing and the electric control housing are integrated. The two motor housings are symmetrically arranged on the opposite sides of the reducer housing, and the two electric control housings are respectively arranged on the outer sides in the axial direction of the two motor housings. One of the motor controllers independently controls one motor, and the motor independently drives the corresponding side of the reducer body. The present invention has the advantages of compact structure, small occupied space, optimized control strategy, and reduced cost.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicles, and in particular to a distributed electric drive system. Background Art

[0002] The electric drive system of new energy vehicles is its core component, which is mainly responsible for converting electrical energy into mechanical energy to drive the vehicle. The electric drive system is usually composed of a motor, a controller and a reducer, which together play the role of the engine, ECU electronic control unit and gearbox in traditional fuel vehicles. Among them, the controller is based on the hardware and software design of power semiconductors to control the working state of the motor in real time. The motor transmits power to the reducer, which reduces the high speed output of the motor through the gear set, increases the output torque, and ensures that the electric drive system continues to operate in the high-efficiency range.

[0003] Dual-motor electric drive systems provide multiple advantages in new energy vehicles, including improved driving efficiency, increased braking energy recovery efficiency, no power interruption, and reduced manufacturing difficulty and total weight. Existing dual-motor electric drive systems require more complex control strategies to coordinate the torque distribution and power output of the two motors, which increases the difficulty of system design. The heat generated by the dual motors when working at high loads needs to be effectively managed, otherwise it may affect the performance and life of the motors. In addition, the existing dual-motor electric drive systems occupy a large space overall.

[0004] Therefore, it is necessary to design a distributed electric drive system with compact structure, small space occupation, optimized control strategy and reduced cost. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide a distributed electric drive system with a compact structure, small footprint, optimized control strategy and reduced cost.

[0006] The technical solution of the present invention provides a distributed electric drive system, comprising an electronically controlled motor assembly and a reducer assembly, wherein two electronically controlled motor assemblies are symmetrically mounted on both sides of the reducer assembly;

[0007] The electronically controlled motor assembly comprises an electronically controlled housing, a motor housing, a motor and a motor controller, wherein the motor is installed in the motor housing, and the motor controller is installed in the electronically controlled housing;

[0008] The reducer assembly comprises a reducer housing and a reducer body, wherein the reducer bodies have two parts and are symmetrically mounted in the reducer housing;

[0009] The motor housing is a hollow cylindrical shape. The motor housing and the electronic control housing are integrated. Two of the motor housings are symmetrically arranged on opposite sides of the reducer housing, and two of the electronic control housings are respectively arranged outside the two motor housings in the axial direction.

[0010] One of the motor controllers independently controls one of the motors, and the motor independently drives the reducer body on the corresponding side.

[0011] Further, the electronic control housing includes a cover and a housing body. The housing body is integrally formed with the motor housing. The cover is detachably connected to the housing body. The housing body includes a partition. The partition divides the inner cavity of the housing body into a main cavity and a secondary cavity. The main cavity is located between the cover and the partition, and the secondary cavity is located on the side facing the motor housing. The secondary cavity is in communication with the inside of the motor housing, and the partition is provided with a plug hole.

[0012] The motor controller includes an electronic control motor connection copper bar. The electronic control motor connection copper bar passes through the plug hole and enters the secondary cavity.

[0013] The motor stator of the motor is connected to the electronic control motor connection copper bar through a flexible cable. The flexible cable passes through the motor housing and enters the secondary cavity.

[0014] Further, it further includes a rear cover plate. A rear opening is provided on the side of the secondary cavity opposite to the cover. The rear cover plate is used to close the rear opening.

[0015] Further, the motor controller further includes a PCB board, a capacitor, and a power module stacked in the main cavity in sequence. The power module is installed on the bottom surface of the housing body. An electronic control cooling circuit for cooling the power module is provided in the housing body.

[0016] Further, the housing body includes a bottom plate and a side enclosure plate. The bottom plate is directly connected to one side of the motor housing.

[0017] The electronic control cooling circuit includes an inlet pipe, a cooling tank, and an outlet pipe. The cooling tank is provided on the bottom plate. The inlet pipe extends from the outside of the side enclosure plate into the inside of the bottom plate and is in communication with the cooling tank. The outlet pipe communicates from the other side of the cooling tank through the inside of the bottom plate to the inside of the motor housing.

[0018] A plurality of heat dissipation members are provided on one side surface of the power module. The heat dissipation members are inserted into the cooling tank. The power module and the edge of the cooling tank are sealed by a sealing ring.

[0019] Furthermore, a motor cooling circuit is provided in the motor housing, the motor cooling circuit is arranged inside the circumferential surface of the motor housing, and the electric control cooling circuit is communicated with the motor cooling circuit;

[0020] The motor cooling circuit comprises a liquid inlet and a liquid outlet, wherein the liquid inlet is directly connected to the electronically controlled cooling circuit, and the liquid outlet extends from the motor housing.

[0021] Furthermore, the reducer housing includes a main shell and two cover plates, the two cover plates are respectively covered on the openings on opposite sides of the main shell, a first mounting cavity and a second mounting cavity are symmetrically arranged in the main shell, and the reducer body includes two groups, and the two groups of reducer bodies are symmetrically installed in the first mounting cavity and the second mounting cavity.

[0022] Furthermore, the reducer body comprises an input shaft system, an intermediate shaft system and an output shaft system, the input shaft system is used to connect with the motor, and the output shaft system is used to connect with the wheel shaft;

[0023] The input shaft system includes an input gear, the intermediate shaft system includes an intermediate large gear and an intermediate small gear, the intermediate large gear and the intermediate small gear are coaxially fixedly connected, the input gear is meshed with the intermediate large gear, and the output shaft system includes an output gear, and the output gear is meshed with the intermediate small gear.

