Motor assembly
By covering and mechanically connecting the housing of the motor and inverter along the circumference of the motor axis, combining multiple power modules and air cooling fins, the problem of compact integration and cooling of the motor and inverter in automobiles is solved, and the problem of compact integration and cooling of the motor and inverter in automobiles is achieved. Efficient power conversion and reduce vehicle weight and cost.
Patent Information
- Application Number
- CN202380040042.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-03-27
- Filing Date
- 2023-01-13
- Publication Date
- 2024-12-24
AI Technical Summary
Existing motors and inverters are difficult to integrate compactly in cars, resulting in problems such as long wiring, large heat loss, complex assembly and excessive weight.
By covering the housing of the motor and inverter along the circumference of the motor axis, mechanical connections are made to form a compact package, eliminating elongated wiring, and using multiple power modules and air-cooled fins to ensure effective cooling of the inverter and efficient operation of the motor. .
The inverter is fully cooled, which reduces heat loss between the motor and the inverter, reduces cost and weight, improves the compactness and safety of assembly, and reduces heat dissipation problems.
Smart Images
Figure CN119183632A_ABST
Abstract
Description
Technical Field
[0001] The present subject matter relates to an electric motor assembly, and more particularly, to an electric motor assembly for a vehicle. Background Art
[0002] An electric motor is an electrical machine that converts electrical energy into mechanical energy. In general, electric motors operate through the interaction between the motor magnetic field and the current transmitted through the windings to produce a force in the form of torque applied to the motor shaft.
[0003] Electric energy can be supplied to the motor from various sources, including a direct current (DC) source, such as a battery or a rectifier. Alternatively, the motor can be powered by an alternating current (AC) source, such as a power grid, an inverter, or a generator. In the case of a car, the motor is mainly powered by a DC power source (such as a battery). Typically, an inverter is used to control the frequency of the power supplied by the power supply to the motor. Without an inverter, the motor will run at full speed immediately after the power is turned on. Therefore, the inverter controls the speed and acceleration of the motor as needed. BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The detailed description is described with reference to the accompanying drawings. The same reference numerals are used throughout the drawings to refer to the same features and components.
[0005] Figure 1 A side view of an exemplary embodiment of a motor assembly is shown.
[0006] Figure 2 A top perspective view of the inverter and inverter housing is shown.
[0007] Figure 3 An exploded view of a power splitter used in an inverter is shown.
[0008] Figure 4 A perspective view showing a power module and a power divider used in an inverter.
[0009] Figure 5 A top cross-sectional view of an inverter is shown.
[0010] Figure 6 A bottom perspective view of the inverter and inverter housing is shown. DETAILED DESCRIPTION
[0011] Traditionally, the inverter and the motor are housed separately in the vehicle and are electrically connected via multiple electrical connections. Therefore, a separate inverter and separate motor housing must be accommodated in the vehicle layout. Another challenge involves the electrical capacity and physical weight contribution of the motor and inverter, especially for two- or three-wheeled vehicles, where heavy electrical components are difficult and cumbersome to fit into the compact vehicle layout space.
[0012] According to known electric motors and inverters, attempts have been made to integrate the electric motor and the inverter together. In known designs, the components of the inverter are mounted on the upper part of the electric motor. However, this design results in an increased length between the output terminals of the power driver of the inverter and the input terminals of the motor coils. This further results in the use of more wires, which leads to increased heat losses due to the increased resistance of the wires. In addition, the thin and long wires can cause assembly and noise related problems.
[0013] According to other known motors, the motor and the inverter are integrated together, and cooling channels are provided in the stator of the motor and the power driver of the inverter, and then connected by a U-shaped pipe. However, in order to achieve proper cooling of the motor and the inverter, the cooling system needs to be large or bulky.
[0014] According to other known motors, a plurality of stator cores of the motor are arranged around a rotation axis at uniform intervals to form a circular stator structure, and a plurality of cooling channels are formed in the stator cores. An inverter that converts direct current into alternating current includes a plurality of power drivers that are respectively arranged on the stator cores.