[0024] Further, the reducer assembly further comprises an oil injection assembly, which is installed in the first installation cavity and the second installation cavity, and is used to transport the oil at the bottom of the first installation cavity and the second installation cavity to the intermediate shaft system and the input shaft system;

[0025] The oil injection assembly includes a collecting tank, a driving gear, an oil pump, a delivery pipeline and an oil nozzle. The collecting tank is located at the bottom of the first mounting cavity and the second mounting cavity. The driving gear is meshed with the output gear. The driving gear is transmission-connected to the oil pump. The delivery pipeline connects the collecting tank, the oil pump and the oil nozzle.

[0026] Further, the oil nozzle includes a bearing oil nozzle and a gear oil nozzle;

[0027] The bearing oil nozzle is arranged along the axial direction, the middle section of the bearing oil nozzle is directly connected to the delivery pipeline, and both ends of the bearing oil nozzle extend above the input bearing of the input shaft system respectively;

[0028] The gear oil nozzle is perpendicular to the bearing oil nozzle and extends from the middle section of the bearing oil nozzle, and the gear oil nozzle extends above the middle large gear.

[0029] After adopting the above technical solution, the following beneficial effects are achieved:

[0030] In the present invention, two electric control motor assemblies are symmetrically arranged on both sides of the reducer assembly, and two electric control housings are arranged outside in the axial direction of the two motor housings. The entire distributed electric drive can be arranged along the axial direction of the motor housing, which is beneficial to realizing a flat design and reducing the space occupation in the front-back direction and up-down direction of the whole vehicle. In addition, the present invention includes two sets of independent electric control motor reducers, and the two motors are respectively controlled by two motor controllers, optimizing the control strategy and reducing the design cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Referring to the drawings, the disclosure of the present invention will become more understandable. It should be understood that these drawings are only for illustrative purposes and are not intended to limit the scope of protection of the present invention. In the figures:

[0032] Figure 1 is a perspective view of a distributed electric drive system in an embodiment of the present invention;

[0033] Figure 2 is an exploded view of a distributed electric drive system in an embodiment of the present invention;

[0034] Figure 3 is a perspective view of an electric control motor assembly in an embodiment of the present invention;

[0035] Figure 4 is an exploded view of an electric control motor assembly in an embodiment of the present invention;

[0036] Figure 5 is a schematic diagram inside an electric control housing in an embodiment of the present invention;

[0037] Figure 6 is an exploded view of an electric control housing in an embodiment of the present invention;

[0038] Figure 7 is a perspective view of a housing body in an embodiment of the present invention;

[0039] Figure 8 is an exploded view of the housing body and a power module in an embodiment of the present invention;

[0040] Figure 9 is a perspective view of the housing body from another perspective in an embodiment of the present invention;

[0041] Figure 10 is a perspective view of a motor stator in an embodiment of the present invention;

[0042] Figure 11 is Figure 10 a partial enlarged view of;

[0043] Figure 12It is a schematic diagram of the connection between the motor stator and the copper busbar connecting the electric control motor in an embodiment of the present invention;

[0044] Figure 13 It is a three-dimensional view of the electric control cooling circuit and the motor cooling circuit in an embodiment of the present invention;

[0045] Figure 14 It is a partial cross-sectional view of the distributed electric drive system in an embodiment of the present invention;

[0046] Figure 15 It is a three-dimensional view of the reducer assembly in an embodiment of the present invention;

[0047] Figure 16 It is an exploded view of the reducer assembly in an embodiment of the present invention;

[0048] Figure 17 It is of the reducer body in an embodiment of the present invention Figure 1 ;

[0049] Figure 18 It is of the reducer body in an embodiment of the present invention Figure 2 ;

[0050] Figure 19 It is a schematic diagram of the reducer body and the oil injection assembly in an embodiment of the present invention;

[0051] Figure 20 It is a schematic diagram of the main housing and the oil injection assembly in an embodiment of the present invention;

[0052] Figure 21 It is Figure 20 a partial enlarged view of;

[0053] Figure 22 It is a schematic diagram of the main housing in an embodiment of the present invention;

[0054] Figure 23 It is the front view of the main housing in an embodiment of the present invention;

[0055] Figure 24 It is a three-dimensional view of the cover plate in an embodiment of the present invention.

[0056] Corresponding table of reference numerals:

[0057] Electric control motor assembly 10:

[0058] Electric control housing 1: cover 11, housing body 12, rear cover plate 13, bottom plate 121, side wall plate 122, rear opening 123, partition plate 124, insertion hole 125, main cavity 12A, auxiliary cavity 12B;

[0059] Motor housing 2;

[0060] Electric control cooling circuit 3: liquid inlet pipe 31, cooling tank 32, liquid outlet pipe 33, drain pipe 34;

[0061] Motor cooling circuit 4: liquid inlet 41, liquid outlet 42;

[0062] Motor 5: resolver stator 51, motor stator 52, motor rotor 53, motor shaft 54, motor bearing 55, flexible cable 521, U-shaped part 522, cable end 522A, winding end 522B;

[0063] Motor controller 6: PCB board 61, capacitor 62, power module 63, heat sink 631, copper busbar for electric control motor connection 64, copper busbar for connection between bus and capacitor 65;

[0064] Reducer assembly 20:

[0065] Reducer housing 7: main housing 71, cover plate 72, bearing installation cavity 73, honeycomb structure 710, first input bearing installation groove 711, first output bearing installation groove 712, first intermediate bearing installation groove 713, first rib 714, third rib 715, installation position 716, first oil guiding hole 717, second oil guiding hole 718, second input bearing installation groove 721, second output bearing installation groove 722, second intermediate bearing installation groove 723, second rib 724, fourth rib 725, fifth rib 726;

[0066] Reducer body 8: input shaft system 81, intermediate shaft system 82, output shaft system 83, reducer bearing 84, oil seal cavity 85, input shaft 86, plug bearing 87, sealing ring 88, input gear 811, intermediate large gear 821, intermediate small gear 822, output gear 831;

[0067] Oil injection assembly 9: collection tank 91, drive gear 92, oil pump 93, delivery pipeline 94, oil nozzle 95, bearing oil nozzle 951, gear oil nozzle 952, bearing oil hole 9511, gear oil hole 9521. Specific implementation manners

[0068] The specific implementation manners of the present invention will be further described below with reference to the accompanying drawings.

[0069] It is easy to understand that according to the technical solution of the present invention, under the condition of not changing the essence of the present invention, those of ordinary skill in the art can adopt various structural forms and implementation manners that can be mutually replaced. Therefore, the following specific implementation manners and the accompanying drawings are only exemplary descriptions of the technical solution of the present invention, and should not be regarded as the whole of the present invention or as a limitation or restriction on the technical solution of the invention.

[0070] In this specification, orientation terms such as above, below, left, right, front, back, front side, back side, top, bottom, etc., which are mentioned or may be mentioned, are defined relative to the structures shown in the respective drawings. They are relative concepts and may accordingly change depending on their different positions and usage states. Therefore, these or other orientation terms should not be construed as restrictive terms.

[0071] In some embodiments of the present invention, the distributed electric drive system includes an electric control motor assembly 10 and a reducer assembly 20. Two electric control motor assemblies 10 are symmetrically installed on both sides of the reducer assembly 20.

[0072] The electric control motor assembly 10 includes an electric control housing 1, a motor housing 2, a motor 5, and a motor controller 6. The motor 5 is installed in the motor housing 2, and the motor controller 6 is installed in the electric control housing 1.

[0073] The reducer assembly 20 includes a reducer housing 7 and a reducer body 8. There are two reducer bodies 8 and they are symmetrically installed in the reducer housing 7.

[0074] The motor housing 2 is a hollow cylindrical shape. The motor housing 2 and the electric control housing 1 are integrated. Two motor housings 2 are symmetrically arranged on opposite sides of the reducer housing 7, and two electric control housings 1 are respectively arranged outside the motor housings 2 in the axial direction.

[0075] One of the motor controllers 6 independently controls one motor 5, and the motor 5 independently drives the corresponding side's reducer body 8.

[0076] Specifically, as Figure 1 shown, the reducer assembly 20 is located at the center, and two electric control motor assemblies 10 are respectively located on the left and right sides of the reducer assembly 20. Two electric control housings 1 are located outside the motor housings 2. The central axis of the motor housing 2 corresponds to the central axis of the input shaft system of the reducer housing 7. Therefore, the reducer housing 7, the motor housing 2, and the electric control housing 1 are arranged in a row along the central axis of the motor housing 2, achieving a flat design of the distributed electric drive system, which can reduce the dimensions in the front - rear direction and the up - down direction, and the arrangement of the internal motor, motor controller, and reducer is more reasonable and compact after being arranged axially.

[0077] As Figure 2 shown, the electric control housing 1 and the motor housing 2 are integrated. Two groups of electric control housings 1 and motor housings 2 are symmetrically arranged on the left and right sides of the reducer housing 7. After the electric control housing 1 and the motor housing 2 form a common housing, it is convenient for the layout of the internal wiring harnesses of the motor 5 and the motor controller 6 and the design of the cooling circuit, and can reduce the design of external pipelines.

[0078] As Figures 3 - 4As shown in the figure, the motor 5 is installed in the motor housing 2, and the motor controller 6 is installed in the electric control housing 1. The coaxial integrated design of the electric control housing 1 and the motor housing 2 is conducive to the layout of the wiring harness and cooling circuit of the motor 5 and the motor controller 6, which will be introduced in detail later.

[0079] As Figure 16 shown, the reducer housing 7 is an integral body, and two sets of reducer bodies 8 are integrated inside the reducer housing 7, making the overall structure compact and occupying less space.

[0080] In this embodiment, the distributed electric drive system includes two sets of motor controller - motor - reducer bodies. The two sets of devices operate independently and respectively input power to a wheel axle. Since one motor controller 6 only controls one motor 5, the control logic strategy is simplified and the design cost is reduced.

[0081] Furthermore, the electric control housing 1 includes a cover 11 and a housing body 12. The housing body 12 is integrally formed with the motor housing 2. The cover 11 is detachably connected to the housing body 12. The housing body 12 includes a partition 124. The partition 124 divides the inner cavity of the housing body 12 into a main cavity 12A and a secondary cavity 12B. The main cavity 12A is located between the cover 11 and the partition 124, and the secondary cavity 12B is located on the side facing the motor housing 2. The secondary cavity 12B is communicated with the inside of the motor housing 2. A plug hole 125 is provided on the partition 124;

[0082] The motor controller 6 includes an electric control motor connection copper bar 64. The electric control motor connection copper bar 64 passes through the plug hole 125 and enters the secondary cavity 12B;

[0083] The motor stator 52 of the motor 5 is connected to the electric control motor connection copper bar 64 through a flexible cable 521. The flexible cable 521 passes through the motor housing 2 and enters the secondary cavity 12B.

[0084] Specifically, as Figure 4 shown, the electric control housing 1 includes a cover 11 and a housing body 12. The cover 11 and the housing body 12 can be detachably connected by a plurality of bolts or screws. The housing body 12 is used to install the motor controller 6. The housing body 12 is integrally formed with the motor housing 2. The motor 5 and the motor controller 6 are separated by the bottom surface of the housing body 12 into two cavities and are respectively arranged. A resolver stator 51, a motor stator 52 and a motor rotor 53 are installed in the motor housing 2.