[0015] According to other known motors and inverters, the inverter is attached to the side wall of the motor to minimize the wiring length. However, such motors do not support large-capacity inverters that generate a lot of heat.
[0016] The object of the present invention is to integrate the motor and the inverter so that the power module of the inverter, which inverts the power supply from direct current to alternating current, is adequately cooled. In addition, the disadvantages of long high-voltage wiring of the inverter and the motor, compactness of assembly, and safety of assembly and disassembly are solved. Furthermore, according to another object of the present invention, the motor and the inverter should not suffer from thermal damage or short circuit, and should not incur high cost or excessive weight.
[0017] Therefore, the present subject matter discloses an improved motor assembly having a motor, a motor housing, an inverter and an inverter housing. The motor housing covers the motor circumferentially along the motor axis, and the inverter housing covers the inverter circumferentially along the motor axis. The inverter housing is mechanically connected to the motor housing. The circumferential housing of the motor and the inverter ensures compact packaging of the motor and the inverter, so that the motor and the inverter are packaged in an integrated manner, and the motor and the inverter are connected together at the shortest distance, eliminating the necessity of slender wiring. Thereby, heat losses during the electrical connection between the motor and the inverter are reduced. In addition, the circumferential housing ensures that the inverter and the motor do not require separate housings. In an embodiment, the motor and the inverter both use a circumferential housing of the same size and the same shape, which significantly reduces the cost of the motor assembly with an integrated motor and inverter.
[0018] In another aspect of the present subject matter, the inverter includes a power distributor, a plurality of power modules, one or more controllers, and a plurality of phase connectors. The plurality of power modules include a first power module, a second power module, and a third power module. The plurality of power modules are connected to the power distributor and the controller. The controller controls power inversion, and the power module distributes the power inversion function to separate modules corresponding to the motor. In an embodiment, a three-phase motor is integrated with an inverter having three power modules. Therefore, the power module effectively acts on the signal distributed by the controller. In addition, each power module is separated from the other power modules by a predetermined distance, which ensures that the heat generated by each power module does not affect the other power modules.
[0019] In another aspect of the present invention, the direct current from the inverter is distributed to different power modules of the power distribution system through a power distributor. The power distributor ensures that the power distributed to each power module is distributed according to the capacity of the power module.
[0020] In another aspect of the invention, power transmission from the inverter to the motor is achieved through multiple phase connectors, which ensures terminal connection between the inverter and the motor, eliminating heat dissipation caused by thin wires or complex layouts in known designs. The present subject matter is further described with reference to the accompanying drawings. It should be noted that the description and the accompanying drawings only illustrate the principles of the present subject matter. Various arrangements that encompass the principles of the present subject matter can be designed, although not explicitly described or shown herein. In addition, all statements herein describing the principles, aspects and examples of the present subject matter and their specific examples are intended to encompass their equivalents.
[0021] Figure 1 A side view of an exemplary embodiment of a motor assembly is shown. Figure 1 A motor assembly (100) is provided. The motor assembly (100) includes a motor (105), a motor housing (121), a motor shaft (115), an inverter (110) and an inverter housing (111). The motor shaft is arranged on a vertical plane forming a motor axis (A-A'). The motor housing (121) surrounds the motor (105) circumferentially along the motor axis (A-A'). The inverter housing (111) covers the inverter (110) circumferentially along the motor axis (A-A'). The motor housing (121) and the inverter housing (111) are mechanically connected to each other, thereby providing a compact package of the motor and the inverter. According to an embodiment, the motor housing (121) and the inverter housing (111) have a plurality of fins (120, 125) on the outer surfaces of the motor housing (121) and the inverter housing (111). A plurality of fins (120, 125) provide air cooling for the inverter (110) and the motor (105).