[0085] As Figures 6 - 8As shown, the housing body 12 includes a partition plate 124. The partition plate 124 divides the inner cavity of the housing body 12 into a main cavity 12A and a secondary cavity 12B. Among them, the main cavity 12A is located between the cover 11 and the partition plate 124. The main cavity 12A is used to install the PCB board 61, capacitor 62, power module 63, electric control motor connection copper bar 64, bus-bar and capacitor connection copper bar 65 of the motor controller 6, etc. That is to say, the motor controller 6 is basically installed in the main cavity 12A.

[0086] As Figures 8 - 9 shown, the secondary cavity 12B is located on the side facing the motor housing 2, and the secondary cavity 12B communicates with the inside of the motor housing 2. Two insertion holes 125 are opened on the partition plate 124. One of the insertion holes 125 is for installing the electric control motor connection copper bar 64.

[0087] As Figures 10 - 12 shown, after the flexible cable 521 of the motor stator 52 passes through the motor housing 2 and enters the secondary cavity 12B, it is connected to the electric control motor connection copper bar 64. As Figure 9 shown, the other insertion hole 125 is for installing a connection terminal, and the connection terminal is used to connect with the cable of the resolver stator 51.

[0088] Therefore, through the setting of the internal structure of the housing of the electric control housing 1 and the motor housing 2, the electrical connection between the motor 5 and the motor controller 6 is realized. The structure of the entire electric control motor assembly 10 is more compact, the layout is reasonable, and the occupied space is smaller.

[0089] Furthermore, as Figure 8 shown, it further includes a rear cover plate 13. On the side of the secondary cavity 12B opposite to the cover 11, that is, on the side facing the motor housing 2, a rear opening 123 is provided, and the rear cover plate 13 is used to close the rear opening 123.

[0090] The setting of the secondary cavity 12B and the rear opening 123 facilitates the electrical connection between the motor 5 and the motor controller 6, and also facilitates later maintenance. After the wiring harness and the copper bar are connected, the rear cover plate 13 is bolted to the rear opening 123.

[0091] Furthermore, as Figure 4 and Figure 13 shown, the motor controller 6 further includes a PCB board 61, a capacitor 62, and a power module 63 stacked in sequence in the main cavity 12A. The power module 63 is installed on the bottom surface of the housing body 12, and an electric control cooling circuit 3 for cooling the power module 63 is provided in the housing body 12.

[0092] Specifically, the power module 63 is tightly connected to the bottom surface of the housing body 12. An electric control cooling circuit 3 is provided inside the housing body 12. When the power module 63 is working, it generates heat. When the temperature is relatively high, it will affect the normal operation of the motor controller 6. Therefore, it is necessary to cool down the power module 63. A coolant flows into the electric control cooling circuit 3. When it passes through the power module 63, it cools the power module 63 and takes away the heat, ensuring the normal operation of the motor controller 6.

[0093] Furthermore, as Figure 7 shown, the housing body 12 includes a bottom plate 121 and a side wall plate 122. The bottom plate 121 is directly connected to one side of the motor housing 2;

[0094] As Figure 6 and Figure 13 shown, the electric control cooling circuit 3 includes an inlet pipe 31, a cooling tank 32, and an outlet pipe 33. The cooling tank 32 is opened on the bottom plate 121. The inlet pipe 31 extends from the outside of the side wall plate 122 into the inside of the bottom plate 121 and communicates with the cooling tank 32. The outlet pipe 33 passes through the inside of the bottom plate 121 from the other side of the cooling tank 32 and communicates with the inside of the motor housing 2;

[0095] As Figure 8 shown, a plurality of heat dissipation members 631 are provided on one side surface of the power module 63. The heat dissipation members 631 are inserted into the cooling tank 32. The power module 63 and the edge of the cooling tank 32 are sealed by a sealing ring.

[0096] Specifically, one end of the inlet pipe 31 of the electric control cooling circuit 3 is located outside the side wall plate 122 for communicating with an external coolant source, and the other end passes through the inside of the bottom plate 121 and communicates with the cooling tank 32; the cooling tank 32 is a groove opened on the inner side surface of the bottom plate 121. Two liquid holes are opened on the cooling tank 32. One liquid hole communicates with the inlet pipe 31, and the other liquid hole communicates with the outlet pipe 33.

[0097] As Figure 13 shown, the outlet pipe 33 passes through the inside of the bottom plate 121 from the other side of the cooling tank 32 and communicates with the motor cooling circuit 4 inside the motor housing 2.

[0098] During cooling, the coolant enters the cooling tank 32 through the inlet pipe 31. The cooling tank 32 cools the power module 63, then flows from the cooling tank 32 into the outlet pipe 33, and finally flows from the outlet pipe 33 into the motor cooling circuit 4 to continue cooling the motor.

[0099] As Figure 8As shown in the figure, on one side of the power module 63 facing the cooling tank 32, there are a plurality of protruding heat dissipation parts 631. The heat dissipation parts 631 are inserted into the cooling tank 32, and then the power module 63 and the edge of the cooling tank 32 are sealed by a sealing ring. In this way, when the coolant flows into the cooling tank 32, the coolant contacts the heat dissipation parts 631 and takes away the heat of the heat dissipation parts 631. Since the sealing ring reduces the gap between the cooling tank 32 and the power module 63 to be sealed, the coolant will not flow into the hollow cavity of the electric control housing 1 and will not affect the motor controller 6.

[0100] This embodiment realizes a common cooling system for the motor and the motor controller, effectively utilizes the coolant, optimizes the layout of the cooling system, and reduces the cost.

[0101] Furthermore, as Figure 7 and Figure 13 shown, the electric control cooling circuit 3 further includes a drain pipe 34. The drain pipe 34 is arranged inside the bottom plate 121. One end of the drain pipe 34 communicates with the cooling tank 32 and is connected to the liquid outlet pipe 33. The other end of the drain pipe 34 extends out from the outer wall of the side wall plate 122.

[0102] Specifically, as Figure 5 shown, one end of the drain pipe 34 communicates with the liquid hole at the bottom of the cooling tank 32, and the other end extends out from the outer wall of the side wall plate 122 for discharging the excess coolant.

[0103] As Figure 13 shown, the middle section of the drain pipe 34 is connected to one end of the liquid outlet pipe 33, and the other end of the liquid outlet pipe 33 is connected to the liquid inlet 41 of the motor cooling circuit 4.

[0104] The coolant first flows from the cooling tank 32 into the drain pipe 34, and then from the drain pipe 34 into the liquid outlet pipe 33. The other end of the drain pipe 34 can be blocked or a valve can be installed. When cooling, the valve is closed; when it is necessary to discharge the excess coolant, the valve is opened.

[0105] It should be noted that Figure 13 the part between the liquid inlet pipe 31 and the drain pipe 34 is not the cooling tank 32, but the shape of the coolant flowing into the cooling tank 32. The coolant is in the cooling tank 32 and cools around a plurality of protruding heat dissipation parts 631.

[0106] Furthermore, a motor cooling circuit 4 is provided in the motor housing 2. The motor cooling circuit 4 is arranged inside the circumferential surface of the motor housing 2, and the electric control cooling circuit 3 is connected to the motor cooling circuit 4;

[0107] The motor cooling circuit 4 includes a liquid inlet 41 and a liquid outlet 42. The liquid inlet 41 is directly connected to the electric control cooling circuit 3, and the liquid outlet 42 extends out from the motor housing 2.

[0108] Specifically, as Figure 13 shown, the motor cooling circuit 4 is a spiral cooling flow channel arranged inside the motor housing 2. The spiral cooling flow channel winds along the circumferential direction of the motor housing 2, and can cool the motor in all directions. The liquid inlet 41 is directly connected to the liquid outlet pipe 33, and the liquid outlet 42 extends outside the motor housing 2 for connection with an external cooling circulation pipeline. After the cooling circulation pipeline cools the coolant again, it flows into the cooling device from the liquid inlet pipe 31 again.

[0109] In this embodiment, the electronic control cooling circuit 3 and the motor cooling circuit 4 are respectively arranged inside the electronic control housing 1 and the motor housing 2. The coolant directly flows from inside the electronic control housing 1 into the motor housing 2, eliminating the need to arrange external cooling pipelines, reducing space occupancy, lowering costs, and improving cooling efficiency at the same time. The two sets of electronic control cooling circuits 3 and motor cooling circuits 4 are also symmetrically arranged on both sides of the reducer housing 7 and are cooled independently, optimizing the cooling effect of the dual motors.

[0110] Due to the symmetrical distribution of the electronic control motor assembly 10, the two sets of electronic control cooling circuits 3 and motor cooling circuits 4 are also symmetrically arranged. Among them, the motor cooling circuit 4 is arranged on the inner side, and the electronic control cooling circuit 3 is arranged on the outer side. In this embodiment, two sets of cooling devices are symmetrically arranged to cool a set of motor and electronic control respectively, improving the cooling efficiency of the dual motors.

[0111] Furthermore, the motor 5 further includes a motor stator 52 and a motor rotor 53, and the motor rotor 53 is installed inside the motor stator 52. As Figure 10 shown, the motor stator 52 is connected to the electronic control motor connection copper bar 64 through a flexible cable 521, and the flexible cable 521 passes through the motor housing 2 and penetrates into the auxiliary cavity 12B.

[0112] Specifically, as Figure 11 shown, there are three flexible cables 521, and each flexible cable 521 is connected to the motor stator 52 through a U-shaped part 522. The U-shaped part 522 includes a cable end 522A and a winding end 522B. The cable end 522A is directly connected to the flexible cable 521, and the winding end 522B includes two terminals respectively connected to two winding copper wires, facilitating the connection between the flexible cable 521 and the motor stator winding copper wire.

[0113] Preferably, the outer layer of the flexible cable 521 is wrapped with an insulating material to achieve electrical insulation.

[0114] Furthermore, as Figure 14 shown, the motor housing 2 and the reducer housing 7 are sealed by an oil seal. The reducer housing 7 is provided with a bearing installation cavity 73, and a reducer bearing 84 is installed in the bearing installation cavity 73. An oil seal sealing cavity 85 is formed between the reducer bearing 84 and the motor 5.

[0115] The oil seal sealing cavity 85 can achieve the seal between the reducer and the motor, preventing the oil from entering the motor housing 2 from the reducer housing 7.

[0116] Further, as Figure 14 shown, a motor bearing 55 is provided between the motor 5 and the motor housing 2, and the motor bearing 55 is a grease-lubricated bearing. Since the motor housing 2 is connected to the electronic control housing 1, the motor bearing 55 is a grease-lubricated bearing instead of an oil-lubricated bearing, which can prevent the oil from entering the interiors of the motor housing 2 and the electronic control housing 1.

[0117] Preferably, as Figure 14 shown, the motor 5 further includes an electric shaft 54, the reducer includes an input shaft 86, and the electric shaft 54 is connected to the input shaft 86 by a spline. The motor 5 transmits power to the reducer through the electric shaft 54. The input shaft 86 is connected to two bearings, one is the reducer bearing 84 and the other is the plug bearing 87. Both the reducer bearing 84 and the plug bearing 87 are oil-lubricated bearings because there is a large amount of oil in the reducer housing 7, and the oil can lubricate the reducer bearing 84 and the plug bearing 87 and can also cool the reducer.