[0022] According to an embodiment, a plurality of fins (120) on the motor housing (121) are coaxial along the motor axis. The coaxial fins (120) are arranged on the outer surface of the motor housing (121) at a predetermined distance from each other. In addition, the plate fins (125) are circumferentially arranged on the outer surface of the inverter housing (111). The inverter is electrically connected to a power source of a device (e.g., a vehicle). The inverter inverts and regulates the power source and supplies the inverted power source to the motor to drive the motor. The motor can then drive the device, e.g., a vehicle. In an embodiment, the motor is a three-phase AC motor, and the power source is a DC power source from one or more batteries. The inverter converts the DC power source into an AC power source, which drives the motor. In another embodiment, the power source can be an AC power source, and the inverter converts the AC power source into a DC power source to drive the motor. In an embodiment, the motor assembly can be mounted to the hub of a vehicle wheel via the hub. In another embodiment, the motor assembly can be mounted to the frame of the vehicle at a suitable position in the transverse direction or longitudinal direction of the vehicle. The motor assembly is mounted so as to ensure that the center of gravity (CG) of the vehicle remains balanced in both the lateral and longitudinal directions.
[0023] Figure 2 A top perspective view of an inverter (110) and an inverter housing (111) is shown. The inverter housing (111) covers the inverter (110). The inverter (110) includes a plurality of power modules (150, 155, 160), a controller (145), and a power distributor (130). The power modules (150, 155, 160) are responsible for inverting the power supply received from the battery. The controller (145) controls the operation of the power modules (150, 155, 160) and the operation of the motor (105) based on various parameters of the motor (e.g., temperature, power supply voltage supplied by the battery, SOC of the battery, etc.). The power distributor (130) distributes the power supply received from the battery to each power module (150, 155, 160). In an embodiment, each power module (150, 155, 160) corresponds to a single-phase alternating current supplied to the motor (105). As Figure 3 As shown, the power distributor (130) includes an anode (135), a cathode (140), and a support plate (165) laminated in an insulating member (132). The power distributor (130) distributes power to a plurality of power modules (150, 155, 160). The plurality of power modules (150, 155, 160) include a first power module (150), a second power module (155), and a third power module (160). Each power module (150, 155, 160) has a plurality of electrical and electronic components mounted on a PCB and attached to the inner surface of the inverter housing by a plurality of fasteners.
[0024] According to an embodiment, the inverter housing (111) is externally connected to the motor housing (121) by a plurality of connection means including a plurality of fasteners.
[0025] Figure 3 An exploded view of a power distributor (130) used in an inverter (110) is shown. An anode (135), a cathode (140) and a support plate (165) are laminated by an insulating member (132). According to a preferred embodiment, the anode (135) has a plate and a power terminal (135'), which together form the anode (135). The anode (135) has an anode power terminal (135') connected to the negative terminal of the battery and a plurality of anode electrical connectors 135a, 135b and 135c extending outward from the side of the anode plate. Each of these electrical connectors (135a, 135b, 135c) is connected to the negative terminal or bus of each power module. According to a preferred embodiment, the cathode (140) has a plate and a cathode power terminal (140'), which together form the cathode (140). Similarly, the cathode (140) has a power terminal (140') connected to the positive terminal of the battery and a plurality of cathode electrical connectors 140a, 140b and 140c extending outwardly from the side of the cathode plate. Each of these electrical connectors (140a, 140b, 140c) is connected to the positive terminal or bus of each power module. The positions of the electrical connectors (135a, 135b, 135c, 140a, 140b, 140c) on the anode plate and the cathode plate are configured at different heights to make the electrical connection between the connectors and the terminals of the power module (150) easily accessible while compactly mounting the power distributor (130) in the center of the inverter. The support plate (165) supports the cathode (140) and the anode (135) and is fastened to the inner surface of the inverter housing at multiple vertices of the support plate (165). The insulating member (132) insulates the support plate (165), the anode (135) and the cathode (140) and also supports their mounting. Slots in the insulating member (132) can also be seen for the electrical connectors of each plate to extend through the insulating member.
[0026] Figure 4A perspective view of an inverter module assembly (170) is shown, including one of a plurality of power modules (150, 155, 160) electrically connected to a distributor (130) via a plurality of electrical connectors. According to the illustrated embodiment, a second power module (155) is electrically coupled to the power distributor (130) and receives power from the power distributor (30) for inversion. Power is transmitted from the power module (155) to the motor (105) via an angle phase terminal (156). Each of the plurality of power modules (150, 155, 160) transmits electrical energy to the motor (105) via a separate angle phase terminal (156). Each power module (150, 155, 160) includes a PCB on which high-voltage capacitors, transistors, and a rectifier bridge are mounted that dissipate more heat. These components are interconnected via wires or buses. Heat from these components is transferred to the PCB and the housing of the inverter (110), and the plate fins (125) of the inverter (110) help remove the extracted heat. Wires from the phase terminals supply single-phase alternating current to the motor (105).
[0027] Figure 5 A cross-sectional view of an inverter (110) is shown, wherein the cover of the inverter is removed. The power terminals (135', 140') of the power distributor (130) extend through the cover to facilitate the electrical connection of the inverter (110) to the battery. Without the cover, three circumferentially arranged power modules (150, 155, 160) connected to the power distributor (130) and the controller (145) can be seen. The three power modules (150, 155, 160) are arranged on three different sides of the inverter (110), and the inverter (110) is covered by the inverter housing (111). According to an embodiment, the first power module (150) is opposite to the third power module (160). In addition, the second power module (155) is arranged adjacent to the first power module (150) and the third power module (160). The first power module (150) is arranged to be a first predetermined gap from the third power module (160). In addition, the first power module (150) is arranged to be a second predetermined gap from the second power module (155). In addition, the third power module (160) forms a third predetermined gap between the second power module (155) and the third power module (160). The first predetermined gap, the second predetermined gap, and the third predetermined gap ensure that the plurality of power modules (150, 155, 160) are spaced apart from each other in such a manner that heat generated by any one of the plurality of power modules (150, 155, 160) does not affect the operation of other power modules in the plurality of power modules (150, 155, 160). In addition, the separation of the plurality of power modules (150, 155, 160) ensures that each of the plurality of power modules (150, 155, 160) is sufficiently cooled by the air cooling plate fins (125) provided on the inverter housing (111).
[0028] Figure 6 A front perspective view of an inverter (110) and an inverter housing (111) is shown, wherein the motor housing is unfastened from the inverter housing. The inverter housing is provided with plate fins (125) circumferentially on the outer surface of the inverter housing (111). In addition, the inverter (110) is provided with a plurality of phase connectors (175) or wires configured to supply current from the inverter (110) to the motor (105). According to an embodiment, three independent phase connectors (175) are provided for connection to a three-phase motor (105).
[0029] Specifically, the aspect of axial integration of the inverter (110) with the motor (105) enables modularization and compactness of the integrated motor assembly (100), with minimal or negligible voltage drop between components during current flow, while providing a technical solution to a technical problem. In addition, due to the compact layout of the inverter (110) on the motor (105), the overhang of the inverter (110) in the vehicle is reduced, thereby eliminating the additional components required to support the integrated motor-inverter assembly (100). In addition, the power control board is installed above the current power distributor (130), thereby alleviating the need for additional space for the control board in the vehicle. In addition, a plurality of fin members (120, 125) are provided on the outer surface of the integrated motor assembly (100), ensuring heat dissipation due to the flow of ambient air, thereby alleviating the need for a separate cooling system. In this way, the number of components in the vehicle is reduced, making the vehicle lighter and thereby improving the performance of the vehicle.
[0030] Improvements and modifications may be incorporated herein without departing from the scope of the present invention.
[0031] Reference numerals list
[0032] 100: Motor components
[0033] 105: Electric motor
[0034] 110: Inverter
[0035] 111: Inverter housing
[0036] 115: Motor shaft
[0037] 120: Coaxial fin
[0038] 121: Motor housing
[0039] 125: Plate fin
[0040] 130: Power divider
[0041] 132: Insulation components
[0042] 135: Anode
[0043] 135a, 135b, 135c: Anode connector
[0044] 135': Power Terminal
[0045] 140: Cathode
[0046] 140a, 140b, 140c: Anode connector
[0047] 140': Cathode power terminal
[0048] 145: Controller
[0049] 150: First power module
[0050] 155: Second power module
[0051] 156: Corner phase terminal
[0052] 160: The third power module
[0053] 165: Support plate
[0054] 170: Inverter module components
Claims
1. A motor assembly (100), comprising: an electric motor (105), the electric motor (105) being configured to convert electrical energy into mechanical energy; A motor housing (121), the motor housing (121) circumferentially covering the motor (105) along a motor axis (A-A'); an inverter (110), the inverter (110) being electrically connected to the electric motor (105); in, The inverter is coaxially positioned with the motor; The inverter housing (111) covers the inverter (110) circumferentially along the motor axis (A-A'); The inverter housing (111) is mechanically connected to the motor housing (121).