[0118] Preferably, as Figure 14 shown, a sealing ring 88 is provided between the electric shaft 54 and the input shaft 86 to achieve the seal between the electric shaft 54 and the input shaft 86.

[0119] Further, the reducer housing 7 includes a main housing 71 and two cover plates 72. The two cover plates 72 are respectively covered on the openings on the opposite sides of the main housing 71. A first installation cavity and a second installation cavity are symmetrically arranged in the main housing 71. The reducer body 8 includes two groups, and the two groups of reducer bodies 8 are symmetrically installed in the first installation cavity and the second installation cavity.

[0120] Specifically, as Figure 15 shown, the reducer housing 7 is an integral body, and the two groups of reducer bodies 8 are integrated inside the reducer housing 7, making the overall structure of the reducer assembly compact and occupying a small space.

[0121] As Figure 16 shown, the first installation cavity and the second installation cavity are symmetrically arranged on the left and right sides of the reducer housing 7. The left and right sides of the main housing 71 are open, and the two cover plates 72 are respectively covered on the openings on the left and right sides of the main housing 71 to close the first installation cavity and the second installation cavity. The two sets of reducer bodies 8 are respectively installed in the first installation cavity and the second installation cavity.

[0122] In this embodiment, integrating the two sets of reducer bodies 8 in one reducer housing 7 can separately control the two wheels, and has a reasonable layout, a compact structure, and a small occupied space.

[0123] Preferably, as Figure 15 shown, a honeycomb structure 710 is provided on the outer surface of one side of the main housing 71. The honeycomb structure 710 can improve the stiffness and strength of the housing and improve the NVH performance.

[0124] Furthermore, as Figure 17 shown, the reducer body 8 includes an input shaft system 81, an intermediate shaft system 82, and an output shaft system 83. The input shaft system 81 is used to connect to the motor, and the output shaft system 83 is used to connect to the wheel shaft.

[0125] As Figure 18 shown, the input shaft system 81 includes an input gear 811, the intermediate shaft system 82 includes an intermediate large gear 821 and an intermediate small gear 822. The intermediate large gear 821 and the intermediate small gear 822 are coaxially and fixedly connected. The input gear 811 meshes with the intermediate large gear 821. The output shaft system 83 includes an output gear 831, and the output gear 831 meshes with the intermediate small gear 822.

[0126] Specifically, the power of the motor is transmitted to the input shaft system 81, the input shaft system 81 is then transmitted to the intermediate shaft system 82, then from the intermediate shaft system 82 to the output shaft system 83, and finally from the output shaft system 83 to the wheel shaft to drive the rotation of the wheel.

[0127] During transmission, the input gear 811 drives the intermediate large gear 821 to rotate, the intermediate large gear 821 drives the intermediate small gear 822 to rotate, and the intermediate small gear 822 drives the output gear 831 to rotate.

[0128] Since the diameter of the input gear 811 is smaller than the diameter of the intermediate large gear 821, a first speed change occurs during the transmission process. The rotational speeds of the intermediate large gear 821 and the intermediate small gear 822 are the same. The diameter of the intermediate small gear 822 is smaller than the diameter of the output gear 831, and a second speed change occurs during the transmission process. Through the transmission of the reducer body 8, the speed is changed.

[0129] Furthermore, as Figures 19 - 20 shown, the reducer assembly further includes an oil injection assembly 9. The oil injection assembly 9 is installed in the first installation cavity and the second installation cavity. The oil injection assembly 9 is used to deliver the oil at the bottom of the first installation cavity and the second installation cavity to the intermediate shaft system 82 and the input shaft system 81.

[0130] As Figure 20 shown, one end of the oil injection assembly 9 is installed at the bottom of the main housing 71, and the other end extends into the positions of the input shaft system 81 and the intermediate shaft system 82. The oil injection assembly 9 can deliver the oil at the bottom of the first installation cavity and the second installation cavity to the intermediate shaft system 82 and the input shaft system 81 to spray oil and cool the input shaft system 81 and the intermediate shaft system 82.

[0131] Since the output gear 831 of the output shaft system 83 has a relatively large diameter and the lower half of the output gear 831 is immersed in the oil, when the output gear 831 rotates, it can drive and splash the oil upward, playing a cooling role. However, the input shaft system 81 and the intermediate shaft system 82 are at a certain distance from the bottom of the installation cavity, and the direct splashing of the oil has a poor cooling effect. Therefore, it is necessary to drive the oil to the intermediate shaft system 82 and the input shaft system 81 through the oil injection assembly 9 to achieve a better cooling effect.

[0132] Furthermore, as Figure 19 shown, the oil injection assembly 9 includes a collection tank 91, a drive gear 92, an oil pump 93, a delivery pipe 94, and an oil nozzle 95. The collection tank 91 is located at the bottom of the first installation cavity and the second installation cavity. The drive gear 92 meshes with the output gear 831, the drive gear 92 is drivingly connected to the oil pump 93, and the delivery pipe 94 connects the collection tank 91, the oil pump 93, and the oil nozzle 95.

[0133] Specifically, the collection tank 91 is located below the output gear 831 and at the bottom of the first installation cavity and the second installation cavity. The drive gear 92 is drivingly connected to the oil pump 93 and meshes with the output gear 831. When the output gear 831 rotates, the output gear 831 drives the drive gear 92 to rotate, and the drive gear 92 drives the oil pump 93 to operate. The oil pump 93 pumps the oil in the collection tank 91 into the delivery pipe 94 and finally sprays it out from the oil nozzle 95, and the oil nozzle 95 leads to the input shaft system 81 and the intermediate shaft system 82.

[0134] When the drive gear 92 rotates, it can also stir the oil at the bottom and drive the oil to the upper intermediate shaft system 82.

[0135] Furthermore, as Figures 19 - 20 shown, the oil nozzle 95 includes a bearing oil nozzle 951 and a gear oil nozzle 952;

[0136] The bearing oil nozzle 951 is arranged along the axial direction. The middle section of the bearing oil nozzle 951 is directly connected to the delivery pipe 94, and both ends of the bearing oil nozzle 951 extend above the input bearings of the input shaft system 81;

[0137] The gear oil nozzle 952 is perpendicular to the bearing oil nozzle 951 and extends from the middle section of the bearing oil nozzle 951, and the gear oil nozzle 952 extends above the intermediate large gear 821.

[0138] Specifically, a bearing oil hole 9511 is provided at each end of the bearing oil nozzle 951. The bearing oil hole 9511 sprays oil into the upper part of the input bearing of the input shaft system 81 to cool the input bearing. The gear oil nozzle 952 is provided with a gear oil hole 9521. The gear oil hole 9521 sprays oil towards the large intermediate gear 821, and the oil can flow from the large intermediate gear 821 to the input gear 811, so as to cool the large intermediate gear 821 and the input gear 811.

[0139] Further, as Figures 22 - 23 shown, a first input bearing mounting groove 711 is provided on the inner wall of the main housing 71. A first oil guiding hole 717 is opened on the first input bearing mounting groove 711, and a plurality of first ribs 714 distributed radially are provided outside the first input bearing mounting groove 711;

[0140] As Figure 24 shown, a second input bearing mounting groove 721 is provided on the inner wall of the cover plate 72. A plurality of second ribs 724 distributed radially are provided outside the second input bearing mounting groove 721;

[0141] As Figure 21 shown, the two ends of the bearing oil nozzle 951 respectively extend into the positions of the first rib 714 and the second rib 724.

[0142] Specifically, after the cover plate 72 is buckled with the main housing 71, the two input bearings of the input shaft system 81 are respectively installed in the first input bearing mounting groove 711 and the second input bearing mounting groove 721. Two first oil guiding holes 717 are opened above the first input bearing mounting groove 711, and a plurality of first ribs 714 distributed radially are provided around the first input bearing mounting groove 711. A plurality of second ribs 724 distributed radially are provided outside the second input bearing mounting groove 721, and the first ribs 714 and the second ribs 724 are arranged correspondingly. Oil grooves are formed between adjacent first ribs 714, and oil grooves are also formed between adjacent second ribs 724. When the oil flows from the bearing oil nozzle 951 into the positions of the first rib 714 and the second rib 724, the oil converges in the oil grooves and then slowly flows into the input bearings through the first oil guiding holes 717 for cooling, improving the cooling effect.

[0143] Further, as Figures 22 - 24 shown, a first output bearing mounting groove 712 is further provided on the inner wall of the main housing 71. A second oil guiding hole 718 is opened on the mounting groove of the first output bearing, and a plurality of third ribs 715 distributed radially are provided outside the first output bearing mounting groove 712;

[0144] The inner wall of the cover plate 72 is provided with a second output bearing mounting groove 722, and a plurality of fourth ribs 725 distributed radially are provided outside the second output bearing mounting groove 722.

[0145] Similarly, when the oil fluid is stirred by the output gear 831 into the oil groove between the upper third rib 715 and the fourth rib 725, the oil fluid converges in the oil groove and then flows into the output bearing through the second oil guiding hole 718, which can continuously cool the output bearing.

[0146] Furthermore, as Figures 22 - 24 shown, a first intermediate bearing mounting groove 713 is provided on the inner wall of the main housing 71;

[0147] The inner wall of the cover plate 72 is provided with a second intermediate bearing mounting groove 723. Outside the second intermediate bearing mounting groove 723, a plurality of fifth ribs 726 are radially distributed. The fifth ribs 726 mainly play a role in increasing the structural strength of the cover plate 72 and the second intermediate bearing mounting groove 723.

[0148] Furthermore, as Figure 23 shown, below the first intermediate bearing mounting groove 713 on the inner wall of the main housing 71, a plurality of mounting positions 716 are provided. The mounting positions 716 are used to mount the oil pump 93. There are three mounting positions 716, which are used to be fixedly connected to the oil pump 93 by bolts or screws.

[0149] In this embodiment, two sets of reducer bodies are integrated in a reducer housing, which can separately control two wheels individually, and has a reasonable layout, a compact structure, and a small occupied space.

[0150] In the present invention, the motor housing and the electric control housing are integrated into one. Through the internal structure setting of the housing, it is beneficial to the electrical connection inside the motor and the motor controller. The layout of the entire distributed electric drive system is compact, has a high integration degree, and occupies less space. The electric control housing and the motor housing are coaxially arranged, which can reduce the X-direction and Z-direction dimensions and realize the flat and miniaturized design of the distributed electric drive system. And two sets of cooling devices are symmetrically arranged to cool a set of motor and electric control respectively, improving the cooling efficiency of the dual motors. The electric control cooling circuit and the motor cooling circuit are respectively arranged inside the electric control housing and the motor housing. The coolant directly flows from the inside of the electric control housing into the motor housing, without the need to arrange external cooling pipelines, reducing the space occupation, lowering the cost, and at the same time improving the cooling efficiency. In addition, the distributed electric drive system includes two sets of motor controller - motor - reducer bodies. The two sets of devices operate independently and respectively input power to a wheel axle. Since one motor controller only controls one motor, the control logic strategy is simplified and the design cost is reduced.