2. The motor assembly (100) according to claim 1, wherein: The inverter (110) includes a power distributor (130), a plurality of power modules (150, 155, 160) for inverting a power supply received from a power source, one or more controllers (145), and a plurality of phase connectors (175).
3. The motor assembly (100) according to claim 2, wherein: The plurality of power modules (150, 155, 160) are arranged on the inner surface of the inverter housing (111); in, The plurality of power modules (150, 155, 160) include: A first power module (150); a second power module (155); and A third power module (160); in, The plurality of power modules (150, 155, 160) are electrically connected to one or more controllers (145) and the power distributor (130).
4. The motor assembly (100) according to claim 3, wherein: The first power module (150) and the third power module (160) are arranged opposite to each other, and a first predetermined gap is formed between the first power module (150) and the third power module (160).
5. The motor assembly (100) according to claim 3, wherein: The first power module (150) and the second power module (155) are arranged adjacent to each other, and a second predetermined gap is formed between the first power module (150) and the second power module (155); in, The second power module (155) is disposed adjacent to the third power module (160), and a third predetermined gap is formed between the second power module (155) and the third power module (160).
6. The motor assembly (100) according to claim 3, wherein: The one or more controllers (145) are arranged opposite to the second power module (155), and a fourth predetermined gap is formed between the second power module (155) and the one or more controllers (145).
7. The motor assembly (100) according to claim 3, wherein: The one or more controllers are arranged on the inner surface of the inverter housing (111).
8. The motor assembly (100) according to claim 2, wherein: The power distributor (130) is configured to receive power from a power source, and the power distributor (130) is capable of transmitting the power to each power module of the plurality of power modules (150, 155, 160).
9. The motor assembly (100) according to claim 2, wherein: The power distributor (130) comprises an anode (135), a cathode (140), a support plate (165) and an insulating member (132); in, The power distributor (130) is configured to receive a direct current from a power source and distribute the direct current to the plurality of power modules (150, 155, 160).
10. The motor assembly (100) according to claim 2, wherein: The inverter (110) is configured to invert a direct current received from a power source into a single-phase alternating current; in, Each phase connector of the plurality of phase connectors (175) is configured to transmit a single-phase alternating current to the motor (105).
11. The electric motor assembly (100) according to claim 1, wherein: The inverter housing (111) has a plurality of fins (125) on an outer surface of the inverter housing (111).
12. The motor assembly (100) according to claim 1, wherein the motor assembly (100) is provided in a two-wheeled vehicle or a three-wheeled vehicle.
13. The motor assembly (100) according to claim 10, wherein: The electric power is transmitted from the power modules (150, 155, 160) to the electric motor (105) through separate angle phase terminals (156).
14. The motor assembly (100) of claim 9, wherein: The anode (135) has a plate and a power terminal (135') that together form the anode (135), and the cathode (140) has a plate and a cathode power terminal (140') that together form the cathode (140).
15. The electric motor assembly (100) of claim 14, wherein: The anode power terminal (135') is connected to the negative terminal of the battery, and the anode (135) has a plurality of anode electrical connectors (135a, 135b, 135c) extending outward from the anode (135), each of the electrical connectors (135a, 135b, 135c) being connected to the negative terminal or bus of each power module (150, 155, 160).
16. The electric motor assembly (100) of claim 14, wherein: The cathode power terminal (140') is connected to the positive terminal of the battery, and the cathode (140) has a plurality of cathode electrical connectors (140a, 140b, 140c) extending outward from the cathode (140), each of the electrical connectors (140a, 140b, 140c) being connected to the positive terminal or bus of each power module (150, 155, 160).