[0151] The above are only the principles and preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, based on the principles of the present invention, several other variations can also be made, which should also be regarded as the protection scope of the present invention.

Claims

1. A distributed electric drive system, characterized in that: It comprises an electronically controlled motor assembly and a reducer assembly, wherein two electronically controlled motor assemblies are symmetrically mounted on both sides of the reducer assembly; The electronically controlled motor assembly comprises an electronically controlled housing, a motor housing, a motor and a motor controller, wherein the motor is installed in the motor housing, and the motor controller is installed in the electronically controlled housing; The reducer assembly comprises a reducer housing and a reducer body, wherein the reducer bodies have two parts and are symmetrically mounted in the reducer housing; The motor housing is a hollow cylindrical shape, the motor housing and the electric control housing are integrated, the two motor housings are symmetrically arranged on opposite sides of the reducer housing, and the two electric control housings are respectively arranged on the outer sides of the two motor housings in the axial direction; One of the motor controllers independently controls one of the motors, and the motor independently drives the reducer body on the corresponding side; the electric control housing includes a cover and a housing body, the housing body is integrally formed with the motor housing, the cover and the housing body are detachably connected, the housing body includes a partition, the partition divides the inner cavity of the housing body into a main cavity and a secondary cavity, the main cavity is located between the cover and the partition, the secondary cavity is located at the angle between the motor housing and the main cavity, the secondary cavity is directly connected to the interior of the motor housing along the radial direction of the motor housing, a plurality of plug holes are opened on the partition, the plug holes are respectively used to install the cables of the motor stator and the cables of the resolver stator of the motor, and the cables of the motor stator and the resolver stator enter the secondary cavity from the motor housing along the radial direction; The motor controller comprises an electric-control motor connecting copper bar, the electric-control motor connecting copper bar passes through the plug hole and enters into the auxiliary cavity, and the motor stator is connected to the electric-control motor connecting copper bar through a flexible cable.

2. The distributed electric drive system according to claim 1, characterized in that: It also includes a rear cover plate. The side of the sub-cavity opposite to the cover is provided with a rear opening, and the rear cover plate is used to close the rear opening.

3. The distributed electric drive system according to claim 1, characterized in that: The motor controller also includes a PCB board, a capacitor and a power module stacked in sequence in the main cavity. The power module is mounted on the bottom surface of the shell body. An electrically controlled cooling circuit for cooling the power module is provided in the shell body.

4. The distributed electric drive system according to claim 3, characterized in that: The shell body includes a bottom plate and a side panel, and the bottom plate is directly connected to one side of the motor housing; The electronically controlled cooling circuit includes a liquid inlet pipe, a cooling groove and a liquid outlet pipe, wherein the cooling groove is provided on the bottom plate, the liquid inlet pipe extends from the outside of the side panel into the inside of the bottom plate and communicates with the cooling groove, and the liquid outlet pipe passes through the inside of the bottom plate from the other side of the cooling groove and communicates with the inside of the motor housing; A plurality of heat sinks are disposed on one side of the power module. The heat sinks are inserted into the cooling grooves. The power module and the edges of the cooling grooves are sealed by a sealing ring.

5. The distributed electric drive system according to claim 3, characterized in that: A motor cooling circuit is provided in the motor housing, the motor cooling circuit is arranged inside the circumferential surface of the motor housing, and the electric control cooling circuit is communicated with the motor cooling circuit; The motor cooling circuit comprises a liquid inlet and a liquid outlet, wherein the liquid inlet is directly connected to the electronically controlled cooling circuit, and the liquid outlet extends from the motor housing.

6. The distributed electric drive system according to claim 1, characterized in that: The reducer housing includes a main shell and two cover plates, the two cover plates are respectively covered on the openings on opposite sides of the main shell, a first installation cavity and a second installation cavity are symmetrically arranged in the main shell, and the reducer body includes two groups, and the two groups of reducer bodies are symmetrically installed in the first installation cavity and the second installation cavity.

7. The distributed electric drive system according to claim 6, characterized in that: The reducer body comprises an input shaft system, an intermediate shaft system and an output shaft system, wherein the input shaft system is used to connect with the motor, and the output shaft system is used to connect with the wheel shaft; The input shaft system includes an input gear, the intermediate shaft system includes an intermediate large gear and an intermediate small gear, the intermediate large gear and the intermediate small gear are coaxially fixedly connected, the input gear is meshed with the intermediate large gear, and the output shaft system includes an output gear, and the output gear is meshed with the intermediate small gear.

8. The distributed electric drive system according to claim 7, characterized in that: The reducer assembly further includes an oil injection assembly, which is installed in the first installation cavity and the second installation cavity, and is used to transport the oil at the bottom of the first installation cavity and the second installation cavity to the intermediate shaft system and the input shaft system; The oil injection assembly includes a collecting tank, a driving gear, an oil pump, a delivery pipeline and an oil nozzle. The collecting tank is located at the bottom of the first mounting cavity and the second mounting cavity. The driving gear is meshed with the output gear. The driving gear is transmission-connected to the oil pump. The delivery pipeline connects the collecting tank, the oil pump and the oil nozzle.

9. The distributed electric drive system according to claim 8, characterized in that: The oil nozzles include bearing oil nozzles and gear oil nozzles; The bearing oil nozzle is arranged along the axial direction, the middle section of the bearing oil nozzle is directly connected to the delivery pipeline, and both ends of the bearing oil nozzle extend above the input bearing of the input shaft system respectively; The gear oil nozzle is perpendicular to the bearing oil nozzle and extends from the middle section of the bearing oil nozzle, and the gear oil nozzle extends above the middle large gear.

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